Coil component

Abstract

The coil component of the present application suppresses protrusion of the adhesive to the outside of the core and the plate-shaped member. The coil component is provided with: a core having a winding core portion, a first flange portion (12), and a second flange portion (13); and a plate-shaped member (50) mounted to the first flange portion (12) and the second flange portion (13). At least one of a distance (D1) between the plate-shaped member (50) and the first flange portion (12) in the height direction (Td) and a distance (D2) between the plate-shaped member (50) and the second flange portion (13) in the height direction (Td) is different in at least one of the length direction (Ld) and the width direction.

Description

[0001] This application is a divisional application of patent application No. 202010311368.5, filed on April 20, 2020, filed by Murata Manufacturing Co., Ltd., entitled "Coil Component". Technical Field

[0002] This disclosure relates to coil components. Background Technology

[0003] Conventionally, as a coil component used as a common-mode choke coil, a coil component is known to include: a core having a core portion and a pair of flange portions disposed at both ends of the core portion; a first wire and a second wire wound around the core portion; and a plate-shaped component disposed at one end of the pair of flange portions in the height direction of the coil component opposite to the end where the electrode is disposed (for example, see Patent Document 1). The plate-shaped component is fixed to the pair of flange portions, for example, by an adhesive.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2002-329618

[0005] However, with the miniaturization of coil components and cores, the thickness of the core portion and the pair of flanges becomes thinner. As a result, the area of ​​the plate-shaped component opposite to the first and second flanges becomes smaller, increasing the concern that adhesive may protrude outwards from the plate-shaped component and the core due to variations in the amount of adhesive applied to the plate-shaped component or the first and second flanges. Summary of the Invention

[0006] The purpose of this disclosure is to provide a coil component capable of suppressing the protrusion of adhesive onto the core and plate-like components.

[0007] One aspect of this disclosure is a coil component comprising: a core having a core portion extending along the length direction of the coil component, a first flange portion disposed at a first end of the core portion along the length direction, and a second flange portion disposed at a second end of the core portion along the length direction; a first wire and a second wire wound in the core portion in the same direction; a first terminal electrode and a second terminal electrode, the first terminal electrode being disposed on the bottom portion of the first flange portion in the height direction of the coil component orthogonal to the length direction and connected to the first end of the first wire, the second terminal electrode being disposed on the bottom portion of the first flange portion and connected to the first end of the second wire; a third terminal electrode and a fourth terminal electrode. The third terminal electrode is disposed on the bottom surface of the second flange portion in the height direction and connected to the second end of the first wire; the fourth terminal electrode is disposed on the bottom surface of the second flange portion and connected to the second end of the second wire; and a plate-shaped member is attached to the first flange portion and the second flange portion by adhesive to bridge the top surface of the first flange portion and the top surface of the second flange portion in the height direction. The direction orthogonal to the length direction and the height direction is set as the width direction of the coil member. The distance between the plate-shaped member and the first flange portion in the height direction is different in at least one of the length direction and the width direction.

[0008] According to this configuration, when the plate-shaped component is mounted on the first flange and the second flange of the core, the adhesive can easily enter to a position where the distance between the plate-shaped component and at least one of the first flange and the second flange is large in the second direction. Therefore, it is possible to suppress the adhesive from protruding to the outside of the core and the plate-shaped component.

[0009] In addition, when the plate-shaped component is a magnetic material, a magnetic circuit is formed between the core and the plate-shaped component, passing through a position where the distance between the other end of at least one of the first flange and the second flange and the plate-shaped component is small. Therefore, the deviation in the length of the magnetic circuit between the core and the plate-shaped component is reduced. Consequently, the deviation in the inductance value can be reduced.

[0010] One aspect of this disclosure is a coil component comprising: a core having a core portion extending along the length direction of the coil component, a first flange portion disposed at a first end of the core portion along the length direction, and a second flange portion disposed at a second end of the core portion along the length direction; a first wire and a second wire wound in the core portion in the same direction; a first terminal electrode and a second terminal electrode, the first terminal electrode being disposed on the bottom portion of the first flange portion in the height direction of the coil component orthogonal to the length direction and connected to a first end of the first wire, the second terminal electrode being disposed on the bottom portion of the first flange portion and connected to a first end of the second wire; a third terminal electrode and a fourth terminal electrode, the third terminal electrode being disposed in the height direction... The bottom surface of the second flange portion is connected to the second end of the first wire, and the fourth terminal electrode is disposed on the bottom surface of the second flange portion and connected to the second end of the second wire; and a plate-shaped member is attached to the first flange portion and the second flange portion by adhesive to bridge the top surface of the first flange portion and the top surface of the second flange portion in the height direction. The direction orthogonal to the length direction and the height direction is set as the width direction of the coil member. At least one of the top surface of the first flange portion in the height direction and the portion of the plate-shaped member opposite to the first flange portion in the height direction is provided with a first recess in the portion of the plate-shaped member that is outer compared to the core portion in the direction along the width direction.

[0011] According to this configuration, when the plate-shaped component is mounted on the first flange of the core, the adhesive can easily enter to a position where, in the second direction, the distance between the first flange and the plate-shaped component increases due to the recess. Therefore, it is possible to suppress the adhesive from protruding to the outside of the core and the plate-shaped component.

[0012] According to one aspect of the present disclosure, the coil component is capable of suppressing the adhesive from protruding outwards from the core and plate-shaped component. Attached Figure Description

[0013] Figure 1 This is a schematic bottom view showing a coil component according to one embodiment.

[0014] Figure 2 This is a schematic top view of a coil component in one embodiment, omitting the top plate.

[0015] Figure 3 This is a schematic side view showing a coil component according to one embodiment.

[0016] Figure 4 This refers to the coil component in one embodiment, and... Figure 3A schematic side view of the opposite side.

[0017] Figure 5 It is a three-dimensional diagram representing the core.

[0018] Figure 6 It means and Figure 5 Three-dimensional images of the core from different angles.

[0019] Figure 7 (a) is a front view of the first flange of the core. Figure 7 (b) is a front view of the second flange of the core.

[0020] Figure 8 This is a schematic cross-sectional view showing the connection structure between the end of the first flange on the circuit board side and the circuit board when the coil component is mounted on the circuit board.

[0021] Figure 9 This is a cross-sectional view obtained by cutting the coil component with a plane along the direction of extension of the core.

[0022] Figure 10 (a) is Figure 9 An enlarged view of the connection between the bottom surface of the core and the first flange. Figure 10 (b) is Figure 9 An enlarged view of the connection between the bottom surface of the core and the second flange.

[0023] Figure 11 (a) is Figure 9 An enlarged view of the connection between the top surface of the core and the first flange. Figure 11 (b) is Figure 9 An enlarged view of the connection between the top surface of the core and the second flange.

[0024] Figure 12 (a) means Figure 9 An enlarged view of the connection structure between the plate-shaped component and the first flange. Figure 12 (b) means Figure 9 An enlarged view of the connection structure between the plate-shaped component and the second flange.

[0025] Figure 13 This is a flowchart illustrating a method for manufacturing a coil component according to one embodiment.

[0026] Figure 14 (a) is a diagram illustrating the process of forming the end face electrode. Figure 14 (b) is a front view of the first flange of the core in the end-face electrode forming process.

[0027] Figure 15 (a) and Figure 15(b) is a diagram used to illustrate the bottom electrode formation process.

[0028] Figure 16 This is a schematic bottom view of the core used to illustrate the first connecting process.

[0029] Figure 17 This is a schematic bottom view of the core used to illustrate the second connection process.

[0030] Figure 18 (a) is a cross-sectional view of the connection between the bottom surface of the core portion and the first flange portion in the modified example. Figure 18 (b) is an enlarged view of the connection between the bottom surface of the core and the first flange in the modified example.

[0031] Figure 19 (a) ~ Figure 19 (c) is a cross-sectional view showing the connection structure between the plate-shaped component and the first flange in the modified example.

[0032] Figure 20 This is a cross-sectional perspective view of the core body representing the second flange portion of the modified example.

[0033] Figure 21 This is a cross-sectional view showing the connection structure between the second flange and the plate-shaped component in the modified example.

[0034] Figure 22 (a) and Figure 22 (b) is a cross-sectional view showing the connection structure between the second flange and the plate-shaped component in the modified example.

[0035] Figure 23 (a) ~ Figure 23 (c) is a perspective view showing a portion of the second flange in the modified example.

[0036] Figure 24 This is a schematic bottom view showing a modified coil component.

[0037] Figure 25 (a) and Figure 25 (b) is a schematic bottom view showing a portion of the second flange of the coil component in a modified example.

[0038] Figure 26 This is a schematic bottom view showing a modified coil component.

[0039] Figure 27 This is a schematic top view of the coil core of the modified coil component, with the first and second wires wound around it.

[0040] Figure 28 This is a schematic side view of the coil component in the modified example.

[0041] Figure 29 This is a front view of the first flange of the coil component in the modified example.

[0042] Explanation of reference numerals in the attached drawings: 1…coil component, 10…core, 11…winding core, 11a…bottom surface, 11b…top surface, 11c…first side surface, 11d…second side surface, 12…first flange, 12a…inner surface, 12b…outer surface, 12c…top surface, 12d…bottom surface, 13…second flange, 13a…inner surface, 13b…outer surface, 13c…top surface, 13d…bottom surface, 14a, 14b…feet (second connecting part), 15a, 15… b…protrusion (first connecting part), 16…slope (first slope), 17a, 17b…recess, 18a, 18b…foot (fourth connecting part), 19a, 19b…protrusion (third connecting part), 20…slope (second slope), 21a, 21b…recess, 22…first curved surface, 23…second curved surface, 24…third curved surface, 25…fourth curved surface, 31…first terminal electrode, 31a…first bottom electrode, 31b…first end electrode, 3 2…Second terminal electrode, 32a…Second bottom electrode, 32b…Second end electrode, 33…Third terminal electrode, 33a…Third bottom electrode, 33b…Third end electrode, 34…Fourth terminal electrode, 34a…Fourth bottom electrode, 34b…Fourth end electrode, 40…Coil, 40a…Winding portion, 40b…First lead-out portion, 40c…Second lead-out portion, 40d…Third lead-out portion, 40e…Fourth lead-out portion, 41…First wire, 41a…First end of the first wire 41b…Second end of the first line, 41c…Third bend, 41d…Fourth bend, 42…Second line, 42a…First end of the second line, 42b…Second end of the second line, 42c…First bend, 42d…Second bend, 43, 43A, 43B…First winding, 44…First intersection, 45…Second intersection, 50…Plate-shaped component, 51…First surface, 100…Coating device, Ld…Length direction, Td…Height direction, Wd…Width direction. Detailed Implementation

[0043] The implementation method will be described below.

[0044] Furthermore, regarding the accompanying drawings, sometimes the constituent elements are shown enlarged to facilitate understanding. There are cases where the dimensional ratios of the constituent elements differ from their actual ratios or from those in other drawings. Additionally, in sectional views, the shaded areas of some constituent elements are sometimes omitted to facilitate understanding.

[0045] like Figures 1-4As shown, the coil component 1 includes a core 10 and a coil 40 wound around the core 10. This coil component 1 is, for example, a surface-mount type coil component. The coil component 1 in this embodiment is, for example, a common-mode choke coil.

[0046] The core 10 is made of a non-conductive material, specifically a non-magnetic material such as alumina or a magnetic material such as nickel (Ni)-zinc (Zn) ferrite. For example, the core 10 is formed by firing a molded body made of compressed non-conductive material. In addition, the core 10 is not limited to being formed by firing a molded body made of compressed non-conductive material. For example, the core 10 can also be formed by thermosetting a resin containing magnetic powders such as metal powder or ferrite powder, a resin containing non-magnetic powders such as silica powder, or a resin without fillers.

[0047] like Figures 1-6 As shown, the core 10 has a core portion 11 extending along the length direction Ld of the coil component 1, a first flange portion 12 provided at a first end of the core portion 11 in the length direction Ld, and a second flange portion 13 provided at a second end of the core portion 11 in the length direction Ld. In this embodiment, the core portion 11, the first flange portion 12, and the second flange portion 13 are integrally formed. In this specification, the length direction Ld can also be referred to as the arrangement direction of the first flange portion 12 and the second flange portion 13. In addition, in this specification, the "height direction Td" and the "width direction Wd" of the coil component 1 are defined as follows. That is, the height direction Td is a direction perpendicular to the length direction Ld and perpendicular to the main surface of the circuit board when the coil component 1 is mounted on the circuit board. The width direction Wd is a direction perpendicular to the length direction Ld and parallel to the main surface of the circuit board when the coil component 1 is mounted on the circuit board. Additionally, in the following description, the length dimension of the length direction Ld is set as "length dimension L", the length dimension of the height direction Td is set as "height dimension T", and the length dimension of the width direction Wd is set as "width dimension W".

[0048] like Figure 3 as well as Figure 5As shown, the dimensions of the core 10 are as follows: The length L10 of the core 10 is approximately 4.6 mm, the width W10 is approximately 3.2 mm, and the height T10 is approximately 2.0 mm. Furthermore, the length L10 is the length along the length direction Ld from the outer surface 12b of the first flange portion 12 to the outer surface 13b of the second flange portion 13, and the width W10 is the length along the width direction Wd from the first side surface 12e of the first flange portion 12 to the second side surface 12f. The height T10 is the length along the height direction Td from the end face of the foot portion 14a of the first flange portion 12 in the height direction Td to the top surface 12c of the first flange portion 12 (described later).

[0049] The length L11 of the core portion 11 is larger than both the width W11 and the height T11 of the core portion 11. The width W11 is larger than the height T11. In this embodiment, the width W11 is approximately 0.6 mm. Preferably, the width W11 is 1.0 mm or less. In this embodiment, the core portion 11 is configured such that its height T11 is shorter than its width W11.

[0050] The cross-sectional shape of the core portion 11, orthogonal to the length direction Ld, is a polygon; in this embodiment, the cross-sectional shape of the core portion 11 is a quadrilateral. Furthermore, in this specification, "polygon" includes polygons with chamfered corners, polygons with rounded corners, and polygons where part of each side is curved. Moreover, the shape of the cross-sectional shape of the core portion 11 is not limited to a polygon and can be arbitrarily changed. In one example, the cross-sectional shape of the core portion 11 may also be a circle, an ellipse, or a combination of these with a polygon.

[0051] In this embodiment, the winding core 11 has a bottom surface 11a and a top surface 11b facing the height direction Td, and a first side surface 11c and a second side surface 11d facing the width direction Wd. The bottom surface 11a, top surface 11b, first side surface 11c, and second side surface 11d are each a surface forming the winding core 11. In this embodiment, the bottom surface 11a is parallel to the top surface 11b, and the first side surface 11c is parallel to the second side surface 11d. The bottom surface 11a is the surface facing the circuit board side when the coil component 1 is mounted on the circuit board.

[0052] like Figure 5 as well as Figure 6As shown, the shape of the first flange portion 12 is substantially the same as the shape of the second flange portion 13. The width dimensions W12 and W13 of the first flange portion 12 and the second flange portion 13 are larger than the height dimensions T12 and T13 of the first flange portion 12 and the second flange portion 13. The height dimensions T12 and T13 of the first flange portion 12 and the second flange portion 13 are larger than the length dimensions L12 and L13 of the first flange portion 12 and the second flange portion 13. The width dimensions W12 and W13 of the first flange portion 12 and the second flange portion 13 are larger than the width dimension W11 of the core portion 11, and the height dimensions T12 and T13 of the first flange portion 12 and the second flange portion 13 are larger than the height dimension T11 of the core portion 11. Furthermore, the height dimension T12 of the first flange portion 12 is the length along the height direction Td from the top surface 12c (described later) to the bottom surface 12d of the first flange portion 12. Furthermore, the height dimension T13 of the second flange portion 13 is the length in the height direction Td from the top surface 13c to the bottom surface 13d of the second flange portion 13, which will be described later.

[0053] The first flange portion 12 has an inner surface 12a, an outer surface 12b, a top surface 12c, a bottom surface 12d, a first side surface 12e, and a second side surface 12f. The inner surface 12a is the surface facing the core portion 11 in the length direction Ld. The outer surface 12b is the surface facing the opposite side of the inner surface 12a in the length direction Ld. The top surface 12c and the bottom surface 12d are surfaces facing the height direction Td and are the surfaces connecting the inner surface 12a and the outer surface 12b. The bottom surface 12d is the surface of the first end portion of the first flange portion 12 provided in the height direction Td, and the top surface 12c is the surface of the second end portion of the first flange portion 12 provided in the height direction Td. The bottom surface 12d is the surface facing the circuit board in the height direction Td when the coil component 1 is mounted on the circuit board. The top surface 12c is the surface facing the opposite side of the bottom surface 12d in the height direction Td. The first side surface 12e and the second side surface 12f are surfaces facing the width direction Wd, and are surfaces connecting the inner surface 12a, the outer surface 12b, the top surface 12c, and the bottom surface 12d. The second side surface 12f is a surface facing the opposite side to the first side surface 12e in the width direction Wd.

[0054] The second flange portion 13 has an inner surface 13a, an outer surface 13b, a top surface 13c, a bottom surface 13d, a first side surface 13e, and a second side surface 13f. The inner surface 13a is the surface facing the core portion 11 in the length direction Ld. The outer surface 13b is the surface facing the opposite side of the inner surface 13a in the length direction Ld. The top surface 13c and the bottom surface 13d are surfaces facing the height direction Td and are the surfaces connecting the inner surface 13a and the outer surface 13b. The bottom surface 13d is the surface of the first end portion of the second flange portion 13 provided in the height direction Td, and the top surface 13c is the surface of the second end portion of the second flange portion 13 provided in the height direction Td. The bottom surface 13d is the surface facing the circuit board in the height direction Td when the coil component 1 is mounted on the circuit board. The top surface 13c is the surface facing the opposite side of the bottom surface 13d in the height direction Td. The first side surface 13e and the second side surface 13f are surfaces facing the width direction Wd, and are surfaces connecting the inner surface 13a, the outer surface 13b, the top surface 13c, and the bottom surface 13d. The second side surface 13f is a surface facing the opposite side to the first side surface 13e in the width direction Wd.

[0055] Thus, the bottom surface 11a of the core portion 11 is on the same side as the bottom surface 12d of the first flange portion 12 and the bottom surface 13d of the second flange portion 13 in the height direction Td. Similarly, the top surface 11b of the core portion 11 is on the same side as the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 in the height direction Td.

[0056] like Figure 1 as well as Figure 5As shown, the first flange portion 12 has two feet 14a and 14b protruding from the bottom surface 12d along the height direction Td. The feet 14a and 14b are spaced apart in the width direction Wd. In the width direction Wd, the foot 14a is located on a first side surface 12e near the first flange portion 12, and the foot 14b is located on a second side surface 12f near the first flange portion 12. Viewed in the length direction Ld, the feet 14a and 14b are positioned inside an imaginary line extending the first side surface 11c and second side surface 11d of the core portion 11 in the length direction Ld. The length dimension Ld of the feet 14a and 14b is smaller than the length dimension L12 of the first flange portion 12. A protrusion 15a is provided in the portion of the first flange portion 12 between the foot 14a and the first side surface 12e. A protrusion 15b is provided in the portion of the first flange portion 12 between the foot 14b and the second side surface 12f. Protrusions 15a and 15b protrude from the bottom surface 12d along the height direction Td. Protrusion 15a extends from the foot 14a to the first side surface 12e in the width direction Wd, and extends from the inner surface 12a of the first flange portion 12 to the outer surface 12b in the length direction Ld. Protrusion 15b extends from the foot 14b to the second side surface 12f in the width direction Wd, and extends from the inner surface 12a of the first flange portion 12 to the outer surface 12b in the length direction Ld.

[0057] A ramp portion 16 is provided on the inner surface 12a of the first flange portion 12. The ramp portion 16 extends along the width direction Wd. The end of the ramp portion 16 on the first side surface 12e side in the width direction Wd is connected to the bottom surface 11a of the core portion 11. The ramp portion 16 is inclined such that it moves away from the bottom surface 11a of the core portion 11 in the height direction Td as it moves from the first side surface 12e toward the second side surface 12f in the width direction Wd. The end of the ramp portion 16 on the second side surface 12f side in the width direction Wd is connected to the protrusion 15b. The portion of the ramp portion 16 on the protrusion 15a side has a decreasing length dimension Ld in the length direction as it moves toward the protrusion 15a. The portion of the ramp portion 16 on the protrusion 15b side has a constant length dimension Ld in the length direction.

[0058] like Figure 1 As shown, a first terminal electrode 31 and a second terminal electrode 32 are provided at the first end of the first flange portion 12 in the height direction Td. Viewed from the height direction Td, the first terminal electrode 31 is provided at the foot portion 14a and the protrusion 15a, and the second terminal electrode 32 is provided at the foot portion 14b and the protrusion 15b. In this embodiment, the second terminal electrode 32 is provided on the portion of the ramp portion 16 on the side of the protrusion 15b.

[0059] like Figure 6As shown, recesses 17a and 17b are provided at the second end of the first flange portion 12 in the height direction Td. Recesses 17a and 17b are recessed from the top surface 12c of the first flange portion 12 along the height direction Td. The two recesses 17a and 17b are spaced apart in the width direction Wd. Recess 17a is located in the first flange portion 12 on the side of the first side surface 12e in the width direction Wd, compared to an imaginary line extending the second side surface 11d of the core portion 11 along the length direction Ld. Recess 17b is located in the first flange portion 12 on the side of the second side surface 12f in the width direction Wd, compared to an imaginary line extending the first side surface 11c of the core portion 11 along the length direction Ld. In this embodiment, recesses 17a and 17b have the same shape and extend along the length direction Ld. Viewed from the height direction Td, the shapes of recesses 17a and 17b are rectangles with the length direction Ld as the long side and the width direction Wd as the short side. In this embodiment, the recesses 17a and 17b are formed to be spaced apart from the inner surface 12a, outer surface 12b, first side surface 12e, and second side surface 12f of the first flange portion 12, respectively. The depth of the recess 17a is equal to the depth of the recess 17b. Furthermore, the depths of the recesses 17a and 17b are constant in the length direction Ld and the width direction Wd. The depths of the recesses 17a and 17b are the depths of the recesses 17a and 17b as observed in the height direction Td, and are defined according to the height dimension from the top surface 12c of the first flange portion 12 to the bottom surface of the recesses 17a and 17b. The recesses 17a and 17b are formed during the molding of the core 10. In one example, the recesses 17a and 17b are integrally formed with the core 10 by means of a protrusion provided in the metal mold for molding the core 10. After the recesses 17a and 17b are integrally formed with the core 10, if a rolling process is performed, the corners of the recesses 17a and 17b become curved surfaces. Here, the corners of the recesses 17a and 17b are, for example, the portions connecting the top surface 12c of the first flange portion 12 and the inner surfaces of the recesses 17a and 17b.

[0060] like Figure 1 as well as Figure 5As shown, the second flange portion 13 has two feet 18a and 18b protruding from the bottom surface 13d along the height direction Td. The feet 18a and 18b are spaced apart in the width direction Wd. In the width direction Wd, foot 18a is located on the first side surface 13e of the second flange portion 13, and foot 18b is located on the second side surface 13f of the second flange portion 13. Viewed in the length direction Ld, the feet 18a and 18b are positioned inside an imaginary line extending the first side surface 11c and the second side surface 11d of the core portion 11 along the length direction Ld. The length dimension Ld of the feet 18a and 18b is smaller than the length dimension L13 of the second flange portion 13. A protrusion 19a is provided in the portion of the second flange portion 13 between the feet 18a and the first side surface 13e. A protrusion 19b is provided in the portion of the second flange portion 13 between the feet 18b and the second side surface 13f. Protrusions 19a and 19b protrude from the bottom surface 13d of the second flange portion 13 along the height direction Td. Protrusion 19a extends from the foot portion 18a to the first side surface 13e in the width direction Wd, and extends from the inner surface 13a to the outer surface 13b of the second flange portion 13 in the length direction Ld. Protrusion 19b extends from the foot portion 18b to the second side surface 13f in the width direction Wd, and extends from the inner surface 13a to the outer surface 13b of the second flange portion 13 in the length direction Ld.

[0061] A ramp portion 20 is provided on the inner surface 13a of the second flange portion 13. The ramp portion 20 extends along the width direction Wd. The end of the ramp portion 20 on the second side surface 13f side in the width direction Wd is connected to the bottom surface 11a of the core portion 11. The ramp portion 20 is inclined such that as it moves from the second side surface 13f toward the first side surface 13e in the width direction Wd, it moves away from the bottom surface 11a of the core portion 11 in the height direction Td. That is, the inclination direction of the ramp portion 20 is opposite to the inclination direction of the ramp portion 16. The end of the ramp portion 20 on the first side surface 13e side in the width direction Wd is connected to the bottom surface 13d. The portion of the ramp portion 20 on the protrusion 19a side is formed such that its length dimension Ld is constant. The portion of the ramp portion 20 on the protrusion 19b side has its length dimension Ld decreasing as it moves toward the protrusion 19b.

[0062] like Figure 1As shown, a third terminal electrode 33 and a fourth terminal electrode 34 are provided at the first end of the second flange portion 13 in the height direction Td. The third terminal electrode 33 is provided in the foot portion 18a, which is on the same side as the foot portion 14a of the first flange portion 12 where the first terminal electrode 31 is provided, in the width direction Wd. The fourth terminal electrode 34 is provided in the foot portion 18b, which is on the same side as the foot portion 14b of the first flange portion 12 where the second terminal electrode 32 is provided, in the width direction Wd. Viewed from the height direction Td, the third terminal electrode 33 is provided on the foot portion 18a and the protrusion 19a, and the fourth terminal electrode 34 is provided on the foot portion 18b and the protrusion 19b. In this embodiment, the third terminal electrode 33 is provided on the portion of the ramp portion 20 on the side of the protrusion 19a. The third terminal electrode 33 and the fourth terminal electrode 34 are not electrically connected to each other.

[0063] like Figure 6 As shown, recesses 21a and 21b are provided at the other end of the second flange portion 13 in the height direction Td. Recesses 21a and 21b are recessed from the top surface 13c of the second flange portion 13 along the height direction Td. The two recesses 21a and 21b are spaced apart in the width direction Wd. Recess 21a is located in the second flange portion 13 on the side of the first side 13e in the width direction Wd compared to the core portion 11. Recess 21b is located in the second flange portion 13 on the side of the second side 13f in the width direction Wd compared to the core portion 11. In this embodiment, recesses 21a and 21b have the same shape and extend along the length direction Ld. Viewed from the height direction Td, the shapes of recesses 21a and 21b are rectangles with the length direction Ld as the long side and the width direction Wd as the short side. In this embodiment, the depth of recess 21a is equal to the depth of recess 21b. Furthermore, the depths of the recesses 21a and 21b are constant in both the length direction Ld and the width direction Wd. The depths of the recesses 21a and 21b are the depths of the recesses 21a and 21b as observed in the height direction Td, and are defined according to the height dimension from the top surface 13c of the second flange portion 13 to the bottom surface of the recesses 21a and 21b. The recesses 21a and 21b are formed during the molding of the core 10. In one example, the recesses 21a and 21b are integrally formed with the core 10 by means of a protrusion provided in the metal mold for molding the core 10. After the recesses 21a and 21b are integrally formed with the core 10, if a rolling process is performed, the corners of the recesses 21a and 21b become curved surfaces. Here, the corners of the recesses 21a and 21b are, for example, the portions where the top surface 13c of the second flange portion 13 connects to the inner surfaces of the recesses 21a and 21b. In this embodiment, the recesses 21a and 21b have the same shape as the recesses 17a and 17b of the first flange portion 12. Alternatively, the shape of at least one of the recesses 17a, 17b, 21a, and 21b may differ from the shapes of the other recesses.

[0064] The first terminal electrode 31, the second terminal electrode 32, the third terminal electrode 33, and the fourth terminal electrode 34, for example, include a base electrode and an electroplated layer formed on the surface of the base electrode. Materials for the base electrode can include, for example, metals such as silver (Ag) and copper (Cu), or alloys such as nickel (Ni)-chromium (Cr). Materials for the electroplated layer can include, for example, metals such as tin (Sn), Cu, and Ni, or alloys such as Ni-Sn. Furthermore, the electroplated layer can also be a multilayer structure.

[0065] When viewed from the height direction Td, the first terminal electrode 31 has a first bottom electrode 31a that includes the end face of the foot 14a in the height direction Td and the area around the foot 14a on the bottom surface 12d. Figure 1 (The area enclosed by the dotted line). For example... Figure 1 As shown, the outer edge of the first bottom electrode 31a is formed into a shape including a convex curve. The outer edge of the first bottom electrode 31a is the boundary between the periphery of the first bottom electrode 31a and the core 10. In this embodiment, a portion of the outer edge of the first bottom electrode 31a is formed into a shape including a convex curve. To elaborate, the portion of the outer edge of the first bottom electrode 31a that does not contact the inner surface 12a, outer surface 12b, and first side surface 12e of the first flange portion 12 is formed into a shape including a convex curve. Specifically, the outer edge of the first bottom electrode 31a bulges towards the foot 14b in the width direction Wd compared to the foot portion 14a, and the bulging end towards the foot 14b is a convex curve.

[0066] like Figure 7As shown in (a), when viewed from the outer surface 12b of the first flange portion 12 in the length direction Ld, the first terminal electrode 31 has a first end face electrode 31b extending from the bottom surface 12d of the first flange portion 12 in the height direction Td. The first end face electrode 31b forms a first region RA1 on the outer surface 12b of the first flange portion 12, where a foot 14a is provided, and a second region RA2 on the side of the first side surface 12e of the first flange portion 12, relative to the first region RA1. The first region RA1 extends in the height direction Td. The size of the first region RA1 in the height direction Td is larger than the size in the width direction Wd. The outer edge of the first region RA1 is shaped to include a convex curve toward the top surface 12c in the height direction Td. The outer edge of the first region RA1 is the boundary between the periphery of the first region RA1 in the first end face electrode 31b and the core 10. In this embodiment, a portion of the outer edge of the first region RA1 is shaped to include a convex curve. In detail, the portion of the first region RA1 on the top surface 12c side, compared to the second region RA2, is formed into a shape containing a convex curve. The second region RA2 is located at its end on the bottom surface 12d side of the outer surface 12b of the first flange portion 12 in the height direction Td. The second region RA2 is formed such that its length dimension in the height direction Td is constant.

[0067] like Figure 1 As shown, when viewed from the height direction Td, the second terminal electrode 32 has a second bottom electrode 32a that includes the end face of the foot 14b in the height direction Td and the area around the foot 14b on the bottom surface 12d. Figure 1 (The area enclosed by the dashed line). For example... Figure 1 As shown, the outer edge of the second bottom electrode 32a is formed to have a convex curve shape. The outer edge of the second bottom electrode 32a is the boundary between the periphery of the second bottom electrode 32a and the core 10. In this embodiment, a portion of the outer edge of the second bottom electrode 32a is formed to have a convex curve shape. To elaborate, the portion of the outer edge of the second bottom electrode 32a that does not contact the inner surface 12a, outer surface 12b, and second side surface 12f of the first flange portion 12 is formed to have a convex curve shape. Specifically, the second bottom electrode 32a is formed to bulge towards the foot 14a in the width direction Wd compared to the foot portion 14b, and the bulging end is formed to have a convex curve towards the foot 14a, and the slope portion 16 is formed to have a convex curve towards the protrusion 15a.

[0068] like Figure 7As shown in (a), when viewed from the outer surface 12b of the first flange portion 12 in the length direction Ld, the second terminal electrode 32 has a second end face electrode 32b extending from the bottom surface 12d of the first flange portion 12 in the height direction Td. The second end face electrode 32b forms a first region RB1 in the outer surface 12b of the first flange portion 12, where a foot portion 14b is provided, and a second region RB2 on the side of the second side surface 12f of the first flange portion 12 compared to the first region RB1. The first region RB1 extends in the height direction Td. The first region RB1 is formed such that the size of the height direction Td is larger than the size of the width direction Wd. The outer edge of the first region RB1 is formed into a shape including a convex curve toward the top surface 12c in the height direction Td. The outer edge of the first region RB1 is the boundary between the periphery of the first region RB1 in the second end face electrode 32b and the core 10. In this embodiment, a portion of the outer edge of the first region RB1 is formed into a shape including a convex curve. In detail, the portion of the first region RB1 on the top surface 12c side, compared to the second region RB2, is formed into a shape containing a convex curve. The second region RB2 is located at the end of the outer surface 12b of the first flange portion 12 on the bottom surface 12d side in the height direction Td. The second region RB2 is formed such that its length dimension in the height direction Td is constant.

[0069] like Figure 1 As shown, when viewed from the height direction Td, the third terminal electrode 33 has a third bottom electrode 33a that includes the end face of the foot 18a in the height direction Td and the area around the foot 18a on the top surface 13c. Figure 1 (The area enclosed by the dashed line). For example... Figure 1 As shown, the outer edge of the third bottom electrode 33a is formed to have a convex curve shape. The outer edge of the third bottom electrode 33a is the boundary between the periphery of the third bottom electrode 33a and the core 10. In this embodiment, a portion of the outer edge of the third bottom electrode 33a is formed to have a convex curve shape. To elaborate, the portion of the outer edge of the third bottom electrode 33a that does not contact the inner surface 13a, outer surface 13b, and first side surface 13e of the second flange portion 13 is formed to have a convex curve shape. Specifically, the third bottom electrode 33a is formed to bulge towards the foot 18b in the width direction Wd compared to the foot portion 18a, and the bulging end towards the foot 18b has a convex curve shape, and the slope portion 20 towards the protrusion 19b has a convex curve shape.

[0070] like Figure 7As shown in (b), when viewed from the outer surface 13b of the second flange portion 13 in the length direction Ld, the third terminal electrode 33 has a third end face electrode 33b extending from the bottom surface 13d of the second flange portion 13 in the height direction Td. The third end face electrode 33b forms a first region RC1 in the outer surface 13b of the second flange portion 13, where a foot portion 18a is provided, and a second region RC2 on the side of the first side surface 13e of the second flange portion 13 compared to the first region RC1. The first region RC1 extends in the height direction Td. The first region RC1 is formed such that the size of the height direction Td is larger than the size of the width direction Wd. The outer edge of the first region RC1 is formed into a shape including a convex curve toward the top surface 13c in the height direction Td. The outer edge of the first region RC1 is the boundary between the periphery of the first region RC1 in the third end face electrode 33b and the core 10. In this embodiment, a portion of the outer edge of the first region RC1 is formed into a shape including a convex curve. In detail, the portion of the first region RC1 on the top surface 13c side, compared to the second region RC2, is formed into a shape containing a convex curve. The second region RC2 is located at its end on the bottom surface 13d side of the outer surface 13b of the second flange portion 13 in the height direction Td. The second region RC2 is formed such that its length dimension in the height direction Td is constant.

[0071] like Figure 1 As shown, when viewed from the height direction Td, the fourth terminal electrode 34 has a fourth bottom electrode 34a that includes the end face of the foot 18b in the height direction Td and the area around the foot 18b on the top surface 13c. Figure 1 (The area enclosed by the dotted line). For example... Figure 1 As shown, the outer edge of the fourth bottom electrode 34a is formed to have a convex curve shape. The outer edge of the fourth bottom electrode 34a is the boundary between the periphery of the fourth bottom electrode 34a and the core 10. In this embodiment, a portion of the outer edge of the fourth bottom electrode 34a is formed to have a convex curve shape. To elaborate, the portion of the outer edge of the fourth bottom electrode 34a that does not contact the inner surface 13a, outer surface 13b, and second side surface 13f of the second flange portion 13 is formed to have a convex curve shape. Specifically, the fourth bottom electrode 34a is formed to bulge towards the foot 18a in the width direction Wd compared to the foot 18b, and the bulging end is a convex curve.

[0072] like Figure 7As shown in (b), when viewed from the outer surface 13b of the second flange portion 13 in the length direction Ld, the fourth terminal electrode 34 has a fourth end face electrode 34b extending from the bottom surface 13d of the second flange portion 13 in the height direction Td. The fourth end face electrode 34b forms a first region RD1 in the outer surface 13b of the second flange portion 13, where a foot portion 18b is provided, and a second region RD2 on the side of the second side 13f of the second flange portion 13 compared to the first region RD1. The first region RD1 extends in the height direction Td. The first region RD1 is formed such that the size of the height direction Td is larger than the size of the width direction Wd. The outer edge of the first region RD1 is shaped to include a convex curve in the height direction Td toward the top surface 13c. The outer edge of the first region RD1 is the boundary between the periphery of the first region RD1 in the fourth end face electrode 34b and the core 10. In this embodiment, a portion of the outer edge of the first region RD1 is shaped to include a convex curve. In detail, the portion of the first region RD1 on the top surface 13c side, compared to the second region RD2, is formed into a shape containing a convex curve. The second region RD2 is located at its end on the bottom surface 13d side of the outer surface 13b of the second flange portion 13 in the height direction Td. The second region RD2 is formed such that its length dimension in the height direction Td is constant.

[0073] Reference Figure 8 The configuration of the first terminal electrode 31 and the bonding structure between the first terminal electrode 31 and the pad portion RX of the circuit board PX when the coil component 1 is mounted on the circuit board PX will be described separately. In addition, the second to fourth terminal electrodes 32 to 34 have the same configuration as the first terminal electrode 31 and the same bonding structure between the first terminal electrode 31 and the pad portion RX, so their description is omitted.

[0074] like Figure 8 As shown, in the first terminal electrode 31, the first bottom surface electrode 31a is connected to the first end surface electrode 31b. When forming the first bottom surface electrode 31a, the bottom surface 12d of the first flange portion 12 in the second region RA2 and the first region RA1 of the first end surface electrode 31b (refer to...) is formed. Figure 7 The end of the first flange portion 12 on the bottom surface 12d side in the first region RA1 of the first end face electrode 31b. Therefore, at the end of the first flange portion 12 on the bottom surface 12d side in the first region RA1 of the first end face electrode 31b, there is a region where the base electrode of the first end face electrode 31b overlaps with the base electrode of the first bottom surface electrode 31a. The thickness of the end of the first flange portion 12 on the bottom surface 12d side in the first region RA1 of the first end face electrode 31b is thicker than the thickness of the portion on the top surface 12c side in the first region RA1. The base electrode of the first end face electrode 31b and the base electrode of the first bottom surface electrode 31a are in the first flange portion 12 and the core portion 11 (see reference) Figure 6 The outer surfaces 12b on opposite sides overlap. Furthermore, the base electrode of the first bottom electrode 31a overlaps the first outer side of the first region RA1 of the base electrode of the first end electrode 31b in the length direction Ld.

[0075] like Figure 8 As shown, the first terminal electrode 31 has an electroplated layer formed on the surface of the base electrode of the first bottom electrode 31a and the base electrode of the first end electrode 31b. In the portion where the base electrode of the first bottom electrode 31a overlaps with the base electrode of the first end electrode 31b, an electroplated layer is formed on the surface of the base electrode of the first bottom electrode 31a.

[0076] Furthermore, the surface of the first end face electrode 31b (the surface of the electroplated layer) is formed in an uneven shape. More specifically, in the height direction Td, the portion of the first region RA1 of the first end face electrode 31b that is closer to the top surface 12c of the first flange portion 12 than the end face of the bottom surface 12d side of the first flange portion 12 (the area where the base electrode of the first end face electrode 31b overlaps with the base electrode of the first bottom surface electrode 31a) is formed in an uneven shape.

[0077] When the coil component 1 is mounted on the circuit board PX, such as Figure 8 As shown, the foot 14a of the core 10 is connected to the pad RX of the circuit board PX via solder SD. The solder SD is sandwiched between the first bottom electrode 31a covering the foot 14a and the pad RX. Furthermore, the solder SD is formed to connect the pad RX to the first end electrode 31b. The solder SD is connected to the first end electrode 31b by entering a recess in the surface of the first end electrode 31b. Moreover, when the coil component 1 is mounted on the pad RX of the circuit board PX, the solder SD is integrated with the plating layer of the first end electrode 31b.

[0078] like Figure 9 As shown, the connection structure between the inner surface 12a of the first flange portion 12 and the bottom surface 11a of the core portion 11, and the connection structure between the inner surface 12a of the first flange portion 12 and the top surface 11b of the core portion 11 are different from each other. Furthermore, the connection structure between the inner surface 13a of the second flange portion 13 and the bottom surface 11a of the core portion 11, and the connection structure between the inner surface 13a of the second flange portion 13 and the top surface 11b of the core portion 11 are different from each other.

[0079] If detailed explanation is required, then... Figure 10As shown in (a), a first curved surface 22 is formed at the connection between the inner surface 12a of the first flange portion 12 and the bottom surface 11a of the core portion 11. In this embodiment, in a cross-section parallel to the length direction Ld and the height direction Td (perpendicular to the width direction Wd), the shape of the first curved surface 22 is a curve that forms part of a perfect circle. Specifically, in a cross-section perpendicular to the width direction Wd, the shape of the first curved surface 22 is a curve that forms approximately 1 / 4 of a perfect circle. Furthermore, as... Figure 11 As shown in (a), a third curved surface 24 is formed at the connection between the inner surface 12a of the first flange portion 12 and the top surface 11b of the core portion 11. In this embodiment, in a cross-section perpendicular to the width direction Wd, the shape of the third curved surface 24 is a curve that forms part of a perfect circle. Specifically, in a cross-section perpendicular to the width direction Wd, the shape of the third curved surface 24 is a curve that forms approximately 1 / 4 of a perfect circle. On the other hand, as... Figure 10 As shown in (a), the radius R1 of the circle (the imaginary circle with double-dotted lines) that forms the first curved surface 22 in a section perpendicular to the width direction Wd is, for example... Figure 11 As shown in (a), the radius R3 of the circle (the imaginary circle with double dots and dashes) of the curve forming the third curved surface 24 in a section perpendicular to the width direction Wd is larger. In other words, the radius of curvature of the curve forming the first curved surface 22 and the third curved surface 24 is larger than the radius of curvature of the curve forming the third curved surface 24.

[0080] Preferably, the magnitude of the height direction Td of the first curved surface 22 is 20% or more and 60% or less relative to the maximum distance along the height direction Td from the bottom surface 11a of the core portion 11 to the first bottom surface electrode 31a of the first terminal electrode 31 and the second bottom surface electrode 32a of the second terminal electrode 32 of the first flange portion 12. In this embodiment, the maximum distance along the height direction Td from the bottom surface 11a of the core portion 11 to the first bottom surface electrode 31a of the first terminal electrode 31 and the second bottom surface electrode 32a of the second terminal electrode 32 of the first flange portion 12 is approximately 0.56 mm. The magnitude of the height direction Td of the first curved surface 22 is 0.1 mm or more and 0.3 mm or less. In other words, the radius R1 of the curve of the first curved surface 22 in a cross-section perpendicular to the width direction Wd is 0.1 mm or more and 0.3 mm or less. In this case, the aforementioned ratio is 20% or more and 60% or less.

[0081] The height direction Td of the third curved surface 24 is approximately 0.05 mm. In other words, the radius R3 of the third curved surface 24 is approximately 0.05 mm. That is, in this embodiment, the height direction Td of the third curved surface 24 is less than 20% of the maximum distance from the top surface 11b of the core portion 11 to the top surface 12c of the first flange portion 12 in the height direction Td. Furthermore, in this embodiment, the maximum distance from the bottom surface 11a of the core portion 11 to the first bottom surface electrode 31a of the first terminal electrode 31 and the second bottom surface electrode 32a of the second terminal electrode 32 of the first flange portion 12 in the height direction Td is defined based on the distance between the bottom surface 11a of the core portion 11 and the first bottom surface electrode 31a of the first terminal electrode 31 and the second bottom surface electrode 32a of the second terminal electrode 32 of the first flange portion 12 in the height direction Td.

[0082] In addition, such as Figure 10 As shown in (b), a second curved surface 23 is formed at the connection between the inner surface 13a of the second flange portion 13 and the bottom surface 11a of the core portion 11. In this embodiment, in a cross-section parallel to the length direction Ld and the height direction Td (perpendicular to the width direction Wd), the shape of the second curved surface 23 is a curve that forms part of a perfect circle. Specifically, in a cross-section perpendicular to the width direction Wd, the shape of the second curved surface 23 is a curve that forms approximately 1 / 4 of a perfect circle. Furthermore, as... Figure 11 As shown in (b), a fourth curved surface 25 is formed at the connection between the inner surface 13a of the second flange portion 13 and the top surface 11b of the core portion 11. In this embodiment, in a cross-section perpendicular to the width direction Wd, the shape of the fourth curved surface 25 is a curve that forms part of a perfect circle. Specifically, in a cross-section perpendicular to the width direction Wd, the shape of the fourth curved surface 25 is a curve that forms approximately 1 / 4 of a perfect circle. On the other hand, as... Figure 10 As shown in (b), the radius R2 of the circle (the imaginary circle with double-dotted lines) forming the second curved surface 23 in a section perpendicular to the width direction Wd is, for example... Figure 11 As shown in (b), the radius R4 of the circle (the imaginary circle with double dots and dashes) forming the curve of the fourth curved surface 25 in a section perpendicular to the width direction Wd is larger. In other words, the radius of curvature of the curve of the second curved surface 23 and the fourth curved surface 25 is larger than the radius of curvature of the curve of the fourth curved surface 25.

[0083] Furthermore, in this embodiment, in a cross-section perpendicular to the width direction Wd, the magnitude of the radius of curvature of the curve of the first curved surface 22 ( Figure 10 The radius R1 of the imaginary circle in (a) and the radius of curvature of the curve of the second curved surface 23 are ( Figure 10The radius R2 of the imaginary circle in (b) is equal. That is, preferably, the size of the height direction Td of the second curved surface 23 is more than 20% and less than 60% relative to the maximum distance from the bottom surface 11a of the core portion 11 to the third bottom surface electrode 33a of the third terminal electrode 33 and the fourth bottom surface electrode 34a of the fourth terminal electrode 34 in the height direction Td. Figure 11 The radius of the imaginary circle (R3) of (a) is the same as the radius of curvature of the curve of the fourth curved surface 25. Figure 11 The radius R4 of the imaginary circle in (b) is equal. That is, in this embodiment, the size of the height direction Td of the fourth curved surface 25 is less than 20% relative to the maximum distance from the top surface 11b of the core portion 11 to the top surface 13c of the second flange portion 13 in the height direction Td. Furthermore, in this embodiment, the maximum distance from the bottom surface 11a of the core portion 11 to the third bottom surface electrode 33a of the third terminal electrode 33 and the fourth bottom surface electrode 34a of the fourth terminal electrode 34 of the second flange portion 13 in the height direction Td is defined based on the distance between the bottom surface 11a of the core portion 11 and the third bottom surface electrode 33a of the third terminal electrode 33 and the fourth bottom surface electrode 34a of the fourth terminal electrode 34 of the second flange portion 13 in the height direction Td.

[0084] like Figure 9 As shown, in a cross-section perpendicular to the width direction Wd, the distance LX1 between the first curved surface 22 and the second curved surface 23 along the length direction Ld is greater than the distance LX2 between the third curved surface 24 and the fourth curved surface 25 along the length direction Ld. Distance LX1 is the distance along the length direction Ld between the boundary of the curve from the bottom surface 12d side of the first curved surface 22 towards the inner surface 12a and the boundary of the curve from the bottom surface 13d side of the second curved surface 23 towards the inner surface 13a, in a cross-section perpendicular to the width direction Wd. Distance LX2 is the distance along the length direction Ld between the boundary of the curve from the top surface 12c side of the third curved surface 24 towards the inner surface 12a and the boundary of the curve from the top surface 13c side of the fourth curved surface 25 towards the inner surface 13a, in a cross-section perpendicular to the width direction Wd. Therefore, the distance along the longitudinal direction Ld between the inner surface 12a of the first flange portion 12 and the inner surface 13a of the second flange portion 13 on the bottom surface 11a side of the core portion 11 is greater than the distance along the longitudinal direction Ld between the inner surface 12a of the first flange portion 12 and the inner surface 13a of the second flange portion 13 on the top surface 11b side of the core portion 11. This allows for a larger acquisition of the distances along the longitudinal direction Ld between the first terminal electrode 31 and the third terminal electrode 33, and between the second terminal electrode 32 and the fourth terminal electrode 34.

[0085] like Figure 9 As shown, the inner surface 12a of one end of the first flange portion 12 in the height direction Td (the end of the first flange portion 12 that protrudes toward the bottom surface 11a of the core portion 11) is inclined in the length direction Ld toward the core portion 11 as it moves away from the bottom surface 11a in the height direction Td. The inner surface 13a of one end of the second flange portion 13 in the height direction Td (the end of the second flange portion 13 that protrudes toward the bottom surface 11a of the core portion 11) is inclined in the length direction Ld toward the core portion 11 as it moves away from the bottom surface 11a in the height direction Td.

[0086] In addition, such as Figure 9 As shown, the coil component 1 includes a plate-shaped component 50. The plate-shaped component 50 is cuboid in shape. The plate-shaped component 50 has a first surface 51 facing the core 10 in the height direction Td, and a second surface 52 facing the opposite side of the first surface 51. The plate-shaped component 50 is configured to connect the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13. In this embodiment, the plate-shaped component 50 is mounted on the first flange portion 12 to cover the entire surface of the top surface 12c of the first flange portion 12, and mounted on the second flange portion 13 to cover the entire surface of the top surface 13c of the second flange portion 13. The plate-shaped component 50 is made of a non-conductive material, specifically a non-magnetic body such as alumina, a magnetic body such as nickel (Ni)-zinc (Zn) ferrite, etc. For example, the plate-shaped component 50 is formed by firing a molded body formed by compressing a non-conductive material. Furthermore, the plate-shaped component 50 is not limited to being formed by firing a molded body made of compressed non-conductive material. For example, the plate-shaped component 50 can also be formed by thermosetting a resin containing magnetic powder such as metal powder or ferrite powder, a resin containing non-magnetic powder such as silica powder, or a resin without fillers.

[0087] The second surface 52 of the cuboid plate-shaped member 50 serves as the adsorption surface for moving the coil member 1. Therefore, for example, when the coil member 1 is mounted on a circuit board, it is easy to move the coil member 1 on the circuit board using an adsorption conveying device. Like the core 10, the plate-shaped member 50 can also be made of a magnetic material. When the plate-shaped member 50 is made of a magnetic material, the core 10 can cooperate with the plate-shaped member 50 to form a closed magnetic circuit, thus improving the efficiency of inductance value acquisition.

[0088] like Figure 1 as well as Figure 3As shown, the length L50 of the plate-shaped component 50 is approximately 3.2 mm, the width W50 is approximately 2.5 mm, and the height T50 is approximately 0.7 mm. Preferably, the height T50 of the plate-shaped component 50 is between 0.7 mm and 1.3 mm. Making it greater than 0.7 mm ensures a good inductance value, while making it less than 1.3 mm allows for a lower height. Preferably, the length L50 and width W50 of the plate-shaped component 50 are approximately 0.1 mm larger than the length L10 and width W10 of the core 10. This ensures a larger contact area (magnetic circuit) overlapping with the first flange 12 and the second flange 13, suppressing a decrease in inductance value, relative to the potential offset in the length direction Ld and width direction Wd that can easily occur during the bonding of the plate-shaped component 50 to the core 10.

[0089] Plate-shaped component 50 is bonded to adhesive AH (see reference). Figure 12 It is installed in the core 10. An epoxy resin-based adhesive is used as the adhesive AH. It is preferable to add an inorganic filler to the adhesive AH. This reduces the coefficient of linear expansion of the adhesive AH, thus improving its thermal shock resistance. In this embodiment, a silica filler is added as the inorganic filler.

[0090] The plate-shaped component 50 is preferably cleaned chemically, thereby improving the wettability of the adhesive AH and the fixing force between the plate-shaped component 50 and the core 10. Preferably, the flatness of the first surface 51 of the plate-shaped component 50 is less than 5 μm, thereby reducing the gap generated between the contact portions with the first flange portion 12 and the second flange portion 13 and suppressing the decrease in inductance.

[0091] like Figure 3 , Figure 4 as well as Figure 9 As shown, the distance between the top surface 11b of the core portion 11 and the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 in the height direction Td is smaller than the distance between the bottom surface 11a of the core portion 11 and the feet 14a (14b) of the first flange portion 12 and the feet 18a (18b) of the second flange portion 13 in the height direction Td. Therefore, the distance between the top surface 11b of the core portion 11 and the first surface 51 of the plate-shaped member 50 can be shortened. Therefore, even if the length dimension of the plate-shaped member 50 in the height direction Td is extended, it is possible to suppress the coil member 1 from having a large height direction Td. In other words, regarding these distance relationships, the distance between the bottom surface 11a of the core portion 11 and the feet 14a (14b) of the first flange portion 12 and the feet 18a (18b) of the second flange portion 13 in the height direction Td is greater than the distance between the top surface 11b of the core portion 11 and the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 in the height direction Td. Therefore, when the coil component 1 is mounted on the circuit board PX (refer to...), Figure 8 In the case of ), the distance between the winding portion 40a and the circuit board PX in the height direction Td increases.

[0092] The distance D1 between the plate-shaped member 50 in the height direction Td and the first flange portion 12 differs in the length direction Ld. In this embodiment, for distance D1, in the first flange portion 12, the distance towards the core portion 11 relative to the center of the length direction Ld is greater than the distance towards the opposite side of the core portion 11 relative to the center of the length direction Ld. In other words, for distance D1, in the first flange portion 12, the distance towards the opposite side of the core portion 11 relative to the center of the length direction Ld is smaller than the distance towards the core portion 11 relative to the center of the length direction Ld.

[0093] Specifically, such as Figure 12 As shown in (a), the first flange portion 12 and the plate-shaped member 50 are configured such that the distance D1 increases from the outer surface 12b of the first flange portion 12 toward the inner surface 12a. In other words, in the first flange portion 12, the distance D1 increases with the direction toward the core portion 11 (see reference 12a). Figure 6 The size decreases on the opposite side (etc.). In this embodiment, the top surface 12c of the first flange portion 12 is inclined such that it moves away from the plate-shaped member 50 from the outer surface 12b of the first flange portion 12 toward the inner surface 12a. On the other hand, the first surface 51 of the plate-shaped member 50 opposite to the core 10 is formed as a plane orthogonal to the height direction Td. Furthermore, the distance D1 is defined as the distance between the top surface 12c of the first flange portion 12 and the plate-shaped member 50 opposite to the top surface 12c in the height direction Td in a cross-section obtained by cutting at the center of the width direction Wd of the core portion 11 with a plane perpendicular to the width direction Wd. In this embodiment, the distance D1 is 0 μm to 3 μm on the outer surface 12b side of the first flange portion 12, and 3 μm to 15 μm on the inner surface 12a side of the first flange portion 12.

[0094] The first surface 51 of the plate-shaped member 50 contacts the end of the first flange portion 12 on the side of the outer surface 12b of the first flange portion 12 in the length direction Ld, but does not contact the end of the first flange portion 12 on the side of the inner surface 12a of the first flange portion 12 in the length direction Ld compared to that end. That is, a gap GA is formed between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12. The size of the gap GA in the height direction Td increases from the outer surface 12b of the first flange portion 12 toward the inner surface 12a. In other words, the size of the gap GA in the height direction Td decreases from the inner surface 12a of the first flange portion 12 toward the outer surface 12b. The adhesive AH that bonds the plate-shaped member 50 to the core 10 enters the gap GA. In addition, the adhesive AH enters the two recesses 17a, 17b of the first flange portion 12 (see reference). Figure 6 ).

[0095] The distance D2 between the plate-shaped member 50 and the second flange portion 13 in the height direction Td is different in the length direction Ld. In this embodiment, for distance D2, in the second flange portion 13, the distance to the core portion 11 side relative to the center of the length direction Ld is greater than the distance to the opposite side of the core portion 11 relative to the center of the length direction Ld. In other words, for distance D2, in the second flange portion 13, the distance to the opposite side of the core portion 11 relative to the center of the length direction Ld is smaller than the distance to the core portion 11 side relative to the center of the length direction Ld.

[0096] Specifically, such as Figure 12 As shown in (b), the second flange portion 13 and the plate-shaped member 50 are configured such that the distance D2 increases from the outer surface 13b of the second flange portion 13 toward the inner surface 13a. In other words, the distance D2 in the second flange portion 13 increases towards the core portion 11 (see reference 13a). Figure 6 (etc.) The size decreases on the opposite side. In this embodiment, the top surface 13c of the second flange portion 13 is inclined such that it moves away from the first surface 51 of the plate-shaped member 50 from the outer surface 13b of the second flange portion 13 toward the inner surface 13a. Furthermore, distance D2 is defined as the distance between the top surface 13c of the second flange portion 13 and the plate-shaped member 50 in the height direction Td opposite to the top surface 13c in the height direction Td, obtained by cutting the core portion 11 at the center in the width direction Wd with a plane perpendicular to the width direction Wd. In this embodiment, distance D2 is the same as distance D1, with the portion on the outer surface 13b side of the second flange portion 13 being 0 μm to 3 μm, and the portion on the inner surface 13a side of the second flange portion 13 being 3 μm to 15 μm.

[0097] The first surface 51 of the plate-shaped member 50 contacts the end of the second flange portion 13 on the side of the outer surface 13b of the second flange portion 13 in the length direction Ld, but does not contact the portion of the second flange portion 13 on the side of the inner surface 13a of the second flange portion 13 in the length direction Ld compared to that end. That is, a gap GB is formed between the plate-shaped member 50 and the top surface 13c of the second flange portion 13. The size of the gap GB in the height direction Td increases from the outer surface 13b of the second flange portion 13 toward the inner surface 13a. In other words, the size of the gap GB in the height direction Td decreases from the inner surface 13a of the second flange portion 13 toward the outer surface 13b. The adhesive AH that bonds the plate-shaped member 50 to the core 10 enters the gap GB. In addition, the adhesive AH enters the two recesses 21a and 21b of the second flange portion 13 respectively (see reference). Figure 6 ).

[0098] like Figures 1-4 As shown, the coil 40 includes a first wire 41 and a second wire 42 wound around the core portion 11. The first wire 41 has a first end 41a and a second end 41b. In this embodiment, the first end 41a of the first wire 41 constitutes the end of the first wire 41 at the beginning of winding, and the second end 41b of the first wire 41 constitutes the end of the first wire 41 at the end of winding. The second wire 42 has a first end 42a and a second end 42b. In this embodiment, the first end 42a of the second wire 42 constitutes the end of the second wire 42 at the beginning of winding, and the second end 42b of the second wire 42 constitutes the end of the second wire 42 at the end of winding.

[0099] The first end 41a of the first wire 41 is connected to the first terminal electrode 31, and the second end 41b of the first wire 41 is connected to the third terminal electrode 33. The first end 42a of the second wire 42 is connected to the second terminal electrode 32, and the second end 42b of the second wire 42 is connected to the fourth terminal electrode 34. More specifically, the first end 41a of the first wire 41 is connected to the portion of the first bottom electrode 31a of the first terminal electrode 31 corresponding to the protrusion 15a, and the first end 42a of the second wire 42 is connected to the portion of the second bottom electrode 32a of the second terminal electrode 32 corresponding to the protrusion 15b. Therefore, the protrusions 15a and 15b constitute a first connecting portion connecting the first end 41a of the first wire 41 and the first end 42a of the second wire 42. Furthermore, the feet 14a and 14b mounted on the circuit board PX constitute a second connecting portion of the wiring pattern (pad portion RX) mounted on the circuit board PX when mounted on the circuit board PX. The second end 41b of the first wire 41 is connected to the portion of the third bottom electrode 33a of the third terminal electrode 33 corresponding to the protrusion 19a, and the second end 42b of the second wire 42 is connected to the portion of the fourth bottom electrode 34a of the fourth terminal electrode 34 corresponding to the protrusion 19b. Therefore, the protrusions 19a and 19b constitute a third connecting portion connecting the second end 41b of the first wire 41 and the second end 42b of the second wire 42. Furthermore, the feet 18a and 18b mounted on the circuit board PX constitute a fourth connecting portion for the wiring pattern (pad portion RX) mounted on the circuit board PX when mounted on the circuit board PX.

[0100] Preferably, the relationship between the protrusions 15a and 15b and the feet 14a and 14b in the height direction Td is set such that the first end 41a of the first line 41 connecting to the protrusion 15a of the first flange portion 12 and the first end 42a of the second line 42 connecting to the protrusion 15b do not protrude more than the feet 14a and 14b of the first flange portion 12 in the height direction Td. Furthermore, it is preferable that the relationship between the protrusions 19a and 19b and the feet 18a and 18b in the height direction Td is set such that the first end 42a of the first line 41 connecting to the protrusion 19a of the second flange portion 13 and the second end 42b of the second line 42 connecting to the protrusion 19b do not protrude more than the feet 18a and 18b of the second flange portion 13 in the height direction Td.

[0101] The first wire 41 and the second wire 42 are connected to the terminal electrodes 31 to 34, for example, by thermoforming, brazing, or welding. When the coil component 1 is mounted on the circuit board, the first terminal electrode 31, the second terminal electrode 32, the third terminal electrode 33, and the fourth terminal electrode 34 are opposite to the circuit board. At this time, the core portion 11 is parallel to the main surface of the circuit board PX. That is, the coil 40 in this embodiment is a common-mode choke coil with a horizontal winding structure (horizontal type) where the winding axes of the first wire 41 and the second wire 42 are parallel to the main surface of the circuit board PX.

[0102] The first wire 41 and the second wire 42 are respectively composed of conductor wires that are good conductors such as copper (Cu), silver (Ag), and gold (Au), and insulating films such as polyurethane, polyamide-imide, and fluorinated resins covering the conductor wires. The diameter of the conductor wire is preferably, for example, about 15 to 100 μm. The thickness of the insulating film is preferably, for example, about 8 to 20 μm. In this embodiment, the diameter of the conductor wire is 30 μm, and the thickness of the insulating film is 10 μm.

[0103] The first wire 41 and the second wire 42 are wound in the same direction on the core portion 11. Therefore, when a differential signal or other inverse signal is input to the first wire 41 and the second wire 42 from the same flange portion of the first flange portion 12 and the second flange portion 13, the magnetic flux generated by the first wire 41 and the second wire 42 cancels each other out, weakening the inductor effect and allowing the inverse signal to pass. On the other hand, when an in-phase signal, such as external noise, is input to the first wire 41 and the second wire 42 from the same flange portion of the first flange portion 12 and the second flange portion 13, the magnetic flux generated by the first wire 41 and the second wire 42 reinforces each other, strengthening the inductor effect and blocking the in-phase signal. Therefore, the coil component 1 functions as a common-mode choke coil that reduces the transmission loss of differential signals such as differential signals and attenuates common-mode signals such as external noise.

[0104] The coil 40 has a winding portion 40a wound around the core portion 11, and first lead-out portions 40b, second lead-out portions 40c, third lead-out portions 40d, and fourth lead-out portions 40e on both sides of the winding portion 40a. Each lead-out portion 40b, 40c, 40d, and 40e includes the vicinity of the end of the first wire 41 and the second wire 42 that is connected to the respective terminal electrodes 31 to 34. The first lead-out portion 40b connects the first end 41a of the first wire 41 that is connected to the first terminal electrode 31 to the winding portion 40a. The second lead-out portion 40c connects the second end 41b of the first wire 41 that is connected to the third terminal electrode 33 to the winding portion 40a. The third lead-out portion 40d connects the first end 42a of the second wire 42 that is connected to the second terminal electrode 32 to the winding portion 40a. The fourth lead-out portion 40e connects the second end 42b of the second wire 42 that is connected to the fourth terminal electrode 34 to the winding portion 40a.

[0105] like Figure 9 As shown, in the winding section 40a, the length LA of the portion of the core portion 11 on the bottom surface 11a side in the longitudinal direction is shorter than the length LB of the portion of the core portion 11 on the top surface 11b side in the longitudinal direction. Furthermore, as described above, the distance LX1 between the first curved surface 22 and the second curved surface 23 in the longitudinal direction is greater than the distance LX2 between the third curved surface 24 and the fourth curved surface 25 in the longitudinal direction. Therefore, the distance LD1 between the portion of the core portion 11 on the bottom surface 11a side and the inner surface 12a of the first flange portion 12 in the longitudinal direction in the longitudinal direction is greater than the distance LD3 between the portion of the core portion 11 on the top surface 11b side and the inner surface 12a of the first flange portion 12 in the longitudinal direction in the longitudinal direction. Furthermore, in the winding section 40a, the distance LD2 between the portion of the core portion 11 on the bottom surface 11a side and the inner surface 13a of the second flange portion 13 in the longitudinal direction Ld is greater than the distance LD4 between the portion of the core portion 11 on the top surface 11b side and the inner surface 13a of the second flange portion 13 in the longitudinal direction Ld. In this embodiment, distance LD2 is greater than distance LD1. Additionally, distances LD1 and LD2 are greater than distances LD3 and LD4. That is, distance LD1 is greater than at least one of distances LD3 and LD4, and distance LD2 is greater than at least one of distances LD3 and LD4.

[0106] In this embodiment, the distance LD2 is greater than the distance LD1. That is, in the length direction Ld, the space for winding the first lead-out portion 40b and the third lead-out portion 40d is smaller than the space for winding the second lead-out portion 40c and the fourth lead-out portion 40e. With this configuration, interference between the first lead-out portion 41 and the second lead-out portion 42 and the inner surface 13a of the second flange portion 13 can be suppressed when the core portion 11 is connected to the third terminal electrode 33 and the fourth terminal electrode 34 after winding the first lead-out portion 41 and the second lead-out portion 42. Therefore, the first lead-out portion 41 and the second lead-out portion 42 can be smoothly connected to the third terminal electrode 33 and the fourth terminal electrode 34.

[0107] Furthermore, the relationship between distances LD1 and LD2 can be arbitrarily changed. In one example, distance LD1 can be larger than distance LD2. That is, the space used for winding the second lead 40c and the fourth lead 40e can be smaller than the space used for winding the first lead 40b and the third lead 40d. According to this configuration, excessive bending of the second lead 40c and the fourth lead 40e can be suppressed during the period when the first wire 41 connected to the first terminal electrode 31 and the second wire 42 connected to the second terminal electrode 32 are wound in the core portion 11. Therefore, stress concentration in the second lead 40c and the fourth lead 40e can be mitigated, and concerns about wire breakage in the second lead 40c and the fourth lead 40e can be reduced.

[0108] like Figure 2 As shown, the winding portion 40a has a first winding portion 43, a first cross portion (crossing portion) 44, and a second cross portion (crossing portion) 45 (see reference). Figure 4 The first winding portion 43 winds the first wire 41 and the second wire 42 side by side in the same direction on the core portion 11 a predetermined number of turns. N first winding portions 43 are arranged in the length direction Ld (N is an even number greater than 2). The first crossing portion 44 is configured such that the first wire 41 and the second wire 42 cross at the top surface 11b of the core portion 11. The first crossing portions 44 are formed between adjacent first winding portions 43 in the length direction Ld. That is, the winding portion 40a is configured to alternately form the first winding portion 43 and the first crossing portion 44 in the length direction Ld. In this embodiment, the number of first crossing portions 44 is one less than the number of first winding portions 43. The second crossing portion 45 is formed in the winding portion 40a at the position closest to the second flange portion 13. The second crossing portion 45 is configured such that the first wire 41 and the second wire 42 cross on the first side surface 11c of the core portion 11. Specifically, in the second crossing portion 45, during the process of passing from the bottom surface 11a to the top surface 11b of the core portion 11 through the first side surface 11c, the first thread 41 and the second thread 42 cross in a state where the first thread 41 and the second thread 42 separate from the first side surface 11c in the width direction Wd. There is one second crossing portion 45. That is, the number of first winding portions 43 is equal to the total number of first crossing portions 44 and second crossing portions 45.

[0109] like Figure 1As shown, a first lead-out portion 40b extending in the height direction Td toward the bottom surface 11a of the core portion 11 extends from the second side surface 11d of the core portion 11 toward the protrusion 15a of the first flange portion 12 in the width direction Wd toward the first side surface 12e of the first flange portion 11, away from the core portion 11. Then, the first lead-out portion 40b extends into a first line 41 that bends and is parallel to the length direction Ld, thereby being placed in the protrusion 15a. The portion of the first line 41 placed in the protrusion 15a and extending parallel to the length direction Ld constitutes the first end portion 41a of the first line 41. The first end portion 41a of the first line 41 is connected to the portion of the first bottom surface electrode 31a of the first terminal electrode 31 that corresponds to the protrusion 15a, spaced apart from the foot portion 14a in the width direction Wd. In this embodiment, the first end portion 41a of the first line 41 is disposed on the first side surface 12e of the first flange portion 12 in the width direction Wd compared to the second side surface 11d of the core portion 11.

[0110] The third lead-out portion 40d, extending from the bottom surface 11a side of the core portion 11 in the height direction Td, extends obliquely from the core portion 11 towards the first flange portion 12, and is placed on the slope portion 16 of the first flange portion 12. The first end portion 42a of the second wire 42 extends parallel to the length direction Ld and connects to the portion of the second bottom surface electrode 32a of the second terminal electrode 32 that corresponds to the protrusion 15b, spaced apart from the foot portion 14b in the width direction Wd. A first bend portion 42c is formed at the end of the second wire 42 on the side of the first end portion 42a in the third lead-out portion 40d. The first bend portion 42c is formed to be convex in the length direction Ld towards the inner surface 12a side of the first flange portion 12. In this embodiment, a second curved portion 42d is formed in the portion of the third lead-out portion 40d opposite to the first end 42a of the second line 42, which is opposite to the first curved portion 42c in the length direction Ld. Thus, the end of the second curved portion 42d in the portion of the third lead-out portion 40d placed in the ramp portion 16 is located on the outer surface 12b side compared to the inner surface 12a of the first flange portion 12.

[0111] In this embodiment, the first end portion 42a of the second thread 42 is disposed on the second side surface 12f side of the first flange portion 12 in the width direction Wd compared to the first side surface 11c of the core portion 11. When viewed from the first flange portion 12 side in the length direction Ld, the first end portion 42a of the second thread 42 is disposed on the second side surface 12f side of the first flange portion 12 (the second side surface 13f side of the second flange portion 13) in the width direction Wd compared to the second end portion 42b of the second thread 42.

[0112] like Figure 2 As shown, the first winding portion 43 formed at the end of the winding portion 40a on the side of the second flange portion 13 is arranged in the length direction Ld from the first flange portion 12 toward the second flange portion 13 in the order of the first line 41 and the second line 42. Furthermore, as... Figure 4 As shown, the first line 41 and the second line 42 intersect on the first side surface 11c of the core portion 11 to form a second intersection portion 45 in the winding portion 40a, which is formed at the end on the side of the second flange portion 13. Therefore, in the length direction Ld, it extends from the first flange portion 12 toward the second flange portion 13 in the order of the second line 42 and the first line 41, and in the height direction Td, it extends toward the bottom surface 11a side of the core portion 11. Thus, at the end on the side of the second flange portion 13 in the winding portion 40a, the second intersection portion 45 is formed as part of the first winding portion 43.

[0113] On the other hand, such as Figure 3 As shown, the first lead-out portion 40b is configured such that it does not intersect the second line 42 on the second side surface 11d of the core portion 11. Specifically, as... Figure 2 As shown, the end portion on the first flange portion 12 side of the winding portion 40a is arranged in the length direction Ld from the second flange portion 13 toward the first flange portion 12 in the order of the first line 41 and the second line 42. In this way, only the first winding portion 43 is formed at the end portion on the first flange portion 12 side of the winding portion 40a.

[0114] like Figure 1 As shown, a fourth lead-out portion 40e, extending in the height direction Td toward the bottom surface 11a side of the core portion 11, extends from the first side surface 11c of the core portion 11 toward the protrusion 19b of the second flange portion 13 in the width direction Wd toward the second side surface 13f of the second flange portion 13, away from the core portion 11. Furthermore, a second wire 42 bends and extends parallel to the length direction Ld to be placed in the protrusion 19b. The portion extending to be placed in the protrusion 19b and parallel to the length direction Ld constitutes the second end portion 42b of the second wire 42. The second end portion 42b of the second wire 42 is connected to the fourth terminal electrode 34. In this embodiment, the second end portion 42b of the second wire 42 is disposed on the second side surface 13f side of the second flange portion 13 compared to the first side surface 11c of the core portion 11 in the width direction Wd.

[0115] The second lead-out portion 40c, extending from the bottom surface 11a of the core portion 11 in the height direction Td, extends obliquely from the core portion 11 towards the second flange portion 13 from the first side surface 11c side towards the second side surface 11d side, and is placed on the slope portion 20 of the second flange portion 13. The second end portion 41b of the first wire 41 is connected to the third terminal electrode 33. In this way, there is no bending position from the second lead-out portion 40c to the second end portion 41b of the first wire 41, so stress is not concentrated on the second lead-out portion 40c and the second end portion 41b. Therefore, the distance between the winding portion 40a and the inner surface 13a of the second flange portion 13 in the length direction Ld can be shortened, and the number of turns of the winding portion 40a can be increased.

[0116] (Manufacturing method of coil components)

[0117] Reference Figures 13-17 The manufacturing method of coil component 1 will be described.

[0118] like Figure 13 As shown, the manufacturing method of coil component 1 includes a core preparation process (step S10), an electrode forming process (step S20), a first connection process (step S30), a coil forming process (step S40), a second connection process (step S50), a wire cutting process (step S60), and a plate component mounting process (step S70).

[0119] In the core preparation process, a core without the first to fourth terminal electrodes 31 to 34 is prepared. This core is formed by firing a molded body of non-conductive material compressed through a metal mold. In this embodiment, when forming the core through the metal mold, a first curved surface 22, a second curved surface 23, a third curved surface 24, and a fourth curved surface 25, as well as recesses 17a, 17b, and 21a, 21b, are formed respectively. That is, the shapes of the first curved surface 22, the second curved surface 23, the third curved surface 24, and the fourth curved surface 25 are adjusted by the shape of the metal mold. Furthermore, the shapes of the recesses 17a, 17b, and 21a, 21b can be determined according to the shape of the metal mold.

[0120] The electrode forming process includes a face electrode forming process (step S21) and a bottom electrode forming process (step S22). In this embodiment, the bottom electrode forming process is performed after the face electrode forming process.

[0121] In the end-face electrode formation process, such as Figure 14As shown in (a), firstly, the core 10 is positioned such that the outer surface 13b of the second flange portion 13 of the core 10 abuts against the reference surface 101 of the coating apparatus 100. In this case, the dispenser 102 of the coating apparatus 100 is positioned opposite the outer surface 12b of the first flange portion 12 of the core 10. Then, a liquid paste (in this embodiment, a silver (Ag) paste) is applied to the outer surface 12b of the first flange portion 12 of the core 10 via the dispenser 102, serving as the base electrode of the first end face electrode 31b of the first terminal electrode 31 and the second end face electrode 32b of the second terminal electrode 32. In this embodiment, as... Figure 14 As shown in (b), the coating apparatus 100 coats the regions where the first end face electrode 31b of the first terminal electrode 31 and the second end face electrode 32b of the second terminal electrode 32 are formed, with three rows of coated portions 35 in the height direction Td and two rows in the width direction Wd. The coated portions 35 are formed as spherical surfaces with the thickest thickness at the center of the coated portions 35 in both the height direction Td and the width direction Wd relative to the outer surface 12b of the first flange portion 12. In this embodiment, portions of the coated portions 35 adjacent in the height direction Td and portions of the coated portions 35 adjacent in the width direction Wd overlap. Thus, a plurality of coated portions 35 (six in this embodiment) are integrally formed as the base electrodes of each end face electrode 31b, 32b. Therefore, the base electrodes of each end face electrode 31b, 32b are formed in an uneven shape. Furthermore, the number of coated portions 35 can be arbitrarily changed. The number of coated portions 35 can be appropriately changed according to the size of the coated portion 35 formed by the coating apparatus 100 through one coating on the outer surface 12b of the first flange portion 12 and the size of each end electrode 31b, 32b.

[0122] In addition, the base electrode of the third end face electrode 33b of the third terminal electrode 33 and the base electrode of the fourth end face electrode 34b of the fourth terminal electrode 34 are also formed by the coating apparatus 100 in the same manner as the base electrode of the first end face electrode 31b of the first terminal electrode 31 and the base electrode of the second end face electrode 32b of the second terminal electrode 32.

[0123] In the bottom electrode forming process, such as Figure 15 As shown in (a) and (b), the base electrodes of the bottom surface electrodes 31a to 34a of each terminal electrode 31 to 34 are formed on the feet 14a and 14b and bottom surface 12d of the first flange portion 12 and the feet 18a and 18b and bottom surface 13d of the second flange portion 13 of the core body 10 by the dip coating apparatus 110. In this embodiment, as Figure 15As shown in (a), the holding device 111 holds the core 10 such that the bottom surface 12d of the first flange portion 12 and the bottom surface 13d of the second flange portion 13 of the core 10 are opposite to the paint tank 112. Silver (Ag) glass paste is contained in the paint tank 112. Figure 15 As shown in (b), the holding device 111 inserts the core 10 into the coating tank 112 so that the feet 14a, 14b and protrusions 15a, 15b of the first flange portion 12 of the core 10 and the feet 18a, 18b and protrusions 19a, 19b of the second flange portion 13 are immersed in Ag glass paste. Thereafter, by firing the Ag glass paste, the base electrodes of the bottom surface electrodes 31a to 34a of each terminal electrode 31 to 34 are formed. Here, in the end face electrode forming process, the base electrode of each end face electrode 31b to 34b of each terminal electrode 31 to 34 is formed in advance, and a part of the base electrode of the first bottom electrode 31a overlaps with the base electrode of the first end face electrode 31b, a part of the base electrode of the second bottom electrode 32a overlaps with the base electrode of the second end face electrode 32b, a part of the base electrode of the third bottom electrode 33a overlaps with the base electrode of the third end face electrode 33b, and a part of the base electrode of the fourth bottom electrode 34a overlaps with the base electrode of the fourth end face electrode 34b.

[0124] The overlapping structure of the base electrode of the first bottom electrode 31a and the base electrode of the first end electrode 31b is as follows: Figure 8 As shown. In detail, during the bottom electrode forming process, the first bottom electrode 31a is formed. Figure 7 The portions of the second region RA2 and the first region RA1 shown in (a) that overlap with the first end face electrode 31b. The second bottom electrode 32a forms the portions of the second region RB2 and the first region RB1 that overlap with the second end face electrode 32b. The third bottom electrode 33a forms the portions of the second region RC2 and the first region RC1 that overlap with the third end face electrode 33b. The fourth bottom electrode 34a forms the portions of the second region RD2 and the first region RD1 that overlap with the fourth end face electrode 34b. The height dimensions of the portions of the first region RA1 that overlap with the first end face electrode 31b, the portions of the first region RB1 that overlap with the second end face electrode 32b, the portions of the first region RC1 that overlap with the third end face electrode 33b, and the portions of the first region RD1 that overlap with the fourth end face electrode 34b are respectively set according to the depth to which the core 10 is inserted into the paint tank 112.

[0125] Furthermore, the overlapping structures of the base electrode of the second bottom electrode 32a and the base electrode of the second end electrode 32b, the overlapping structures of the base electrode of the third bottom electrode 33a and the base electrode of the third end electrode 33b, and the overlapping structures of the base electrode of the fourth bottom electrode 34a and the base electrode of the fourth end electrode 34b are the same as the overlapping structures of the base electrode of the first bottom electrode 31a and the base electrode of the first end electrode 31b.

[0126] After the base electrodes of the bottom surface electrodes 31a-34a and the end surface electrodes 31b-34b of each terminal electrode 31-34 are formed, an electroplated layer is formed, for example, by electrolytic barrel plating, as a layer stacked on the base electrodes of the bottom surface electrodes 31a-34a and the end surface electrodes 31b-34b. The electroplated layer is formed in the order of nickel (Ni) layer and tin (Sn) layer.

[0127] The first connection process involves connecting the first wire 41 to the first bottom electrode 31a of the first terminal electrode 31, and connecting the second wire 42 to the second bottom electrode 32a of the second terminal electrode 32. Specifically, firstly, the core 10 is placed on the winding machine 120. Then, as... Figure 16 As shown, the first nozzle 121 of the winding machine 120 supplies a first wire 41 and places it on the first bottom electrode 31a of the first terminal electrode 31 formed on the protrusion 15a of the first flange portion 12. Then, a pressure welding device (not shown) is used to pressure weld the first wire 41 to the first bottom electrode 31a of the first terminal electrode 31. Simultaneously, the second nozzle 122 supplies a second wire 42 and places it on the second bottom electrode 32a of the second terminal electrode 32 formed on the protrusion 15b. Then, a pressure welding device is used to pressure weld the second wire 42 to the second bottom electrode 32a of the second terminal electrode 32.

[0128] Then, during the coil forming process, the second nozzle 122 moves toward the second side 11d side of the core portion 11 of the core 10. At this time, the second wire 42 connected to the second terminal electrode 32 is bent by the first hook member 123 provided on the winding machine 120 to form a first bend 42c. Then, the second wire 42 is bent by the second hook member 124 provided on the winding machine 120 to form a second bend 42d. Then, the second wire 42 extending from the second bend 42d toward the second side 11d side of the core portion 11 is placed on the slope portion 16 of the core 10.

[0129] In the coil forming process, the first nozzle 121 and the second nozzle 122 revolve around the core portion 11, thereby winding the first wire 41 and the second wire 42 around the core portion 11. At this time, the first nozzle 121 and the second nozzle 122 operate to cross the first wire 41 and the second wire 42 once every predetermined number of turns.

[0130] In the coil forming process, the first nozzle 121 and the second nozzle 122 finish winding the first wire 41 and the second wire 42 onto the first side 11c of the core portion 11. At this time, the first nozzle 121 and the second nozzle 122 operate to cross the first wire 41 and the second wire 42 on the first side 11c of the core portion 11.

[0131] The second connection process involves connecting the first wire 41 to the third terminal electrode 33 and the second wire 42 to the fourth terminal electrode 34. Specifically, as follows... Figure 17 As shown, the first nozzle 121 of the winding machine 120 operates to place the first wire 41 onto the third bottom electrode 33a of the third terminal electrode 33 formed on the protrusion 19a of the second flange portion 13. At this time, the first nozzle 121 moves to place the first wire 41 from the first side 11c of the core portion 11 onto the ramp portion 20 of the second flange portion 13. The second nozzle 122 of the winding machine 120 operates to place the second wire 42 onto the fourth bottom electrode 34a of the fourth terminal electrode 34 formed on the protrusion 19b of the second flange portion 13. Then, the first wire 41 is pressure-welded to the third bottom electrode 33a of the third terminal electrode 33 by a pressure welding device, and the second wire 42 is pressure-welded to the fourth bottom electrode 34a of the fourth terminal electrode 34.

[0132] In the online cutting process, a cutting device (not shown) cuts the portion of the first wire 41 that connects to the first bottom electrode 31a of the first terminal electrode 31 and extends towards the side opposite to the core portion 11 compared to the first flange portion 12. Thus, the portion of the first wire 41 connected to the first terminal electrode 31 constitutes the first end 41a of the first wire 41. Furthermore, the cutting device also cuts the portion of the first wire 41 that connects to the third bottom electrode 33a of the third terminal electrode 33 and extends towards the outside of the first side surface 13e of the second flange portion 13 via the first nozzle 121. Thus, the portion of the first wire 41 connected to the third bottom electrode 33a of the third terminal electrode 33 constitutes the second end 41b of the first wire 41.

[0133] In the online cutting process, the portion of the second wire 42 connected to the second bottom electrode 32a of the second terminal electrode 32 is cut by a cutting device, extending towards the side opposite to the core portion 11 compared to the first flange portion 12. Thus, the portion of the second wire 42 connected to the second bottom electrode 32a of the second terminal electrode 32 constitutes the first end 42a of the second wire 42. Furthermore, the portion of the second wire 42 connected to the fourth bottom electrode 34a of the fourth terminal electrode 34 via the second nozzle 122 is cut by the cutting device, extending towards the side opposite to the core portion 11 compared to the second flange portion 13. Thus, the portion of the second wire 42 connected to the fourth bottom electrode 34a of the fourth terminal electrode 34 constitutes the second end 42b of the second wire 42.

[0134] In the plate-shaped component mounting process, the plate-shaped component 50 is mounted to the core 10 using an adhesive. In this embodiment, adhesive AH is applied to the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 of the core 10, respectively. The adhesive AH is an epoxy resin-based adhesive with added silica filler. The adhesive AH can be applied using known methods. At this time, the adhesive AH is applied to the entire surface of the top surface 12c of the first flange portion 12. Next, the plate-shaped component 50 is pressed towards the core 10 with the first surface 51 of the plate-shaped component 50 facing the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13. At this time, in the first flange portion 12, excess adhesive AH between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 enters the recesses 17a and 17b of the first flange portion 12, so the end of the first flange portion 12 on the outer surface 12b side contacts the first surface 51 of the plate-shaped member 50. Furthermore, because excess adhesive AH enters the recesses 17a and 17b, the adhesive AH is not easily removed from... Figure 12 The slit GA protrudes as shown in (a). Similarly, in the second flange portion 13, excess adhesive AH between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 enters the recesses 21a and 21b of the second flange portion 13, so the end on the outer surface 13b side of the second flange portion 13 contacts the first surface 51 of the plate-shaped member 50. In addition, because excess adhesive AH enters the recesses 21a and 21b, adhesive AH is not easily removed from the recesses. Figure 12 The gap GB shown in (b) protrudes. Through the above processes, coil component 1 is manufactured.

[0135] According to this embodiment, the following effects can be obtained.

[0136] (1) A first curved surface 22 is formed at the connection between the bottom surface 11a of the core portion 11 of the core body 10 and the inner surface 12a of the first flange portion 12. The ratio of the first curved surface 22 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the first terminal electrode 31 in the height direction Td is 20% or more and 60% or less. According to this configuration, by making the ratio of the first curved surface 22 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the first terminal electrode 31 in the height direction Td 20% or more, the first curved surface 22 can be obtained in a larger manner, and the bending strength between the core portion 11 and the first flange portion 12 can be improved. Therefore, the flexural strength of the core body 10 can be improved. Furthermore, by ensuring that the size of the first curved portion 22 in the height direction Td is less than 60% of the ratio of the size of the bottom surface 11a of the core portion 11 in the height direction Td to the distance between the first terminal electrode 31 and the first terminal electrode 31, it is possible to suppress the excessively small thickness of the first flange portion 12 in the length direction Ld. Therefore, it is possible to suppress the excessively small size of the first bottom surface electrode 31a of the first terminal electrode 31 and the second bottom surface electrode 32a of the second terminal electrode 32 in the length direction Ld, allowing for proper mounting of the coil component 1 onto the circuit board PX.

[0137] Furthermore, a second curved surface 23 is formed at the connection between the bottom surface 11a of the core portion 11 and the inner surface 13a of the second flange portion 13. The ratio of the second curved surface 23 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the third terminal electrode 33 in the height direction Td is 20% or more and 60% or less. According to this configuration, by making the ratio of the second curved surface 23 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the third terminal electrode 33 in the height direction Td 20% or more, a larger second curved surface 23 can be obtained, which can further improve the bending strength between the core portion 11 and the second flange portion 13. Therefore, the flexural strength of the core 10 can be improved. In addition, by making the ratio of the size of the second curved surface 23 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the third terminal electrode 33 in the height direction Td 60% or less, the thickness of the second flange portion 13 in the length direction Ld can be suppressed from being too small. Therefore, it is possible to suppress the excessively small size of the third bottom electrode 33a of the third terminal electrode 33 and the fourth bottom electrode 34a of the fourth terminal electrode 34 in the length direction Ld, so that the coil component 1 can be mounted on the circuit board PX more appropriately.

[0138] (2) The first curved surface 22 is configured as a curve that is a perfect circle in a cross section perpendicular to the width direction Wd. According to this configuration, compared with the case where the first curved surface 22 is configured as an elliptical curve in a cross section perpendicular to the width direction Wd, the first curved surface 22 can be formed more easily.

[0139] Furthermore, the second curved surface 23 is configured as a curve that is circular in cross-section perpendicular to the width direction Wd. According to this configuration, compared to cases where the second curved surface 23 is configured as an elliptical curve in cross-section perpendicular to the width direction Wd, the second curved surface 23 can be formed more easily.

[0140] (3) A third curved surface 24 is formed at the connection between the top surface 11b of the core portion 11 of the core 10 and the inner surface 12a of the first flange portion 12. The size of the first curved surface 22 in the height direction Td is larger than the size of the third curved surface 24 in the height direction Td. According to this configuration, the bending strength of the core 10 on the side of the coil component 1 closest to the circuit board PX is improved, so the reliability of the connection between the coil component 1 and the circuit board PX can be improved.

[0141] Furthermore, a fourth curved surface 25 is formed at the connection between the top surface 11b of the core portion 11 and the inner surface 13a of the second flange portion 13. The size of the second curved surface 23 in the height direction Td is larger than the size of the fourth curved surface 25 in the height direction Td. According to this configuration, the bending strength of the core 10 on the side of the coil component 1 closest to the circuit board PX is improved, thus further improving the reliability of the connection between the coil component 1 and the circuit board PX.

[0142] (4) In a cross-section perpendicular to the width direction Wd, the size of the first curved portion 22 in the length direction Ld is larger than the size of the third curved portion 24 in the length direction Ld. With this configuration, the distance between the end of the first flange portion 12 on the length direction Ld of the portion of the winding portion 40a on the circuit board PX side in the height direction Td (the winding portion 40a corresponding to the bottom surface 11a) and the first terminal electrode 31 and the second terminal electrode 32 of the first flange portion 12 can be obtained more significantly. Therefore, when the first terminal electrode 31 and the second terminal electrode 32 heat up, their heat is less likely to affect the winding portion 40a, thus improving the quality of the coil component 1.

[0143] Furthermore, in a cross-section perpendicular to the width direction Wd, the size of the second curved portion 23 in the length direction Ld is larger than the size of the fourth curved portion 25 in the length direction Ld. With this configuration, the distance between the end of the second flange portion 13 on the length direction Ld of the portion of the circuit board PX side in the height direction Td of the winding portion 40a and the third terminal electrode 33 and the fourth terminal electrode 34 of the second flange portion 13 can be obtained more significantly. Therefore, when the third terminal electrode 33 and the fourth terminal electrode 34 generate heat, their heat is less likely to affect the winding portion 40a, thus improving the quality of the coil component 1.

[0144] (5) In a cross-section obtained by cutting the core portion 11 along the length direction Ld with a plane, the distance LX1 between the first curved portion 22 and the second curved portion 23 in the length direction Ld is greater than the distance LX2 between the third curved portion 24 and the fourth curved portion 25 in the length direction Ld. According to this configuration, when viewed from the height direction Td, the distance between the winding portion 40a of the bottom surface 11a of the core portion 11 in the length direction Ld and the inner surface 12a of the first flange portion 12 is greater than the distance between the winding portion 40a of the top surface 11b of the core portion 11 in the length direction Ld and the inner surface 12a of the first flange portion 12. As a result, a larger distance can be obtained between the first terminal electrode 31, the second terminal electrode 32 and the winding portion 40a, and the heat from the first terminal electrode 31 and the second terminal electrode 32 is less likely to affect the winding portion 40a when they are heated. Therefore, the quality of the coil component 1 is improved.

[0145] Furthermore, when viewed from the height direction Td, the distance between the winding portion 40a of the bottom surface 11a of the core portion 11 and the inner surface 13a of the second flange portion 13 in the length direction Ld is greater than the distance between the winding portion 40a of the top surface 11b of the core portion 11 and the inner surface 13a of the second flange portion 13 in the length direction Ld. Therefore, a larger distance can be obtained between each terminal electrode 31-34 and the winding portion 40a, and the heat from each terminal electrode 31-34 is less likely to affect the winding portion 40a when it heats up. Thus, the quality of the coil component 1 is improved.

[0146] (6) The coil component 1 includes a plate-shaped component 50 disposed opposite to the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 in the height direction Td. The distance between the first surface 51 of the plate-shaped component 50 and the top surface 12c of the first flange portion 12 in the height direction Td is different in the length direction Ld. According to this configuration, when the plate-shaped component 50 is a magnetic material, a position in the height direction Td where the distance between the first surface 51 of the plate-shaped component 50 and the top surface 12c of the first flange portion 12 in the height direction is smaller is partially formed between the plate-shaped component 50 and the first flange portion 12, thus defining the magnetic circuit between the core 10 and the plate-shaped component 50. Therefore, the deviation of the magnetic circuit length of each coil component 1 is small, so the deviation of the inductance value of each coil component 1 can be suppressed.

[0147] In the second flange portion 13, the distance between the first surface 51 of the plate-shaped member in the height direction Td and the top surface 13c of the second flange portion 13 is different in the length direction Ld. Therefore, in the second flange portion 13, similar to the first flange portion 12, the magnetic circuit between the core 10 and the plate-shaped member 50 is defined, and the deviation of the magnetic circuit length of each coil member 1 is small, so the deviation of the inductance value of each coil member 1 can be further suppressed.

[0148] In addition, when the plate-shaped component 50 is fixed to the first flange portion 12 and the second flange portion 13 by the adhesive AH, the adhesive AH at the position where the distance in the height direction Td between the first surface 51 of the plate-shaped component 50 and the top surface 12c of the first flange portion 12 is smaller moves to the position where the distance in the height direction Td between the first surface 51 of the plate-shaped component 50 and the top surface 12c of the first flange portion 12 is larger. Therefore, it is possible to suppress the adhesive AH from protruding outwards from the core 10 and the plate-shaped component 50.

[0149] Furthermore, in the second flange portion 13, the adhesive AH at the position where the distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 is smaller moves to the position where the distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 is larger, so that the adhesive AH can be further suppressed from protruding to the outside of the core 10 and the plate-shaped member 50.

[0150] (7) The position where the distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 is larger is located on the inner surface 12a side of the first flange portion 12. According to this configuration, the adhesive AH between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 moves towards the inner surface 12a side of the first flange portion 12 and is not easily moved towards the outer surface 12b side. Therefore, the adhesive AH is not easily protruded towards the outside of the core 10 and the plate-shaped member 50.

[0151] In the second flange portion 13, the position with a larger distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 is located on the inner surface 13a side of the second flange portion 13. Therefore, the adhesive AH between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 moves towards the inner surface 13a side of the second flange portion 13 and is less likely to move towards the outer surface 13b side, so the adhesive AH is less likely to protrude outward from the core 10 and the plate-shaped member 50.

[0152] (8) The distance D1 between the first surface 51 of the plate member 50 and the top surface 12c of the first flange portion 12 in the height direction Td decreases from the inner surface 12a side of the first flange portion 12 towards the outer surface 12b side. According to this configuration, the magnetic circuit between the core 10 and the plate member 50 is defined on the inner surface 12a of the first flange portion 12. Therefore, the deviation of the magnetic circuit length of each coil member 1 is small, so the deviation of the inductance value of each coil member 1 can be suppressed.

[0153] In addition, when the plate-shaped member 50 and the first flange portion 12 are fixed by adhesive AH, the portion of adhesive AH on the outer surface 12b side of the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 in the longitudinal direction Ld moves towards the inner surface 12a side of the longitudinal direction Ld. Therefore, it is possible to suppress the adhesive AH from protruding outwards from the core 10 and the plate-shaped member 50.

[0154] Similar to the first flange 12, in the second flange portion 13, the distance D2 in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 decreases from the inner surface 13a side of the second flange portion 13 towards the outer surface 13b side. Therefore, the deviation in the magnetic circuit length of each coil member 1 is small, thus suppressing the deviation in the inductance value of each coil member 1. In addition, since the portion of adhesive AH fixing the plate-shaped member 50 and the second flange portion 13 on the outer surface 13b side of the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 in the length direction Ld moves towards the inner surface 13a side in the length direction Ld, the protrusion of adhesive AH towards the core 10 and the outside of the plate-shaped member 50 can be further suppressed.

[0155] (9) Recesses 17a and 17b are provided on the top surface 12c of the first flange portion 12, which faces the first surface 51 of the plate-shaped member 50, on the outer side of the portion in the width direction Wd compared to the core portion 11. According to this configuration, when the plate-shaped member 50 is fixed to the first flange portion 12 and the second flange portion 13 using adhesive AH, the adhesive AH enters the recesses 17a and 17b respectively, so it is possible to further suppress the adhesive AH from protruding to the outside of the core 10 and the plate-shaped member 50.

[0156] In addition, the recesses 17a and 17b are formed on the outer side of the core portion 11 in the width direction Wd. Therefore, within the width range of the core portion 11, the recesses 17a and 17b prevent the plate-shaped member 50 from being separated from the first flange portion 12, thus suppressing any impact on the magnetic circuit between the core 10 and the plate-shaped member 50. As a result, the reduction in the inductance value of the coil member 1 can be suppressed.

[0157] Furthermore, the top surface 13c of the second flange portion 13 is the same as that of the first flange portion 12, and recesses 21a and 21b are provided. Therefore, it is possible to further suppress the adhesive AH from protruding outwards from the core 10 and the plate-shaped member 50. In addition, it is possible to further suppress the impact on the magnetic circuit between the core 10 and the plate-shaped member 50. Therefore, it is possible to further suppress the decrease in the inductance value of the coil member 1.

[0158] (10) The outer edge of the first end face electrode 31b, which forms the first terminal electrode 31, is a convex curve. With this configuration, stress is less likely to concentrate on the outer edge of the first end face electrode 31b of the first terminal electrode 31, so the first end face electrode 31b of the first terminal electrode 31 is less likely to peel off from the core 10. Therefore, the reliability of the coil component 1 can be improved.

[0159] Furthermore, the outer edges of the terminal electrodes forming the second end face electrode 32b of the second terminal electrode 32, the third end face electrode 33b of the third terminal electrode 33, and the fourth end face electrode 34b of the fourth terminal electrode 34 are convex curves. With this configuration, stress is less likely to concentrate on the outer edges of the terminal electrodes 32b-34b of each terminal electrode 32-34, thus preventing the terminal electrodes 32b-34b from easily peeling off from the core 10. Therefore, the reliability of the coil component 1 can be further improved.

[0160] (11) The outer edge of the first bottom electrode 31a, which forms the first terminal electrode 31, is a convex curve. With this configuration, stress is less likely to concentrate on the outer edge of the terminal electrode in the first bottom electrode 31a of the first terminal electrode 31, so the first bottom electrode 31a of the first terminal electrode 31 is less likely to peel off from the core 10. Therefore, the reliability of the coil component 1 can be improved.

[0161] Furthermore, the outer edges of the terminal electrodes forming the second bottom electrode 32a of the second terminal electrode 32, the third bottom electrode 33a of the third terminal electrode 33, and the fourth bottom electrode 34a of the fourth terminal electrode 34 are convex curves. With this configuration, stress is less likely to concentrate on the outer edges of the terminal electrodes 32a-34a of each terminal electrode 32-34, thus preventing the bottom electrodes 32a-34a of each terminal electrode 32-34 from peeling off from the core 10. Therefore, the reliability of the coil component 1 can be further improved.

[0162] (12) The first end face electrode 31b of the first terminal electrode 31 is formed in a concave-convex shape when viewed from the width direction Wd or the height direction Td. According to this configuration, when the coil component 1 is mounted on the circuit board PX by a conductive connection member such as solder SD, the conductive connection member enters the concave-convex portion of the first end face electrode 31b of the first terminal electrode 31. As a result, the connection strength between the coil component 1 and the circuit board PX is improved.

[0163] Furthermore, each of the second end face electrode 32b of the second terminal electrode 32, the third end face electrode 33b of the third terminal electrode 33, and the fourth end face electrode 34b of the fourth terminal electrode 34 is formed in an uneven shape when viewed from the width direction Wd or the height direction Td. According to this configuration, when the coil component 1 is mounted on the circuit board PX via conductive connection members such as solder SD, the aforementioned conductive connection members penetrate into the uneven portions of the end face electrodes 32b to 34b of each terminal electrode 32 to 34. As a result, the connection strength between the coil component 1 and the circuit board PX is further improved.

[0164] (13) The first flange portion 12 has protrusions 15a and 15b connecting the first end portion 41a of the first line 41 and the first end portion 42a of the second line 42, and feet 14a and 14b for wiring patterns (pad portions RX) mounted on the circuit board PX when mounted on the circuit board PX. The second flange portion 13 has protrusions 19a and 19b connecting the second end portion 41b of the first line 41 and the second end portion 42b of the second line 42, and feet 18a and 18b for wiring patterns (pad portions RX) mounted on the circuit board PX when mounted on the circuit board PX. The feet 14a, 14b, 18a, and 18b are configured to protrude toward the circuit board PX compared to the protrusions 15a, 15b, 19a, and 19b. The first bottom electrode 31a of the first terminal electrode 31 is disposed at the portion corresponding to the foot 14a and the protrusion 15a, and the second bottom electrode 32a of the second terminal electrode 32 is disposed at the portion corresponding to the foot 14b and the protrusion 15b. The third bottom electrode 33a of the third terminal electrode 33 is disposed at the portion corresponding to the foot 18a and the protrusion 19a, and the fourth bottom electrode 34a of the fourth terminal electrode 34 is disposed at the portion corresponding to the foot 18b and the protrusion 19b. According to this configuration, the first wire 41 and the second wire 42 are electrically connected to each of the terminal electrodes 31 to 34, and the feet 14a, 14b, 18a, and 18b can avoid the influence of the ends 41a and 41b of the first wire 41 and the ends 42a and 42b of the second wire 42 when mounting on the circuit board PX. Therefore, it is possible to avoid the coil component 1 tilting relative to the circuit board PX due to the contact between the ends 41a, 41b of the first wire 41 and the ends 42a, 42b of the second wire 42 and the circuit board PX, so that the coil component 1 can be properly connected to the circuit board PX.

[0165] (14) In the manufacturing method of coil component 1, in the end face electrode forming process, each end face electrode 31b to 34b of each terminal electrode 31 to 34 is formed by the coating apparatus 100 (distributor). According to this configuration, the uneven shape of each end face electrode 31b to 34b of each terminal electrode 31 to 34 can be easily formed by forming multiple rows of coated portions 35 in the width direction Wd and the height direction Td.

[0166] (15) In the bottom electrode forming process, since the outer surface 12b of the first flange portion 12 and the outer surface 13b of the second flange portion 13 are placed on the reference surface 101 of the coating apparatus 100, if a portion of each bottom electrode 31a to 34a of each terminal electrode 31 to 34 is formed on the outer surface 12b of the first flange portion 12 and the outer surface 13b of the second flange portion 13, the core 10 may be tilted relative to the reference surface 101 of the coating apparatus 100 due to the bottom electrodes 31a to 34a. Therefore, it is necessary to take into account the tilt of the core 10 relative to the reference surface 101 of the coating apparatus 100 when forming each end electrode 31b to 34b of each terminal electrode 31 to 34.

[0167] In view of this, in the manufacturing method of coil component 1, the end face electrode forming process is performed before the bottom face electrode forming process in the electrode forming process. Therefore, when the core 10 is placed on the reference surface 101 of the coating apparatus 100, the bottom face electrodes 31a to 34a are not formed on each of the terminal electrodes 31 to 34, thus suppressing the tilt of the core 10 relative to the reference surface 101. Therefore, regardless of the tilt of the core 10 relative to the reference surface 101, the end face electrodes 31b to 34b of each of the terminal electrodes 31 to 34 can be formed with greater precision by the coating apparatus 100.

[0168] (16) The winding section 40a has N (N is an even number of 2 or more) first winding sections 43 in which the first wire 41 and the second wire 42 are wound side by side in the same direction in the core section 11 with a predetermined number of turns, and a first crossing section 44 in the length direction Ld where the first wire 41 and the second wire 42 cross once between adjacent first winding sections 43. Therefore, the polarities of the first winding sections 43 on both sides of the first crossing section 44 in the length direction Ld are opposite. With an even number of such configurations, a balance of polarity of the winding section 40a can be achieved.

[0169] In addition, a second intersection 45 is formed on the first side 11c of the core portion 11 closest to the second flange portion 13 in the first winding portion 43 of the winding portion 40a, where the first wire 41 and the second wire 42 intersect. Therefore, by not forming the second intersection 45 adjacent to the first winding portion 43 in the longitudinal direction Ld, it is possible to suppress the winding portion 40a from excessively approaching the third terminal electrode 33 and the fourth terminal electrode 34 of the second flange portion 13. Therefore, the quality of the coil component 1 is improved. Furthermore, when the first wire 41 and the second wire 42 are connected to the third terminal electrode 33 and the fourth terminal electrode 34, the first wire 41 and the second wire 42 can be bent slowly respectively, thus reducing concerns about the first wire 41 and the second wire 42 breaking.

[0170] (17) A second cross portion 45 is formed on the first side surface 11c of the core portion 11 closest to the second flange portion 13 in the first winding portion 43 of the winding portion 40a. With this configuration, the first wire 41 can be wound towards the third terminal electrode 33 from the intersection point of the first wire 41 and the second wire 42 in the second cross portion 45, and the second wire 42 can be wound towards the fourth terminal electrode 34. Therefore, the degrees of freedom of the first wire 41 and the second wire 42 when connected to the third terminal electrode 33 and the fourth terminal electrode 34 are increased. Furthermore, since the first wire 41 and the second wire 42 are connected to the third terminal electrode 33 and the fourth terminal electrode 34 while being slowly bent, the stress concentration in the second lead-out portion 40c and the fourth lead-out portion 40e can be reduced.

[0171] (18) A winding portion 40a is formed by double-winding the first wire 41 and the second wire 42. According to this configuration, the noise of the first wire 41 and the second wire 42 that are adjacent in the length direction Ld in the winding portion 40a can cancel each other out. Therefore, the quality of the coil component 1 can be improved.

[0172] (19) The second wire 42 has a first end portion 42a extending in the length direction Ld, a first curved portion 42c bending from the first end portion 42a toward the outer surface 12b of the first flange portion 12, and a second curved portion 42d bending from the first curved portion 42c toward the width direction Wd. According to this configuration, the third lead-out portion 40d can be disposed on the side of the first flange portion 12 via the first curved portion 42c and the second curved portion 42d. Therefore, the lead-out portion 40b of the second wire 42 can be suitably placed on the slope portion 16 of the first flange portion 12.

[0173] (20) The third lead-out portion 40d is routed along the slope portion 16 of the first flange portion 12. With this configuration, so-called overhead routing where the third lead-out portion 40d is routed separately from the first flange portion 12 in the height direction Td can be suppressed, thus reducing concerns about the second wire 42 breaking. The second lead-out portion 40c is routed along the slope portion 20 of the second flange portion 13. With this configuration, since the second lead-out portion 40c is routed separately from the second flange portion 13 in the height direction Td can be suppressed, reducing concerns about the first wire 41 breaking.

[0174] (21) In the length direction Ld, the length LA of the winding portion 40a on the bottom surface 11a of the core portion 11 is shorter than the length LB of the winding portion 40a on the top surface 11b of the core portion 11. With this configuration, the distance between the winding portion 40a and the pad portion RX of the circuit board PX is increased when the coil component 1 is mounted on the circuit board PX. Therefore, the thermal impact of the pad portion RX of the circuit board PX on the winding portion 40a can be further reduced.

[0175] (22) The distance LD1 between the inner surface 12a of the first flange portion 12 in the length direction Ld and the winding portion 40a on the bottom surface 11a of the core portion 11 is greater than at least one of the distance LD3 between the inner surface 12a of the first flange portion 12 in the length direction Ld and the winding portion 40a on the top surface 11b of the core portion 11, and the distance LD4 between the inner surface 13a of the second flange portion 13 in the length direction Ld and the winding portion 40a on the top surface 11b of the core portion 11. According to this configuration, when the coil component 1 is mounted on the circuit board PX, the distance between the winding portion 40a and the pad portion RX of the circuit board PX is larger. Therefore, the thermal impact of the pad portion RX of the circuit board PX on the winding portion 40a can be further reduced.

[0176] The distance LD2 between the inner surface 13a of the second flange portion 13 in the length direction Ld and the winding portion 40a on the bottom surface 11a of the core portion 11 is greater than at least one of the distance LD3 between the inner surface 12a of the first flange portion 12 in the length direction Ld and the winding portion 40a on the top surface 11b of the core portion 11, and the distance LD4 between the inner surface 13a of the second flange portion 13 in the length direction Ld and the winding portion 40a on the top surface 11b of the core portion 11. Therefore, the second flange portion 13, like the first flange portion 12, can further reduce the thermal impact of the pad portion RX of the circuit board PX on the winding portion 40a.

[0177] (23) In the length direction Ld, the distance between the winding portion 40a on the bottom surface 11a of the core portion 11 and the inner surface 13a of the second flange portion 13 is greater than the distance between the winding portion 40a on the bottom surface 11a of the core portion 11 and the inner surface 12a of the first flange portion 12. According to this configuration, the space for drawing out the first wire 41 and the second wire 42 from the winding portion 40a can be ensured in the second lead-out portion 40c and the fourth lead-out portion 40e, so the degree of freedom of the winding end portion of the first wire 41 and the second wire 42 is increased.

[0178] (24) The distance between one end of the first flange portion 12 in the height direction Td and the bottom surface 11a of the core portion 11 is greater than the distance between the other end of the first flange portion 12 in the height direction Td and the top surface 11b of the core portion 11. With this configuration, when the coil component 1 is mounted on the circuit board PX, the distance between the winding portion 40a and the circuit board PX in the height direction Td is larger. Therefore, the thermal impact of the circuit board PX on the winding portion 40a can be further reduced. The configuration of the second flange portion 13 can also be the same as that of the first flange portion 12, further reducing the thermal impact.

[0179] (25) The first line 41 and the second line 42 constituting the first intersection 44 intersect at the top surface 11b of the core portion 11. According to this configuration, when the coil component 1 is mounted on the circuit board PX, compared with the configuration where the first line 41 and the second line 42 constituting the first intersection 44 intersect at the bottom surface 11a of the core portion 11, the distance between the winding portion 40a in the height direction Td and the main surface of the circuit board PX is larger. Therefore, the thermal impact from the circuit board PX and each terminal electrode 31 to 34 to the winding portion 40a when the coil component 1 is mounted on the circuit board PX can be further reduced.

[0180] (Example of the change)

[0181] The above embodiments are examples of possible ways in which the coil component and the method for manufacturing the coil component involved in this disclosure can be adopted, and are not intended to limit the scope of the embodiments. The coil component and the method for manufacturing the coil component involved in this disclosure can be adopted in ways different from those illustrated in the above embodiments. One example is the substitution, modification, or omission of a part of the structure of the above embodiments, or the addition of a new structure to the above embodiments. In the following modification examples, the same reference numerals are used as in the above embodiments for the parts that are the same as those in the above embodiments, and their descriptions are omitted.

[0182] [Examples of changes in the shape of the first flange and the second flange]

[0183] In the above embodiment, the protrusions 15a and 15b may be omitted from the first flange portion 12. In this case, for example, the foot portions 14a and 14b are formed to the region including the protrusions 15a and 15b. In this case, the first end portion 41a of the first wire 41 is connected to the first bottom surface electrode 31a of the first terminal electrode 31 formed on the foot portion 14a, and the first end portion 42a of the second wire 42 is connected to the second bottom surface electrode 32a of the second terminal electrode 32 formed on the foot portion 14b.

[0184] In the above embodiment, the protrusions 19a and 19b may be omitted from the second flange portion 13. In this case, for example, the foot portions 18a and 18b are formed to the region including the protrusions 19a and 19b. In this case, the second end portion 41b of the first wire 41 is connected to the third bottom surface electrode 33a of the third terminal electrode 33 formed on the foot portion 18a, and the second end portion 42b of the second wire 42 is connected to the fourth bottom surface electrode 34a of the fourth terminal electrode 34 formed on the foot portion 18b.

[0185] In the above embodiment, at least one of the inner surface 12a of the bottom part of the first flange portion 12 (the end of the first flange portion 12 that protrudes toward the bottom surface 11a of the core portion 11) and the bottom part of the second flange portion 13 (the end of the second flange portion 13 that protrudes toward the bottom surface 11a of the core portion 11) in the height direction Td may extend along the height direction Td.

[0186] In the above embodiment, at least one of the inner surface 12a of the top surface of the first flange portion 12 (the end of the first flange portion 12 that protrudes toward the top surface 11b of the core portion 11) in the height direction Td and the top surface of the second flange portion 13 in the height direction Td (the end of the second flange portion 13 that protrudes toward the top surface 11b of the core portion 11) may be inclined in the length direction Ld toward the direction away from the core portion 11 as the height direction Td moves toward the direction away from the top surface 11b.

[0187] [Examples of modifications related to the connection between the core portion and the first flange portion and the second flange portion]

[0188] In the above embodiments, at least one of the shapes of the first curved portion 22 connecting the inner surface 12a of the first flange portion 12 of the core 10 to the bottom surface 11a of the core portion 11, and the second curved portion 23 connecting the inner surface 13a of the second flange portion 13 to the bottom surface 11a of the core portion 11, can be arbitrarily changed. Alternatively, in a cross-section perpendicular to the width direction Wd, the curve of the first curved portion 22 may change curvature in the length direction Ld from the bottom surface 11a of the core portion 11 towards the inner surface 12a of the first flange portion 12. By changing the curvature of the first curved portion 22 between the core portion 11 and the first flange portion 12, the flexural strength of the core 10 can be improved, and excessive shrinkage of the size of the first flange portion 12 in the length direction Ld can be further suppressed. Therefore, excessive shrinkage of the size of the first terminal electrode 31 in the length direction Ld can be suppressed, and the coil component 1 can be appropriately mounted on the circuit board PX. By making the second curved face 23 the same shape as the first curved face 22, the same effect can be further obtained.

[0189] In one example, such as Figure 18As shown in (a), the first curved surface 22 is formed in a cross-section parallel to the length direction Ld and the height direction Td (perpendicular to the width direction Wd) as a part of an elliptical shape (an imaginary circle with double-dotted lines), where the height direction Td is the major axis and the length direction Ld is the minor axis. According to this configuration, the planar portion of the bottom surface 11a of the core portion 11 along the length direction Ld and the width direction Wd is longer in the length direction Ld. Therefore, the area where the winding portion 40a can be formed in the length direction Ld is increased, thus increasing the number of turns of the coil 40. Furthermore, the second curved surface 23 can also be modified to be... Figure 18 The first curve of (a) has the same shape as face 22.

[0190] In addition, such as Figure 18 As shown in (b), the first curved surface 22 is formed in a cross-section parallel to the length direction Ld and the height direction Td (perpendicular to the width direction Wd) as a part of an elliptical shape (an imaginary circle with double-dotted lines), where the length direction Ld is the major axis and the height direction Td is the minor axis. According to this configuration, the first wire 41 and the second wire 42 can also be wound around the core portion 11 on the first curved surface 22. Therefore, the area where the winding portion 40a can be formed in the length direction Ld is larger, thus increasing the number of turns of the coil 40. Furthermore, the second curved surface 23 can also be modified to be... Figure 18 The first curve of (b) has the same shape as face 22.

[0191] In the above embodiments, the shapes of the first curved surface 22 and the second curved surface 23 in a cross-section parallel to the length direction Ld and the height direction Td (perpendicular to the width direction Wd) may be different from each other. In one example, one of the surfaces constituting the first curved surface 22 and the second curved surface 23 may be a circular surface in a cross-section perpendicular to the width direction Wd, while the other surface may be an elliptical surface or have a change in curvature in a cross-section perpendicular to the width direction Wd. Alternatively, the shapes of the third curved surface 24 and the fourth curved surface 25 in a cross-section perpendicular to the width direction Wd may be different from each other.

[0192] In the above embodiment, the height direction Td of at least one of the first curved surface 22 and the second curved surface 23 in the cross section perpendicular to the width direction Wd may be less than the height direction Td of the third curved surface 24 and the fourth curved surface 25.

[0193] In the above embodiments, the size of the length direction Ld of at least one of the first curved surface 22 and the second curved surface 23 in the cross section perpendicular to the width direction Wd may be less than the size of the length direction Ld of the third curved surface 24 and the fourth curved surface 25.

[0194] In the above embodiment, the first curved portion 22 may be omitted from the connection portion between the portion of the core portion 11 in the width direction Wd on the side of the first side surface 12e of the first flange portion 12 relative to the center and the inner surface 12a of the first flange portion 12. In this case, for example, the slope portion 16 corresponding to the portion of the core portion 11 in the width direction Wd on the side of the first side surface 12e of the first flange portion 12 relative to the center is configured to be on the same plane as the bottom surface 11a of the core portion 11.

[0195] In the above embodiment, the second curved portion 23 may be omitted from the connection portion between the portion of the core portion 11 in the width direction Wd that is on the second side surface 13f side of the second flange portion 13 relative to the center and the inner surface 13a of the second flange portion 13. In this case, for example, the slope portion 20 corresponding to the portion of the core portion 11 in the width direction Wd that is on the second side surface 13f side of the second flange portion 13 relative to the center becomes a plane with the bottom surface 11a of the core portion 11.

[0196] In the above embodiment, if the size of the first curved surface 22 in the height direction Td is more than 20% and less than 60% of the ratio between the bottom surface 11a of the core portion 11 in the height direction Td and the distance between the first terminal electrode 31, the size of the second curved surface 23 in the height direction Td is less than 20% or more than 60% of the ratio between the bottom surface 11a of the core portion 11 in the height direction Td and the distance between the third terminal electrode 33.

[0197] In the above embodiment, if the size of the second curved surface 23 in the height direction Td is more than 20% and less than 60% of the ratio of the size of the second curved surface 23 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 in the height direction Td and the third terminal electrode 33, then the size of the first curved surface 22 in the height direction Td is less than 20% or more than 60% of the ratio of the size of the first curved surface 22 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 in the height direction Td and the first terminal electrode 31.

[0198] In the above embodiment, at least one of the following ratios may be less than 20% or greater than 60%: the size of the first curved surface 22 in the height direction Td relative to the distance between the bottom surface 11a of the core portion 11 in the height direction Td and the first terminal electrode 31, and the size of the second curved surface 23 in the height direction Td relative to the distance between the bottom surface 11a of the core portion 11 in the height direction Td and the third terminal electrode 33.

[0199] When the size of the first curved portion 22 in the height direction Td is less than 20% or greater than 60% of the distance between the bottom surface 11a of the core portion 11 and the first terminal electrode 31 in the height direction Td, preferably in a cross section perpendicular to the width direction Wd, the curve of the first curved portion 22 changes curvature in the length direction Ld from the bottom surface 11a of the core portion 11 toward the inner surface 12a of the first flange portion 12.

[0200] When the size of the second curved portion 23 in the height direction Td is less than 20% or greater than 60% of the distance between the bottom surface 11a of the core portion 11 and the third terminal electrode 33 in the height direction Td, preferably in a cross section perpendicular to the width direction Wd, the curve of the second curved portion 23 changes curvature in the length direction Ld from the bottom surface 11a of the core portion 11 toward the inner surface 13a of the second flange portion 13.

[0201] When the ratio of the size of the first curved portion 22 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the first terminal electrode 31 in the height direction Td, and the ratio of the size of the second curved portion 23 in the height direction Td to the distance between the bottom surface 11a of the core portion 11 and the third terminal electrode 33 in the height direction Td, are both less than 20% or greater than 60%, it is preferable that, in a cross-section perpendicular to the width direction Wd, the curve of the first curved portion 22 changes curvature in the length direction Ld from the bottom surface 11a of the core portion 11 toward the inner surface 12a of the first flange portion 12. Furthermore, it is preferable that, in a cross-section perpendicular to the width direction Wd, the curve of the second curved portion 23 changes curvature in the length direction Ld from the bottom surface 11a of the core portion 11 toward the inner surface 13a of the second flange portion 13.

[0202] In the above embodiment, at least one of the following ratios may be 20% or more and 60% or less: the size of the third curved portion 24 in the height direction Td relative to the distance between the top surface 11b of the core portion 11 and the top surface 12c of the first flange portion 12 in the height direction Td; and the size of the fourth curved portion 25 in the height direction Td relative to the distance between the top surface 11b of the core portion 11 and the top surface 13c of the second flange portion 13 in the height direction Td. According to this configuration, since at least one of the ratio of the size of the third curved portion 24 in the height direction Td to the distance between the top surface 11b of the core portion 11 and the top surface 12c of the first flange portion 12 in the height direction Td, and the ratio of the size of the fourth curved portion 25 in the height direction Td to the distance between the top surface 11b of the core portion 11 and the top surface 13c of the second flange portion 13 in the height direction Td, is 20% or more, at least one of the third curved portion 24 and the fourth curved portion 25 can be obtained to a greater extent, thereby improving at least one of the bending strength between the core portion 11 and the first flange portion 12 and the bending strength between the core portion 11 and the second flange portion 13. Therefore, the flexural strength of the core 10 can be improved. Furthermore, since at least one of the ratio of the size of the third curved portion 24 in the height direction Td to the distance between the top surface 11b of the core portion 11 and the top surface 12c of the first flange portion 12 in the height direction Td, and the ratio of the size of the fourth curved portion 25 in the height direction Td to the distance between the top surface 11b of the core portion 11 and the top surface 13c of the second flange portion 13 in the height direction Td, excessive shrinkage of at least one of the first flange portion 12 and the second flange portion 13 in the length direction Ld can be suppressed. Therefore, in the length direction Ld, excessive shrinkage of the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 can be suppressed, ensuring the adhesive strength between the core 10 and the plate-shaped member 50.

[0203] • In the above embodiments, it is also possible to... Figure 18 The first curved face 22 shown in (a) and Figure 18 As shown in (b), at least one of the third curved surface 24 and the fourth curved surface 25 can be changed to an elliptical shape, similar to the second curved surface 23. That is, at least one of the third curved surface 24 and the fourth curved surface 25 can be configured to change curvature from the top surface 11b of the core portion 11 toward the inner surface 12a of the first flange portion 12 or the inner surface 13a of the second flange portion 13.

[0204] [Examples of modifications to the connection structure between the first flange and the second flange of the core and the plate-shaped component]

[0205] • In the above embodiments, the connection structure between the first flange portion 12 and the second flange portion 13 and the plate-shaped member 50 can be arbitrarily changed.

[0206] In the first case, such as Figure 19 As shown in (a), the portion of the top surface 12c of the first flange portion 12 on the inner surface 12a side of the first flange portion 12 contacts the plate-shaped member 50. The distance D1 between the top surface 12c of the first flange portion 12 and the first surface 51 of the plate-shaped member 50 increases from the inner surface 12a of the first flange portion 12 toward the outer surface 12b. In other words, for distance D1, the distance on the core portion 11 side of the first flange portion 12 relative to the center of the length direction Ld is smaller than the distance on the opposite side of the core portion 11 relative to the center of the length direction Ld. That is, the size of the gap GA between the first flange portion 12 and the plate-shaped member 50 in the height direction Td increases from the inner surface 12a of the first flange portion 12 toward the outer surface 12b. In other words, the size of the gap GA in the height direction Td decreases in the length direction Ld toward the core portion 11 side. Thus, the position where the distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 is smaller is located on the inner surface 12a side of the first flange portion 12. With this configuration, when the plate-shaped member 50 is a magnetic material, the length of the magnetic circuit formed between the core 10 and the plate-shaped member 50 can be shortened. By also making the second flange portion 13 have the same configuration as the first flange portion 12, the length of the magnetic circuit can be further shortened.

[0207] In the second example, such as Figure 19As shown in (b), a protrusion 26 is provided on the portion of the first flange portion 12 on the outer surface 12b side of the top surface 12c of the first flange portion 12. The protrusion 26 may be provided entirely along the width direction Wd of the first flange portion 12, or it may be provided on a portion of the width direction Wd of the first flange portion 12. Multiple protrusions 26 may also be provided at intervals along the width direction Wd. Thus, the distance between the portion of the first flange portion 12 on the outer surface 12b side and the plate-shaped member 50 in the height direction Td is smaller than the distance between the portion of the first flange portion 12 on the inner surface 12a side and the plate-shaped member 50. In other words, the height direction Td of the gap between the portion of the first flange portion 12 on the inner surface 12a side and the plate-shaped member 50 is larger than the height direction Td of the gap between the portion of the first flange portion 12 on the outer surface 12b side and the plate-shaped member 50. According to this configuration, when the plate-shaped member 50 is a magnetic material, the portion where the distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 12c of the first flange portion 12 is smaller is partially formed between the plate-shaped member 50 and the first flange portion 12 due to the protrusion 26. Therefore, the magnetic circuit between the core 10 and the plate-shaped member 50 can be defined. As a result, the deviation in the magnetic circuit length of each coil member 1 becomes smaller, and thus the deviation in the inductance value of each coil member 1 can be suppressed. By making the second flange portion 13 have the same configuration as the first flange portion 12, the deviation in the inductance value can be further suppressed.

[0208] In addition, Figure 19 In (b), adhesive AH is applied to the end face 26a and top face 12c of the protrusion 26 of the first flange portion 12. Alternatively, adhesive AH is applied to the surface of the first face 51 of the plate-shaped member 50 opposite to the first flange portion 12. The plate-shaped member 50 is mounted on the protrusion 26. In this case, for example, the adhesive AH on the protrusion 26 of the first flange portion 12 and the first face 51 of the plate-shaped member 50 moves toward the gap formed on the inner surface 12a side of the first flange portion 12 compared to the protrusion 26 due to the pressing of the protrusion 26 and the plate-shaped member 50. Therefore, it is possible to suppress the adhesive AH from protruding to the outside of the core 10 and the plate-shaped member 50. By making the second flange portion 13 have the same configuration as the first flange portion 12, it is possible to further suppress the protrusion of adhesive AH.

[0209] In addition, such as Figure 19As shown in (c), a protrusion 26 may also be provided on the portion of the first flange portion 12 on the inner surface 12a side of the top surface 12c of the first flange portion 12. In this case, the distance between the portion of the first flange portion 12 on the inner surface 12a side and the plate-shaped member 50 in the height direction Td is smaller than the distance between the portion of the first flange portion 12 on the outer surface 12b side and the plate-shaped member 50. In other words, the height direction Td of the gap between the portion of the first flange portion 12 on the outer surface 12b side and the plate-shaped member 50 is larger than the height direction Td of the gap between the portion of the first flange portion 12 on the inner surface 12a side and the plate-shaped member 50. According to this configuration, when the plate-shaped member 50 is a magnetic material, the length of the magnetic circuit formed between the core 10 and the plate-shaped member 50 can be shortened. By making the second flange portion 13 have the same configuration as the first flange portion 12, the length of the magnetic circuit can be further shortened.

[0210] Furthermore, the position of the protrusion 26 in the length direction Ld is not limited to the end on the outer surface 12b side or the end on the inner surface 12a side of the top surface 12c of the first flange portion 12, and can be arbitrarily changed. For example, the protrusion 26 may also be provided at the center of the length direction Ld in the top surface 12c of the first flange portion 12. The second flange portion 13 may also have the same configuration as the first flange portion 12.

[0211] ·exist Figure 19 In the modified examples shown in (a) to (c), the distance Td between the top surface 12c of the first flange 12 (the top surface 13c of the second flange 13) and the first surface 51 of the plate-shaped member 50 in the length direction Ld varies, but is not limited to this. For example, Figures 20-22 As shown, the distance between the top surface 13c of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50 in the height direction Td can also vary. Furthermore, for convenience, Figure 20 as well as Figure 21 The core 10 is shown schematically with the recesses 21a and 21b of the second flange portion 13 omitted.

[0212] In the first case, such as Figure 20 As shown, the top of the top surface 13c of the second flange portion 13 is located at the center of its width direction Wd, and slopes towards the bottom surface 13d as it moves towards either the first side surface 13e or the second side surface 13f of the second flange portion 13. In this case, as... Figure 21As shown, in the connection structure between the second flange portion 13 and the plate-shaped member 50, in the width direction Wd, as the distance in the height direction Td between the top surface 13c of the second flange portion 13 and the first surface 51 of the plate-shaped member 50 decreases from the first side surface 13e or the second side surface 13f of the second flange portion 13 toward the center of the second flange portion 13. In other words, as the distance in the height direction Td between the top surface 13c of the second flange portion 13 and the first surface 51 of the plate-shaped member 50 increases toward the first side surface 13e or the second side surface 13f of the second flange portion 13. According to this configuration, when the plate-shaped member 50 is a magnetic body, a position with a smaller distance in the height direction Td between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 is partially formed between the plate-shaped member 50 and the second flange portion 13, thus defining the magnetic circuit between the core 10 and the plate-shaped member 50. Therefore, the deviation in the magnetic circuit length of each coil member 1 becomes smaller, thus suppressing the deviation in the inductance value of each coil member 1. By making the first flange portion 12 the same as the second flange portion 13, the deviation of the inductance value can be further suppressed.

[0213] In addition, when the plate-shaped member 50 and the second flange portion 13 are fixed by adhesive AH, the adhesive AH at the center of the width direction Wd of the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 moves toward the end of the top surface 13c of the second flange portion 13, where the gap between the first surface 51 of the plate-shaped member 50 and the top surface 13c of the second flange portion 13 is larger. Therefore, it is possible to suppress the adhesive AH from protruding outwards from the core 10 and the plate-shaped member 50. By making the first flange portion 12 also have the same configuration as the second flange portion 13, it is possible to further suppress the protrusion of the adhesive AH.

[0214] In the second example, such as Figure 22 As shown in (a), a protrusion 27 is provided at the center of the top surface 13c of the second flange portion 13 in the width direction Wd. The protrusion 27 can be provided entirely on the top surface 13c of the second flange portion 13 in the length direction Ld, or it can be provided on a portion of the top surface 13c. Alternatively, multiple protrusions 27 can be provided at intervals in the length direction Ld. By providing the protrusion 27, the distance in the height direction Td between the end of the top surface 13c of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50 is greater than the distance in the height direction Td between the central portion of the top surface 13c of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50. In other words, the height direction Td of the gap between the end of the second flange portion 13 in the width direction Wd and the plate-shaped member 50 is greater than the height direction Td of the gap between the central portion of the second flange portion 13 in the width direction Wd and the plate-shaped member 50. Based on this configuration, it is possible to obtain a... Figure 20 as well as Figure 21 The structure shown in the first example achieves the same effect. By making the first flange portion 12 also have the same configuration as the second flange portion 13, the same effect can be further obtained.

[0215] In the third example, such as Figure 22 As shown in (b), protrusions 27 are provided at both ends of the top surface 13c of the second flange portion 13 in the width direction Wd. In this case, the distance in the height direction Td between the central portion of the top surface 13c of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50 is greater than the distance in the height direction Td between the two ends of the top surface 13c of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50. In other words, the size of the gap in the height direction Td between the central portion of the second flange portion 13 in the width direction Wd and the plate-shaped member 50 is greater than the size of the gap in the height direction Td between the two ends of the second flange portion 13 in the width direction Wd and the plate-shaped member 50. According to this configuration, the magnetic circuit between the plate-shaped member 50 and the second flange portion 13 is defined by the protrusions 27, so the deviation of the magnetic circuit length of each coil member 1 is reduced. Therefore, the deviation of the inductance value of each coil member 1 can be suppressed. By making the first flange portion 12 the same as the second flange portion 13, the deviation of the inductance value can be further suppressed.

[0216] In addition, when the plate-shaped member 50 and the second flange portion 13 are fixed by adhesive AH, the adhesive AH between the protrusions 27 at both ends of the second flange portion 13 in the width direction Wd and the first surface 51 of the plate-shaped member 50 moves towards the center of the second flange portion 13 in the width direction Wd, where the gap between the first surface 51 of the plate-shaped member 50 and the second flange portion 13 in the height direction Td is larger. Therefore, it is possible to suppress the adhesive AH from protruding outwards from the core 10 and the plate-shaped member 50. By making the first flange portion 12 also have the same configuration as the second flange portion 13, it is possible to further suppress the protrusion of the adhesive AH.

[0217] In the above embodiment, by changing the shapes of the first flange portion 12 and the second flange portion 13, the distance between the top surface 12c of the first flange portion 12 and the first surface 51 of the plate-shaped member 50 in the height direction Td, and the distance between the top surface 13c of the second flange portion 13 and the first surface 51 of the plate-shaped member 50 in the height direction Td, respectively, are changed, but this is not a limitation. For example, the distance between the top surface 12c of the first flange portion 12 and the first surface 51 of the plate-shaped member 50 in the height direction Td, and the distance between the top surface 13c of the second flange portion 13 and the first surface 51 of the plate-shaped member 50 in the height direction Td, respectively, can also be changed by changing the shape of the first surface 51 of the plate-shaped member 50. Specifically, the portion of the first surface 51 of the plate-shaped member 50 that faces the first flange portion 12 in the height direction Td may be inclined such that it moves away from the top surface 12c of the first flange portion 12 in the height direction Td as it moves from the inner surface 12a of the first flange portion 12 toward the outer surface 12b. Alternatively, the portion of the first surface 51 of the plate-like member 50 that faces the first flange 12 in the height direction Td may be inclined such that it moves away from the top surface 12c of the first flange 12 in the height direction Td as it moves from the outer surface 12b of the first flange 12 towards the inner surface 12a. Alternatively, a protrusion (not shown) may be provided in the portion of the first surface 51 of the plate-like member 50 that faces the first flange 12 in the height direction Td, protruding from the first surface 51 toward the top surface 12c of the first flange 12. The number and position of the protrusions can be arbitrarily changed. The protrusion may be entirely opposite to the top surface 12c of the first flange 12 in the width direction Wd, or it may be partially opposite to the top surface 12c of the first flange 12 in the width direction Wd. Furthermore, the protrusion may be entirely opposite to the top surface 12c of the first flange 12 in the length direction Ld, or it may be partially opposite to the top surface 12c of the first flange 12 in the length direction Ld. Furthermore, the portion of the first surface 51 of the plate-shaped member 50 that faces the top surface 13c of the second flange portion 13 in the height direction Td can also be modified in the same way as the portion of the first surface 51 of the plate-shaped member 50 that faces the top surface 12c of the first flange portion 12 in the height direction Td. With this configuration, the second surface 52 of the plate-shaped member 50 can remain flat, so the adsorption conveying device can properly convey the coil member 1. Alternatively, the configuration described above, formed on the first surface 51 of the plate-shaped member 50, can also be formed on the second surface 52. With this configuration, the orientation of the plate-shaped member 50 is eliminated, so during the plate-shaped member installation process of mounting the plate-shaped member 50 onto the core 10, it is not necessary to check the orientation of the plate-shaped member 50, thus reducing operational complexity.

[0218] In the above embodiment, the distance between the top surface 12c of the first flange portion 12 and the top surface 13c of the second flange portion 13 in the height direction Td and the plate-shaped member 50 can be varied in both the length direction Ld and the width direction Wd. With this configuration, the adhesive AH can be suppressed from protruding outwards from the core 10 and the plate-shaped member 50, and the inductance value can be set more precisely by adjusting the magnetic circuit length.

[0219] In the above embodiment, the distance between one of the top surfaces 12c of the first flange portion 12 and 13c of the second flange portion 13 in the height direction Td and the plate-shaped member 50 may be constant in both the length direction Ld and the width direction Wd. In this configuration, since the distances between the other of the top surfaces 12c of the first flange portion 12 and 13c of the second flange portion 13 in the height direction Td and the plate-shaped member 50 are different, the magnetic circuit between the other of the first flange portion 12 and the second flange portion 13 and the plate-shaped member 50 is also defined when the plate-shaped member 50 is a magnetic material. Therefore, the deviation in the magnetic circuit length of each coil member 1 is reduced, thus suppressing the deviation in the inductance value of each coil member 1.

[0220] In the above embodiment, the distances between the first flange portion 12 and the second flange portion 13 in the height direction Td and the plate-shaped member 50 may be constant in the length direction Ld and the width direction Wd.

[0221] [Examples of modifications related to the recesses of the first flange and the second flange]

[0222] In the above embodiments, at least one of the shapes of the recesses 17a and 17b of the first flange portion 12 and the recesses 21a and 21b of the second flange portion 13 can be arbitrarily changed.

[0223] In the first case, such as Figure 23 As shown in (a), the recess 21a of the second flange portion 13 can also be formed from the inner surface 13a of the second flange portion 13 to the outer surface 13b. With this configuration, the recess 21a is easier to form during the molding of the core 10. It is also easier to mold the first flange portion 12 by making it the same as the second flange portion 13.

[0224] In the second example, such as Figure 23 As shown in (b), the recess 21a of the second flange 13 can also be configured such that the width direction Wd is the long side direction and the length direction Ld is the short side direction. In this case, as Figure 23 As shown in (b), the recess 21a can also be formed to the second side surface 13f of the second flange portion 13. It is also possible to make the first flange portion 12 have the same configuration as the second flange portion 13.

[0225] In the third example, such as Figure 23 As shown in (c), a recess 21a of the second flange portion 13 is provided at the end of the second flange portion 13 on the second side surface 13f side in the width direction Wd. The recess 21a is formed from the inner surface 13a of the second flange portion 13 to the outer surface 13b, and also forms on the second side surface 13f. It is also possible for the first flange portion 12 to have the same configuration as the second flange portion 13.

[0226] Furthermore, for the recess 21a in the first and third examples, the length of the recess 21a in the length direction Ld can be arbitrarily changed. The recess 21a can also be formed from the inner surface 13a of the second flange portion 13 to the portion in the length direction Ld that is on the side of the inner surface 13a relative to the outer surface 13b of the second flange portion 13. Alternatively, the recess 21a can also be formed from the outer surface 13b of the second flange portion 13 to the portion in the length direction Ld that is on the side of the outer surface 13b relative to the inner surface 13a of the second flange portion 13. It is also possible for the first flange portion 12 to have the same configuration as the second flange portion 13.

[0227] In the above embodiment, the recesses 17a, 17b, 21a, 21b are rectangular when viewed from the height direction Td, but are not limited to this. At least one of the shapes of the recesses 17a, 17b, 21a, 21b when viewed from the height direction Td may be a shape other than a rectangle, such as a circle, a square, or a polygon other than a quadrilateral.

[0228] In the above embodiment, when viewed from the height direction Td, the depths of recesses 17a and 17b are equal to the depths of recesses 21a and 21b, but this is not a limitation; the depths of recesses 17a and 17b may differ from the depths of recesses 21a and 21b. Furthermore, when viewed from the height direction Td, the depths of recesses 17a and 17b may differ, and the depths of recesses 21a and 21b may also differ.

[0229] In the above embodiments, at least one depth of the recesses 17a, 17b, 21a, 21b may vary in at least one of the length direction Ld and the width direction Wd.

[0230] In the above embodiment, the positions of the recesses 17a and 17b of the first flange portion 12 can be arbitrarily changed. In one example, at least one of the recesses 17a and 17b may be provided in the portion of the first flange portion 12 that overlaps with the core portion 11 when viewed from the length direction Ld.

[0231] • In the above embodiment, the positions of the recesses 21a and 21b of the second flange portion 13 can be arbitrarily changed. In one example, at least one of the recesses 21a and 21b may be provided in the portion of the second flange portion 13 that overlaps with the core portion 11 when viewed from the length direction Ld.

[0232] In the above embodiment, at least one of the recesses 17a and 17b of the first flange portion 12 may be omitted. Additionally, at least one of the recesses 21a and 21b of the second flange portion 13 may also be omitted.

[0233] [Examples of changes related to the first thread, second thread, and winding section]

[0234] In the above embodiment, the connection shape between the second end 41b of the first wire 41 and the third bottom electrode 33a of the third terminal electrode 33 can be arbitrarily changed. In the first example, such as Figure 24 As shown, the second end 41b of the first line 41 is connected to the third bottom surface electrode 33a of the third terminal electrode 33 formed in the protrusion 19a, and is parallel to the length direction Ld. In this case, as... Figure 24 As shown, the first end 41a and the second end 41b of the first line 41 are parallel to the length direction Ld, as are the first end 42a and the second end 42b of the second line 42.

[0235] In the second example, such as Figure 25 As shown in (a), the second end 41b of the first wire 41 bends from the portion of the first wire 41 placed in the ramp portion 20 of the second flange portion 13 and connects to the third bottom surface electrode 33a of the third terminal electrode 33 formed in the protrusion 19a. With this configuration, the contact area between the second end 41b of the first wire 41 and the third bottom surface electrode 33a is increased, thus improving the connectivity between the first wire 41 and the third terminal electrode 33.

[0236] In the third example, such as Figure 25 As shown in (b), the second end 41b of the first wire 41 bends from the portion of the first wire 41 placed in the ramp portion 20 of the second flange portion 13, and connects adjacent to the foot portion 18a to the third bottom surface electrode 33a of the third terminal electrode 33 formed in the protrusion 19a. With this configuration, the contact area between the second end 41b of the first wire 41 and the third bottom surface electrode 33a is increased, thus improving the connectivity between the first wire 41 and the third terminal electrode 33. Furthermore, since the second end 41b of the first wire 41 is adjacent to the foot portion 18a, the position of the second end 41b of the first wire 41 can be easily controlled.

[0237] In the above embodiments, such as Figure 26As shown, a third bend 41c and a fourth bend 41d can also be formed in the lead-out portion 40c of the first wire 41, similar to the first bend 42c and the second bend 42d of the lead-out portion 40b on the second wire 42. With this configuration, the first wire 41 can be easily placed at the lead-out portion 40c of the first wire 41 on the slope portion 20 of the second flange portion 13.

[0238] • In the above embodiment, the second curved portion 42d may be omitted from the lead-out portion 40b of the second line 42.

[0239] In the above embodiment, the coil 40 is wound with a first wire 41 and a second wire 42 on the circumferential surface of the core portion 11, but it is not limited to this. For example, the coil 40 may also be a double-layered winding portion with the first wire 41 and the second wire 42 wound from the outside of the first wire 41 and the second wire 42 wound on the circumferential surface of the core portion 11. Figure 27 This is an example of a double-layered winding configuration based on the first thread 41 and the second thread 42. Figure 27 For convenience, two first winding portions 43 arranged in the length direction Ld and a first intersection portion 44 arranged between the two first winding portions 43 are shown. Additionally, in Figure 27 In order to distinguish the two first winding portions 43, they are referred to as first winding portions 43A and 43B. For example, the first winding portion 43 in winding portion 40a that is closest to the first flange portion 12 is the first winding portion 43.

[0240] like Figure 27 As shown, to form the first winding portions 43A and 43B, the first wire 41 and the second wire 42 are each wound eight turns. The first wire 41 is wound a predetermined number of turns in the core portion 11 (in... Figure 27 (The middle has four turns), the second wire 42 winds a predetermined number of turns from the outside of the first wire 41 wound on the core portion 11 (in Figure 27 The first winding portion 43A, consisting of four turns, forms a double-layered first winding portion 43A. The second wire 42 of the fourth turn is wound onto the core portion 11 and, as the fifth turn (the first turn of the first winding portion 43B), is wound onto the core portion 11. The first wire 41 forming the first winding portion 43B is wound onto the core portion 11 a predetermined number of turns (in... Figure 27 (The middle section has four turns). The sixth to eighth turns of the second line 42 are wound around the outside of the first line 41 (forming the second to fourth turns of the second line 42 of the first winding section 43B).

[0241] The first wire 41 of the fourth turn of the first winding portion 43A intersects with the second wire 42 of the fourth turn of the first winding portion 43A to form a first intersection portion 44. As a result, the positional relationship of the first wire 41 and the second wire 42 of the fourth turn in the length direction Ld is the opposite of the positional relationship of the first wire 41 and the second wire 42 of the fifth turn in the length direction Ld.

[0242] like Figure 27 As shown by the double-dotted line, the first line 41 of the eighth turn of the first winding portion 43B intersects with the second line 42 of the eighth turn of the first winding portion 43B to form a second intersection portion 45. Thus, in the second intersection portion 45, the first line 41 located in the first layer and the second line 42 located in the second layer intersect at the second side surface 11d of the core portion 11 in the winding portion 40a, the portion closest to the second flange portion 13. Furthermore, when both the first line 41 and the second line 42 of the eighth turn are located in the second layer, in the second intersection portion 45, the first line 41 and the second line 42 intersect at the second side surface 11d of the core portion 11 in the winding portion 40a, the portion closest to the second flange portion 13, in the second layer of the winding portion 40a.

[0243] In the above embodiment, the winding portion 40a is formed by crossing the first line 41 and the second line 42 at a predetermined number of turns every other first line 41 and second line 42, but it is not limited to this. For example, in the winding portion 40a, the portion where the first line 41 and the second line 42 intersect, that is, the first crossing portion 44 and the second crossing portion 45, may be omitted. That is, the winding portion 40a may be constituted only by the first winding portion 43.

[0244] In the above embodiment, the first line 41 and the second line 42 are in Figure 4 The winding section 40a shown is configured such that the first side surface 11c of the core portion 11 at the end of the second flange portion 13 (the end where winding ends) intersects with the second side surface 11c of the core portion 11 at the end of the second flange portion 13 (the end where winding ends) in the winding section 40a, but it is not limited to this configuration. For example, the first line 41 and the second line 42 may also intersect on a circumferential surface other than the first side surface 11c of the core portion 11 at the end of the second flange portion 13 (the end where winding ends) in the winding section 40a. That is, the first line 41 and the second line 42 may intersect on any one of the bottom surface 11a, top surface 11b, and second side surface 11d of the core portion 11 at the end of the second flange portion 13 (the end where winding ends) in the winding section 40a. Alternatively, the second intersection portion 45 where the first line 41 and the second line 42 intersect at the end of the second flange portion 13 (the end where winding ends) in the winding section 40a may be omitted.

[0245] In the above embodiment, instead of the first side surface 11c of the core portion 11 intersecting at the ends of the first thread 41 and the second thread 42 on the second flange portion 13 side (the end where winding ends) in the winding portion 40a, it can be configured as follows: Figure 28As shown, the first wire 41 and the second wire 42 are configured to cross the second side surface 11d of the core portion 11 at the end of the first flange portion 12 (the end at which winding begins) in the winding portion 40a. That is, the first wire 41 and the second wire 42 cross the second side surface 11d of the core portion 11 in the winding portion 40a that is closest to the first flange portion 12. According to this configuration, the second crossing portion 45 is not formed to be adjacent to each other in the length direction Ld of the first winding portion 43, so it is possible to suppress the winding portion 40a from getting too close to the first terminal electrode 31 and the second terminal electrode 32 of the first flange portion 12. Therefore, the quality of the coil component 1 is improved. In addition, when the first wire 41 and the second wire 42 are connected to the first terminal electrode 31 and the second terminal electrode 32, the first wire 41 and the second wire 42 can be bent slowly respectively, so the concern about the first wire 41 and the second wire 42 breaking can be reduced.

[0246] In addition, Figure 28 In the winding section 40a, a second crossing portion 45 is formed on a portion of the first winding section 43 at the end on the side of the first flange 12. Similarly, for example, the first wire 41 and the second wire 42 may cross on the circumferential surface other than the second side surface 11d of the core portion 11 at the end on the side of the first flange 12 (the end where winding begins) of the winding section 40a. That is, the first wire 41 and the second wire 42 may cross on any one of the bottom surface 11a, top surface 11b, and first side surface 11c of the core portion 11 at the end on the side of the first flange 12 (the end where winding begins) of the winding section 40a. With this configuration, the first wire 41 and the second wire 42 can be connected to the first terminal electrode 31 and the second terminal electrode 32 in a slowly bent state, thus reducing stress concentration in the second lead-out portion 40c and the fourth lead-out portion 40e. Alternatively, the second intersection 45 where the first line 41 and the second line 42 intersect at the end of the first flange portion 12 (the end where winding begins) in the winding portion 40a can be omitted.

[0247] In the above embodiment, a second crossing portion 45 is formed on a portion of the first winding portion 43 at the end (end where winding ends) on the second flange portion 13 side of the winding portion 40a, but this is not a limitation. For example, the second crossing portion 45 at the end (end where winding ends) on the second flange portion 13 side of the winding portion 40a is formed so that it is adjacent to the first winding portion 43 in the length direction Ld. Alternatively, if the second crossing portion 45 is formed at the end (end where winding begins) on the first flange portion 12 side of the winding portion 40a, for example, the second crossing portion 45 may be formed so that it is adjacent to the first winding portion 43 at the end (end where winding begins) on the first flange portion 12 side of the winding portion 40a in the length direction Ld.

[0248] In the above embodiment, the first line 41 and the second line 42 constituting the first intersection 44 intersect on the top surface 11b of the core portion 11, but it is not limited to this. For example, the first line 41 and the second line 42 constituting the first intersection 44 may intersect on any one of the bottom surface 11a, the first side surface 11c, and the second side surface 11d of the core portion 11.

[0249] • In the above embodiment, the length LA of the winding portion 40a on the bottom surface 11a of the core portion 11 may be greater than the length LB of the winding portion 40a on the top surface 11b of the core portion 11 in the length direction Ld.

[0250] In the above embodiment, the distance LD2 between the winding portion 40a on the bottom surface 11a of the core portion 11 and the inner surface 13a of the second flange portion 13 in the length direction Ld may be less than the distance LD1 between the winding portion 40a on the bottom surface 11a of the core portion 11 and the inner surface 12a of the first flange portion 12 in the length direction Ld.

[0251] [Examples of changes related to terminal electrodes]

[0252] In the above embodiments, the height direction Td of each end face electrode 31b-34b of each terminal electrode 31-34 can be arbitrarily changed. In one example, such as Figure 29 As shown, the height direction Td of the first end face electrode 31b of the first terminal electrode 31 can be larger than the height direction Td of the second end face electrode 32b of the second terminal electrode 32. Alternatively, although not shown, the height direction Td of the first end face electrode 31b of the first terminal electrode 31 can be smaller than the height direction Td of the second end face electrode 32b of the second terminal electrode 32. With this configuration, the user can visually confirm the orientation of the coil component 1. Furthermore, the height direction Td of the third end face electrode 33b of the third terminal electrode 33 and the height direction Td of the fourth end face electrode 34b of the fourth terminal electrode 34 can also be changed in the same way as the height direction Td of the first end face electrode 31b of the first terminal electrode 31 and the height direction Td of the second end face electrode 32b of the second terminal electrode 32.

[0253] In the above embodiments, the methods for forming the first end face electrode 31b of the first terminal electrode 31 and the second end face electrode 32b of the second terminal electrode 32 may differ from the methods for forming the third end face electrode 33b of the third terminal electrode 33 and the fourth end face electrode 34b of the fourth terminal electrode 34. In one example, the first end face electrode 31b and the second end face electrode 32b may be formed by the coating apparatus 100, and the third end face electrode 33b and the fourth end face electrode 34b may be formed by screen printing. Alternatively, the third end face electrode 33b and the fourth end face electrode 34b may be formed by the coating apparatus 100, and the first end face electrode 31b and the second end face electrode 32b may be formed by screen printing. In this case, only one square portion of the first end face electrode 31b, the second end face electrode 32b, the third end face electrode 33b, and the fourth end face electrode 34b becomes concave-convex. Furthermore, the methods for forming each end face electrode 31b to 34b may be set independently. In this case, at least one of the end face electrodes 31b to 34b is formed by using the coating apparatus 100, and at least one of the end face electrodes 31b to 34b is formed in an uneven shape.

[0254] In the above embodiments, at least one of the outer edges of each bottom surface electrode 31a-34a of each terminal electrode 31-34 may include a straight portion. In short, it is acceptable as long as the outer edge of each bottom surface electrode 31a-34a has a shape that does not form a corner where stress is easily concentrated.

[0255] In the above embodiments, at least one of the outer edges of each end face electrode 31b to 34b of each terminal electrode 31 to 34 may include a straight portion. In short, it is acceptable as long as the outer edge of each end face electrode 31b to 34b has a shape that does not form a corner where stress is easily concentrated.

[0256] In the above embodiments, at least one of the outer edges of the bottom surface electrodes 31a to 34a of each terminal electrode 31 to 34 may be formed only by a straight line. That is, at least one of the outer edges of each bottom surface electrode 31a to 34a may be formed by a shape that does not include a convex curve.

[0257] In the above embodiments, at least one of the outer edges of each end face electrode 31b to 34b of each terminal electrode 31 to 34 may be formed only by a straight line. That is, at least one of the outer edges of each end face electrode 31b to 34b may be formed by a shape that does not include a convex curve.

[0258] In the above embodiments, the relationship between the height direction Td and the width direction Wd of each end face electrode 31b-34b of each terminal electrode 31-34 can be arbitrarily changed. Alternatively, the height direction Td of at least one end face electrode 31b-34b may be less than the width direction Wd.

[0259] • In the above embodiments, the end face electrodes 31b to 34b of each terminal electrode 31 to 34 may also be omitted.

[0260] • In the above embodiments, the plate-shaped component 50 may also be omitted.

[0261] In the above embodiment, after forming the end face electrodes 31b to 34b of each terminal electrode 31 to 34 by the coating apparatus 100, the bottom face electrodes 31a to 34a of each terminal electrode 31 to 34 are formed by the dip coating apparatus 110, but this is not a limitation. Alternatively, the end face electrodes 31b to 34b may be formed by the coating apparatus 100 after forming the bottom face electrodes 31a to 34a by the dip coating apparatus 110. In this case, the end face electrodes 31b to 34b are formed on the outer side of the bottom face electrodes 31a to 34a at the portion where the bottom face electrodes 31a to 34a overlap with the end face electrodes 31b to 34b.

[0262] In the above embodiment, the end face electrodes 31b to 34b of each terminal electrode 31 to 34 are formed by the coating apparatus 100, but the method of forming each end face electrode 31b to 34b is not limited thereto. For example, the end face electrodes 31b to 34b of each terminal electrode 31 to 34 may also be formed by a screen printing apparatus.

[0263] • In the end-face electrode forming process of the above embodiment, the number of coated portions 35 in the width direction Wd may be different in the height direction Td. In one example, the number of coated portions 35 in the width direction Wd may increase as they approach the bottom surface 12d of the first flange portion 12 and the bottom surface 13d of the second flange portion 13.

Claims

1. A coil component comprising: The core has a core portion extending along the length direction of the coil component, a first flange portion disposed at a first end of the core portion in the length direction, and a second flange portion disposed at a second end of the core portion in the length direction. The first thread and the second thread are wound in the same direction around the core portion; A first terminal electrode and a second terminal electrode, wherein the first terminal electrode is disposed on the bottom part of the first flange portion in the height direction of the coil component orthogonal to the length direction and is connected to the first end of the first wire, and the second terminal electrode is disposed on the bottom part of the first flange portion and is connected to the first end of the second wire. A third terminal electrode and a fourth terminal electrode, wherein the third terminal electrode is disposed on the bottom portion of the second flange in the height direction and connected to the second end of the first wire, and the fourth terminal electrode is disposed on the bottom portion of the second flange and connected to the second end of the second wire; and A plate-shaped component is attached to the first flange portion and the second flange portion by adhesive to bridge the top surface of the first flange portion and the top surface of the second flange portion in the height direction. The direction orthogonal to the aforementioned length direction and height direction is defined as the width direction of the aforementioned coil component. At least one of the top surface of the first flange portion in the aforementioned height direction and the portion of the plate-shaped member opposite to the first flange portion in the aforementioned height direction is provided with a first recess. The first recess is closed in the width and length directions and open in the height direction. When viewed from the aforementioned height direction, the first recess is smaller than the top surface of the first flange.

2. The coil component according to claim 1, wherein, The first recess is provided on the top surface of the first flange in the height direction.

3. A coil component, comprising: The core has a core portion extending along the length direction of the coil component, a first flange portion disposed at a first end of the core portion in the length direction, and a second flange portion disposed at a second end of the core portion in the length direction, wherein the first flange portion and the second flange portion each have a top surface portion. The first thread and the second thread are wound in the same direction around the core portion; A first terminal electrode and a second terminal electrode, wherein the first terminal electrode is disposed on the bottom part of the first flange portion in the height direction of the coil component orthogonal to the length direction and is connected to the first end of the first wire, and the second terminal electrode is disposed on the bottom part of the first flange portion and is connected to the first end of the second wire. A third terminal electrode and a fourth terminal electrode, wherein the third terminal electrode is disposed on the bottom portion of the second flange in the height direction and connected to the second end of the first wire, and the fourth terminal electrode is disposed on the bottom portion of the second flange and connected to the second end of the second wire; and A plate-shaped component is attached to the first flange portion and the second flange portion by adhesive to bridge the top surface portion of the first flange portion and the top surface portion of the second flange portion in the height direction. The direction orthogonal to the aforementioned length direction and height direction is defined as the width direction of the aforementioned coil component. A first recess is provided on the top surface of the first flange portion in the aforementioned height direction. A second recess is provided in the plate-shaped member in the aforementioned height direction.

4. A coil component comprising: The core has a core portion extending along the length direction of the coil component, a first flange portion disposed at a first end of the core portion in the length direction, and a second flange portion disposed at a second end of the core portion in the length direction. The first thread and the second thread are wound in the same direction around the core portion; A first terminal electrode and a second terminal electrode, wherein the first terminal electrode is disposed on the bottom part of the first flange portion in the height direction of the coil component orthogonal to the length direction and is connected to the first end of the first wire, and the second terminal electrode is disposed on the bottom part of the first flange portion and is connected to the first end of the second wire. A third terminal electrode and a fourth terminal electrode, wherein the third terminal electrode is disposed on the bottom portion of the second flange in the height direction and connected to the second end of the first wire, and the fourth terminal electrode is disposed on the bottom portion of the second flange and connected to the second end of the second wire; and A plate-shaped component is attached to the first flange portion and the second flange portion by adhesive to bridge the top surface of the first flange portion and the top surface of the second flange portion in the height direction. The direction orthogonal to the aforementioned length direction and height direction is defined as the width direction of the aforementioned coil component. At least one of the top surface of the first flange portion in the aforementioned height direction and the portion of the plate-shaped member opposite to the first flange portion in the aforementioned height direction is provided with a first recess. The first flange portion has an inner surface facing the core portion side in the length direction, an outer surface facing the opposite side to the inner surface in the length direction, a first side surface and a second side surface connecting the outer surface and the inner surface in the length direction. The first recess is formed by separating the inner surface, outer surface, first side surface, and second side surface of the first flange.

Images