Coil component

Abstract

The invention provides a coil component capable of improving the bonding strength between an electrode and a wire rod extending from a winding core part. A coil component (100) is provided with: a core body (10) having a winding core part (11) extending in the axial direction, and a first flange part (12a) and a second flange part (12b) respectively provided at both end parts of the winding core part in the axial direction; electrodes (20) including a first electrode (20a) and a second electrode (20b) provided on the first flange portion and the second flange portion, respectively; and a first wire (30) wound around the winding core portion and having a first end portion (30a) joined to the first electrode and a second end portion (30b) joined to the second electrode, the first electrode having a first joining surface (21a) to which the first end portion is joined, and at least one protrusion (25) provided on the first joining surface. The first end portion is joined to the first joining surface in a state in which the first wire extends across at least one protrusion provided on the first joining surface.

Description

Technical Field

[0001] The present invention relates to a coil component. Background Art

[0002] Coil components are used, for example, to filter radiation noise of various electronic devices. Patent document 1 discloses the following structure: as a coil component, two wires are wound around a winding core of a ferrite core in a pair, and a locking portion consisting of a recess is provided on the winding core. By hooking a pair of wires on the locking portion of the winding core, the deviation of the wires is suppressed, and the generation of a gap between the pair of wires is suppressed.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2007-208227

[0004] However, in the coil component of Patent Document 1, there is no disclosure about the bonding between the electrodes provided at both ends of the winding core and the wire. In the case where the wire falls off from the electrode, the coil component cannot function as it should and becomes a defective product. Therefore, it is required to improve the bonding strength between the electrode and the wire. Summary of the invention

[0005] Therefore, a main object of the present invention is to provide a coil component capable of improving the joining strength between an electrode and a wire extending from a winding core.

[0006] The coil component involved in the present invention comprises: a core body, having a winding core portion extending along an axial direction and a first flange portion and a second flange portion respectively arranged at two ends of the winding core portion in the axial direction; an electrode, including a first electrode and a second electrode respectively arranged at the first flange portion and the second flange portion; and a first wire material, wound on the winding core portion and having a first end portion connected to the first electrode and a second end portion connected to the second electrode.

[0007] The first electrode has a first bonding surface to which the first end portion is bonded.

[0008] At least one protrusion is arranged on the first joint surface.

[0009] The first end portion is joined to the first joining surface in a state where the first wire rod straddles over at least one protrusion provided on the first joining surface.

[0010] The protrusion serves as an anchor for fixing the first end of the first wire to the first joint surface, so that the first end of the first wire is unlikely to fall off from the first electrode. Thus, the joint strength between the first electrode and the first end of the first wire can be increased.

[0011] According to the present invention, it is possible to provide a coil component capable of improving the joining strength between an electrode and a wire extending from a winding core. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The above-mentioned object, other objects, features and advantages of the present invention will become more apparent from the following description of the embodiment of the present invention with reference to the accompanying drawings.

[0013] Figure 1 It is an external perspective view showing an example of a coil component according to an embodiment of the present invention.

[0014] Figure 2 yes Figure 1 Bottom view of .

[0015] Figure 3 yes Figure 1 Top view of the .

[0016] Figure 4 yes Figure 1 Side view of.

[0017] Figure 5 yes Figure 2 Cross-sectional view at line VV of .

[0018] Figure 6 (a) and (b) are Figure 2 A cross-sectional view of the line VI-VI, Figure 6 (a) is a cross-sectional view showing an end portion of a wire having a rectangular cross-sectional shape, Figure 6 (b) is a cross-sectional view showing an end portion of a wire having a cross-sectional shape in which thickness varies depending on a part.

[0019] Figure 7 This is an enlarged bottom view of another embodiment 1 showing the arrangement positions of the protrusions.

[0020] Figure 8 This is an enlarged bottom view showing another embodiment 2 of the arrangement position of the protrusions.

[0021] Fig. 9 This is an enlarged bottom view showing another embodiment 3 of the arrangement position of the protrusions.

[0022] Fig.10 (a) and (b) are other ways of showing the shape of the protrusion. Figure 2 The cross-sectional view corresponding to line VV, Fig.10 (a) is a cross-sectional view of the shape of the protrusion at the end portion of the first winding core portion, Fig.10 (b) is a cross-sectional view showing the shape of the protrusion at the end portion on the opposite side of the first winding core portion.

[0023] Fig.11 It is a perspective view showing the appearance of an example of a coil component according to a modification of the present invention.

[0024] Fig.12It is a bottom view showing an example of a coil component according to another modified example of the present invention.

[0025] Fig.13 A coil component having an electrode using a coated electrode Figure 2 Cross-sectional view at line VV of .

[0026] Explanation of reference numerals: 10...core; 11...winding core; 12...flange; 12a, 12b...first and second flanges; 12a1, 12b1...first and second bottom surfaces; 12a2, 12b2...first and second upper surfaces; 12a3, 12b3...first and second side surfaces; 20...electrode; 20a-20d...first to fourth electrodes; 21...joining surface; 21a-21d...first to fourth joint surfaces; 22...side end of winding core; 22a-22d...side end of first to fourth winding core; 23 ...end portion on the opposite side of the winding core portion; 23a~23d...end portions on the opposite side of the first to fourth winding core portions; 25...protrusion; 25a, 25b...protrusion; 26...core protrusion; 27...joining portion; 27a~27d...first to fourth joining portions; 30...first wire (wire); 32...second wire; 30a~30d...first to fourth ends (ends); 31...separation portion; 31a, 31b...first and second separation portions; 100...coil component; 100A...coil component; 100B...coil component. DETAILED DESCRIPTION

[0027] 1. Coil components

[0028] A coil component according to an embodiment of the present invention will be described. Figure 1 It is an external perspective view showing an example of a coil component according to an embodiment of the present invention. Figure 2 yes Figure 1 Bottom view of . Figure 3 yes Figure 1 Top view of the . Figure 4 yes Figure 1 Side view of. Figure 5 yes Figure 2 In addition, in Figure 5 In the figure, the winding core portion 11 is deleted and the first flange portion 12a, the protrusion 25, the first end portion 30a, etc. are shown. Figure 6 (a) and (b) are Figure 2 A cross-sectional view of the line VI-VI, Figure 6 (a) is a cross-sectional view showing an end portion of a wire having a rectangular cross-sectional shape, Figure 6(b) is a cross-sectional view showing an end portion of a wire having a cross-sectional shape in which thickness varies depending on a part.

[0029] The coil component 100 includes a core 10, an electrode 20, and a wire 30. In the present embodiment, a common mode choke coil is described as an example of the coil component 100. However, the coil component is not limited to the common mode choke coil, and winding type coils such as transformers and coupled inductors can be listed, for example. Each part is described below.

[0030] The core 10 has a winding core portion 11 and a pair of flange portions 12. Figure 1 to Figure 4 In the figure, the direction in which the pair of flanges 12 face each other is the L direction, which is the length direction of the core 10. The surface on which the electrode 20 is arranged in the flange 12 of the core 10 is the bottom surface, and the direction perpendicular to the L direction in the bottom surface direction is the W direction, which is the width direction of the core 10. The direction perpendicular to the L direction and the W direction is the T direction, which is the height direction of the core 10.

[0031] The winding core 11 extends in the axial direction (here, the L direction). The winding core 11 is wound with the wire 30. The pair of flanges 12 includes a first flange 12a and a second flange 12b, which are respectively provided at both ends of the winding core 11 in the axial direction. Electrodes 20 to which both ends of the wire 30 are connected are respectively arranged on the first flange 12a and the second flange 12b.

[0032] The first flange 12a and the second flange 12b are formed to be slightly larger than the winding core 11. The first flange 12a is disposed at one of the two ends of the winding core 11 and extends from the winding core 11 in a direction perpendicular to the axial direction. Figure 1 In the example of , the first flange portion 12a is formed into a rectangular parallelepiped, and has a first bottom surface 12a1 on which a first electrode 20a described later is arranged, a first upper surface 12a2 opposite to the first bottom surface 12a1, and a pair of first side surfaces 12a3 connecting the first bottom surface 12a1 and the first upper surface 12a2. In addition, the first flange portion 12a has an inner surface facing the winding core portion 11 side and an outer surface facing the opposite side of the winding core portion 11.

[0033] The second flange portion 12b is arranged at the other end of the winding core portion 11 so as to extend from the winding core portion 11 in a direction perpendicular to the axial direction. Figure 1In the example of , the second flange portion 12b has the same shape as the first flange portion 12a. The second flange portion 12b is formed into a rectangular parallelepiped and has a second bottom surface 12b1 on which a second electrode 20b described later is arranged, a second upper surface 12b2 opposite to the second bottom surface 12b1, and a pair of second side surfaces 12b3 connecting the second bottom surface 12b1 and the second upper surface 12b2. In addition, the second flange portion 12b has an inner surface facing the winding core portion 11 side and an outer surface facing the opposite side of the winding core portion 11.

[0034] exist Figure 1 In the example of , the winding core 11 and the pair of flanges 12 are respectively rectangular parallelepiped. However, the shapes of the winding core 11 and the pair of flanges 12 are not limited thereto, and examples thereof include cylindrical, elliptical, cubic, and polygonal shapes. The core 10 may be formed of a magnetic material such as ferrite or amorphous alloy, or may be formed of a non-magnetic material such as alumina or resin.

[0035] In this embodiment, the wire 30 is composed of one piece. Figure 1 The wire of the example is called the first wire 30 (an example of a wire). The first wire 30 is wound on the winding core 11 of the core 10. The first wire 30 is formed by covering the conductive wire arranged inside with a covering material as an insulating material. The conductive wire is formed of, for example, copper, silver, gold, etc. In addition, the conductive wire is formed into a thin cylindrical shape, for example. However, the conductive wire may also have a width and be formed into a plate shape. The covering material is formed of, for example, enamel resin, polyurethane resin, polyamide-imide resin, etc. The first wire 30 has two ends. The first end 30a as one end of the first wire 30 is joined to the first electrode 20a. The second end 30b as the other end of the first wire 30 is joined to the second electrode 20b. In addition, the number of wires is not limited to one.

[0036] The electrode 20 includes a first electrode 20a to which the first end portion 30a is joined and a second electrode 20b to which the second end portion 30b is joined. The first electrode 20a is provided on the first flange portion 12a, and the second electrode 20b is provided on the second flange portion 12b. The first electrode 20a may be arranged at one end portion in the W direction of the first bottom surface 12a1 in the first flange portion 12a, or at the other end portion in the W direction of the first bottom surface 12a1, or near the center. In addition, the first electrode 20a may also be arranged to cover the entire surface of the first bottom surface 12a1 in the first flange portion 12a. In addition, in the present embodiment, the first electrode 20a is arranged at one end portion in the W direction of the first bottom surface 12a1 in the first flange portion 12a. In addition, the second electrode 20b may be arranged at one end portion in the W direction of the second bottom surface 12b1 in the second flange portion 12b, or at the other end portion in the W direction of the second bottom surface 12b1, or near the center. In addition, the second electrode 20b may be arranged to cover the entire surface of the second bottom surface 12b1 in the second flange portion 12b. In addition, in the present embodiment, the second electrode 20b is arranged at one end portion of the second bottom surface 12b1 in the W direction in the second flange portion 12b. That is, in the present embodiment, the first electrode 20a and the second electrode 20b are arranged on the same side relative to the winding core portion 11 in the bottom surface direction.

[0037] In the present embodiment, the first and second electrodes 20a and 20b are formed of metal plates. The first and second electrodes 20a and 20b have a bonding surface 21 that is bonded to the first end 30a and the second end 30b of the first wire 30. Specifically, the first electrode 20a on the first bottom surface 12a1 has a first bonding surface 21a for bonding the first electrode 20a and the first end 30a. The second electrode 20b on the second bottom surface 12b1 has a second bonding surface 21b for bonding the second electrode 20b and the second end 30b. Figure 1 In a state where the first and second bottom surfaces 12a1 and 12b1 of the first and second flange portions 12a and 12b face upward, the first and second bonding surfaces 21a and 21b are upper surfaces of the first and second electrodes 20a and 20b.

[0038] The first and second electrodes 20a and 20b are not limited thereto, and are bonded to the first and second bottom surfaces 12a1 and 12b1 by, for example, an adhesive such as epoxy resin. The first and second electrodes 20a and 20b are formed of, for example, a metal such as Cu, Ag, Au, or Fe, and the bonding surface 21 is plated by, for example, Sn plating, Ni plating, or double-layer plating of Sn and Ni.

[0039] The ends 30a and 30b of the first wire 30 are joined to the electrode 20 by laser welding, thermocompression bonding, etc. The covering material of the ends 30a and 30b of the first wire 30 is removed during laser welding, thermocompression bonding, etc., and the electrode 20 and the conductive wires of the ends 30a and 30b of the first wire 30 are thermally fused. An alloy layer is formed at the joint 27 of the electrode 20 and the conductive wires of the ends 30a and 30b of the first wire 30. For example, when the conductive wire of the first wire 30 includes Cu and the electrode 20 includes Sn and Ni, the Cu of the first wire 30 and the Sn and Ni of the electrode 20 are mutually diffused between the conductive wire and the electrode 20 by laser welding, thermocompression bonding, etc. Thus, an alloy layer containing at least one of Sn and Ni and Cu is formed. As for the alloy layer, the gap between the first wire 30 and the electrode 20 disappears due to mutual diffusion, and the alloy layer becomes a mixed state of different types of metals, so that the bonding strength between the end of the first wire 30 and the electrode 20 can be relatively large. The first electrode 20a and the first end portion 30a are bonded to each other via a first bonding portion 27a formed of an alloy layer, and the second electrode 20b and the second end portion 30b are bonded to each other via a second bonding portion 27b formed of an alloy layer.

[0040] In addition, the joint surface 21 has at least one protrusion 25 protruding from the flat portion of the joint surface 21. In addition, the protrusion 25 also has a function as the electrode 20 and is a part of the electrode 20. In the joint portion 27 between the electrode 20 and the end of the first wire 30, the end of the first wire 30 is joined to the joint surface 21 in a state where the first wire 30 straddles at least one protrusion 25 provided on the joint surface 21, for example, in a state where the first wire 30 is hung on the protrusion 25. At this time, the end of the first wire 30 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the joint portion 27. As described above, the end of the first wire 30 is integrated with the electrode 20 and forms an alloy layer at the joint portion 27. However, there is a case where a part of the end of the first wire 30 remains in the state of a wire. Therefore, regarding the end of the first wire 30 being joined to the joint surface 21 in a state where the first wire 30 straddles the protrusion 25 of the joint surface 21, the following cases are considered: the end of the first wire 30 is joined to the joint surface 21 in a state where the alloy layer composed of the end of the first wire 30 and the electrode 20 straddles the protrusion 25, the end of the first wire 30 is joined to the joint surface 21 in a state where the end of the first wire 30 in the state of a wire straddles the protrusion 25, and the end of the first wire 30 in the state of an alloy layer and a wire straddles the protrusion 25. In any case, it is assumed that "the end of the first wire 30 is joined to the protrusion 25".

[0041] Specifically, at least one protrusion 25 is formed on at least one of the first joint surface 21a and the second joint surface 21b. In the present embodiment, the protrusion 25 is provided on the first joint surface 21a. In addition, in a state where the first wire 30 crosses over at least one protrusion 25 provided on the first joint surface 21a, the first electrode 20a and the first end 30a of the first wire 30 are joined to the first joint surface 21a. At this time, the first end 30a of the first wire 30 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the first joint portion 27a. In addition, the protrusion 25 is provided on the second joint surface 21b. In addition, in a state where the first wire 30 crosses over at least one protrusion 25 provided on the second joint surface 21b, the second electrode 20b and the second end 30b of the first wire 30 are joined to the second joint surface 21b. At this time, the second end 30b of the first wire 30 is in direct contact with the protrusion 25, or is in contact with the protrusion 25 via the second joint portion 27b. In addition, the protrusion 25 may be provided on any one of the first and second joint surfaces 21a and 21b, and in any one of the first and second joint portions 27a and 27b, when the first wire 30 crosses the protrusion 25, any one of the first and second end portions 30a and 30b is joined to any one of the first and second joint surfaces 21a and 21b.

[0042] In addition, if Figure 4 , Figure 5 As shown in FIG. 1 and FIG. 2 , it is preferred that the end of the first wire 30 is joined to the joint surface 21 by embedding the protrusion 25 in at least one of the first and second joint portions 27a and 27b. The state in which the protrusion 25 is embedded in the first and second ends 30a and 30b includes a state in which the protrusion 25 is embedded in the alloy layer, a state in which the protrusion 25 is embedded in the end of the first wire 30 in a wire state, and a state in which the protrusion 25 is embedded in both the alloy layer and the end of the first wire 30 in a wire state. Since the protrusion 25 of the electrode 20 is embedded in the end of the first wire 30, the force of the protrusion 25 as an anchor for fixing the first wire 30 to the joint surface 21 becomes larger. Therefore, the bonding strength between the electrode 20 and the first wire 30 can be further improved.

[0043] In the present embodiment, the protrusion 25 is provided at the end of the core portion 11 side of the joint surface 21, that is, the core portion side end portion 22. The core portion side end portion 22 is along the end surface of the electrode 20 on the core portion 11 side extending in the W direction. In addition, the protrusion 25 is formed long along the core portion side end portion 22 in the joint surface 21.

[0044] The protrusion 25 is provided along the end of the first joint surface 21a on the side of the core portion 11, that is, the first core portion side end 22a. In addition, the protrusion 25 is provided along the end of the second joint surface 21b on the side of the core portion 11, that is, the second core portion side end 22b. In addition, in the case where the protrusion 25 is provided on any one of the first and second joint surfaces 21a, 21b, the protrusion 25 may be provided on any one of the first core portion side end 22a of the first joint surface 21a and the second core portion side end 22b of the second joint surface 21b.

[0045] The first wire 30 may be configured such that the separated portion 31 separated from the winding core 11 and the end of the first wire 30 face each other across the winding core 11 near the winding end or the winding start. Furthermore, the protrusion 25 is provided on the bonding surface 21 of the electrode 20.

[0046] In this embodiment, if Figure 1 As shown in the example of FIG. 1 , the first separation portion 31a of the first wire 30 located closest to the first flange portion 12a is separated from the winding core portion 11 and is opposite to the first end portion 30a across the winding core portion 11. Between the first separation portion 31a and the first electrode 20a, the first wire 30 is separated from the winding core portion 11 and passes through the air in a non-contact state. Hereinafter, the portion in the non-contact state is referred to as the aerial wiring portion.

[0047] In addition, Figure 1 In the example of FIG. 1 , the second separated portion 31 b and the second end portion 30 b of the first wire 30 located closest to the second flange portion 12 b are separated from the winding core 11 and are located on the same side relative to the winding core 11 . Figure 1 In the example, the protrusion 25 is provided on the second joint surface 21b of the second electrode 20b. However, the protrusion 25 may not be provided on the second joint surface 21b. Between the second separation portion 31b and the second electrode 20b, the first wire 30 is separated from the winding core portion 11 and passes through the air in a non-contact state. Hereinafter, the non-contact state portion is referred to as the air wiring portion.

[0048] In addition, for example, the protrusion 25 can be formed by pressing a mold having a protrusion onto the electrode 20 to deform the electrode 20 in accordance with the protrusion of the mold. In addition, a concave portion 251 ( Figure 5 ). The concave portion 251 may contain air or may be filled with an adhesive.

[0049] As another forming method, the protrusion 25 can be formed by pressing a mold on the bonding surface 21 other than the protrusion 25 to make it depressed, thereby relatively raising the portion to be the protrusion 25 .

[0050] Next, the cross-sectional shape of the end portion of the first wire 30 joined to the joining surface 21 will be described. Here, the second end portion 30b of the first wire 30 will be described, but the same applies to the first end portion 30a. Figure 6 It is recorded in Figure 2 The cross-sectional shape of the second end portion 30b may be a rectangular shape as shown in (a), or may be a shape with different thicknesses in some parts as shown in (b). In addition, the second end portion 30b may have only a rectangular cross-sectional shape, or may have only a cross-sectional shape with different thicknesses in some parts, or may be a mixture of these.

[0051] right Figure 6 To further explain (a), the second bottom surface 12b1 of the second flange portion 12b is provided with a second electrode 20b. In the second bonding surface 21b of the second electrode 20b, the second end portion 30b of the first wire 30 is bonded to the second electrode 20b via the second bonding portion 27b. Figure 6 In the example of (a), the cross-sectional shape of the second end portion 30b in the second bonding portion 27b is a rectangle. In addition, here, the cross-sectional shape of the second end portion 30b is described as a rectangle, but it may also be a square.

[0052] right Figure 6 (b) is further explained, and Figure 6 Different from (a), the cross-sectional shape of the second end portion 30b in the second joint portion 27b is different on the left and right. Figure 6 In the example (b), the thickness of the second end portion 30 b gradually decreases as it moves from the winding core 11 toward the opposite side along the axial direction of the winding core 11 .

[0053] The height of the protrusion 25 from the joint surface 21 is such that the protrusion 25 is embedded in the end of the first wire 30 but does not cut off the end of the first wire 30. For example, it is preferred that the height of the protrusion 25 from the joint surface 21 does not exceed the height of the first wire 30 from the joint surface 21. Alternatively, it is preferred that the height of the protrusion 25 does not exceed the height of the joint portion 27. Figure 5 , it is preferred that the height h1 of the protrusion 25 (the protruding height from the first joint surface 21a) is 1 / 10 or more and 1 / 4 or less of the wire diameter r (the diameter r of the wire) of the first wire 30. Thus, it is possible to suppress damage such as breakage of the first wire 30 caused by excessive embedding of the protrusion 25 into the first wire 30. In addition, the embedding depth h2 of the protrusion 25 into the first wire 30 (the distance that the protrusion 25 is embedded into the inside of the wire from the surface of the wire) is such that the end of the first wire 30 is not cut off.

[0054] 2. Effects (1)

[0056] According to the above-mentioned embodiment, the protrusion 25 is provided on the joint surface 21 (first and second joint surfaces 21a, 21b) of the electrode 20 (first and second electrodes 20a, 20b) and the end portion of the first wire 30 (first and second end portions 30a, 30b), and the end portion of the first wire 30 is joined to the joint surface 21 of the electrode 20 in a state where the first wire 30 straddles the protrusion 25. Therefore, the protrusion 25 serves as an anchor for fixing the end portion of the first wire 30 to the joint surface 21, so that the end portion of the first wire 30 is difficult to fall off from the electrode 20. Thus, the joint strength between the electrode 20 and the end portion of the first wire 30 can be improved. For example, when the joint surface 21 is flat and the end portion of the first wire 30 is less hooked on the electrode 20, the end portion of the first wire 30 is easy to fall off from the electrode 20. However, with the above-mentioned structure, the joint strength between the electrode 20 and the end portion of the first wire 30 can be improved by the protrusion 25.

[0057] Here, the first wire 30 is wound around the winding core 11, and tension is generated in the first wire 30 from the end toward the winding core 11. This tension changes, for example, according to a change in the temperature of the atmosphere in which the coil component 100 is placed. In the case where a large tension is generated from the end of the first wire 30 toward the winding core 11 with such a change in tension, the end of the first wire 30 may be separated from the electrode 20. However, as described above, the end of the first wire 30 can be fixed to the electrode 20 by the protrusion 25, and the bonding strength between the electrode 20 and the end of the first wire 30 can be improved. (2)

[0059] According to the above-described embodiment, the protrusion 25 is provided at the core-side end portion 22 on the side close to the core portion 11 in the joint surface 21. Here, the first wire 30 is wound around the core portion 11, and tension is generated in the first wire 30 from the end portion toward the core portion 11. In this way, when the end portion of the first wire 30 is pulled toward the core portion 11, the protrusion 25 on the core-side end portion 22 becomes an anchor that effectively fixes the first wire 30 to the joint surface 21. That is, the tension applied to the end portion of the first wire 30 toward the core portion 11 side can be blocked by the protrusion 25 on the core-side end portion 22 on the side of the core portion 11 in the joint surface 21, that is, on the side of the end portion of the first wire 30 in the joint surface 21 close to the core portion 11. In particular, when the first wire 30 is pulled from the joint surface 21 toward the surface of the core 11 in a state where the joint surface 21 is located at a higher position than the surface of the core 11, the tension of the end of the first wire 30 acts largely on the corner of the joint surface 21 near the core side end 22. The tension of the end of the first wire 30 applied to the corner can be effectively blocked by the protrusion 25 of the core side end 22. Therefore, the joint strength between the electrode 20 and the end of the first wire 30 can be further improved.

[0060] Even when the first wire 30 does not extend to the opposite-core-side end 23 facing the core-side end 22 , the end of the first wire 30 can be reliably fixed to the joint surface 21 by the protrusion 25 of the core-side end 22 . (3)

[0062] According to the above-mentioned embodiment, the protrusion 25 is formed long along the core-side end portion 22 in the joint surface 21. In this way, when the protrusion 25 is formed long, the contact area between the protrusion 25 and the end portion of the first wire 30 can be increased, and the end portion of the first wire 30 can be reliably joined to the joint surface 21 in a state where the first wire 30 crosses the protrusion 25. Therefore, the joining strength between the electrode 20 and the end portion of the first wire 30 can be further improved.

[0063] In addition, even if the joining position of the first wire 30 is shifted, the end of the first wire 30 can be reliably joined to the joining surface 21 so as to straddle the protrusion 25 . (4)

[0065] According to the above-mentioned embodiment, the first separation portion 31a is opposed to the first end portion 30a of the first wire 30 across the winding core 11. Thus, when the first separation portion 31a is opposed to the first end portion 30a across the winding core 11, the aerial wiring portion is longer than when the first separation portion 31a and the first end portion 30a are on the same side relative to the winding core 11. Moreover, when the aerial wiring portion is longer, there is a tendency for the tension from the first end portion 30a toward the winding core 11 to become larger than when the aerial wiring portion is shorter. Thus, even when the tension is large, since the protrusion 25 is provided on the first electrode 20a that is opposed to the first separation portion 31a across the winding core 11, the protrusion 25 of the first electrode 20a becomes an anchor that fixes the first end portion 30a to the first joint surface 21a. Thus, the bonding strength between the first electrode 20a and the first end portion 30a of the first wire 30 can be improved.

[0066] Furthermore, according to the above-described embodiment, the second separation portion 31b and the second end portion 30b of the first wire 30 are located on the same side relative to the winding core portion 11. Thus, when the second separation portion 31b and the second end portion 30b are located on the same side relative to the winding core portion 11, the aerial wiring portion is shorter than when the second separation portion 31b and the second end portion 30b are located on opposite sides relative to the winding core portion 11. Moreover, when the aerial wiring portion is shorter, there is a tendency for the tension from the second end portion 30b toward the winding core portion 11 to become smaller than when the aerial wiring portion is longer. Even in this case, if the protrusion 25 is provided on the second joint surface 21b, the joint strength between the second electrode 20b and the second end portion 30b can be further improved. (5)

[0068] In the above-mentioned implementation mode, if Figure 6 As shown in (b), the thickness of the second end portion 30b (first end portion 30a) on the side of the winding core 11 is greater than the thickness on the opposite side of the winding core 11. In this way, it is considered that the difference in thickness of the second end portion 30b (first end portion 30a) depending on the position is due to differences in the shape of the electrode 20, the inclination of the electrode 20, the pressing force when the second end portion 30b (first end portion 30a) is joined to the electrode 20, and the like. Moreover, due to the difference in thickness, the bonding strength of the second end portion 30b (first end portion 30a) to the electrode 20 is different. For example, the portion of the second end portion 30b (first end portion 30a) with a larger thickness on the side of the winding core 11 is a portion where the pressing force during bonding is weak, and there is a case where the bonding strength between the second end portion 30b (first end portion 30a) and the electrode 20 is weakened. Even in such a case, especially when the protrusion 25 is provided on the core-side end portion 22, the second end portion 30b (first end portion 30a) can be joined to the second joining surface 21b (first joining surface 21a) in a state where the portion with a larger thickness on the core-side end portion 22 of the second end portion 30b (first end portion 30a) crosses the protrusion 25 of the core-side end portion 22. Therefore, the joining strength between the second end portion 30b (first end portion 30a) and the electrode 20 can be improved.

[0069] Furthermore, as described above, although the embodiments of the present invention are disclosed by the above description, the present invention is not limited thereto.

[0070] That is, various changes may be made to the above-described embodiments with respect to mechanism, shape, material, number, position, or arrangement without departing from the technical idea and scope of the purpose of the present invention, and these are included in the present invention.

[0071] 3. Modifications

[0072] (1) Regarding the protrusion method

[0073] In the above-mentioned embodiment, the protrusion 25 is provided at the core-side end portion 22 in the joining surface 21. The position where the protrusion 25 is arranged is not limited thereto. Other forms 1 to 3 are given to explain other forms of the arrangement position of the protrusion 25. Figure 7 This is an enlarged bottom view of another embodiment 1 showing the arrangement positions of the protrusions. Figure 8 This is an enlarged bottom view showing another embodiment 2 of the arrangement position of the protrusions. Fig. 9 This is an enlarged bottom view showing another embodiment 3 of the arrangement position of the protrusions.

[0074] In the above-described embodiment, the protrusion 25 is formed by protruding only a part of the winding core side end portion 22. The shape of the protrusion 25 is not limited thereto. Another embodiment 1 is cited to describe another shape of the protrusion 25. Fig.10 (a) and (b) are other ways of showing the shape of the protrusion. Figure 2 The cross-sectional view corresponding to line VV, Fig.10 (a) is a cross-sectional view of the shape of the protrusion at the end portion of the first winding core portion, Fig.10 (b) is a cross-sectional view showing the shape of the protrusion at the end portion on the opposite side of the first winding core portion.

[0075] (1-1) Other ways to configure the location 1

[0076] exist Figure 7 In the embodiment, the protrusion 25 is provided at the end opposite to the winding core portion 11 side in the bonding surface 21, that is, the end portion 23 on the opposite side of the winding core portion. Specifically, on the first bonding surface 21a, the protrusion 25 is provided at the end portion 23a on the opposite side of the first winding core portion. The end portion 23a on the opposite side of the first winding core portion is along the end surface extending in the W direction of the first electrode 20a on the opposite side of the winding core portion 11. In addition, the protrusion 25 is formed long along the end portion 23a on the opposite side of the first winding core portion in the first bonding surface 21a. Similarly, on the second bonding surface 21b (refer to Figure 1 ), the protrusion 25 can be at the end portion 23b on the opposite side of the second winding core portion (refer to Figure 1 ) is formed long along the end surface of the second electrode 20b extending in the W direction. The protrusion 25 of the end 23 on the opposite side of the winding core also becomes an anchor that effectively fixes the end of the first wire 30 to the bonding surface 21. Therefore, the bonding strength between the electrode 20 and the end of the first wire 30 can be further improved. In addition, the protrusion 25 can be provided in a shape that extends long at least one of the end 22 on the winding core side and the end 23 on the opposite side of the winding core in at least any one of the first bonding surface 21a and the second bonding surface 21b.

[0077] (1-2) Other ways to configure the position 2

[0078] exist Figure 8 In the embodiment, the protrusion 25 is provided in the center portion between the core portion side end portion 22 and the core portion opposite side end portion 23 in the joint surface 21. Specifically, the protrusion 25 is formed long in the W direction at the center portion of the first joint surface 21a. Similarly, the protrusion 25 can be provided on the second joint surface 21b (refer to Figure 1 ) is formed long in the central part along the W direction. In addition, the protrusion 25 can be provided in at least any one of the first joint surface 21a and the second joint surface 21b in a shape extending long at at least any one of the core side end 22, the core opposite side end 23 and the central part.

[0079] (1-3) Other ways to configure the location 3

[0080] exist Fig. 9 In the embodiment, the protrusion 25 is not a shape that extends long in the W direction, but is formed by a partially protruding shape. Fig. 9 In the example, a plurality of protrusions 25 of a partially protruding shape are dispersedly formed in the first joint surface 21a. Similarly, a plurality of protrusions 25 of a partially protruding shape can be dispersedly formed in the second joint surface 21b. In addition, the protrusion 25 can be provided in at least any one of a shape extending longer at the end portion 22 on the side of the core portion, a shape extending longer at the end portion 23 on the opposite side of the core portion, a shape extending longer in the central portion, and a partially protruding shape, and a plurality of shapes can be combined. In addition, a plurality of protrusions 25 of a partially protruding shape can be provided along the W direction at the end portion 22 on the side of the core portion, can be provided along the W direction at the end portion 23 on the opposite side of the core portion, or can be provided along the W direction at the central portion. In addition, as long as, in the joining of the electrode 20 and the first wire 30, the end portion of the first wire 30 is joined to the joint surface 21 in a state where the first wire 30 crosses the protrusion 25, the number of protrusions 25 of a partially protruding shape is not limited, and for example, it can be one.

[0081] (1-4) Other forms of shape 1

[0082] exist Fig.10 In the embodiment, the protrusion 25a of the first electrode 20a is described, but the protrusion 25b of the second electrode 20b can also be formed in the same manner. Fig.10 In (a), the protrusion 25a is formed by forming the first winding core side end 22a in the first electrode 20a into a warped shape. The protrusion 25a floats from the first bottom surface 12a1 by warping the first winding core side end 22a in an inclined state relative to the flat portion other than the first winding core side end 22a on the side away from the first bottom surface 12a1 in the T direction (direction orthogonal to the axial direction). That is, in the first electrode 20a, the first winding core side end 22a is in a state of floating from the first bottom surface 12a1 to the side closest to the winding core 11.

[0083] In addition, Fig.10In (b), the first winding core portion opposite side end 23a in the first electrode 20a is formed into a warped shape to form a protrusion 25b. The protrusion 25b floats from the first bottom surface 12a1 by warping the first winding core portion opposite side end 23a in an inclined state relative to the flat portion other than the first winding core portion opposite side end 23a on the side away from the first bottom surface 12a1 in the T direction. That is, in the first electrode 20a, the first winding core portion opposite side end 23a is in a state of floating from the first bottom surface 12a1 to the opposite side of the winding core 11.

[0084] like Fig.10 As shown in (a) and (b), the protrusions 25a and 25b are formed in a state where the core-side end portion 22 and the core-opposite end portion 23 are raised from the bottom surface of the flange portion 12, so that it is easier to hook the end portion of the first wire 30 on the raised protrusions 25a and 25b. Therefore, the raised protrusions 25a and 25b can improve the bonding strength between the electrode 20 and the end portion of the first wire 30. In addition, the protrusion 25a in the shape of the raised end portion 22 on the core-side can improve the bonding strength between the electrode 20 and the end portion of the first wire 30 more than the protrusion 25b. As described above, the tension of the end portion of the first wire 30 acts more strongly on the corner portion of the joint surface 21 near the core-side end portion 22. The protrusion 25a corresponds to the corner portion, so the end portion of the first wire 30 can be hooked on the protrusion 25a at the portion where the tension of the first wire 30 is greater, and it is easier to improve the bonding strength.

[0085] like Fig.10 In this way, when at least one of the end portion 22 on the winding core portion side and the end portion 23 on the opposite side of the winding core portion is formed as a protrusion 25a, 25b in the electrode 20 composed of a metal plate, for example, when the electrode 20 composed of a metal plate is formed, a protrusion is provided at the end of the mold so as to correspond to the protrusion 25a, 25b. By pressing the mold having the protrusion formed at the end to the metal plate that becomes the electrode 20, the end of the electrode 20 is in a warped state, and the protrusions 25a, 25b can be formed. In this way, when the protrusions 25a, 25b are formed at the end of the electrode 20, the force generated by the warping due to the pressing can be released to the outside of the mold and the electrode 20, so that a large force is not required during the forming, and the protrusions 25a, 25b can be formed by a relatively small force. Therefore, the stress applied to the electrode 20 can be suppressed when the protrusions 25a, 25b are formed, and the strength reduction of the electrode 20 can be suppressed. Furthermore, by forming the protrusions 25 a and 25 b at the ends of the bonding surface 21 , for example, the pressing force between the mold and the electrode 20 can be relatively small, thereby making molding easier.

[0086] On the other hand, the above-mentioned embodiment Figure 1 、Other methods 1 to 3 Figures 7 to 9 The protrusion 25 and Fig.10 Unlike the protrusions 25a and 25b in a warped state, the protrusions 25a and 25b are formed to partially protrude in the plane of the flat portion of the electrode 20 composed of a flat metal plate. In the case of forming such a protrusion 25, for example, when the electrode 20 composed of a metal plate is formed, a protrusion is partially provided at a desired position in the plane of the flat surface of the mold so as to correspond to the protrusion 25. The protrusion 25 can be formed by pressing the mold on which the protrusion is partially formed against the metal plate that becomes the electrode 20, so that the desired position of the electrode 20 is pressed and raised. In this way, when the protrusion 25 is partially formed in the plane of the electrode 20, the electrode 20 is partially bent up and down to a large extent. Therefore, when the protrusion 25 is partially formed in the plane of the bonding surface 21, it is necessary to press the mold more strongly than when the protrusions 25a and 25b in a warped state are formed at the end of the bonding surface 21.

[0087] (1-5) Other methods

[0088] (a)

[0089] In the above-mentioned embodiments and Figure 7 , Figure 8 In the embodiment, the protrusion 25 is formed to be elongated in the W direction. However, as long as the end of the first wire 30 is bonded to the bonding surface 21 of the electrode 20 while the first wire 30 straddles the protrusion 25, the protrusion 25 may be formed to be elongated in the L direction.

[0090] (b)

[0091] In addition, in the above-mentioned embodiment, the cross-sectional shape of the protrusion 25 is a shape that is substantially symmetrical in the L direction when viewed in cross section. However, the shape of the protrusion 25 is not limited thereto. For example, the protrusion 25 may be inclined and protruded toward the side opposite to the winding core 11 side when viewed in cross section. That is, the direction in which the protrusion 25 protrudes from the joint surface 21 toward the front end and the direction of the tension generated in the first wire 30 may also intersect. In this case, the end of the first wire 30 is easily hooked on the protrusion 25 relative to the tension of the first wire 30 from the winding core 11 side, and the end of the first wire 30 is difficult to fall off from the protrusion 25. Therefore, the protrusion 25 becomes an anchor that efficiently fixes the first wire 30 to the electrode 20, and can improve the bonding strength between the electrode 20 and the end of the first wire 30.

[0092] (c)

[0093] The protrusion 25 is not limited to a tapered shape as in the above-mentioned embodiment in cross-section, and may have a rectangular or square cross-sectional shape as long as the end of the first wire 30 is joined to the joining surface 21 while straddling the protrusion 25 .

[0094] (d)

[0095] In the above-mentioned embodiment, the protrusion 25 is provided corresponding to the joint surface 21. Figure 1 In the embodiment, the protrusion 25 is provided at the core-side end portion 22 in the joint surface 21. However, the protrusion 25 may be provided corresponding to the position of the end portion of the first wire 30 on the joint surface 21. For example, the protrusion 25 may be provided corresponding to the front end of the end portion of the first wire 30 in the joint surface 21, or the protrusion 25 may be provided corresponding to the root portion of the end portion of the first wire 30 in the joint surface 21.

[0096] (2) Regarding the electrode configuration position

[0097] (2-1) Arrangement of electrodes on the side surfaces of the flange portion

[0098] In the above-mentioned embodiment, the first and second electrodes 20a, 20b are arranged on the first bottom surface 12a1 of the first flange portion 12a and the second bottom surface 12b1 of the second flange portion 12b. However, as long as the first and second ends 30a, 30b of the first wire 30 and the first and second electrodes 20a, 20b are joined, the arrangement positions of the first and second electrodes 20a, 20b are not limited thereto. For example, the first and second electrodes 20a, 20b may also be arranged on the first side surface 12a3 of the first flange portion 12a and the second side surface 12b3 of the second flange portion 12b. With regard to this example, the coil component 100A involved in the modified example is listed below for explanation. Fig.11 It is a perspective view showing the appearance of an example of a coil component according to a modification of the present invention.

[0099] The coil component 100A involved in the modification is different from the coil component 100 of the above-mentioned embodiment, and the first and second electrodes 20a, 20b are arranged on the first side surface 12a3 and the second side surface 12b3. The first end 30a of the first wire 30 extends toward the first electrode 20a on the first side surface 12a3 side and is joined to the first electrode 20a through the first joint 27a while crossing the protrusion 25. In addition, the second end 30b of the first wire 30 extends toward the second electrode 20b on the second side surface 12b3 side and is joined to the second electrode 20b through the second joint 27b while crossing the protrusion 25. In the following, the coil component 100 of the above-mentioned embodiment is described mainly with the difference therebetween.

[0100] exist Fig.11In the example, the first electrode 20a is arranged at one end of the first bottom surface 12a1 in the W direction in the first flange portion 12a, and is bent from the first bottom surface 12a1 and continuously arranged along the first side surface 12a3. The second electrode 20b is arranged at one end of the second bottom surface 12b1 in the W direction in the second flange portion 12b, and is bent from the second bottom surface 12b1 and continuously arranged along the second side surface 12b3.

[0101] The first electrode 20a on the first side surface 12a3 has a first joint surface 21a for joining the first electrode 20a and the first end 30a. The second electrode 20b on the second side surface 12b3 has a second joint surface 21b for joining the second electrode 20b and the second end 30b. Fig.11 When the first and second bottom surfaces 12a1 and 12b1 of the first and second flange portions 12a and 12b face upward, the first and second bonding surfaces 21a and 21b face the sides of the first and second electrodes 20a and 20b. At this time, the first and second bottom surfaces 12a1 and 12b1 serve as mounting surfaces.

[0102] In each of the first and second joint surfaces 21a, 21b, a protrusion 25 is provided along the first and second winding core side ends 22a, 22b along the end surface extending in the T direction in the first and second electrodes 20a, 20b. In a state where the first wire 30 crosses the protrusion 25 of the first joint surface 21a, the first electrode 20a and the first end 30a are joined by the first joint portion 27a composed of the alloy layer. In addition, in a state where the first wire 30 crosses the protrusion 25 of the second joint surface 21b, the second electrode 20b and the second end 30b are joined by the second joint portion 27b composed of the alloy layer.

[0103] exist Fig.11 In the example, the first separated portion 31a and the first end portion 30a of the first wire 30, where the turn located closest to the first flange portion 12a is separated from the winding core portion 11, are on the same side with respect to the winding core portion 11. In addition, the second separated portion 31b and the second end portion 30b of the first wire 30, where the turn located closest to the second flange portion 12b is separated from the winding core portion 11, are on the same side with respect to the winding core portion 11.

[0104] In addition, Fig.11 In the example, the first and second electrodes 20a and 20b are arranged on the first and second side surfaces 12a3 and 12b3 in addition to the first and second bottom surfaces 12a1 and 12b1. However, the first and second electrodes 20a and 20b may be arranged only on the first and second side surfaces 12a3 and 12b3.

[0105] (2-2) Arrangement of the First and Second Electrodes on the Same Side

[0106] In the above-mentioned embodiment, the first and second electrodes 20a and 20b are arranged on the same side relative to the winding core 11. However, according to the performance of the coil component 100, the first and second electrodes 20a and 20b may be arranged diagonally to each other across the winding core 11. For example, the first electrode 20a can be arranged at one end of the first bottom surface 12a1 in the W direction in the first flange portion 12a. On the other hand, the second electrode 20b can be arranged at the other end of the second bottom surface 12b1 in the W direction in the second flange portion 12b.

[0107] (3) Regarding the number of wires

[0108] In the above-mentioned embodiment, the wire 30 includes only one first wire 30. However, the number of wires is not limited thereto, and more than two wires may be included. The electrode includes a plurality of pairs of electrodes for respectively joining the two ends (one end and the other end) of each wire. At least one protrusion is provided in at least any one of the joining surfaces with the ends of the wires in each electrode.

[0109] As an example, the wire may include two first wires 30 and two second wires 32. The coil component 100B including the first wire 30 and the second wire 32 will be described below. Fig.12 1 is a bottom view showing an example of a coil component according to another modified example of the present invention. The following description will focus on points different from the coil component 100 according to the embodiment.

[0110] The coil component 100B includes a core 10, an electrode 20, a first wire 30, and a second wire 32. The core 10 has a winding core 11 and a pair of flanges 12. The first and second wires 30 and 32 are wound on the winding core 11 by a double wire winding method. The first wire 30 includes a first end 30a as one end and a second end 30b as the other end. The second wire 32 includes a third end 30c as one end and a fourth end 30d as the other end.

[0111] The electrode 20 includes a first electrode 20a, a second electrode 20b, a third electrode 20c, and a fourth electrode 20d. The first electrode 20a and the third electrode 20c are opposed to each other in the first flange portion 12a, separated by the axial direction that is the center of the winding core portion 11. The first electrode 20a is provided at one end of the first flange portion 12a, and the third electrode 20c is provided at the other end of the first flange portion 12a. In addition, the second electrode 20b and the fourth electrode 20d are opposed to each other in the second flange portion 12b, separated by the axial direction that is the center of the winding core portion 11. The second electrode 20b is provided at one end of the second flange portion 12b, and the fourth electrode 20d is provided at the other end of the second flange portion 12b.

[0112] The first end 30a of the first wire 30 is bonded to the first electrode 20a. The second end 30b of the first wire 30 is bonded to the second electrode 20b. The third end 30c of the second wire 32 is bonded to the third electrode 20c. The fourth end 30d of the second wire 32 is bonded to the fourth electrode 20d.

[0113] The first electrode 20a on the first bottom surface 12a1 has a first bonding surface 21a that bonds the first electrode 20a to the first end 30a. The second electrode 20b on the second bottom surface 12b1 has a second bonding surface 21b that bonds the second electrode 20b to the second end 30b. The third electrode 20c on the first bottom surface 12a1 has a third bonding surface 21c that bonds the third electrode 20c to the third end 30c. The fourth electrode 20d on the second bottom surface 12b1 has a fourth bonding surface 21d that bonds the fourth electrode 20d to the fourth end 30d.

[0114] At least one protrusion 25 is provided on at least one of the first to fourth joint surfaces 21a to 21d. Fig.12 In the example, a protrusion 25 is formed on the first joint surface 21a so as to protrude from the first core-side end 22a. A protrusion 25 is formed on the second joint surface 21b so as to protrude from the second joint surface 21b at the second core-side end 22b. A protrusion 25 is formed on the third joint surface 21c so as to protrude from the third joint surface 21c at the third core-side end 22c. A protrusion 25 is formed on the fourth joint surface 21d so as to protrude from the fourth joint surface 21d at the fourth core-side end 22d. Fig.12 In the example of FIG. 1 , the first to fourth winding core side end portions 22 a to 22 d are arranged along the end surface of the electrode 20 extending in the W direction, similarly to the above-described embodiment.

[0115] Although not described here, the protrusion 25 may be provided in at least any one of the first to fourth winding core portion opposite side ends 23a to 23d.

[0116] In a state where the first wire 30 straddles the protrusion 25 provided on the first joint surface 21a, the first electrode 20a and the first end 30a of the first wire 30 are joined by the first joint portion 27a composed of the alloy layer. At this time, the first end 30a of the first wire 30 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the first joint portion 27a. In addition, in a state where the first wire 30 straddles the protrusion 25 provided on the second joint surface 21b, the second electrode 20b and the second end 30b of the first wire 30 are joined by the second joint portion 27b composed of the alloy layer. At this time, the second end 30b of the first wire 30 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the second joint portion 27b. In a state where the second wire 32 straddles the protrusion 25 provided on the third joint surface 21c, the third electrode 20c and the third end 30c of the second wire 32 are joined by the third joint portion 27c composed of the alloy layer. At this time, the third end 30c of the second wire 32 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the third joint portion 27c. In addition, in a state where the second wire 32 straddles the protrusion 25 provided on the fourth joint surface 21d, the fourth electrode 20d and the fourth end 30d of the second wire 32 are joined by the fourth joint portion 27d composed of the alloy layer. At this time, the fourth end 30d of the second wire 32 is in direct contact with the protrusion 25 or in contact with the protrusion 25 via the fourth joint portion 27d.

[0117] According to the above configuration, even if the number of wires is plural, the bonding strength between the electrode 20 and the end of the wire can be improved by the protrusion 25 as in the present embodiment.

[0118] (4) Regarding coated electrodes coated with conductive metal

[0119] In the above embodiment, the electrode 20 is a metal terminal electrode formed by forming a metal plate, but the electrode 20 is not limited thereto, and the electrode 20 may be formed by applying a conductive paste containing a conductive metal to the flange portion 12 of the core 10 and firing it to form a coated electrode. Fig.13 A coil component having an electrode using a coated electrode Figure 2 In addition, in Fig.13 In FIG. 1 , the winding core 11 is deleted, and the first flange 12a, the protrusion 25, the first end portion 30a, etc. are shown. Hereinafter, the first and second electrodes 20a and 20b have the same structure, so the first electrode 20a will be described.

[0120] Fig.13The first electrode 20a composed of the coating electrode shown is formed to have a protrusion 25. Such a first electrode 20a can be formed by providing a core protrusion 26 protruding from the first bottom surface 12a1 on the first flange portion 12a of the core body 10. A mold having a concave portion corresponding to the core protrusion 26 is prepared, for example, and the material of the core body 10 is cast into the mold, and the material of the core body 10 is pressed and fired by the mold, thereby forming a core body 10 having a core protrusion 26 formed on the first bottom surface 12a1 of the first flange portion 12a. Fig.13 In the example of , the core protrusion 26 is formed on the winding core 11 side of the first bottom surface 12a1. When the conductive paste is applied to the first bottom surface 12a1 on which the core protrusion 26 is formed, the conductive paste is applied along the protrusion of the core protrusion 26. By firing the conductive paste, the coated electrode having the protrusion 25, that is, the first electrode 20a is formed.

[0121] The first electrode 20 a as a coating electrode and the first end portion 30 a of the first wire 30 are joined by the first joining portion 27 a composed of an alloy layer in a state where the first wire 30 straddles the protrusion 25 provided on the first joining surface 21 a .

[0122] (5) About aerial wiring

[0123] In the above-mentioned embodiment, the first separation portion 31a and the first end portion 30a of the first wire 30, which are separated from the winding core portion 11 by the turn located closest to the first flange portion 12a, are opposite to each other across the winding core portion 11. Moreover, the aerial wiring portion from the first separation portion 31a to the first electrode 20a is relatively long. However, depending on the type of coil component, the first separation portion 31a and the first end portion 30a may be on the same side relative to the winding core portion 11, and the aerial wiring portion may be shorter.

[0124] In addition, when the separation portion 31 where the first wire 30 is separated from the winding core 11 and the end of the first wire 30 are on the same side relative to the winding core 11, as described above, the aerial wiring portion is short, so the tension from the end of the first wire 30 toward the winding core 11 side is small. Even in this case, if the protrusion 25 is provided on the joint surface 21, the joint strength between the electrode 20 and the end of the first wire 30 can be further improved.

[0125] (6) Regarding the bonding of electrodes and wires

[0126] In the above-mentioned embodiment, the electrode 20 and the end of the first wire 30 are joined by the joint portion 27 composed of the alloy layer in a state where the first wire 30 straddles the protrusion 25 provided on the joint surface 21. In this case, the alloy layer is formed by laser welding and thermocompression bonding. As long as the end of the electrode 20 and the first wire 30 are joined, laser welding and thermocompression bonding may not be used. In addition, it is not necessary to form an alloy layer at the joint portion 27 between the electrode 20 and the end of the first wire 30.

[0127] For example, the electrode 20 and the end of the first wire 30 may be joined by bonding the end of the first wire 30 to the electrode 20 using a conductive adhesive while the first wire 30 straddles the protrusion 25 provided on the joint surface 21 of the electrode 20. In addition, for example, the end of the first wire 30 may be joined to the electrode 20 using a conductive material such as solder while the first wire 30 straddles the protrusion 25 provided on the joint surface 21 of the electrode 20.

[0128] <1> A coil component comprising:

[0129] The core body has a winding core portion extending in the axial direction and a first flange portion and a second flange portion respectively provided at both ends of the winding core portion in the axial direction;

[0130] Electrodes, including a first electrode and a second electrode respectively disposed on the first flange portion and the second flange portion; and

[0131] a first wire material wound on the winding core and having a first end portion joined to the first electrode and a second end portion joined to the second electrode,

[0132] The first electrode has a first bonding surface to which the first end portion is bonded,

[0133] At least one protrusion is provided on the first joint surface,

[0134] The first end portion is joined to the first joining surface in a state where the first wire rod straddles over at least one of the protrusions provided on the first joining surface.

[0135] <2> The coil component according to <1>, wherein:

[0136] The above-mentioned protrusion is arranged on at least any one of the first core part side end portion and the first core part opposite side end portion, the first core part side end portion is the end portion on the core part side of the above-mentioned first joint surface, and the first core part opposite side end portion is the end portion opposite to the first core part side and opposite to the core part side.

[0137] <3> The coil component according to <2>, wherein:

[0138] The protrusion is provided at an end portion on the first winding core side.

[0139] <4> The coil component according to any one of <1> to <3>, wherein:

[0140] The protrusion is embedded in the first end portion of the first wire member.

[0141] <5> The coil component according to any one of <1> to <4>, wherein

[0142] The first electrode and the second electrode are metal terminal electrodes composed of metal plates disposed at least on the first flange portion and the second flange portion, or,

[0143] The first electrode and the second electrode are coated electrodes formed by coating a conductive metal on at least the first flange portion and the second flange portion.

[0144] <6> The coil component according to any one of <1> to <5>, wherein

[0145] A first separation portion where a turn of the first wire located closest to the first flange portion is separated from the winding core portion faces the first end portion across the winding core portion, and the protrusion is provided on the first joint surface of the first electrode.

[0146] <7> The coil component according to any one of <1> to <6>, wherein

[0147] comprising a second wire having a third end and a fourth end,

[0148] The electrode further includes: a third electrode disposed on the first flange portion and facing the first electrode across the axial direction; and a fourth electrode disposed on the second flange portion and facing the second electrode across the axial direction.

[0149] The third end portion is an end portion of the second wire material joined to the third electrode.

[0150] The fourth end portion is the other end portion of the second wire material joined to the fourth electrode.

[0151] The third electrode and the fourth electrode respectively have a third bonding surface to be bonded to the third end portion and a fourth bonding surface to be bonded to the fourth end portion.

[0152] At least one protrusion is provided on the third joint surface,

[0153] The third end portion is joined to the third joining surface in a state where the second wire rod straddles over at least one of the protrusions provided on the third joining surface.

[0154] <8> The coil component according to any one of <1> to <7>, wherein

[0155] comprising a second wire having a third end and a fourth end,

[0156] The electrode further includes: a third electrode disposed on the first flange portion and facing the first electrode across the axial direction; and a fourth electrode disposed on the second flange portion and facing the second electrode across the axial direction.

[0157] The third end portion is an end portion of the second wire material joined to the third electrode.

[0158] The fourth end portion is the other end portion of the second wire material joined to the fourth electrode.

[0159] The third electrode and the fourth electrode respectively have a third bonding surface to be bonded to the third end portion and a fourth bonding surface to be bonded to the fourth end portion.

[0160] At least one protrusion is provided on the fourth joint surface,

[0161] The fourth end portion is joined to the fourth joining surface in a state where the second wire rod straddles over at least one of the protrusions provided on the fourth joining surface.

[0162] <9> The coil component according to any one of <1> to <8>, wherein:

[0163] The first electrode and the first end portion are bonded to each other via an alloy layer.

[0164] <10> The coil component according to <9>, wherein:

[0165] The alloy layer contains Cu and at least one of Sn and Ni.

[0166] <11> The coil component according to any one of <1> to <10>, wherein

[0167] The height of the protrusion provided on the first joint surface is in a range of not less than 1 / 10 and not more than 1 / 4 of the wire diameter of the first wire.

[0168] <12> The coil component according to any one of <1> to <11>, wherein

[0169] The protrusion provided at the first core-side end portion, which is the end portion on the core-side of the first joint surface, is formed in a shape that the first core-side end portion of the first electrode rises in a direction away from the first flange portion.

Claims

1. A coil component, wherein: have: The core body has a winding core portion extending in the axial direction and a first flange portion and a second flange portion respectively provided at both ends of the winding core portion in the axial direction; Electrodes, including a first electrode and a second electrode respectively disposed on the first flange portion and the second flange portion; as well as a first wire material wound on the winding core and having a first end portion joined to the first electrode and a second end portion joined to the second electrode, The first electrode has a first bonding surface to which the first end is bonded, At least one protrusion is provided on the first joint surface, The first end portion is joined to the first joining surface in a state where the first wire rod straddles over at least one of the protrusions provided on the first joining surface.

2. The coil component according to claim 1, wherein The protrusion is arranged on at least any one of the first core part side end portion and the first core part opposite side end portion, the first core part side end portion is the end portion on the core part side of the first joint surface, and the first core part opposite side end portion is the end portion opposite to the first core part side end portion.

3. The coil component according to claim 2, wherein: The protrusion is provided at the first winding core side end portion.

4. The coil component according to any one of claims 1 to 3, wherein: The protrusion is embedded in the first end portion of the first wire.

5. The coil component according to claim 1 or 2, wherein: The first electrode and the second electrode are metal terminal electrodes composed of metal plates disposed at least on the first flange portion and the second flange portion, or, The first electrode and the second electrode are coated electrodes formed by coating a conductive metal on at least the first flange portion and the second flange portion.

6. The coil component according to claim 1 or 2, wherein: A first separation portion where a turn of the first wire located closest to the first flange portion is separated from the winding core portion faces the first end portion across the winding core portion, and the protrusion is provided on the first joint surface of the first electrode.

7. The coil component according to claim 1 or 2, wherein: comprising a second wire having a third end and a fourth end, The electrode further includes: a third electrode disposed on the first flange portion and facing the first electrode across the axial direction; and a fourth electrode disposed on the second flange portion and facing the second electrode across the axial direction. The third end portion is an end portion of the second wire material joined to the third electrode, The fourth end portion is the other end portion of the second wire material joined to the fourth electrode, The third electrode and the fourth electrode respectively have a third bonding surface to be bonded to the third end portion and a fourth bonding surface to be bonded to the fourth end portion, At least one protrusion is provided on the third joint surface, The third end portion is joined to the third joining surface in a state where the second wire rod straddles over at least one of the protrusions provided on the third joining surface.

8. The coil component according to claim 1 or 2, wherein: comprising a second wire having a third end and a fourth end, The electrode further includes: a third electrode disposed on the first flange portion and facing the first electrode across the axial direction; and a fourth electrode disposed on the second flange portion and facing the second electrode across the axial direction. The third end portion is an end portion of the second wire material joined to the third electrode, The fourth end portion is the other end portion of the second wire material joined to the fourth electrode, The third electrode and the fourth electrode respectively have a third bonding surface to be bonded to the third end portion and a fourth bonding surface to be bonded to the fourth end portion, At least one protrusion is provided on the fourth joint surface, The fourth end portion is joined to the fourth joining surface in a state where the second wire rod straddles over at least one of the protrusions provided on the fourth joining surface.

9. The coil component according to claim 1 or 2, wherein: The first electrode and the first end portion are bonded to each other via an alloy layer.

10. The coil component according to claim 9, wherein The alloy layer includes Cu and at least any one of Sn and Ni.

11. The coil component according to claim 1 or 2, wherein: The height of the protrusion provided on the first joint surface is in a range of not less than 1 / 10 and not more than 1 / 4 of the wire diameter of the first wire.

12. The coil component according to claim 1 or 2, wherein: The protrusion provided at the first joint surface at the end portion on the winding core side, that is, the first winding core side end portion is formed in a shape that the first winding core side end portion of the first electrode rises in a direction away from the first flange portion.

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