Coil component

Abstract

Provided is a winding-type coil component having a structure in which a wire material is wound around a core, in which a metal terminal comprising a metal plate attached to a flange portion of the core is unlikely to fall off from the flange portion. Flange portions (3, 4) of a core (5) have attachment surfaces (7, 8), top surfaces (9, 10), inner end surfaces (11, 12), outer end surfaces (13, 14), first side surfaces (15, 16), and second side surfaces (17, 18). The metal terminals (23, 24) comprise metal plates, and have mounting surface facing sections (25, 26), outer end surface facing sections (27, 28), and side surface facing sections (29, 30, 31, 32), which respectively face the mounting surface, the outer end surface, and at least one of the first side surface and the second side surface. The coil component (1) is further provided with second restricting portions (45, 47, 49, 51) for restricting movement of the metal terminal in the L direction with respect to the flange portion, and first restricting portions (46, 48, 50, 52) for restricting movement of the metal terminal in the T direction with respect to the flange portion.

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 mounting structure for mounting a metal terminal composed of a metal plate on 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 respectively 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 during installation; a top surface, which faces the opposite side of the mounting surface during installation; an inner end surface, which connects the mounting surface and the top surface, faces the core portion side during installation 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 during installation.

[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 opposed to the mounting surface, the outer end surface and the top surface of the above-mentioned flange portion, and is continuous from the mounting surface opposing portion to the outer end surface opposing portion via the bending portion, and is continuous 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 by the outer end surface and the mounting surface in the flange portion and the angle formed by the outer end surface and the top surface is set to an acute angle, whereby the flange portion is clamped by the mounting surface opposing portion and the top surface opposing portion, so that the metal terminal is not easily removed from the flange portion.

[0006] In addition, Patent Document 1 describes 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 with a spherical surface is provided on the mounting surface opposing portion and the top surface opposing portion of the metal terminal. The convex portion is embedded in the concave portion, so that the positioning of the metal terminal relative to the flange portion becomes easy, and the metal terminal is not easily misaligned with respect to the flange portion, which also helps to prevent the metal terminal from falling off from the flange portion.

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

[0008] As for the direction of the external force acting on the core body, more precisely, the direction of the external force that causes the metal terminal to fall off from the flange portion, typically, it can be considered that 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 connecting the mounting surface and the top surface (hereinafter also referred to as the "T direction"), and the positive and negative directions in the direction in which the mounting surface and the top surface extend (hereinafter also referred to as the "W direction"). Therefore, in order to prevent the metal terminal from falling off 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, the external force is usually not generated when the coil component is installed on the mounting substrate, but it is possible that the external force is generated instantaneously due to the impact when falling, etc.

[0009] In the coil component described in patent document 1, it can be considered that a pair of metal terminals each have an installation surface opposing portion, an outer end surface opposing portion and a top surface opposing portion. Therefore, through the abutment between a specific surface of the metal terminal and a specific surface of the flange portion, it is possible to fully withstand external forces in four directions: positive and negative directions in the T direction and positive and negative directions in the L direction.

[0010] On the other hand, when the temperature changes while the coil component is mounted on the mounting substrate, the mounting substrate thermally expands more than the core due to the thermal expansion difference between the core and the mounting substrate. As a result, an external force may be generated on the metal terminal, for example, to rotate the metal terminal around an axis extending in the W direction. The external force in the rotation direction has the effect of causing the outer end surface of the metal terminal to detach from the outer end surface of the flange of the core, thus causing the metal terminal to fall off from the flange. However, the coil component described in Patent Document 1 does not have a structure that can fully resist the external force in the rotation direction.

[0011] In addition, it can be considered that, as described above, Patent Document 1 describes 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 with a spherical surface is provided on the mounting surface opposing portion and the top surface opposing portion of the metal terminal. However, the resistance against external force formed by the convex portion being embedded in the concave portion is relatively weak and cannot fully cope with the external force in the above-mentioned rotation direction. Summary of the invention

[0012] Therefore, an object of the present invention is to provide a coil component having a structure that can withstand external force in the rotation direction better than the technology described in Patent Document 1.

[0013] The present invention is suitable for the following coil component, which comprises: a core body having 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; at least one pair of metal terminals installed on each flange portion and respectively composed of metal plates; and at least one wire rod connected to each of the at least one pair of metal terminals and wound around the winding core portion.

[0014] Each flange portion has: a mounting surface, which faces the mounting substrate side when installed; a top surface, which faces the opposite side of the mounting surface when installed; an inner end surface, which connects the mounting surface and the top surface, and faces the core portion side when installed 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 installed; and a first side surface and a second side surface, which connect the inner end surface and the outer end surface and face in opposite directions when installed.

[0015] In order to solve the above technical problems, the present invention is characterized in that each metal terminal has: a mounting surface facing portion facing the mounting surface; an outer end surface facing portion facing the outer end surface; and a side surface facing portion facing at least one of the first side surface and the second side surface. In addition, the coil component further has: a first limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction (a direction in the L direction) in which the outer end surface facing portion is separated from the outer end surface; and a second limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction (a direction in the T direction) in which the mounting surface facing portion is separated from the mounting surface.

[0016] According to the present invention, the first limiting portion for limiting the movement in the direction (L direction) in which at least the outer end surface opposing portion is separated from the outer end surface, and the second limiting portion for limiting the movement in the direction (T direction) in which at least the mounting surface opposing portion is separated from the mounting surface, can prevent the metal terminal from easily falling off the flange portion not only for external forces in the L direction and the T direction, but also for external forces rotating around the axis extending in the W direction. This is because the external force rotating around the axis extending in the W direction can be regarded as a force obtained by synthesizing the external force in the L direction and the external force in the T direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] 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.

[0018] Figure 2 It is shown Figure 1 The illustrated perspective view is of the installed state of the coil component 1 .

[0019] Figure 3 is used for Figure 2A perspective view for explaining typical external forces acting on the coil component 1 in the mounted state shown.

[0020] Figure 4 is used for Figure 2 A perspective view for explaining the external force acting on the coil component 1 in the rotational direction in the mounted state shown.

[0021] 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.

[0022] 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.

[0023] Figure 7 This 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.

[0024] 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

[0025] Reference Figures 1 to 4 , a coil component 1 according to a first embodiment of the present invention will be described.

[0026] The coil component 1 has a drum-shaped core 5, which has a winding core portion 2 extending in the axial direction (L direction), and a pair of flange portions, namely a first flange portion 3 and a second flange portion 4, respectively provided at the ends of the winding core portion 2 in the L direction and in opposite directions. 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. In the figure, the cross-sectional shape of the winding core portion 2 is roughly a quadrilateral shape, but it can also be a polygonal shape such as a hexagonal shape, a circular shape, an elliptical shape, or a shape composed of a combination of the above shapes.

[0027] The first flange portion 3 has a mounting surface 7 that faces the mounting substrate 6 (see FIG. Figure 2 ) side; a top surface 9, facing the opposite side of the mounting surface 7; an inner end surface 11, connecting the mounting surface 7 and the top surface 9, facing the core portion 2 side and positioning the end of the core portion 2 in the L direction; an outer end surface 13, facing the opposite side of the inner end surface 11; and a first side surface 15 and a second side surface 17, connecting the inner end surface 11 and the outer end surface 13, and facing in opposite directions to each other.

[0028] Similarly, the second flange portion 4 has: a mounting surface 8, which faces the mounting substrate 6 side during installation; a top surface 10, which faces the opposite side of the mounting surface 8; an inner end surface 12, which connects the mounting surface 8 and the top surface 10, faces the core portion 2 side 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; 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.

[0029] The size of the core 5 is not limiting. As an example, the size in the L direction is 3.2 mm, the size in the direction perpendicular to the L direction and in which the mounting surfaces 7, 8 and top surfaces 9, 10 extend (W direction) is 2.5 mm, and the size in the direction connecting the mounting surfaces 7, 8 and top surfaces 9, 10 (T direction) is 1.8 mm.

[0030] The coil component 1, for example, constitutes a wound wire inductor, and includes a wire 21 wound on the winding core 2 of the core body 5. The wire 21 includes: a core wire, for example, made of a good conductive metal such as copper, silver or gold; and an insulating film, which covers the core wire and is 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, for example, it is preferred to use a core wire with a diameter of 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.

[0031] 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.

[0032] 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 made of phosphor bronze.

[0033] 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.

[0034] In this embodiment, on the first metal terminal 23, the outer end surface opposing portion 27 is connected to the mounting surface opposing portion 25 via the first bent portion 33, and the first side surface opposing portion 29 and the second side surface opposing portion 31 are connected to the mounting surface opposing portion 25 via the second bent portion 35. Similarly, on the second metal terminal 24, the outer end surface opposing portion 28 is connected to the mounting surface opposing portion 26 via the first bent portion 34, and the first side surface opposing portion 30 and the second side surface opposing portion 32 are connected to the mounting surface opposing portion 26 via the second bent portion 36.

[0035] The first end portion and the second end portion of the wire material 21 are connected to the mounting surface opposing portion 25 of the first metal terminal 23 and the mounting surface opposing portion 26 of the second metal terminal 24 , respectively, for example, by thermocompression bonding.

[0036] For the coil component 1, if Figure 2 As shown, the metal terminals 23 and 24 are mounted on the conductive lands 37 and 38 provided on the mounting substrate 6 in a state of being connected to the conductive lands 37 and 38 via solder. Figure 2 The middle figure shows a solder fillet 39 formed of solder connecting the conductive land 37 and the first metal terminal 23 .

[0037] 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 5 and the top surface 10 of the second flange portion 4. The top plate 40 is bonded to the core 5 by an adhesive. As the 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 may also be added to the adhesive. As a method for applying the adhesive, a printing method of applying the adhesive on the top plate 40, a method of immersing the flange portions 3, 4 of the core 5 on the top surface 9, 10 side in the adhesive, a method of dispersing the adhesive on both the top plate 40 and the core 5, etc. can be adopted.

[0038] As the material of the top plate 40, for example, a magnetic body such as ferrite, a resin containing ferrite powder or metal magnetic powder, or a non-magnetic body such as alumina is used. In the case where both the core 5 and the top plate 40 are made of magnetic bodies, the core 5 and the top plate 40 form a closed magnetic circuit. It is also possible to implement a coating with a resin to replace the top plate 40. In addition, even if there is no top plate 40, there is no resin coating.

[0039] According to the structure described above, the following effects are achieved.

[0040] Reference Figures 1 to 4To explain, when the coil component 1 is in the installed state, the external forces acting on the core body 5 in the positive and negative directions in the L direction 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 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.

[0041] In addition, when the coil component 1 is in the installed state, the external forces acting on the core body 5 in the positive and negative directions in the W direction 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.

[0042] In addition, when the coil component 1 is in the installed state, the external force acting on the core body 5 in the T direction from the top surfaces 9 and 10 toward the mounting surfaces 7 and 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.

[0043] As described above, the external forces in at least the five directions can be received, so that the metal terminals 23 and 24 do not fall off from the flange parts 3 and 4 .

[0044] In this embodiment, the metal terminals 23 and 24 are provided with a structure that makes it more difficult to fall off the flanges 3 and 4. That is, a restricting portion is further provided for restricting the movement of the metal terminals 23 and 24 relative to the flanges 3 and 4 at least in the direction in which the mounting surface opposing portions 25 and 26 are separated from the mounting surfaces 7 and 8.

[0045] As described above, when the coil component 1 is mounted on the mounting substrate, 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 acting on the core body 5 is usually not generated, but the external force may be generated instantaneously due to the impact when 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 acting on the core body 5.

[0046] More specifically, with respect to the first metal terminal 23, the limiting portion is provided by a first protrusion 41 arranged on 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 on 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 accommodating the first protrusion 41.

[0047] In addition, with respect to the second metal terminal 24, the limiting portion is provided by a first protrusion 43 arranged 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.

[0048] 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 setting the notch portion 42, it is possible to ensure that the outer end surface facing portion 27 and the mounting surface facing portion 25 of the first metal terminal 23, which are subjected to a large external force, have a large area. The same can be said for the notch portion 44 at the second metal terminal 24. Therefore, the effect of making it difficult for the metal terminals 23 and 24 to fall off from the flange portions 3 and 4 can be further improved.

[0049] In the present embodiment, with respect to the first metal terminal 23, the first convex portion 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, with respect to the second metal terminal 24, the first convex portion 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.

[0050] 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 fall off from the flange portions 3 and 4 can be further improved.

[0051] According to the limiting portion formed by the combination of the first protrusions 41, 43 and the notch portions 42, 44 as described above, not only can the movement of the mounting surface opposing portions 25, 26 in the direction of separation from the mounting surfaces 7, 8 be limited, but also the movement of the outer end surface opposing portions 27, 28 in the direction of separation from the outer end surfaces 13, 14 can be limited.

[0052] In this embodiment, with respect to the first metal terminal 23, the first protrusion 41 provides a first rising wall 45 extending in a direction opposite to the top surface 9 of the first flange portion 3 and the mounting surface 7, and a second rising wall 46 extending in a direction opposite to the outer end surface 13 and the inner end surface 11, and the notch portion 42 provides a first opposing wall 47 opposite to the first rising wall 45 and a second opposing wall 48 opposite to the second rising wall 46.

[0053] In addition, with respect to the second metal terminal 24, the first protrusion 43 provides a first rising wall 49 extending in a direction opposite to the top surface 10 of the second flange portion 4 and the mounting surface 8, and a second rising wall 50 extending in a direction opposite to the outer end surface 14 and the inner end surface 12, and the notch portion 44 provides a first opposing wall 51 opposite to the first rising wall 49 and a second opposing wall 52 opposite to the second rising wall 50.

[0054] In addition, the abutment between the first rising walls 45, 49 and the first opposing walls 47, 51 respectively limits the movement of the metal terminals 23, 24 relative to the flange portions 3, 4 at least in the direction in which the outer end surface opposing portions 27, 28 detach from the outer end surfaces 13, 14, but it is not necessary to maintain this abutment state when no external force is applied.

[0055] Preferably, when viewed toward the first side surfaces 15 , 16 and the second side surfaces 17 , 18 , the first rising walls 45 , 49 extend linearly parallel to the inner end surfaces 11 , 12 , and the second rising walls 46 , 50 extend linearly parallel to the mounting surfaces 7 , 8 .

[0056] In this way, if the first upright walls 45, 49 extend in a straight line parallel to the inner end surfaces 11, 12, and the second upright 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 detach from the mounting surfaces 7, 8 and in the direction in which the outer end surface opposing portions 27, 28 detach from the outer end surfaces 13, 14, thereby reliably preventing the metal terminals 23, 24 from falling off from the flange portions 3, 4.

[0057] In addition, when viewing toward the first side surface 15 and the second side surface 17 of the first flange portion 3, the first convex portion 41 is arranged on the first side surface 15 and the second side surface 17 to be close to the angle formed by the intersection with the outer end surface 13 and the mounting surface 7, and the notch portion 42 is arranged at a predetermined distance from the end edge of the inner end surface 11 side and the end edge of the top surface 9 side in the first side surface opposing portion 29 and the second side surface opposing portion 31 relative to the first metal terminal 23. In other words, the first side surface opposing portion 29 and the second side surface opposing portion 31 are L-shaped near the inner end surface 11 side and the top surface 9 side.

[0058] Similarly, when viewing toward the first side surface 16 and the second side surface 18 of the second flange portion 4, the first convex portion 43 is arranged on the first side surface 16 and the second side surface 18 to be close to the angle formed by the intersection with the outer end surface 14 and the mounting surface 8, and the notch portion 44 is arranged at a predetermined distance from the end edge of the inner end surface 12 side and the end edge of the top surface 10 side in the first side surface opposing portion 30 and the second side surface opposing portion 32 relative to the second metal terminal 24. In other words, the first side surface opposing portion 30 and the second side surface opposing portion 32 are L-shaped close to the inner end surface 12 side and the top surface 10 side.

[0059] 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 rising walls along the mounting surfaces 7, 8 of the first protrusions 41, 43 are coplanar with the mounting surfaces 7, 8, and the rising walls along the outer end surfaces 13, 14 of the first protrusions 41, 43 are coplanar with the outer end surfaces 13, 14, so that the core 5 having the first protrusions 41, 43 can be easily formed.

[0060] In addition, preferably, the first flange portion 3 further includes a second protrusion 53, which 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 opposed to each other, and the second flange portion 4 further includes a second protrusion 54, which 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 opposed to each other.

[0061] According to the second convex parts 53 and 54, Figure 4 The external forces R1 and R2 in the rotational direction shown can more reliably suppress the metal terminals 23 and 24 from falling off from the flange portions 3 and 4. The external force R1 in the rotational direction is generated around the axis toward the W direction, and the external force R2 in the rotational direction is generated around the axis toward the L direction. For the external force R1 in the above-mentioned external forces R1 and R2 in the rotational direction, for example, when the coil component 1 is installed on the mounting substrate 6, when the temperature changes, due to the thermal expansion difference between the core body 5 and the mounting substrate 6, the mounting substrate 6 thermally expands to a greater extent than the core body 5, thereby generating the external force R1. The above-mentioned 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 detach from the core body 5, thus becoming the cause of the metal terminals 23 and 24 falling off from the flange portions 3 and 4.

[0062] In the present 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 .

[0063] With regard to the resistance formed by the external forces R1 and R2 in the rotational direction mentioned above, the second protrusion 53 is arranged to be opposite to 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 side of the top surface 9, and the second protrusion 54 is arranged to be opposite to 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 side of the top surface 10. This structure is particularly effective.

[0064] In addition, the outer end surface facing portions 27 and 28 of the metal terminals 23 and 24 can form a step at 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 at the outer end surface 13 and 14 helps to eliminate or reduce the step. Therefore, for example, it is less likely to cause the tip of a tweezer or the like to enter 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.

[0065] Figure 5 , Figure 6 , Figure 7 as well as Figure 8 The coil component 1a according to the second embodiment, the coil component 1b according to the third embodiment, the coil component 1c according to the fourth embodiment, and the coil component 1d according to the fifth embodiment are shown respectively. Figure 1 Quite a picture. Figures 5 to 8 In, with Figure 1 Elements equivalent to the elements shown, or in Figures 5 to 8 The same reference numerals are used to designate the elements corresponding to each other, and duplicate descriptions are omitted.

[0066] and Figure 1 Compared with the coil component 1 shown, Figure 5 In the coil component 1 a shown, the shapes and bending forms of the metal plates constituting the metal terminals 23 a and 24 a are different.

[0067] More specifically, on the first metal terminal 23 a , 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 connected to the outer end surface opposing portion 27 via the second bending portion 57 , respectively.

[0068] Similarly, on the second metal terminal 24 a , the outer end surface facing portion 28 is connected to the mounting surface facing portion 26 via the first bent portion 56 , and the first side surface facing portion 30 and the second side surface facing portion 32 are respectively connected to the outer end surface facing portion 28 via the second bent portion 58 .

[0069] Figure 6 The coil component 1b shown can be regarded as a pair of metal terminals 23b, 24b. Figure 5 The coil component 1a shown is deformed.

[0070] More specifically, on 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 clamped by the first mounting surface opposing end portion 61 and the second mounting surface opposing end portion 63. The above-mentioned 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.

[0071] Similarly, on 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 clamped 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.

[0072] exist Figure 6 In the coil component 1 b shown, when mounted on a mounting substrate, solder is applied to the mounting surfaces of the metal terminals 23 b and 24 b at the central portions 65 and 66 facing each other.

[0073] On the other hand, on the first metal terminal 23b, at any one of the first mounting surface opposing end 61 and the second mounting surface opposing end 63, for example, at the first mounting surface opposing end 61, the first end of the wire 21 is connected, and on the second metal terminal 24b, at any one of the first mounting surface opposing end 62 and the second mounting surface opposing end 64, for example, at the second mounting surface opposing end 64, the second end of the wire 21 is connected.

[0074] according to Figure 6In the coil component 1b shown, as described above, the mounting surface opposing central portions 65 and 66 to which solder is applied during mounting and the first mounting surface opposing ends 61 and 62 or the second mounting surface opposing ends 63 and 64 to which the wire 21 is connected are separated from each other. Therefore, the first mounting surface opposing ends 61 and 62 or the second mounting surface opposing ends 63 and 64 can be made less susceptible to loads such as heat and stress acting on the mounting surface opposing central portions 65 and 66, and the mounting surface opposing central portions 65 and 66 can be made less susceptible to loads such as heat and stress acting on 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 21 can be improved.

[0075] Figure 7 The coil component 1c shown can be regarded as a Figure 6 The coil component 1b is shown deformed.

[0076] More specifically, on the first metal terminal 23c, Figure 6 The same as the case of the coil component 1b shown, the mounting surface opposing portion 25 is divided into a first mounting surface opposing end portion 61 close to the first side surface 15 side, a second mounting surface opposing end portion 63 close to the second side surface 17 side, 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 bent 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 bent portion 67, respectively.

[0077] Similarly, on 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.

[0078] exist Figure 7 In the coil component 1c shown, Figure 6 As in the case of the coil component 1 b shown, solder is applied to the mounting surfaces of the metal terminals 23 c and 24 c at the center portions 65 and 66 facing each other when the metal terminals 23 c and 24 c are mounted on the mounting substrate.

[0079] In addition, on the first metal terminal 23c, on any one of the first mounting surface opposing end 61 and the second mounting surface opposing end 63, for example, on the first mounting surface opposing end 61, the first end of the wire 21 is connected, and on the second metal terminal 24c, on any one of the first mounting surface opposing end 62 and the second mounting surface opposing end 64, for example, on the second mounting surface opposing end 64, the second end of the wire 21 is connected.

[0080] 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 and the mounting surface facing end portions 61 to 64 to which the wire 21 is connected are separated from each other. Figure 7 In the coil component 1c shown in the figure, the mounting surface facing end portions 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 loads such as heat and stress acting on the mounting surface facing central portions 65 and 66, and the mounting surface facing central portions 65 and 66 are less susceptible to loads such as heat and stress acting on the mounting surface facing ends 61 to 64. Figure 6 Compared with the coil component 1 b shown in the figure, 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 can be further improved.

[0081] and Figure 5 Compared with the coil component 1a shown, Figure 8 In the coil component 1d shown, the positions of the first protrusions 41d and 43d are different.

[0082] More specifically, in Figure 5 In the coil component 1a shown, the first convex portion 41 is arranged on the first side surface 15 and the second side surface 17 of the first flange portion 3 to be close to the angle of intersection with the outer end surface 13 and the mounting surface 7, and the first convex portion 43 is arranged on the first side surface 16 and the second side surface 18 of the second flange portion 4 to be close to the angle of intersection with the outer end surface 14 and the mounting surface 8. Figure 8 In the coil component 1d shown, on the first side surface 15 and the second side surface 17 of the first flange portion 3, the first protrusion 41d is arranged to form an angular separation that intersects the outer end surface 13 and the mounting surface 7, and on the first side surface 16 and the second side surface 18 of the second flange portion 4, the first protrusion 43d is arranged to form an angular separation that intersects the outer end surface 14 and the mounting surface 8.

[0083] In accordance with the above-mentioned change in the first protrusions 41d and 43d, the positions of the notches 42d and 44d provided in the metal terminals 23d and 24d are also changed.

[0084] 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 .

[0085] As mentioned above, although this invention was demonstrated combining with the embodiment shown in figure, other various embodiments are possible within the scope of this invention.

[0086] For example, the coil component to which the present invention is directed may be a coil component constituting a single coil as in the illustrated embodiment, or a coil component constituting a common mode choke coil, a transformer, a balanced-unbalanced transformer, etc. Therefore, the number of wires is also changed according to the function of the coil component, and accordingly, the number of metal terminals provided on each flange portion can also be changed. Typically, there is also a case where two metal terminals are arranged in the W direction on one flange portion.

[0087] As described above, when two metal terminals are arranged in a row on one flange portion in the W direction, each metal terminal has a mounting surface facing portion facing an area less than half of the width direction dimension of the mounting surface, an outer end surface facing portion facing an area less than half of the width direction dimension of the outer end surface, and a side surface facing portion facing one of the first side surface and the second side surface. In addition, the mounting surface facing portion has a mounting connection portion that can be connected to a conductor on the mounting substrate side during mounting, and a wire connection portion that can be connected to a wire, but the mounting surface facing central portion that serves as the mounting connection portion has a mounting surface facing end portion that is less than half of the width direction dimension of the illustrated case and serves as a wire connection portion.

[0088] In addition, in the present invention, the metal terminals 23 and 24 are not necessarily fixed by an adhesive when being attached to the flanges 3 and 4. In addition, fixing by an adhesive may encounter the following problems.

[0089] (1) The more firmly the fixation formed by the adhesive is made, the less meaningful the metal terminal is. The advantage of the metal terminal is that it utilizes the elasticity of the metal plate. Even if a certain external force is applied, the stress is released by the bending of the metal terminal itself to prevent damage. However, when fixing the metal terminal with an adhesive, the more firmly the fixation is made, the less the elasticity of the metal plate can be utilized. In other words, the expansion of solder cracks during long-term reliability tests and flexure tests appear to be weakened.

[0090] (2) Adhesives are generally not heat-resistant and lose their adhesive function after being heated to about 300°C for only a few minutes. 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.

[0091] However, according to the present invention, when the metal terminals 23 and 24 are mounted to the flanges 3 and 4, they are not necessarily fixed by adhesive, so when the wire is connected to the metal terminals, sufficient heating can be performed. Therefore, a relatively thick wire can be used in the coil component. In addition, the present invention does not exclude the use of adhesive.

[0092] Furthermore, when configuring the coil component according to the present invention, partial substitution or combination of structures between different embodiments described in this specification is permitted.

[0093] The present invention may be implemented in the following aspects.

[0094] <1>

[0095] A coil component, comprising:

[0096] The core body has a winding core portion extending in the axial direction, and a pair of flange portions respectively provided at ends of the winding core portion in opposite directions in the axial direction;

[0097] at least one pair of metal terminals, mounted on each of the flanges, each of which is made of a metal plate; and

[0098] at least one wire is connected to each of the at least one pair of metal terminals and is wound around the winding core.

[0099] Each of the flange portions comprises: a mounting surface, which faces the mounting substrate side during mounting; a top surface, which faces the opposite side of the mounting surface during mounting; an inner end surface, which connects the mounting surface and the top surface, faces the winding core side during mounting and positions the end of the winding core in the axial direction; an outer end surface, which faces the opposite side of the inner end surface during mounting; and a first side surface and a second side surface, which connect the inner end surface and the outer end surface and face in opposite directions to each other.

[0100] Each of the metal terminals has: a mounting surface facing portion facing the mounting surface; an outer end surface facing portion facing the outer end surface; and a side surface facing portion facing at least one of the first side surface and the second side surface.

[0101] The coil component further comprises: a first limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction in which the mounting surface opposing portion is detached from the mounting surface; and a second limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction in which the outer end surface opposing portion is detached from the outer end surface.

[0102] <2>

[0103] The coil component according to <1>, wherein:

[0104] The flange portion has a first rising wall extending in a direction in which the inner end surface extends.

[0105] The metal terminal has a first opposing wall opposed to the first rising wall.

[0106] The first restriction portion is provided by the contact between the first rising wall and the first opposing wall.

[0107] <3>

[0108] The coil component according to <2>, wherein:

[0109] The flange portion has a second rising wall extending in a direction in which the mounting surface extends.

[0110] The metal terminal has a second opposing wall opposed to the second rising wall.

[0111] The second restriction portion is provided by the contact between the first rising wall and the first opposing wall.

[0112] <4>

[0113] The coil component according to <3>, wherein:

[0114] A first convex portion is provided on at least one of the first side surface and the second side surface,

[0115] A notch portion for receiving the first protrusion is provided at the side surface opposing portion.

[0116] The first protrusion includes an outer peripheral wall providing the first rising wall and the second rising wall.

[0117] The cutout portion includes an inner peripheral wall that provides the first opposing wall and the second opposing wall.

[0118] <5>

[0119] The coil component according to any one of <1> to <4>, wherein:

[0120] The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the mounting surface facing portion via a second bent portion.

[0121] <6>

[0122] The coil component according to any one of <1> to <4>, wherein:

[0123] The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the outer end surface facing portion via a second bent portion.

[0124] <7>

[0125] The coil component according to <6>, wherein:

[0126] The metal terminal further includes a mounting surface facing end portion that is adjacent to the mounting surface facing portion at an end of at least one of the first side surface side and the second side surface side of the mounting surface and faces the mounting surface.

[0127] <8>

[0128] The coil component according to <7>, wherein:

[0129] The mounting surface facing end portion is connected to the outer end surface facing portion via a third bent portion.

[0130] <9>

[0131] The coil component according to <7>, wherein:

[0132] The mounting surface facing end portion is connected to the side surface facing portion via a third bent portion.

[0133] <10>

[0134] The coil component according to <4>, wherein:

[0135] When viewed toward each of the first side surface and the second side surface, at least one of the first side surface and the second side surface, the first protrusion is arranged close to an angle formed by an intersection with the outer end surface and the mounting surface,

[0136] The notch portion is disposed at a predetermined distance from an end edge on the inner end surface side and an end edge on the top surface side of the side surface facing portion.

[0137] <11>

[0138] The coil component according to <4>, wherein:

[0139] The flange portion further includes a second protrusion, and the second protrusion faces at least a portion of an end edge of the metal terminal on the top surface side.

[0140] <12>

[0141] The coil component according to <11>, wherein:

[0142] The second protrusion faces an end edge of the side surface facing portion that is closer to the top surface.

[0143] <13>

[0144] The coil component according to any one of <1> to <12>, wherein:

[0145] Each of the metal terminals has a first side surface opposing portion opposing the first side surface and a second side surface opposing portion opposing the second side surface as the side surface opposing portions, and the first side surface opposing portion and the second side surface opposing portion are connected via the outer end surface opposing portion.

[0146] Description of Reference Numerals

[0147] 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 opposing portion; 27, 28…outer end surface opposing portion; 29, 30…first side surface opposing portion; 31, 32 2…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 connection plate; 39…the soldering foot; 41, 43, 41d, 43d…the first protrusion; 42, 44, 42d, 44d…the notch; 45, 49…the first upright wall; 46, 50…the second upright 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 central portion; 67, 68…the third bending portion.

Claims

1. A coil component, characterized in that: have: The core body has a winding core portion extending in the axial direction, and a pair of flange portions respectively provided at ends of the winding core portion in opposite directions in the axial direction; at least one pair of metal terminals, mounted on each of the flange portions, each of which is made of a metal plate; and at least one wire is connected to each of the at least one pair of metal terminals and is 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, faces the winding core side when mounted and positions the end of the winding core 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 when mounted. Each of the metal terminals has: a mounting surface facing portion facing the mounting surface; an outer end surface facing portion facing the outer end surface; and a side surface facing portion facing at least one of the first side surface and the second side surface. The coil component further comprises: a first limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction in which the outer end surface opposite portion is separated from the outer end surface; and a second limiting portion for limiting the movement of the metal terminal relative to the flange portion at least in a direction in which the mounting surface opposite portion is separated from the mounting surface.

2. The coil component according to claim 1, characterized in that The flange portion has a first rising wall extending in the direction in which the inner end surface extends, The metal terminal has a first opposing wall opposed to the first rising wall. The first restriction portion is provided by abutment between the first rising wall and the first opposing wall.

3. The coil component according to claim 2, characterized in that The flange portion has a second rising wall extending in the direction in which the mounting surface extends, The metal terminal has a second opposing wall opposed to the second rising wall, The second restriction portion is provided by abutment between the first rising wall and the first opposing wall.

4. The coil component according to claim 3, characterized in that A first convex portion is provided on at least one of the first side surface and the second side surface, A notch portion for receiving the first convex portion is provided at the side surface opposing portion, The first protrusion has an outer peripheral wall that provides the first rising wall and the second rising wall. The notch portion includes an inner peripheral wall that provides the first opposing wall and the second opposing wall.

5. The coil component according to any one of claims 1 to 4, characterized in that: The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the mounting surface facing portion via a second bent portion.

6. The coil component according to any one of claims 1 to 4, characterized in that: The outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the outer end surface facing portion via a second bent portion.

7. The coil component according to claim 6, characterized in that The metal terminal further includes a mounting surface facing end portion that is adjacent to the mounting surface facing portion at an end of at least one of the first side surface side and the second side surface side of the mounting surface and faces the mounting surface.

8. The coil component according to claim 7, characterized in that The mounting surface facing end portion is connected to the outer end surface facing portion via a third bent portion.

9. The coil component according to claim 7, characterized in that: The mounting surface facing end portion is connected to the side surface facing portion via a third bent portion.

10. The coil component according to claim 4, characterized in that When viewed toward each of the first side surface and the second side surface, at least one of the first side surface and the second side surface, the first protrusion is arranged close to an angle formed by an intersection with the outer side end surface and the mounting surface, The notch portion is disposed at a predetermined distance from an end edge on the inner end surface side and an end edge on the top surface side of the side surface facing portion.

11. The coil component according to claim 4, characterized in that The flange portion further includes a second protrusion that faces at least a portion of an end edge of the metal terminal on the top surface side.

12. The coil component according to claim 11, characterized in that The second convex portion faces an end edge of the side surface facing portion that is closer to the top surface.

13. The coil component according to any one of claims 1 to 12, characterized in that: Each of the metal terminals has a first side surface opposing portion opposing the first side surface and a second side surface opposing portion opposing the second side surface as the side surface opposing portions, and the first side surface opposing portion and the second side surface opposing portion are connected via the outer end surface opposing portion.

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