Coil component

Abstract

A coil subassembly (1) has a first core (10), a second core (20), and a base portion (30) formed with a housing recess (32). The second core (20) includes a flat plate portion (22) and a leg portion (24). The leg portion (24) extends from an end portion of the flat plate portion (22) in an axial direction of a coil (50) toward a bottom surface of the housing recess (32). The housing recess (32) includes a first space (34) and a second space (36). The first core (10) is housed in the first space (34). The second space (36) is a space different from the first space (34). The leg portion (24) is housed in the second space (36). The base portion (30) has a leg portion restricting portion (38). The leg portion restricting portion (38) is disposed on an inner side in the axial direction of the leg portion (24).

Description

Technical Field

[0001] This invention relates to a coil component. Background Technology

[0002] Among coil components, there exist coil components that have multiple cores and a coil wound around a portion of these cores. Regarding this technology, Patent Document 1 discloses a coil component (100) having an insulating frame (24), two cores (a magnetic core (10) and a second magnetic core (23)), and a coil (54). Specifically, a U-shaped magnetic core (10) is housed in the insulating frame (24), and a coil (54) is wound around the insulating frame (24) and the U-shaped magnetic core (10). Furthermore, an I-shaped second magnetic core (23) is positioned above the U-shaped magnetic core (10).

[0003] The side of a portion of the second magnetic core (23) of the I-shape is surrounded by the first wall portion (27) of the insulating frame (24) and other wall portions.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2020-126909 Summary of the Invention

[0007] The problem the invention aims to solve

[0008] However, in the coil component (100) of Patent Document 1, there may be a problem that the second magnetic core (23) may be offset relative to the insulating frame (24). Specifically, there may be a problem that the second magnetic core (23) is offset relative to the insulating frame (24) in the axial direction of the coil (54), or is offset in a way that it rotates relative to the insulating frame (24) when viewed from above.

[0009] For example, when a coil component is placed on a mounting substrate for surface mounting, there may be a situation where the position and orientation of the upper magnetic core, as seen from above, are considered as the position and orientation of the coil component as a whole, and the alignment is performed relative to the mounting substrate. In this case, if the second magnetic core (23), which is positioned above, is offset relative to the insulating frame (24) in the axial or rotational direction, a problem may occur where the coil component is not positioned or oriented properly relative to the mounting substrate.

[0010] Furthermore, if the upper magnetic core (second magnetic core (23)) is offset relative to the insulating frame (24) in the axial or rotational direction, the upper magnetic core (second magnetic core (23)) may be offset relative to the lower magnetic core (magnetic core (10)). In this case, it may be impossible to obtain appropriate magnetic properties.

[0011] The present invention was made in view of the above-mentioned problems, and provides a coil component that suppresses the offset of the core disposed above relative to the base portion in the axial direction of the coil, or the offset of the core disposed above relative to the base portion when viewed from above.

[0012] Solution for solving the problem

[0013] The coil component of the present invention comprises: a first core; a base portion having a receiving recess for receiving the first core; a terminal portion disposed on the base portion; at least one coil connected to the terminal portion and spirally arranged around the core portion of the first core and the base portion; and a second core disposed above the first core, the second core comprising: a flat plate portion; and a leg portion extending from one axial end of the flat plate portion toward the bottom surface of the receiving recess, the receiving recess comprising: a first space for receiving the core portion; and a second space, different from the first space, for receiving the leg portion, the base portion having a leg portion restraint portion disposed on the axially inner side of the leg portion.

[0014] In the coil component of the present invention, the second core disposed on the upper part has a support leg extending downward, and a support leg limiting part (limiting part) of the base part is disposed on the inner side of the support leg part in the axial direction. Thus, when the second core is to be offset relative to the base part in the axial direction, or to be offset in a way that allows rotation when viewed from above, the limiting part restricts the movement of the second core, thereby suppressing the offset of the second core.

[0015] The effects of the invention

[0016] According to the coil component of the present invention, the offset of the second core relative to the base portion is suppressed by the limiting portion. Thus, a coil component is provided that suppresses the offset of the second core disposed above relative to the base portion in the axial direction of the coil, or the offset of the second core disposed above relative to the base portion in a manner that allows it to rotate relative to the base portion when viewed from above. Attached Figure Description

[0017] The above-described objectives and other objectives, features, and advantages will become clearer from the preferred embodiments described below and the accompanying drawings attached to the preferred embodiments.

[0018] Figure 1This is a perspective view showing an example of a coil component according to the first embodiment of the present invention.

[0019] Figure 2 This is an exploded perspective view of the coil components of the first embodiment.

[0020] Figure 3 This is a left view of the coil component according to the first embodiment.

[0021] Figure 4 This is a top view of the coil components according to the first embodiment.

[0022] Figure 5 This is a front view of the coil components of the first embodiment.

[0023] Figure 6 This is a bottom view of the coil components according to the first embodiment.

[0024] Figure 7 (a) is a Figure 3 A sectional view taken along the section with the single-dotted line in the direction of arrow line VII-VII. Figure 7 (b) refers to the case where the second core is in a rotating state. Figure 3 A sectional view taken along the section with the single-dotted line in the direction of arrow line VII-VII.

[0025] Figure 8 Yes Figure 4 A sectional view taken along the section with the single-dotted line in the direction of the arrow line VIII-VIII.

[0026] Figure 9 (a) is a top view of the front end of the coil component and its vicinity. The second core is omitted from the diagram. Figure 9 (b) is for Figure 4 A sectional view taken along the section with the single-dotted line in the direction of the arrow line IX-IX.

[0027] Figure 10 This is a cross-sectional view of the front end and surrounding area of ​​the coil component according to the second embodiment of the present invention. It is a cross-sectional view of the coil component according to the second embodiment, and... Figure 3 The section view corresponding to the single-dotted line in the diagram, and is oriented towards... Figure 3 A cross-sectional view viewed in the direction corresponding to the direction of the arrow line VIII-VIII in the diagram.

[0028] Figure 11 (a) is a longitudinal sectional view showing an example of a coil component according to a third embodiment of the present invention. Figure 11 (b) is a longitudinal sectional view showing another example of the coil component of the third embodiment. Detailed Implementation

[0029] The various constituent elements of the coil components of the present invention do not need to be independent entities. It is permissible for many constituent elements to form a single component, for a single constituent element to be formed by multiple components, for a certain constituent element to be part of other constituent elements, or for a part of a certain constituent element to be repeated by a part of other constituent elements.

[0030] Hereinafter, embodiments of the present invention will be described based on the accompanying drawings. Furthermore, in each drawing, corresponding constituent elements will be labeled with common reference numerals, and repetitive descriptions will be omitted where appropriate.

[0031] Furthermore, in this embodiment, the directions of front-back, left-right, up-down, and back-forward are defined as shown in the illustration. However, this is a convenient definition for simply illustrating the relative relationships of the constituent elements and does not limit the direction during manufacturing or use of the product implementing the present invention. In this embodiment, the up-down direction refers to the direction orthogonal to the surface of the mounting substrate when the coil component is placed on the mounting substrate. When the coil component is placed on a horizontal mounting substrate, the up-down direction is consistent with the vertical direction; when the coil component is placed on an inclined mounting substrate, the up-down direction becomes an inclined direction relative to the vertical direction. There are cases where the front-back direction and the left-right direction are referred to as the lateral direction. In this embodiment, the front-back direction is consistent with the axial direction of the coil. In addition, there are cases where the left-right direction is referred to as the width direction of the coil component, and there are cases where the up-down direction is referred to as the height direction of the coil component or the components within the coil component.

[0032] Furthermore, in this invention, a plane refers to a shape that is physically formed with a plane as its target, and of course, it does not need to be a geometrically perfect plane.

[0033] <First Implementation>

[0034] (Coil components)

[0035] Figure 1 This is a perspective view showing an example of the coil component 1 according to the first embodiment of the present invention. Figure 2 This is an exploded perspective view of coil component 1.

[0036] First, an overview of the coil component 1 in this embodiment will be described.

[0037] like Figure 2As illustrated, the coil component 1 of this embodiment includes a first core 10, a base portion 30, a terminal portion 40, at least one coil 50, and a second core 20. A receiving recess 32 is formed in the base portion 30. The first core 10 is received in the receiving recess 32. The terminal portion 40 is disposed in the base portion 30. The coil 50 is connected to the terminal portion 40. The coil 50 is spirally arranged around the core portion 12 in the first core 10 and around the base portion 30. The second core 20 is disposed above the first core 10.

[0038] The second core 20 includes a flat plate portion 22 and a support portion 24. The support portion 24 extends from one end of the flat plate portion 22 in the axial direction of the coil 50 (core end 14) toward the bottom surface of the receiving recess 32.

[0039] The receiving recess 32 includes a first space 34 and a second space 36. The first space 34 receives the core portion 12. The second space 36 is a different space from the first space 34. The second space 36 receives the support leg portion 24.

[0040] The base portion 30 has a foot restriction portion (restriction portion 38). The restriction portion 38 is disposed on the inner side of the foot portion 24 in the axial direction.

[0041] The coil component 1 of the present invention has a second core 20 positioned at the top, which has a downwardly extending support leg 24. A limiting portion of the base portion is disposed on the inner side of the support leg 24 in the axial direction. Therefore, when the second core 20 is to be offset axially relative to the base portion 30, or to be offset in a manner that allows rotation when viewed from above, the limiting portion 38 suppresses the offset of the second core by restricting its movement. Thus, a coil component 1 can be provided that suppresses the offset of the second core 20 positioned at the top relative to the base portion 30 in the axial direction of the coil 50, or its offset in a manner that allows rotation relative to the base portion 30 when viewed from above. Furthermore, there are cases where the offset of the second core 20 relative to the base portion 30 in the axial direction of the coil 50 is referred to as lateral offset, and the offset of the second core 20 relative to the base portion 30 in a manner that allows rotation when viewed from above is referred to as rotational offset.

[0042] Next, the coil component 1 of this embodiment will be described in detail.

[0043] Coil component 1 refers to an electronic component having a coil 50. An electronic component is a component that can form part of an electronic circuit. Examples of coil component 1 include transformers, antennas, or inductors. In this embodiment, the coil component 1 is configured and mounted on a mounting substrate (not shown) such that the mounting surface of the terminal portion 40 (described later) is in contact with the mounting substrate (not shown).

[0044] Coil 50 refers to a component made of conductive material arranged in a spiral. In this embodiment, coil 50 is a coil made of coil wire with a circular cross-section arranged in a spiral. Coil 50 may also be formed of coil wire with a flat cross-section (rectangular or elliptical, etc.). The manufacturing method of coil 50 is not limited, and it can be any coil made of conductive material in a spiral. In this embodiment, coil 50 is formed by winding coil wire around first core 10 and base portion 30. The coil wire in coil 50 may be pressed or abutted against the upper surface of first core 10, or the core side portion 35 or bottom portion 30a of base portion 30. Alternatively, the coil wire may be arranged in a manner that is embedded in the upper surface of first core 10, or the core side portion 35 or bottom portion 30a of base portion 30. Alternatively, the coil wire may be separate from the upper surface of first core 10, or the core side portion 35 or bottom portion 30a of base portion 30.

[0045] Alternatively, the coil 50 can be formed by pre-arranging conductive material in a spiral shape with a hollow core, instead of this embodiment. In this case, the first core 10 and the base portion 30 can be inserted into the hollow portion of the coil after it has been formed. The inner surface (circumferential surface of the flat line) of the winding portion 53 can be either separate from or in contact with the first core 10 or the base portion 30.

[0046] The coil component 1 may have one or more coils 50. In this embodiment, the coil component 1 has two coils 50 (a first coil 51 and a second coil 52). The axial direction of both the first coil 51 and the second coil 52 is in the front-rear direction, and the axial directions of the first coil 51 and the second coil 52 are arranged parallel to each other. More specifically, the reel of the first coil 51 and the reel of the second coil 52 are arranged on the same straight line.

[0047] The coil 50 has a winding portion 53 formed by winding coil wire. The coil 50 has lead-out portions 54, which are the two ends of the coil wire and are part of the coil wire, extending out from the winding portion 53. In the coil 50 of this embodiment, the two ends of the coil wire are led out, and the two ends are respectively connected to the terminal portion 40.

[0048] like Figure 3 As shown in the diagram, the lead-out portion 54 extends toward the terminal portion 40 (connecting wire portion 42). More specifically, as... Figure 6 As shown in the diagram, the lead-out portion 54 is wired along the lower surface of the base portion 30, extending from the winding portion 53 to the connecting wire portion 42. The lead-out portion 54 is electrically connected to the connecting wire portion 42.

[0049] Terminal portion 40 is an electrode component electrically connected to coil 50. Terminal portion 40 serves as an input electrode or output electrode for coil component 1. Terminal portion 40 is formed of a conductive component such as metal.

[0050] like Figure 6 As shown in the figure, two terminal portions 40 are provided on the two side wall portions 37, which will be discussed later. Each terminal portion 40 has a connecting wire portion 42, a middle portion 44, and a mounting portion 46.

[0051] The connecting wire portion 42 refers to the part for connecting to the end of the lead-out portion 54. During the manufacturing process, the end of the lead-out portion 54 is wound around the connecting wire portion 42, and the ends of the connecting wire portion 42 and the lead-out portion 54 are soldered together to manufacture the coil component 1 of this embodiment. The connecting wire portion 42 and the lead-out portion 54 can also be joined by means of soldering or the like.

[0052] Mounting section 46 is a part of the terminal section 40 that contacts (grounds) the substrate (not shown) when mounting the coil component 1. Specifically, mounting section 46 includes a downward-facing mounting surface that contacts the substrate surface. Mounting section 46 is joined to the substrate by means of soldering or the like.

[0053] The middle portion 44 is the part sandwiched between the connecting wire portion 42 and the mounting portion 46. In this embodiment, the middle portion 44 is embedded in the base portion 30. The connecting wire portion 42 and the mounting portion 46 are exposed relative to the base portion 30.

[0054] The cores (first core 10 and second core 20) are components formed of magnetic material. In this embodiment, the first core 10 is a so-called I-core, and the second core 20 is a so-called U-core. The first core 10 and the second core 20 are combined to form a closed magnetic circuit. The shapes of the first core 10 and the second core 20 are not limited to the shapes described above. For example, the first core 10 and the second core 20 may each have an L-shape, and they may be combined to form a closed magnetic circuit. Alternatively, both the first core 10 and the second core 20 may be U-cores.

[0055] An adhesive (not shown) may also be disposed between the first core 10 and the second core 20. Specifically, the upper surface 10a of the core end 14, discussed later, may also be bonded to the lower surface 24c of the support portion 24 by means of an adhesive. Alternatively, a sheet (a non-magnetic spacer) for forming a gap may be disposed between the first core 10 and the second core 20. Two spacers may be disposed between the front core end 14 and the lower surface 24c of the support portion 24, and between the rear core end (core end 14) and the lower surface 24c of the support portion 24, respectively. Alternatively, a single spacer may be disposed across both ends (core ends 14, 14) of the first core 10. That is, a spacer may be disposed substantially entirely on the upper surface of the first core 10, between the front core end 14 and the support portion 24, and between the rear core end 14 and the support portion 24.

[0056] The first core 10 is a core disposed below the second core 20. In this embodiment, the first core 10 is a laterally extending flat plate. A coil 50 is wound around the core portion 12 located at the center in the front-rear direction of the first core 10. The phrase "the coil 50 is wound around a predetermined component (such as the first core 10 or the base portion 30)" means that the coil 50 is arranged around the predetermined component. Some components may be arranged between the predetermined component and the coil 50, or some components may not be arranged. That is, "the coil 50 is wound around a predetermined component" includes cases where the coil 50 is wound indirectly or directly around the predetermined component. In this embodiment, it can be said that the first core 10 is indirectly wound with the coil 50 across the base portion 30. The two ends of the first core 10 in the front-rear direction are core end portions 14.

[0057] The second core 20 is disposed above the first core 10. The second core 20 may be in contact with the first core 10 and directly mounted on the first core 10, or it may be disposed separately above the first core 10 from its upper surface. In this embodiment, the lower surface of the support portion 24 of the second core 20, which will be discussed later, contacts the core end portion 14 of the first core 10, and the second core 20 is directly mounted on the first core 10.

[0058] The second core 20 has a flat plate portion 22 and one or more support portions 24. Specifically, the second core 20 has two support portions 24 adjacent to each end of the flat plate portion 22 in the front-rear direction. The flat plate portion 22 refers to a portion of the second core 20 having a laterally extending flat plate shape. The support portion 24 is a portion of the second core 20 extending in a direction intersecting the main surface of the flat plate portion 22. The support portion 24 is formed in a manner that protrudes downward from the flat plate portion 22. The support portion 24 may extend in a direction orthogonal to the main surface of the flat plate portion 22 or in an inclined direction.

[0059] The base portion 30 refers to the component that holds the first core 10 and the second core 20. The base portion 30 is formed of an insulating material such as resin.

[0060] The receiving recess 32 in the base portion 30 refers to the space for the first core 10 or the second core 20 to be disposed. In this embodiment, the receiving recess 32 is formed by the base portion 30 being recessed downward.

[0061] The receiving recess 32 receives the first core 10. Receiving the first core 10 means that at least a portion of the first core 10 is disposed in the receiving recess 32. In this embodiment, the entire first core 10 is disposed in the receiving recess 32. More specifically, the first core 10 is disposed across the first space 34 and the second space 36.

[0062] The first space 34 is the space that houses the core portion 12 of the first core 10. Specifically, the first space 34 is formed by dividing the bottom portion 30a and the core side portion 35. In this embodiment, the upper end of the first space 34 terminates on the imaginary upper surface of the base portion 30 (an imaginary surface including the upper end of the side wall portion 37, which will be discussed later). The front-rear boundaries of the first space 34 will then be discussed.

[0063] The core side portion 35 is a part of the base portion 30 that is erected from the bottom portion 30a. In this embodiment, the two core side portions 35 are arranged separately in the left-right direction. The core portion 12 is disposed between the two core side portions 35.

[0064] The second space 36 is a space different from the first space 34, meaning that the second space 36 does not overlap with the first space 34.

[0065] The second space 36 is a space for accommodating at least a portion of the support leg 24 of the second core 20. In this embodiment, the receiving recess 32 includes two second spaces 36 that respectively accommodate a pair of support legs 24 arranged separately in the front-rear direction. The two second spaces 36 are arranged apart from the first space 34 in the front-rear direction.

[0066] The second space 36 is formed by dividing a bottom portion 30a and sidewall portions 37. The bottom portion 30a refers to a part including the lower surface of the base portion 30. The sidewall portion 37 is a part of the wall formed by rising from the bottom portion 30a in the base portion 30, and is U-shaped when viewed from above, surrounding the sides of the support portion 24. Specifically, the sidewall portions 37 are arranged on the outer side in the front-rear direction and on both sides in the left-right direction of the support portion 24. The outer side in the front-rear direction refers to the periphery of the base portion 30 in the front-rear direction (the periphery of the base portion 30 when viewed from above). The inner side in the front-rear direction refers to the center of the base portion 30 in the front-rear direction (the center of the base portion 30 when viewed from above). In addition, the upper end of the second space 36 in this embodiment is an imaginary surface (a laterally extending imaginary surface) including the upper end of the sidewall portion 37. In this embodiment, as Figure 5 As illustrated, a portion of the upper surface of the second core 20 (especially the flat plate portion 22) is positioned above the upper end of the sidewall portion 37. That is, a portion of the upper surface of the flat plate portion 22 is positioned outside the envelope volume of the base portion 30. In other words, a portion of the lower surface of the flat plate portion 22 of the second core 20 is positioned within the receiving recess 32 (especially the second space 36 or the first space 34), while a portion of the upper surface of the flat plate portion 22 is positioned outside the receiving recess 32.

[0067] In this embodiment, in addition to the support portion 24 of the second core 20, the second space 36 also houses the core end portion 14 of the first core 10. As in the third embodiment discussed later, the core end portion 14 may not be disposed in the second space 36.

[0068] In addition, such as Figure 7 As illustrated in (a), the receiving recess 32 includes a space sandwiched between the second side 38d of each of the pair of limiting portions 38 discussed later (the space for the boundary portion between the core end 14 in the first core 10 and the winding core portion 12 is referred to as the boundary space). This boundary space may belong to either the first space 34 or the second space 36.

[0069] like Figure 7 As illustrated in (a), the limiting part 38 refers to a portion of the base part 30 and is a part capable of limiting the movement of the support leg 24. The limiting part 38's ability to limit the movement of the support leg 24 means that during the manufacturing process or in the finished product of the coil component 1, the limiting part 38 can restrict the movement of the support leg 24 relative to the base part 30. The limiting part 38's ability to limit the movement of the support leg 24 includes not only restricting the movement of the support leg 24 relative to the base part 30 in a certain direction in the finished product of the coil component 1, but also allowing the support leg 24 to abut against the limiting part 38 during the manufacturing process of the coil component 1, thereby restricting the movement of the support leg 24 relative to the base part 30 in a certain direction.

[0070] The limiting part 38 restricts the movement of the support leg 24 by being arranged adjacent to it. Adjacent to the support leg 24 means that the separation distance between the limiting part 38 and the support leg 24 is less than a predetermined distance. Specifically, the separation distance (distance D3) between the limiting part 38 and the support leg 24 is preferably smaller than the separation distance (distance D4 or distance D5) between the side wall part 37 and the support leg 24. More specifically, the distance in the front-rear direction between the limiting part 38 and the support leg 24 is preferably smaller than the distance in the front-rear direction (distance D4) between the side wall part 37 and the support leg 24, or the distance in the left-right direction (distance D5) between the side wall part 37 and the support leg 24.

[0071] In this embodiment, the limiting portion 38 is an inner wall portion extending in the left-right direction. This inner wall portion can be said to divide and form a first space 34 and a second space 36. This inner wall portion extends from the bottom portion 30a of the base portion 30 (see reference 30a)... Figure 2 It is configured to stand upright. In addition, the inner wall portion and the side wall portion 37 are integrally formed.

[0072] The shape of the limiting portion 38 is not limited to an inner wall portion as in this embodiment. For example, the limiting portion 38 may also be a columnar portion protruding upward from the bottom portion 30a, and this columnar portion may be formed separately from the side wall portion 37. Alternatively, the limiting portion 38 may also be a protrusion formed in a manner that protrudes inward from the side wall portion 37 in a left-right direction. This protrusion may also be connected to the bottom portion 30a in the base portion 30 (see reference). Figure 2 )separate.

[0073] In this embodiment, the front-rear dimension of the base portion 30 is larger than its left-right dimension, but the left-right dimension of the base portion 30 is a predetermined size relative to its front-rear dimension. In other words, for a portion of the base portion 30 constituting the first space 34, the left-right dimension is larger than the front-rear dimension. The limiting portion 38 is positioned near the center of the base portion 30 in the front-rear direction. More specifically, the left-right distance (distance D8) between the center of the base portion 30 in the left-right direction and the limiting portion 38 (second side surface 38d) is larger than the front-rear distance (distance D9) between the center of the base portion 30 in the front-rear direction and the limiting portion 38 (the center of the limiting portion 38 in the front-rear direction or the main surface of the winding portion 53 side of the limiting portion 38). Furthermore, the relative spacing between the second side surfaces 38d of the pair of limiting portions 38 arranged in the left-right direction is greater than the distance in the front-back direction between the first leg portion 24f and the second leg portion 24g (the relative spacing between the inner side surfaces 24d of the pair of legs 24). Based on this dimensional relationship, the inner side surfaces 24d of the legs 24 can easily contact the limiting portions 38 (especially the second side surfaces 38d) as discussed later.

[0074] In this embodiment, the limiting part 38 is also the winding frame part of the auxiliary coil 50. That is, the limiting part 38 is arranged axially on the outer side of the coil 50 (winding part 53). More specifically, the limiting part 38 is arranged axially sandwiched between the coil (coil wire in the winding part 53) and the support part 24.

[0075] like Figure 7 As illustrated in (a), the base portion 30 has two paired limiting portions 38 (first limiting portion 38a and second limiting portion 38b). These two paired limiting portions 38 are arranged on both sides of the first core 10 in the width direction of the base portion 30. The first limiting portion 38a and the second limiting portion 38b are respectively adjacent to the two ends of a support portion 24 in the left-right direction. This allows for better suppression of the offset of the support portion 24.

[0076] Furthermore, in this embodiment, the second core 20 has two support legs 24. Therefore, in this embodiment, the limiting portions 38 are arranged adjacent to both ends of each support leg 24. That is, in this embodiment, the base portion 30 has four limiting portions 38.

[0077] like Figure 7 As shown in (b), the support leg 24 has an inner surface 24d facing the limiting part 38. Figure 7 The orthogonal direction represented by the dashed line II in (b) can also be relative to the axial direction. Figure 7 (b) The direction indicated by the dashed line I is tilted. That is, when viewed from above, the second core 20 can also be configured to rotate relative to the axial direction. The orthogonal direction refers to the direction orthogonal to the inner surface. In this embodiment, the orthogonal direction can also be described as the direction in which the pair of legs 24, 24 are arranged.

[0078] By rotatably configuring the second core 20 in a predetermined direction, product errors regarding the angular difference between the linear direction and the axial direction can be reduced. That is, product errors caused by the magnetic properties resulting from the misalignment of the second core 20 relative to the first core 10 can be reduced.

[0079] In this embodiment, the inner surface 24d is a flat surface, but it can also be a slightly curved surface. When the inner surface 24d is a curved surface, the direction orthogonal to the tangent near the center in the left-right direction of the inner surface 24d when viewed from above can be set as the orthogonal direction.

[0080] Furthermore, in this embodiment, the inner surface 24d is opposite to the main surface of the limiting portion 38, which serves as the inner wall (the first surface 38c, discussed later). The inner surface 24d and the first surface 38c can be arranged parallel to each other, or the inner surface 24d can be arranged at a position where it intersects with the first surface 38c.

[0081] In this embodiment, the second core 20 is configured to rotate counterclockwise relative to the axial direction, but the second core 20 may also be configured to rotate clockwise relative to the axial direction. The angle (rotation angle) between the orthogonal direction and the axial direction is preferably greater than 0 degrees and less than 10 degrees. The rotation angle is further preferably greater than 0 degrees and less than 5 degrees. As a result, it is possible to reduce the occurrence of positional or orientation offsets when the coil component 1 is placed on the mounting substrate for surface mounting.

[0082] In this embodiment, the left-right dimension (width dimension) of the support leg 24 is larger than the left-right dimension (width dimension) of the core end 14. Therefore, even when the second core 20 is rotatably configured relative to the axial direction, it is possible to suppress the second core 20 (the lower surface 24c of the support leg 24 (see reference)). Figure 9 (b))) and the upper surface 10a of the first core 10 (core end 14) (refer to) Figure 9 The area of ​​the overlapping region in the vertical direction of (b) is significantly reduced. As a result, the generation of large magnetic flux leakage can be suppressed.

[0083] Furthermore, in this embodiment, the front-to-back distance between the first limiting part 38a and the inner side surface 24d in the pair of limiting parts 38 separated in the left-right direction is smaller than the front-to-back distance between the second limiting part 38b and the inner side surface 24d. The front-to-back distance between the first limiting part 38a and the inner side surface 24d also includes the case where the first limiting part 38a and the inner side surface 24d are in contact and the distance is zero.

[0084] It could also be, such as Figure 7 As illustrated in (a), the orthogonal direction is parallel to the axis instead of... Figure 7 As shown in (b), the orthogonal direction is tilted relative to the axis.

[0085] like Figure 7 As illustrated in (b), the leg portion 24 contacts the first limiting portion 38a of the pair of limiting portions 38. On the other hand, the leg portion 24 is separated from the second limiting portion 38b of the pair of limiting portions 38. Specifically, the inner surface 24d of the leg portion 24 contacts the first surface 38c of the first limiting portion 38a. In the second embodiment discussed later, in Figure 10 The first side 38c shown can contact the inner side 24d, and the second side 38d can contact the side of the step portion 24e (especially the outer side facing left and right). By pre-making the support leg portion 24 contact the limiting portion 38, product errors can be reduced more effectively to address the misalignment of the second core 20 relative to the first core 10.

[0086] In this embodiment, the outward-facing side of the support leg 24 abuts against the sidewall 37 in the front-rear direction. The support leg 24 abuts against both the sidewall 37 and the limiting portion 38, thereby securing the second core 20 firmly in the base portion 30. This embodiment illustrates a configuration where a pair of support legs 24 abut against both the sidewall 37 and the limiting portion 38, but alternatively, one support leg 24 may abut against the sidewall 37 and be separated from the limiting portion 38, while the other support leg 24 abuts against the limiting portion 38 and is separated from the sidewall 37.

[0087] like Figure 8As illustrated, the first side surface 38c is the side of the limiting portion 38 facing the support leg portion 24. The first side surface 38c is also the main surface of the limiting portion 38, which serves as the inner wall portion. In this embodiment, the first side surface 38c is inclined relative to the mounting direction (vertical direction). The mounting direction refers to the direction in which the second core 20 is mounted on the first core 10. In other words, the mounting direction is also the direction orthogonal to the upper surface of the first core 10 or the lower surface of the second core 20 (the lower surface 24c of the support leg portion 24).

[0088] The distance (distance D1) between the limiting part 38 and the lower end 24a of the support leg 24 is smaller than the distance (distance D2) between the limiting part 38 and the upper end 24b of the support leg 24.

[0089] According to the above structure, the second space 36 has a larger opening at the opening portion and narrows near the bottom portion 30a. As a result, it is possible to maintain the ease of arranging the second core 20 in the second space 36 while placing the second core 20 in the desired position on the first core 10.

[0090] In addition, for convenience, Figure 8 The first side 38c is shown in the illustration at a significant angle.

[0091] More specifically, the first side 38c tilts outward in the front-rear direction relative to the vertical direction. As it faces the bottom surface 30a (facing downward), the first side 38c tilts outward in the front-rear direction. Therefore, the second space 36 is wider at the top and narrower at the bottom. In particular, the front-rear dimension of the second space 36 is larger at the top and smaller at the bottom.

[0092] In this embodiment, the first side surface 38c is an inclined flat surface, but it is not limited to this. The first side surface 38c can also be a curved surface. For example, the first side surface 38c can be a convex surface protruding towards the support leg side, or it can be a concave surface.

[0093] The distance (distance D2) between the upper end portion 24b of the support leg 24 and the first side surface 38c refers to the front-back direction distance between the surface of the upper end portion 24b (a portion of the upper side of the inner side surface 24d) and a portion of the upper side surface of the first side surface 38c (near the upper end). The distance (distance D1) between the lower end portion 24a of the support leg 24 and the first side surface 38c refers to the front-back direction distance between the surface of the lower end portion 24a (a portion of the lower side of the inner side surface 24d) and a portion of the lower side surface of the first side surface 38c (near the lower end).

[0094] like Figure 9 As illustrated in (a), the bottom surface 30a has two paired raised sections 31. Figure 9As illustrated in (b), the two paired raised portions 31 protrude upward from the surface of the bottom portion 30a on which the first core 10 is mounted (bottom surface 30b). Furthermore, the two paired raised portions 31 are positioned apart from the first core 10 in the width direction of the base portion 30. Misalignment of the first core 10 is effectively suppressed by the pair of raised portions 31.

[0095] In this embodiment, such as Figure 2 As illustrated, the side surface of the raised platform 31 (the inner surface facing the left-right direction) is continuously connected to the side surface of the core side 35 (the inner surface facing the left-right direction). Furthermore, this side surface of the raised platform 31 is also connected to the second side surface 38d of the limiting portion 38 (see reference). Figure 7 (a) are continuously connected. That is, the side of the raised section 31, the side of the core side 35, and the second side 38d in the limiting section 38 are arranged on the same plane (a plane extending in the axial direction). The first core 10 is positioned in the axial direction using the plane including the side of the raised section 31, the side of the core side 35, and the second side 38d in the limiting section 38.

[0096] like Figure 9 As illustrated in (b), in this embodiment, the side surface of the first core 10 is separated from each of the raised platform portions 31 (their side surfaces). That is, a gap is provided between the side surface of the first core 10 and the side surface of the raised platform portion 31. Adhesives and the like can flow into this gap. Alternatively, this embodiment could be replaced by having the side surface of the first core 10 abut against the side surface of at least one raised platform portion 31.

[0097] like Figure 9 As illustrated in (b), the lower surface 24c of the support leg 24 is disposed opposite to the upper surface 10a of the core end portion 14 of the first core 10. More specifically, the lower surface 24c of the support leg 24 is in surface contact with the upper surface 10a of the first core 10. As a result, compared to the case where the lower surface end portion 24h of the support leg 24 of the second core 20 is not in contact with the upper surface 10a of the first core 10, the leakage magnetic flux between the lower surface end portion 24h of the second core 20 and the upper surface 10a of the first core 10 is reduced. In this embodiment, the support leg 24 is wider than the core end portion 14. Specifically, the two ends (lower surface end portions 24h) of the lower surface 24c of the support leg 24 in the width direction (left-right direction) of the base portion 30 are respectively disposed at a position further outward in the width direction than the two ends (upper surface end portions 10a1) of the upper surface 10a of the core end portion 14. In other words, the side of the support leg 24 (the side facing the outside in the left and right direction) is positioned on the outside side in the left and right direction of the side of the core end 14 (the side facing the outside in the left and right direction).

[0098] The two ends (lower surface ends 24h) of the lower surface 24c of the support portion 24 are opposite to and separated from the upper surface of the platform portion 31. That is, there is a gap between the lower surface ends 24h and the upper surface of the platform portion 31. By separating the platform portion 31 from the second core 20, the first core 10 and the second core 20 can make more reliable contact, thus reducing the leakage magnetic flux between the first core 10 and the second core 20. In addition, the coefficient of thermal expansion of the platform portion 31, which is made of resin, is generally greater than that of the first core 10, which is made of magnetic materials such as ferrite. To address this, by providing a gap in the vertical direction between the platform portion 31 and the second core 20, even if the platform portion 31 expands and deforms unpredictably upwards due to heat generated when using the coil component 1, it is possible to prevent the platform portion 31 from contacting the second core 20 and pushing the second core 20 upwards to separate the first core 10 and the second core 20.

[0099] <Second Implementation>

[0100] Figure 10 This is a cross-sectional view showing an example of the coil component 1 of this embodiment. First, an overview of the coil component 1 of this embodiment will be described.

[0101] The coil component 1 in this embodiment has the same features as the coil component 1 in the first embodiment.

[0102] The base portion 30 has a foot restriction portion (restriction portion 38). The restriction portion 38 is disposed on the inner side of the foot portion 24 in the axial direction.

[0103] The distance between the limiting part 38 and the lower end 24a of the support leg 24 is smaller than the distance between the limiting part 38 and the upper end 24b of the support leg 24 (refer to the first embodiment). Figure 8 ).

[0104] The bottom part 30a has two paired raised portions 31, which are arranged apart from the first core 10 in the width direction of the base part 30 (refer to the first embodiment). Figure 9 (a) and Figure 9 (b)

[0105] The two ends of the lower surface 24c (lower surface ends 24h) are opposite to and separate from the upper surface of the raised platform 31 (refer to the first embodiment). Figure 9 (a) and Figure 9 (b)

[0106] The support leg 24 in this embodiment differs from the first embodiment in that it has a protrusion (step 24e). The step 24e extends from the inner side surface 24d of the support leg 24 in the orthogonal direction ( Figure 10The inner side of the step 24e protrudes in the front-back direction. The step portion 24e is configured to be sandwiched between a pair of limiting portions 38.

[0107] By having a stepped portion 24e in the support portion 24, the cross-sectional area of ​​the magnetic circuit formed by the second core 20 and the first core 10 can be increased by an amount corresponding to the cross-sectional area of ​​the stepped portion 24e without extending the length of the magnetic circuit. In addition, the stepped portion 24e is clamped by the limiting portion 38 in the width direction, thereby better suppressing the lateral or rotational displacement of the second core 20.

[0108] Next, the coil component 1 of this embodiment will be described in detail.

[0109] The shape of the support leg of the second core in this embodiment of the coil component 1 differs from that in the first embodiment described above.

[0110] In this embodiment, the stepped portion 24e extends from the upper end to the lower end of the support portion 24. That is, the stepped portion 24e extends in the vertical direction ( Figure 10 It extends in the depth direction of the paper. Alternatively, the step portion 24e may be formed only in a portion of the vertical direction of the foot portion 24 instead of this embodiment. For example, the step portion 24e may not be formed near the upper or lower end of the foot portion 24.

[0111] In this embodiment, the width dimension (left-right dimension) of the stepped portion 24e is the same as the width dimension of the first core 10. Therefore, the lower surface of the stepped portion 24e is approximately the same as the upper surface 10a of the first core 10 (see reference). Figure 9 (b) Contact.

[0112] Similar to the first embodiment, the pair of limiting portions 38 (first limiting portion 38a, second limiting portion 38b) arranged separately in the left-right direction in this embodiment have a second side surface 38d facing the space between the pair of limiting portions 38. The step portion 24e is configured to be sandwiched between the pair of limiting portions 38. More specifically, the step portion 24e is configured to be sandwiched between the second side surface 38d of each of the pair of limiting portions 38.

[0113] In this embodiment, such as Figure 10 As shown in the diagram, the orthogonal direction of the second core 20 is consistent with the front and rear directions.

[0114] It can also be as in the first embodiment. Figure 7 As illustrated in (b), the orthogonal direction of the second core 20 is tilted relative to the axial direction instead of... Figure 10 The shape shown in the diagram.

[0115] In this case, the distance between the second side 38d of one limiting part 38 (first limiting part 38a) and the step part 24e is preferably greater than the distance between the second side 38d of the other limiting part 38 (second limiting part 38b) and the step part 24e. Here, the distance between the second side 38d of the limiting part 38 and the step part 24e refers, for example, the distance in the left-right direction between the second side 38d of the limiting part 38 and the side (the outer side facing left-right) of the step part 24e.

[0116] Preferably, the leg portion 24 contacts the first limiting portion 38a of the pair of limiting portions 38, and the leg portion 24 is separated from the second limiting portion 38b of the pair of limiting portions 38. The second side surface 38d of the first limiting portion 38a may also contact the side surface (outer side facing left and right) of the step portion 24e of the leg portion 24, and the first side surface 38c of the first limiting portion 38a may also contact the inner side surface 24d of the leg portion 24.

[0117] <Third Implementation Method>

[0118] Figure 11 (a) and Figure 11 (b) is a longitudinal sectional view showing an example of the coil component 1 of this embodiment.

[0119] First, an overview of the coil component 1 in this embodiment will be described.

[0120] The coil component 1 in this embodiment has the same features as the coil component 1 in the first embodiment.

[0121] The base portion 30 has a foot restriction portion (restriction portion 38). The restriction portion 38 is disposed on the inner side of the foot portion 24 in the axial direction.

[0122] The orthogonal direction of the second core 20 can also be tilted relative to the axial direction (refer to the first embodiment). Figure 7 (b)

[0123] The support leg 24 contacts the first limiting part 38a of the pair of limiting parts 38, and the support leg 24 separates from the second limiting part 38b of the pair of limiting parts 38 (refer to the first embodiment). Figure 7 (b)

[0124] The distance between the limiting part 38 and the lower end 24a of the support leg 24 is smaller than the distance between the limiting part 38 and the upper end 24b of the support leg 24 (refer to the first embodiment). Figure 8 ).

[0125] like Figure 11As illustrated in (a), the second core 20 of this embodiment shares the same characteristic as the first embodiment, having support portions 24 at both ends in the axial direction. On the other hand, the first core 10 of this embodiment differs from the first embodiment in that it is axially positioned between the two support portions 24.

[0126] According to the above structure, the axial end of the first core 10 and the support portion 24 of the second core 20 can be separated axially. Therefore, compared with the case where the second core 20 is placed on the core end 14 of the first core 10 as in the first embodiment or the second embodiment, a gap can be provided between the first core 10 and the second core 20 without using a spacer made of a non-magnetic material.

[0127] Next, the coil component 1 of this embodiment will be described in detail.

[0128] The coil component 1 in this embodiment differs from the first and second embodiments described above in terms of the shape of the first core and the shape of the second core.

[0129] like Figure 11 As illustrated in (a), in this embodiment, the second core 20 is placed on the bottom surface 30a. Similarly to the first embodiment, the support leg 24 is disposed in the second space 36 within the receiving recess 32.

[0130] On the other hand, in this embodiment, the first core 10 is disposed only in the first space 34 and not in the second space 36. That is, the first core 10 is not disposed below the support leg portion 24. The first core 10 is integrally formed as the core portion 12, and the first core 10 is disposed substantially entirely on the inner diameter side of the coil 50. The first core 10 is disposed in the front-back direction by the inner surfaces 24d of each of a pair of support legs 24 that are separately disposed in the front-back direction.

[0131] The distance between the first foot 24f and the first core 10 ( Figure 11 The distance D6 in (a) can be greater than the distance between the second foot 24g and the first core 10. Figure 11 The distance D7 in (a) is large.

[0132] By arranging the first core 10 close to one of the support portions 24 of the second core 20, the position of the first core 10 relative to the position of the second core 20 can be effectively reduced, thus minimizing product errors. In other words, by arranging the first core 10 biased towards the side of the support portion 24, especially by abutting against the support portion 24, the front-back positioning of the first core 10 can be achieved, thereby reducing manufacturing errors.

[0133] Furthermore, when the first core 10 is positioned at the center of a pair of legs 24 in the front-back direction, or when the first core 10 is positioned forward or backward of the center of the pair of legs 24, the total distance between the first core 10 and each leg 24 (the sum of distance D6 and distance D7) remains constant. That is, by separating the first core 10 and the second core 20 (leg 24) in the front-back direction to form a gap, errors in magnetic properties caused by the position of the first core 10 can be reduced.

[0134] More specifically, the distance between the support leg 24 and the first core 10 refers to the distance in the front-back direction between the inner side 24d of the support leg 24 and the outer side of the surface of the first core 10 facing the front-back direction.

[0135] Furthermore, the condition that distance D6 is greater than distance D7 includes the case where distance D7 is zero. That is, if... Figure 11 As shown in (b), the inner side 24d of the second leg 24g can also contact the side of the first core 10.

[0136] Furthermore, the present invention is not limited to the above-described embodiments, but also includes various modifications and improvements within the scope of achieving the purpose of the present invention.

[0137] The above implementation methods include the following technical concepts.

[0138] (1) A coil component, comprising:

[0139] First chip;

[0140] The base portion has a receiving recess for receiving the first core;

[0141] A terminal portion is disposed on the base portion;

[0142] At least one coil, connected to the terminal portion, is spirally arranged around the core portion and the base portion in the first core; and

[0143] The second core is positioned above the first core.

[0144] The second core includes: a flat plate portion; and a support leg portion extending from one end of the flat plate portion in the axial direction of the coil toward the bottom surface of the receiving recess.

[0145] The receiving recess includes: a first space for receiving the core portion; and a second space, different from the first space, for receiving the support leg portion.

[0146] The base portion has a foot portion restriction portion disposed on the inner side of the foot portion in the axial direction.

[0147] (2) The coil component according to (1), wherein the support leg has an inner side facing the side of the support leg limiting portion.

[0148] The orthogonal direction, which is orthogonal to the inner surface, is inclined relative to the axial direction.

[0149] (2-1) In coil components, the angle between the orthogonal direction and the axial direction is greater than 0 degrees and less than 10 degrees.

[0150] (2-2) In coil components, the angle between the orthogonal direction and the axial direction is greater than 0 degrees and less than 5 degrees.

[0151] (2-3) In the coil components, the dimension of the lower surface of the support portion in the width direction of the coil component is larger than the dimension of the upper surface of the core end portion in the width direction of the coil component.

[0152] (3) Based on the coil components in (2), wherein,

[0153] The base portion has two paired support leg limiting portions arranged on both sides of the first core in the width direction of the base portion.

[0154] The support leg contacts the first support leg limiting portion of the pair of support leg limiting portions and separates from the second support leg limiting portion of the pair of support leg limiting portions.

[0155] (3-1) In the coil components, the side of the support leg facing outward in the axial direction abuts against the side wall.

[0156] (4) Based on the coil components in (3), among which,

[0157] The support leg has a protrusion that extends inward from the inner side in the orthogonal direction.

[0158] The protrusion is positioned between the pair of leg-shaped limiting portions.

[0159] (4-1) In a coil component, the distance between the second side of a limiting part and the step part is greater than the distance between the second side of a limiting part and the step part in another limiting part.

[0160] (5) Based on the coil components in (1) to (4), among which,

[0161] The side of the foot-restricting portion facing the foot is inclined relative to the mounting direction when the second core is placed on the first core.

[0162] The distance between the foot limiting part and the lower end of the foot is smaller than the distance between the foot limiting part and the upper end of the foot.

[0163] (5-1) In the coil component, the first side is inclined to the outward side in the front-back direction as it faces the bottom side.

[0164] (6) The coil components according to (1) to (5), wherein,

[0165] The base portion has a bottom portion that divides the second space into two pairs of raised portions that protrude upward from the surface of the bottom portion on which the first core is placed and are arranged apart from the first core in the width direction of the base portion.

[0166] (7) The coil component according to (6), wherein,

[0167] The lower surface of the support leg is disposed opposite to the upper surface of the one end.

[0168] The lower surface of the support leg is positioned at both ends in the width direction of the base portion, which are located further outward in the width direction than the upper surface of the first end portion.

[0169] The two ends of the bottom surface of the second core are opposite to and separate from the upper surface of the platform portion.

[0170] (8) Based on the coil components from (1) to (7), among which,

[0171] The second core has the support legs at both ends in the axial direction.

[0172] The first core is disposed axially between the two support legs.

[0173] (9) Based on the coil components in (8), wherein,

[0174] The distance between the first support leg and the first core is greater than the distance between the second support leg and the first core.

[0175] Explanation of reference numerals in the attached figures

[0176] 1. Coil components; 10. First core; 10a. Upper surface; 10a1. Upper surface end; 12. Core section; 14. Core end; 20. Second core; 22. Flat section; 24. Support leg section; 24a. Lower end; 24b. Upper end; 24c. Lower surface; 24d. Inner surface; 24e. Stepped section; 24f. First support leg section; 24g. Second support leg section; 24h. Lower surface end; 30. Base section; 30a. Bottom section; 30b. Bottom surface; 31, raised platform; 32, receiving recess; 34, first space; 35, core side; 36, second space; 37, side wall; 38, limiting part; 38a, first limiting part; 38b, second limiting part; 38c, first side; 38d, second side; 40, terminal part; 42, connecting wire part; 44, middle part; 46, mounting part; 50, coil; 51, first coil; 52, second coil; 53, winding part; 54, lead-out part.

Claims

1. A coil component, comprising: First chip; The base portion has a receiving recess for receiving the first core; A terminal portion is disposed on the base portion; At least one coil, which is connected to the terminal portion, is arranged in a spiral shape around the core portion and the base portion in the first core; as well as The second core is positioned above the first core. The second core includes: a flat plate portion; and a support leg portion extending from one end of the flat plate portion in the axial direction of the coil toward the bottom surface of the receiving recess. The receiving recess includes: a first space for receiving the core portion; and a second space, different from the first space, for receiving the support leg portion. The base portion has a foot portion restriction portion disposed on the inner side of the foot portion in the axial direction.

2. The coil component according to claim 1, wherein, The support leg has an inner side facing the side of the support leg limiting portion. The orthogonal direction, which is orthogonal to the inner surface, is inclined relative to the axial direction.

3. The coil component according to claim 2, wherein, The base portion has two paired support leg limiting portions arranged on both sides of the first core in the width direction of the base portion. The support leg contacts the first support leg limiting portion of the pair of support leg limiting portions and separates from the second support leg limiting portion of the pair of support leg limiting portions.

4. The coil component according to claim 3, wherein, The support leg has a protrusion that extends inward from the inner side in the orthogonal direction. The protrusion is positioned between the pair of leg-shaped limiting portions.

5. The coil component according to any one of claims 1 to 4, wherein, The side of the foot-restricting portion facing the foot is inclined relative to the mounting direction when the second core is placed on the first core. The distance between the foot limiting part and the lower end of the foot is smaller than the distance between the foot limiting part and the upper end of the foot.

6. The coil component according to any one of claims 1 to 4, wherein, The base portion has a bottom portion that divides the second space into two pairs of raised portions that protrude upward from the surface of the bottom portion on which the first core is placed and are arranged apart from the first core in the width direction of the base portion.

7. The coil component according to claim 6, wherein, The lower surface of the support leg is disposed opposite to the upper surface of the one end. The lower surface of the support leg is positioned at both ends in the width direction of the base portion, which are located further outward in the width direction than the upper surface of the first end portion. The two ends of the bottom surface of the second core are opposite to and separate from the upper surface of the platform portion.

8. The coil component according to any one of claims 1 to 4, wherein, The second core has the support legs at both ends in the axial direction. The first core is disposed axially between the two support legs.

9. The coil component according to claim 8, wherein, The distance between the first support leg and the first core is greater than the distance between the second support leg and the first core.

Images