Coil component

Abstract

Provided is a winding-type coil component having a structure in which a wire material is wound around a core. The coil component has a structure in which a metal terminal made of a metal plate attached to a flange portion of the core is not easily separated from the flange portion. The flange parts (3, 4) of the core body (5) are provided with: mounting surfaces (7, 8) facing the mounting substrate side during mounting; top surfaces (9, 10) facing the opposite side of the mounting surface during mounting; inner end surfaces (11, 12) that connect the attachment surface and the top surface, face the winding core section (2) during attachment, and position the end of the winding core section in the axial direction (L); outer end surfaces (13, 14) facing the opposite side of the inner end surface during mounting; and first side surfaces (15, 16) and second side surfaces (17, 18) connecting the inner end surface and the outer end surface and facing in opposite directions to each other. The metal terminals (23, 24) are formed of a single metal plate, and have mounting surface facing portions (25, 26), outer end surface facing portions (27, 28), first side surface facing portions (29, 30), and second side surface facing portions (31, 32), which respectively face the mounting surface, the outer end surface, the first side surface, and the second side surface, and the mounting surface facing portions (25, 26), the outer end surface facing portions (27, 28), the first side surface facing portions (29, 30), and the second side surface facing portions (31, 32) are respectively facing the mounting surface, the outer end surface, the first side surface, and the second side surface.

Description

Technical Field

[0001] The present invention relates to a winding type coil component having a structure in which a wire is wound around a core, and more particularly to a method in which a metal terminal composed of a metal plate is attached to the core. Background Art

[0002] For example, Japanese Patent Publication No. 2006-4989 (Patent Document 1) describes a winding type coil component having a structure in which a wire is wound on a core. In more detail, the core has: a winding core extending in the axial direction; and a pair of flanges provided at the ends of the winding core in the axial direction that are opposite to each other. A metal terminal composed of a metal plate is installed at each flange. A wire is wound on the winding core, and the wire is connected to the metal terminal.

[0003] The flange portion has: a mounting surface, which faces the mounting substrate side when installing; a top surface, which faces the opposite side of the mounting surface when installing; an inner end surface, which is the inner end surface connecting the mounting surface and the top surface, and faces the core portion side when installing and positions the end of the core portion in the axial direction; and an outer end surface, which faces the opposite side of the inner end surface when installing.

[0004] On the other hand, the metal terminal has a mounting surface opposing portion, an outer end surface opposing portion and a top surface opposing portion, which are respectively opposite to the mounting surface, the outer end surface and the top surface of the above-mentioned flange portion, and a connection is formed from the mounting surface opposing portion to the outer end surface opposing portion via the bending portion, and a connection is formed from the outer end surface opposing portion to the top surface opposing portion via the bending portion.

[0005] In the invention described in Patent Document 1, at least one of the angles formed between the outer end face of the flange portion and the mounting surface and the angle formed between the outer end face and the top surface becomes an acute angle, whereby the flange portion is clamped by the mounting surface opposing portion and the top surface opposing portion, and the metal terminal is not easily detached from the flange portion.

[0006] In addition, Patent Document 1 states that: a concave portion with a circular opening is provided on the mounting surface and the top surface of the flange portion, and a convex portion forming a spherical surface is provided at the mounting surface opposing portion and the top surface opposing portion of the metal terminal. By embedding the convex portion into the concave portion, it is easier to position the metal terminal relative to the flange portion, and it is less likely to cause the metal terminal to be misaligned relative to the flange portion, which also helps prevent the metal terminal from being easily detached from the flange portion.

[0007] Patent Document 1: Japanese Patent Application Publication No. 2006-4989

[0008] It can be considered that, for the direction of the external force applied to the core body, more specifically, the direction of the external force that causes the metal terminal to detach from the flange portion, typically, there are 6 directions. That is, the positive and negative directions in the axial direction of the winding core portion (hereinafter, also referred to as the "L direction"), the positive and negative directions in the direction orthogonal to the L direction and in the direction connecting the mounting surface and the top surface (hereinafter, also referred to as the "T direction"), and the positive and negative directions in the extension direction of the mounting surface and the top surface (hereinafter, also referred to as the "W direction"). Therefore, in order to prevent the metal terminal from detaching from the flange portion, it is necessary to withstand the external forces in the above 6 directions. In addition, with respect to the external force from the mounting surface toward the top surface in the T direction, this external force is usually not generated when the coil component is mounted on the mounting substrate, so it can also be ignored.

[0009] For the coil component recorded in patent document 1, a pair of metal terminals respectively have an installation surface opposing portion, an outer end surface opposing portion and a top surface opposing portion. Therefore, it can be considered that, in the installed state, a specific surface of the metal terminal abuts against a specific surface of the flange portion, and therefore, it can be sufficient to withstand external forces in four directions, namely, the positive and negative directions in the T direction and the positive and negative directions in the L direction.

[0010] On the other hand, there is no part that can bear the external forces in the positive and negative directions in the W direction and achieve the abutment between the surfaces. Patent document 1 records that, as mentioned above, a concave portion with a circular opening is provided on the mounting surface and the top surface of the flange portion, and a convex portion forming a spherical surface is provided on the mounting surface opposing portion and the top surface opposing portion of the metal terminal. However, the resistance to the external force generated by the convex portion being embedded in the concave portion is weaker than the resistance to the external force generated by the abutment between the surfaces, and it may not be possible to eliminate the concern that the metal terminal will detach from the flange portion. Summary of the invention

[0011] Therefore, an object of the present invention is to provide a coil component having a structure capable of reducing the ease of detachment of a metal terminal from a flange portion compared with the technique described in Patent Document 1.

[0012] The present invention is directed to a coil component, comprising: a core body, which has a winding core portion extending in an axial direction and a pair of flange portions respectively arranged at the ends of the winding core portion in opposite directions in the axial direction; a pair of metal terminals, which are installed on each flange portion and are respectively composed of a metal plate; and a wire material, which is respectively connected to the pair of metal terminals and is wound around the winding core portion.

[0013] Each flange portion has: a mounting surface, which faces the mounting substrate side when installing; a top surface, which faces the opposite side of the mounting surface when installing; an inner end surface, which connects the mounting surface and the top surface, and faces the core portion side when installing and positions the end of the core portion in the axial direction; an outer end surface, which faces the opposite side of the inner end surface when installing; and a first side surface and a second side surface, which connect the inner end surface and the outer end surface and face opposite directions to each other.

[0014] In order to solve the above-mentioned technical problems, the present invention is characterized in that each metal terminal has a mounting surface opposing portion, an outer end surface opposing portion, a first side surface opposing portion and a second side surface opposing portion which are respectively opposite to the mounting surface, the outer end surface, the first side surface and the second side surface.

[0015] According to the present invention, the external forces applied to the core body in at least five directions, namely, the positive and negative directions in the L direction, the positive and negative directions in the W direction, and the direction from the top surface toward the mounting surface in the T direction, can be borne by the abutment between the surfaces. Therefore, it is possible to sufficiently withstand the external forces in at least the five directions and prevent the metal terminal from detaching from the flange portion, and compared with the technology described in Patent Document 1, it is possible to further reduce the ease with which the metal terminal detaches from the flange portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a perspective view showing the appearance of the coil component 1 according to the first embodiment of the present invention, with the mounting surfaces 7 and 8 facing upward.

[0017] Figure 2 Yes means Figure 1 The illustrated perspective view is of the installed state of the coil component 1 .

[0018] Figure 3 is used for Figure 2 A perspective view illustrating typical external forces applied to the coil component 1 in the mounted state shown.

[0019] Figure 4 is used for Figure 2 A perspective view for explaining the external force in the rotational direction applied to the coil component 1 in the mounted state shown.

[0020] Figure 5 This is a perspective view showing the appearance of a coil component 1 a according to a second embodiment of the present invention, with the mounting surfaces 7 and 8 facing upward.

[0021] Figure 6 This is a perspective view showing the appearance of a coil component 1 b according to a third embodiment of the present invention, with the mounting surfaces 7 and 8 facing upward.

[0022] Figure 7This is a perspective view showing the appearance of a coil component 1 c according to a fourth embodiment of the present invention, with the mounting surfaces 7 and 8 facing upward.

[0023] Figure 8 It is a perspective view showing the appearance of a coil component 1 d according to a fifth embodiment of the present invention, with the mounting surfaces 7 and 8 facing upward. DETAILED DESCRIPTION

[0024] Reference Figure 1 to Figure 4 , a coil component 1 according to a first embodiment of the present invention will be described.

[0025] The coil component 1 has a drum-shaped core 5, which has a winding core 2 extending in the axial direction (L direction), and a pair of flanges, namely a first flange 3 and a second flange 4, respectively provided at the ends of the winding core 2 in the L direction that are opposite to each other. The core 5 is composed of a magnetic body such as ferrite, a resin containing ferrite powder or metal magnetic powder, or a non-magnetic body such as alumina. The cross-sectional shape of the winding core 2 is roughly a quadrilateral shape in the figure, but in addition, it can also be a polygonal shape such as a hexagonal shape, a circular shape, an elliptical shape, or a shape composed of a combination thereof.

[0026] The first flange portion 3 has a mounting surface 7 which faces the mounting substrate 6 (see Figure 2 ) side; a top surface 9, which faces the opposite side of the mounting surface 7 when installed; an inner end surface 11, which connects the mounting surface 7 and the top surface 9, and faces the side of the winding core 2 when installed and positions the end of the winding core 2 in the L direction; an outer end surface 13, which faces the opposite side of the inner end surface 11 when installed; and a first side surface 15 and a second side surface 17, which connect the inner end surface 11 and the outer end surface 13, and face opposite directions to each other when installed.

[0027] Similarly, the second flange portion 4 has: a mounting surface 8, which faces the mounting substrate 6 side when installed; a top surface 10, which faces the opposite side of the mounting surface 8 when installed; an inner end surface 12, which connects the mounting surface 8 and the top surface 10, and faces the core portion 2 side when installed and positions the end of the core portion 2 in the L direction; an outer end surface 14, which faces the opposite side of the inner end surface 12 when installed; and a first side surface 16 and a second side surface 18, which connect the inner end surface 12 and the outer end surface 14, and face opposite directions to each other when installed.

[0028] The size of the core 5 is not limited, but as an example, the size in the L direction is 3.2 mm, the size in the extension direction (W direction) perpendicular to the L direction and in the mounting surfaces 7, 8 and the top surfaces 9, 10 is 2.5 mm, and the size in the direction connecting the mounting surfaces 7, 8 and the top surfaces 9, 10 (T direction) is 1.8 mm.

[0029] The coil component 1 is, for example, a structure constituting a winding-type inductor, and includes a wire 21 wound around the winding core 2 of the core body 5. The wire 21 includes: a core wire made of a good conductive metal such as copper, silver or gold; and an insulating film covering the core wire and made of an electrically insulating resin such as polyamide-imide, polyurethane or polyester-imide. The diameter of the core wire of the wire 21 is not limited, but it is preferred to use a core wire with a diameter of, for example, 80 μm or more and 200 μm or less. In addition, the number of turns of the wire 21 on the winding core 2 is not limited.

[0030] A pair of metal terminals 23 and 24 are mounted on the flanges 3 and 4. More specifically, the first metal terminal 23 is mounted on the first flange 3, and the second metal terminal 24 is mounted on the second flange 4. The first end and the second end of the wire 21, which are opposite to each other, are connected to the first metal terminal 23 and the second metal terminal 24, respectively.

[0031] The first metal terminal 23 and the second metal terminal 24 are each formed of a metal plate and have substantially the same shape or point-symmetrical shapes. The metal plates forming the metal terminals 23 and 24 are, for example, plates obtained by plating Ni and Sn on a base material formed of phosphor bronze.

[0032] The first metal terminal 23 includes a mounting surface facing portion 25, an outer end surface facing portion 27, a first side surface facing portion 29, and a second side surface facing portion 31, which are respectively opposed to the mounting surface 7, the outer end surface 13, the first side surface 15, and the second side surface 17 of the first flange portion 3. The second metal terminal 24 includes a mounting surface facing portion 26, an outer end surface facing portion 28, a first side surface facing portion 30, and a second side surface facing portion 32, which are respectively opposed to the mounting surface 8, the outer end surface 14, the first side surface 16, and the second side surface 18 of the second flange portion 4.

[0033] In this embodiment, in the first metal terminal 23, the outer end surface facing portion 27 is connected to the mounting surface facing portion 25 via the first bent portion 33, and the first side surface facing portion 29 and the second side surface facing portion 31 are connected to the mounting surface facing portion 25 via the second bent portion 35. Similarly, in the second metal terminal 24, the outer end surface facing portion 28 is connected to the mounting surface facing portion 26 via the first bent portion 34, and the first side surface facing portion 30 and the second side surface facing portion 32 are connected to the mounting surface facing portion 26 via the second bent portion 36.

[0034] The first end portion and the second end portion of the wire material 21 are connected to the mounting surface facing portion 25 of the first metal terminal 23 and the mounting surface facing portion 26 of the second metal terminal 24 , respectively, by, for example, thermocompression bonding.

[0035] like Figure 2 As shown, the coil component 1 is mounted on the conductive pads 37 and 38 provided on the mounting substrate 6 via solder in a state where the metal terminals 23 and 24 are connected. Figure 2 The figure shows a fillet 39 formed of solder that connects the conductive pad 37 and the first metal terminal 23 .

[0036] A top plate 40 is provided on the coil component 1 to connect the top surface 9 of the first flange portion 3 of the core body 5 and the top surface 10 of the second flange portion 4. The top plate 40 is bonded to the core body 5 by an adhesive. As an adhesive, for example, a thermosetting epoxy resin is used. In order to improve the thermal shock resistance of the adhesive, an inorganic filler such as a silica filler can also be added to the adhesive. As a method for applying the adhesive, a printing method for applying the adhesive on the top plate 40, a method for immersing the top surfaces 9, 10 sides of the flange portions 3, 4 of the core body 5 in an adhesive, a method for distributing the adhesive on both the top plate 40 and the core body 5, etc. can be adopted.

[0037] As the material of the top plate 40, a magnetic body such as ferrite, a resin containing ferrite powder or metal magnetic powder, or a non-magnetic body such as aluminum oxide is used. When both the core 5 and the top plate 40 are made of magnetic bodies, the core 5 and the top plate 40 constitute a closed magnetic circuit. A coating formed by resin may also be applied instead of the top plate 40. In addition, the top plate 40 may not exist, and the resin coating may not exist.

[0038] According to the structure described above, the following effects are achieved.

[0039] If you refer to Figure 1 to Figure 4 To explain, when the coil component 1 is in the installed state, the external force in the positive and negative directions in the L direction applied to the core body 5 can be borne by the abutment between the outer end face 13 of the first flange portion 3 and the outer end face opposing portion 27 of the first metal terminal 23, and by the abutment between the outer end face 14 of the second flange portion 4 and the outer end face opposing portion 28 of the second metal terminal 24.

[0040] In addition, when the coil component 1 is in the installed state, the external forces in the positive and negative directions in the W direction among the external forces applied to the core body 5 can be borne by the abutment between the first side surface 15 of the first flange portion 3 and the first side surface opposing portion 29 of the first metal terminal 23, the abutment between the second side surface 17 of the first flange portion 3 and the second side surface opposing portion 31 of the first metal terminal 23, the abutment between the first side surface 16 of the second flange portion 4 and the first side surface opposing portion 30 of the second metal terminal 24, and the abutment between the second side surface 18 of the second flange portion 4 and the second side surface opposing portion 32 of the second metal terminal 24.

[0041] In addition, when the coil component 1 is in the installed state, the external force applied to the core body 5 in the T direction from the top surfaces 9, 10 toward the mounting surfaces 7, 8 can be borne by the abutment between the mounting surface 7 of the first flange portion 3 and the mounting surface opposing portion 25 of the first metal terminal 23, and the abutment between the mounting surface 8 of the second flange portion 4 and the mounting surface opposing portion 26 of the second metal terminal 24.

[0042] As described above, the external forces in at least the five directions can be received without the metal terminals 23 and 24 being separated from the flange portions 3 and 4 .

[0043] In this embodiment, the metal terminals 23 and 24 are provided with a structure that makes it more difficult to detach from the flanges 3 and 4. That is, a restricting portion is further provided to restrict the movement of the metal terminals 23 and 24 relative to the flanges 3 and 4 at least in the direction of separating the mounting surface opposing portions 25 and 26 from the mounting surfaces 7 and 8.

[0044] As mentioned above, among the external forces applied to the core body 5, the external force in the T direction from the mounting surfaces 7 and 8 toward the top surfaces 9 and 10 is not usually generated when the coil component 1 is mounted on the mounting substrate, but it may be generated instantly due to the impact of falling, etc. The above-mentioned limiting portion is effective for the external force in the T direction from the mounting surfaces 7 and 8 toward the top surfaces 9 and 10 among the external forces applied to the core body 5.

[0045] More specifically, with respect to the first metal terminal 23, the limiting portion is provided by a first protrusion 41 provided at at least one of the first side surface 15 and the second side surface 17 of the first flange portion 3, and a notch portion 42 located at at least one of the first side surface opposing portion 29 and the second side surface opposing portion 31 of the first metal terminal 23 and receiving the first protrusion 41.

[0046] In addition, with respect to the second metal terminal 24, the limiting portion is provided by a first protrusion 43 provided on at least one of the first side surface 16 and the second side surface 18 of the second flange portion 4, and a notch portion 44 located on at least one of the first side surface opposing portion 30 and the second side surface opposing portion 32 of the second metal terminal 24 and receiving the first protrusion 43.

[0047] In this way, by selecting at least one of the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23 as the position for providing the notch portion 42, it is possible to ensure a larger area of ​​the outer end surface facing portion 27 and the mounting surface facing portion 25 of the first metal terminal 23 that bear a large external force. The same can be said for the notch portion 44 of the second metal terminal 24. Therefore, the effect of making it difficult for the metal terminals 23 and 24 to be separated from the flange portions 3 and 4 can be further improved.

[0048] In this embodiment, regarding the first metal terminal 23, the first protrusion 41 is provided on both the first side surface 15 and the second side surface 17 of the first flange portion 3, and the notch portion 42 is located on both the first side surface opposing portion 29 and the second side surface opposing portion 31 of the first metal terminal 23. In addition, regarding the second metal terminal 24, the first protrusion 43 is provided on both the first side surface 16 and the second side surface 18 of the second flange portion 4, and the notch portion 44 is located on both the first side surface opposing portion 30 and the second side surface opposing portion 32 of the second metal terminal 24.

[0049] In this way, if the first protrusion 41 is provided on both the first side surface 15 and the second side surface 17 of the first flange portion 3, and the first protrusion 43 is provided on both the first side surface 16 and the second side surface 18 of the second flange portion 4, the effect of making it difficult for the metal terminals 23 and 24 to detach from the flange portions 3 and 4 can be further improved.

[0050] The limiting portion formed by the combination of the first protrusions 41, 43 and the notches 42, 44 as described above can not only limit the movement of the mounting surface opposing portions 25, 26 away from the mounting surfaces 7, 8, but also limit the movement of the outer end surface opposing portions 27, 28 away from the outer end surfaces 13, 14.

[0051] In this embodiment, with respect to the first metal terminal 23, the first protrusion 41 provides a first protrusion wall 45 extending in a direction opposite to the mounting surface 7 along the top surface 9 of the first flange portion 3 and a second protrusion wall 46 extending in a direction opposite to the inner end surface 11 along the outer end surface 13, and the notch portion 42 provides a first opposing wall 47 opposite to the first protrusion wall 45 and a second opposing wall 48 opposite to the second protrusion wall 46.

[0052] In addition, with respect to the second metal terminal 24, the first protrusion 43 provides a first protruding wall 49 extending in a direction opposite to the mounting surface 8 along the top surface 10 of the second flange portion 4 and a second protruding wall 50 extending in a direction opposite to the inner end surface 12 along the outer end surface 14, and the notch portion 44 provides a first opposing wall 51 opposite to the first protruding wall 49 and a second opposing wall 52 opposite to the second protruding wall 50.

[0053] Preferably, when viewed toward the first side surfaces 15 , 16 and the second side surfaces 17 , 18 , the first protruding walls 45 , 49 extend linearly parallel to the inner end surfaces 11 , 12 , and the second protruding walls 46 , 50 extend linearly parallel to the mounting surfaces 7 , 8 .

[0054] In this way, if the first raised walls 45, 49 extend in a straight line parallel to the inner end faces 11, 12, and the second raised walls 46, 50 extend in a straight line parallel to the mounting surfaces 7, 8, the forces are balanced in the direction in which the mounting surface opposing portions 25, 26 leave the mounting surfaces 7, 8 and in the direction in which the outer end surface opposing portions 27, 28 leave the outer end faces 13, 14, thereby effectively preventing the metal terminals 23, 24 from detaching from the flange portions 3, 4.

[0055] Furthermore, when viewed toward the first side surface 15 and the second side surface 17 of the first flange portion 3, the first protrusion 41 is located at a position close to the angle formed by the intersection with the outer end surface 13 and the mounting surface 7 on the first side surface 15 and the second side surface 17, and the notch 42 is located at a position separated by a predetermined distance from the end edge of the first side surface opposing portion 29 and the second side surface opposing portion 31 of the first metal terminal 23 on the inner end surface 11 side and the end edge on the top surface 9 side. In other words, the first side surface opposing portion 29 and the second side surface opposing portion 31 are formed into an L-shape that is biased toward the inner end surface 11 side and the top surface 9 side.

[0056] Similarly, when viewing toward the first side surface 16 and the second side surface 18 of the second flange portion 4, the first protrusion 43 is located at a position close to the angle formed by the intersection with the outer end surface 14 and the mounting surface 8 on the first side surface 16 and the second side surface 18, and the notch 44 is located at a position spaced a predetermined distance from the end edge of the first side surface opposing portion 30 and the second side surface opposing portion 32 of the second metal terminal 24 on the inner end surface 12 side and the end edge on the top surface 10 side. In other words, the first side surface opposing portion 30 and the second side surface opposing portion 32 are formed into an L-shape that is biased toward the inner end surface 12 side and the top surface 10 side.

[0057] According to the arrangement of the first protrusions 41, 43 and the notches 42, 44 as described above, the area of ​​each of the first protrusions 41, 43 can be made larger. In addition, the protrusion walls of the first protrusions 41, 43 along the mounting surfaces 7, 8 are coplanar with the mounting surfaces 7, 8, and the protrusion walls of the first protrusions 41, 43 along the outer end surfaces 13, 14 are coplanar with the outer end surfaces 13, 14, so that the core 5 having the first protrusions 41, 43 can be easily formed.

[0058] In addition, it is preferred that the first flange portion 3 also has a second protrusion 53, and the second protrusion 53 is at least partially opposite to the end edge of the first metal terminal 23 on the side of the top surface 9 in the direction in which the top surface 9 and the mounting surface 7 are opposite to each other, and the second flange portion 4 also has a second protrusion 54, and the second protrusion 54 is at least partially opposite to the end edge of the second metal terminal 24 on the side of the top surface 10 in the direction in which the top surface 10 and the mounting surface 8 are opposite to each other.

[0059] According to the second protrusions 53 and 54, Figure 4The external forces R1 and R2 in the rotational direction shown can more effectively suppress the metal terminals 23 and 24 from detaching from the flange portions 3 and 4. The external force R1 in the rotational direction is an external force generated around an axis in the W direction, and the external force R2 in the rotational direction is an external force generated around an axis in the L direction. For example, when the coil component 1 is mounted on the mounting substrate 6 and a temperature change occurs, the mounting substrate 6 thermally expands more than the core 5 due to the thermal expansion difference between the core 5 and the mounting substrate 6, thereby generating the external force R1 of the external forces R1 and R2 in the rotational direction. The external forces R1 and R2 in the rotational direction have the effect of causing the outer end surface opposing portions 27 and 28 of the metal terminals 23 and 24 to leave the core 5, and thus become the cause of the metal terminals 23 and 24 detaching from the flange portions 3 and 4.

[0060] In this embodiment, the second protrusion 53 is provided across the first side surface 15 , the outer end surface 13 , and the second side surface 17 of the first flange portion 3 , and the second protrusion 54 is provided across the first side surface 16 , the outer end surface 14 , and the second side surface 18 of the second flange portion 4 .

[0061] With respect to the resistance force formed by the external forces R1 and R2 in the above-mentioned rotational directions, it is particularly effective that the second protrusion 53 is arranged to be opposite to the end edges of the first side surface opposing portion 29 and the second side surface opposing portion 31 of the first metal terminal 23 on the side close to the top surface 9, and the second protrusion 54 is arranged to be opposite to the end edges of the first side surface opposing portion 30 and the second side surface opposing portion 32 of the second metal terminal 24 on the side close to the top surface 10.

[0062] In addition, the outer end surface facing portions 27 and 28 of the metal terminals 23 and 24 may form a step on the outer end surface 13 and 14 side of the flange portions 3 and 4, but the portion of the second protrusions 53 and 54 located on the outer end surface 13 and 14 helps to eliminate or reduce such a step. Therefore, it is not easy to cause an undesirable situation such as the tip of a small pliers or the like entering between the outer end surface facing portions 27 and 28 of the metal terminals 23 and 24 and the outer end surface 13 and 14 of the flange portions 3 and 4.

[0063] Figure 5 , Figure 6 , Figure 7 and Figure 8 1a, 1b, 1c, 1d ... Figure 1 Quite a picture. Figures 5 to 8 In, with Figure 1 Elements equivalent to the elements shown or Figures 5 to 8 The same reference numerals are used to designate the elements corresponding to each other, and overlapping descriptions are omitted.

[0064] and Figure 1 Compared with the coil component 1 shown, Figure 5 The coil component 1a shown is different in the shape and bending method of the metal plates constituting each of the metal terminals 23a and 24a.

[0065] More specifically, in the first metal terminal 23a, the outer end surface opposing portion 27 is connected to the mounting surface opposing portion 25 via the first bending portion 55, and the first side surface opposing portion 29 and the second side surface opposing portion 31 are respectively connected to the outer end surface opposing portion 27 via the second bending portion 57.

[0066] Similarly, in the second metal terminal 24a, the outer end surface opposing portion 28 is connected to the mounting surface opposing portion 26 via the first bending portion 56, and the first side surface opposing portion 30 and the second side surface opposing portion 32 are respectively connected to the outer end surface opposing portion 28 via the second bending portion 58.

[0067] Figure 6 The coil component 1b shown can be regarded as a coil component for use with the metal terminals 23b, 24b. Figure 5 The coil component 1a shown has a modified structure.

[0068] More specifically, in the first metal terminal 23b, the mounting surface opposing portion 25 is divided into a first mounting surface opposing end portion 61 on the first side surface 15 side, a second mounting surface opposing end portion 63 on the second side surface 17 side, and a mounting surface opposing center portion 65 sandwiched by the first mounting surface opposing end portion 61 and the second mounting surface opposing end portion 63. The first mounting surface opposing end portion 61, the second mounting surface opposing end portion 63 and the mounting surface opposing center portion 65 are connected to the outer end surface opposing portion 27 via the first bending portion 55.

[0069] Similarly, in the second metal terminal 24b, the mounting surface opposing portion 26 is divided into a first mounting surface opposing end portion 62 on the first side surface 16 side, a second mounting surface opposing end portion 64 on the second side surface 18 side, and a mounting surface opposing center portion 66 sandwiched by the first mounting surface opposing end portion 62 and the second mounting surface opposing end portion 64. The above-mentioned first mounting surface opposing end portion 62, the second mounting surface opposing end portion 64 and the mounting surface opposing center portion 66 are connected to the outer end surface opposing portion 28 via the first bending portion 56.

[0070] for Figure 6 In the coil component 1 b shown, solder is applied to the mounting surface-facing center portions 65 and 66 of the metal terminals 23 b and 24 b when the coil component 1 b is mounted on the mounting substrate.

[0071] On the other hand, in the first metal terminal 23b, the first end of the wire 21 is connected to either the first mounting surface opposing end 61 or the second mounting surface opposing end 63, for example, at the first mounting surface opposing end 61, and in the second metal terminal 24b, the second end of the wire 21 is connected to either the first mounting surface opposing end 62 or the second mounting surface opposing end 64, for example, at the second mounting surface opposing end 64.

[0072] according to Figure 6 In the coil component 1b shown, as described above, the mounting surface opposing central portions 65 and 66 to which solder is applied during mounting are separated from the first mounting surface opposing ends 61 and 26 or the second mounting surface opposing ends 63 and 64 to which the wire material 21 is connected. Therefore, the first mounting surface opposing ends 61 and 62 or the second mounting surface opposing ends 63 and 64 are less susceptible to loads such as heat and stress applied to the mounting surface opposing central portions 65 and 66, and the mounting surface opposing central portions 65 and 66 are less susceptible to loads such as heat and stress applied to the first mounting surface opposing ends 61 and 62 or the second mounting surface opposing ends 63 and 64. Therefore, the connection reliability between the mounting substrate and the metal terminals 23b and 24b and the connection reliability between the metal terminals 23b and 24b and the wire material 21 can be improved.

[0073] Figure 7 The coil component 1c shown can be regarded as a coil component for use with the metal terminals 23c, 24c. Figure 6 The coil component 1b shown has a deformed structure.

[0074] More specifically, in the first metal terminal 23c, Figure 6 The same as the case of the coil component 1b shown in FIG. 1 , the mounting surface opposing portion 25 is divided into a first mounting surface opposing end portion 61 close to the first side surface 15, a second mounting surface opposing end portion 63 close to the second side surface 17, and a mounting surface opposing central portion 65 sandwiched by the first mounting surface opposing end portion 61 and the second mounting surface opposing end portion 63. Moreover, the mounting surface opposing central portion 65 is connected to the outer end surface opposing portion 27 via the first bending portion 55, but the first mounting surface opposing end portion 61 and the second mounting surface opposing end portion 63 are connected to the first side surface opposing portion 29 and the second side surface opposing portion 31 via the third bending portion 67, respectively.

[0075] Similarly, in the second metal terminal 24c, the mounting surface opposing portion 26 is divided into a first mounting surface opposing end portion 62 on the first side surface 16 side, a second mounting surface opposing end portion 64 on the second side surface 18 side, and a mounting surface opposing central portion 66 sandwiched by the first mounting surface opposing end portion 62 and the second mounting surface opposing end portion 64. Moreover, the mounting surface opposing central portion 66 is connected to the outer end surface opposing portion 28 via the first bent portion 56, but the first mounting surface opposing end portion 62 and the second mounting surface opposing end portion 64 are connected to the first side surface opposing portion 30 and the second side surface opposing portion 32 via the third bent portion 68, respectively.

[0076] for Figure 7 As for the coil component 1c shown, Figure 6 The same is true for the coil component 1 b shown in the figure. When mounted on a mounting substrate, solder is applied to the mounting surface-facing center portions 65 and 66 of the metal terminals 23 c and 24 c.

[0077] In addition, in the first metal terminal 23c, the first end of the wire 21 is connected to either the first mounting surface opposing end 61 or the second mounting surface opposing end 63, for example, at the first mounting surface opposing end 61, and in the second metal terminal 24c, the second end of the wire 21 is connected to either the first mounting surface opposing end 62 or the second mounting surface opposing end 64, for example, at the second mounting surface opposing end 64.

[0078] according to Figure 7 The coil component 1c shown, and Figure 6 The same is true for the coil component 1b shown in the figure, where the mounting surface facing central portions 65 and 66 to which solder is applied during mounting are separated from the mounting surface facing end portions 61 to 64 to which the connecting wire 21 exists. Figure 7 In the coil component 1c shown in FIG. 1 , the mounting surface facing ends 61 to 64 are connected to the outer end surface facing portions 27 and 28 via the side surface facing portions 29 to 32. Figure 6 Compared with the coil component 1b shown in FIG. 1 , the mounting surface facing ends 61 to 64 are less susceptible to the loads such as heat and stress applied to the mounting surface facing central portions 65 and 66, and the mounting surface facing central portions 65 and 66 are less susceptible to the loads such as heat and stress applied to the mounting surface facing ends 61 to 64. Figure 6 The coil component 1 b shown further improves the connection reliability between the mounting substrate and the metal terminals 23 c and 24 c and the connection reliability between the metal terminals 23 c and 24 c and the wire material 21 .

[0079] and Figure 5 Compared with the coil component 1a shown, Figure 8The coil component 1d shown is different in the positions of the first protrusions 41d and 43d.

[0080] More specifically, for Figure 5 For the coil component 1a shown in FIG. 1 , the first protrusion 41 is located at a position close to the angle formed by the intersection with the outer end surface 13 and the mounting surface 7 between the first side surface 15 and the second side surface 17 of the first flange portion 3, and the first protrusion 43 is located at a position close to the angle formed by the intersection with the outer end surface 14 and the mounting surface 8 between the first side surface 16 and the second side surface 18 of the second flange portion 4. In contrast, for Figure 8 For the coil component 1d shown, the first protrusion 41d is located at a position separated from the intersection angle formed by the outer end surface 13 and the mounting surface 7 among the first side surface 15 and the second side surface 17 of the first flange portion 3, and the first protrusion 43d is located at a position separated from the intersection angle formed by the outer end surface 14 and the mounting surface 8 among the first side surface 16 and the second side surface 18 of the second flange portion 4.

[0081] The positions of the notches 42d and 44d provided in the metal terminals 23d and 24d are also changed in accordance with the changes of the first protrusions 41d and 43d described above.

[0082] In addition, the functions of the first protrusions 41 d and 43 d are substantially the same as those of the first protrusions 41 and 43 .

[0083] As mentioned above, although this invention was demonstrated in connection with the embodiment shown in figure, there are various other embodiments possible within the scope of this invention.

[0084] For example, a limiting portion that limits the movement of the metal terminals 23, 24 relative to the flange portions 3, 4 at least in the direction in which the mounting surface opposing portions 25, 26 leave the mounting surfaces 7, 8 is not required in the present invention, but when a limiting portion is provided, it may be provided in association with only one of the first side surface 15 and the second side surface 17 of the first flange portion 3, or it may be provided in association with only one of the first side surface 16 and the second side surface 18 of the second flange portion 4.

[0085] In addition, in the present invention, fixation by adhesive is not essential when attaching the metal terminals 23 and 24 to the flanges 3 and 4. In addition, fixation by adhesive may cause the following problems.

[0086] (1) The more firmly the adhesive is fixed, the more meaningless the use of metal terminals is. The advantage of metal terminals is that even if a small external force is applied, the metal terminal itself will bend to release stress and prevent damage due to the elasticity of the metal plate. However, the more firmly the metal terminal is fixed with an adhesive, the less it can use the elasticity of the metal plate. In other words, the above approach becomes weaker against the development of solder cracks during long-term reliability tests and flexure tests.

[0087] (2) Adhesives are generally not heat-resistant and lose their adhesive function in just a few minutes at temperatures of about 300°C. However, when manufacturing coil components using existing metal terminals, after the metal terminals are mounted on the core body, heat must be used to connect the wire to the metal terminals, so it is inevitable to apply heat to the adhesive.

[0088] However, according to the present invention, when the metal terminals 23 and 24 are mounted on the flanges 3 and 4, fixing by an adhesive is not necessary, so that sufficient heating can be applied when the wire is connected to the metal terminals. Therefore, a relatively thick wire can be used in the coil component. In addition, the present invention does not exclude the use of an adhesive.

[0089] Furthermore, when configuring the coil component according to the present invention, it is possible to partially replace or combine the structures among the different embodiments described in this specification.

[0090] The present invention may be implemented in the following ways.

[0091] <1> A coil component, comprising: a core body having a winding core portion extending in an axial direction and a pair of flange portions respectively provided at the ends of the winding core portion in opposite directions in the axial direction; a pair of metal terminals, which are mounted on each of the flange portions and each of which is composed of a metal plate; and a wire material, which is respectively connected to the pair of metal terminals and wound around the winding core portion, wherein each of the flange portions in the coil component has: a mounting surface, which faces the mounting substrate side when mounted; a top surface, which faces the opposite side of the mounting surface; and an inner end surface, which faces the mounting surface connected to the above-mentioned top surface, and when installed, faces the side of the above-mentioned core portion and positions the end of the above-mentioned core portion in the above-mentioned axial direction; an outer end face, which when installed faces the opposite side of the above-mentioned inner end face; and a first side surface and a second side surface, which connect the above-mentioned inner end face with the above-mentioned outer end face and face opposite directions to each other, each of the above-mentioned metal terminals has a mounting surface opposing portion, an outer end surface opposing portion, a first side surface opposing portion and a second side surface opposing portion, which are respectively opposite to the above-mentioned mounting surface, the above-mentioned outer end face, the above-mentioned first side surface and the above-mentioned second side surface.

[0092] <2> In the coil component described in <1>, the outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the first side surface facing portion and the second side surface facing portion are connected to the mounting surface facing portion via a second bent portion.

[0093] <3> In the coil component described in <1>, the outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the first side surface facing portion and the second side surface facing portion are connected to the outer end surface facing portion via a second bent portion.

[0094] <4> In the coil component described in <3>, the above-mentioned mounting surface opposing portion is divided into a first mounting surface opposing end portion close to the above-mentioned first side surface side, a second mounting surface opposing end portion close to the above-mentioned second side surface side, and a mounting surface opposing center portion clamped by the above-mentioned first mounting surface opposing end portion and the above-mentioned second mounting surface opposing end portion, and the above-mentioned first mounting surface opposing end portion, the above-mentioned second mounting surface opposing end portion and the above-mentioned mounting surface opposing center portion are connected to the above-mentioned outer end face opposing portion via the above-mentioned first bending portion.

[0095] <5> The coil component according to any one of <1> to <4>, further comprising a restriction portion for restricting movement of the metal terminal relative to the flange portion at least in a direction in which the mounting surface opposing portion is separated from the mounting surface.

[0096] <6> In the coil component described in <5>, the above-mentioned limiting portion is provided by a first protrusion arranged on at least one of the above-mentioned first side surface and the above-mentioned second side surface of each of the above-mentioned pair of flange portions, and a notch portion located at at least one of the above-mentioned first side surface opposing portion and the above-mentioned second side surface opposing portion of the above-mentioned metal terminal and receiving each of the above-mentioned first protrusions.

[0097] <7> In the coil component described in <6>, the restriction portion not only restricts movement in a direction in which the mounting surface opposing portion moves away from the mounting surface, but also restricts movement in a direction in which the outer end surface opposing portion moves away from the outer end surface.

[0098] <8> In the coil component described in <6> or <7>, the above-mentioned first protrusion provides a first protrusion wall extending in a direction opposite to the above-mentioned top surface and the above-mentioned mounting surface, and a second protrusion wall extending in a direction opposite to the above-mentioned outer end surface and the above-mentioned inner end surface, and the above-mentioned notch portion provides a first opposing wall opposite to the above-mentioned first protrusion wall and a second opposing wall opposite to the above-mentioned second protrusion wall.

[0099] <9> In the coil component described in <8>, when viewed toward the first side surface and the second side surface respectively, the first protrusion wall extends linearly parallel to the inner end surface, and the second protrusion wall extends linearly parallel to the mounting surface.

[0100] <10> In the coil component described in any one of <6> to <9>, when observed toward the first side surface and the second side surface respectively, the first protrusion is located at a position close to the angle of intersection formed by the outer end surface and the mounting surface in at least one of the first side surface and the second side surface of each of the pair of flange portions, and the notch portion is located at a position spaced a predetermined distance from the end edge on the inner end surface side and the end edge on the top surface side of at least one of the first side surface opposing portion and the second side surface opposing portion of the metal terminal.

[0101] <11> In the coil component according to any one of <5> to <10>, the restriction portion is provided in association with both the first side surface and the second side surface of each of the pair of flange portions.

[0102] <12> In the coil component according to any one of <1> to <11>, each of the pair of flange portions further includes a second protrusion, and the second protrusion faces at least a portion of an end edge on the top surface side of the metal terminal.

[0103] <13> In the coil component described in <12>, the second protrusion faces end edges of the first side surface facing portion and the second side surface facing portion of the metal terminal on the top surface side.

[0104] Description of Reference Numerals

[0105] 1, 1a, 1b, 1c, 1d...coil component; 2...winding core; 3...first flange; 4...second flange; 5...core; 6...mounting substrate; 7, 8...mounting surface; 9, 10...top surface; 11, 12...inner end surface; 13, 14...outer end surface; 15, 16...first side surface; 17, 18...second side surface; 21...wire; 23, 23a, 23b, 23c, 23d...first metal terminal; 24, 24a, 24b, 24c, 24d...second metal terminal; 25, 26...mounting surface opposite portion; 27, 28...outer end surface opposite portion; 29, 30...first side surface Opposing portion; 31, 32... the second side surface opposing portion; 33, 34, 55, 56... the first bending portion; 35, 36, 57, 58... the second bending portion; 37, 38... the conductive pad; 39... the solder foot; 41, 43, 41d, 43d... the first protrusion; 42, 44, 42d, 44d... the notch; 45, 49... the first protruding wall; 46, 50... the second protruding wall; 47, 51... the first opposing wall; 48, 52... the second opposing wall; 53, 54... the second protrusion; 61, 62... the first mounting surface opposing end portion; 63, 64... the second mounting surface opposing end portion; 65, 66... ​​the mounting surface opposing center portion.

Claims

1. A coil component, characterized in that: have: A core body having a winding core portion extending in an axial direction and a pair of flange portions respectively provided at ends of the winding core portion in opposite directions in the axial direction; a pair of metal terminals mounted on each of the flange portions and each consisting of a metal plate; and a wire material connected to the pair of metal terminals respectively and wound around the winding core, Each of the flange portions comprises: a mounting surface, which faces the mounting substrate side when mounted; a top surface, which faces the opposite side of the mounting surface when mounted; an inner end surface, which connects the mounting surface and the top surface, and faces the winding core portion side when mounted and positions the end of the winding core portion in the axial direction; an outer end surface, which faces the opposite side of the inner end surface when mounted; and a first side surface and a second side surface, which connect the inner end surface and the outer end surface and face opposite directions to each other, Each of the metal terminals has a mounting surface facing portion, an outer end surface facing portion, a first side surface facing portion, and a second side surface facing portion respectively facing the mounting surface, the outer end surface, the first side surface, and the second side surface.

2. The coil component according to claim 1, characterized in that The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the first side surface facing portion and the second side surface facing portion are connected to the mounting surface facing portion via a second bent portion.

3. The coil component according to claim 1, characterized in that The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the first side surface facing portion and the second side surface facing portion are connected to the outer end surface facing portion via a second bent portion.

4. The coil component according to claim 3, characterized in that The mounting surface facing portion is divided into a first mounting surface facing end portion close to the first side surface, a second mounting surface facing end portion close to the second side surface, and a mounting surface facing center portion sandwiched by the first mounting surface facing end portion and the second mounting surface facing end portion. The first mounting surface facing end portion, the second mounting surface facing end portion, and the mounting surface facing center portion are connected to the outer end surface facing portion via the first bent portion.

5. The coil component according to any one of claims 1 to 4, characterized in that: A restriction portion is further provided for restricting movement of the metal terminal relative to the flange portion at least in a direction in which the mounting surface opposing portion is separated from the mounting surface.

6. The coil component according to claim 5, characterized in that The limiting portion is provided by a first protrusion arranged on at least one of the first side surface and the second side surface of each of the pair of flange portions, and a notch portion located on at least one of the first side surface opposing portion and the second side surface opposing portion of the metal terminal and receiving each of the first protrusions.

7. The coil component according to claim 6, characterized in that The restricting portion restricts not only movement in a direction in which the mounting surface opposing portion is separated from the mounting surface, but also movement in a direction in which the outer end surface opposing portion is separated from the outer end surface.

8. The coil component according to claim 6 or 7, characterized in that: The first protrusion provides a first protrusion wall extending in a direction opposite to the top surface and the mounting surface, and a second protrusion wall extending in a direction opposite to the outer end surface and the inner end surface, and the notch provides a first opposing wall opposite to the first protrusion wall and a second opposing wall opposite to the second protrusion wall.

9. The coil component according to claim 8, characterized in that When viewed toward the first side surface and the second side surface, the first protrusion wall extends linearly in parallel with the inner end surface, and the second protrusion wall extends linearly in parallel with the mounting surface.

10. The coil component according to any one of claims 6 to 9, characterized in that: When viewed toward the first side surface and the second side surface, respectively, the first protrusion is located at a position close to an angle formed by an intersection between the outer end surface and the mounting surface in at least one of the first side surface and the second side surface of each of the pair of flange portions, The notch portion is located at a position spaced a predetermined distance from an end edge on the inner end surface side and an end edge on the top surface side of at least one of the first side surface facing portion and the second side surface facing portion of the metal terminal.

11. The coil component according to any one of claims 5 to 10, characterized in that: The restriction portion is provided in association with both the first side surface and the second side surface of each of the pair of flange portions.

12. The coil component according to any one of claims 1 to 11, characterized in that: Each of the pair of flange portions further includes a second protrusion that faces at least a portion of an edge of the metal terminal on the top surface side in a direction in which the top surface and the mounting surface face each other.

13. The coil component according to claim 12, characterized in that The second protrusion faces end edges of the first side surface facing portion and the second side surface facing portion of the metal terminal that are closer to the top surface.

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