Coil component

Abstract

Provided is a coil component capable of preventing external force from being easily concentrated at a specific position in a process of connecting a wire rod to a metal terminal and a process of mounting the coil component on a mounting substrate. Flange parts (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) have mounting surface facing portions (25, 26), outer end surface facing portions (27, 28), and side surface facing portions (29, 30, 31, 32) that respectively face the mounting surface, the outer end surface, and at least one of the first side surface and the second side surface. The mounting surface facing portion has mounting connection portions (63, 64) and wire connection portions (61-64), and the mounting connection portions and the wire connection portions are separated from each other. The mounting connection portion is connected to any one of the outer end surface facing portion and the side surface facing portion, but the wire connection portion is connected to the other of the outer end surface facing portion and the side surface facing 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 structure of a metal terminal composed of a metal plate attached to the core. Background Art

[0002] For example, Japanese Patent Gazette No. 2017-199841 (Patent Document 1) describes a winding type coil component having a structure in which a wire is wound around a core. In more detail, the core has a winding core portion extending in the axial direction and a pair of flange portions respectively arranged at the ends of the winding core portion in the axial direction opposite to each other. A metal terminal composed of a metal plate is installed at each flange portion, and the metal terminal is fixed by an adhesive. A wire is wound around the winding core portion, and the wire is connected to the metal terminal.

[0003] The flange portion comprises: 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, faces the core portion side and provides positioning for 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.

[0004] On the other hand, the metal terminal has a mounting surface facing portion and an outer end surface facing portion, which are respectively opposite to the mounting surface and the outer end surface of the flange portion. The mounting surface facing portion has: a mounting connection portion, which is connected to the conductor on the mounting substrate side during mounting; and a wire connection portion, which is connected to the wire, and the mounting connection portion and the wire connection portion are separated from each other.

[0005] Patent Document 1 describes the application of laser welding to connect a wire and a wire connection portion. As described above, if the mounting connection portion and the wire connection portion are separated from each other, it is desirable to prevent heat from the wire during welding from being easily transferred to the mounting connection portion.

[0006] Patent Document 1: Japanese Patent Application Publication No. 2017-199841

[0007] In the coil component described in Patent Document 1, both the mounting connection portion and the wire connection portion constituting the mounting surface facing portion of the metal terminal are connected to the outer end surface facing portion via the bent portion.

[0008] If you want to connect the wire and the wire connection part by thermal compression, the external force that affects the wire connection part during thermal compression will affect the outer end surface opposite to the wire connection part. In addition, when the coil component is installed on the mounting substrate, the external force that affects the mounting connection part will also affect the outer end surface opposite to the mounting connection part. The concentration of external force that affects the outer end surface opposite to the mounting connection part may sometimes cause the terminal electrode to detach from the flange part. Summary of the invention

[0009] Therefore, an object of the present invention is to provide a coil component having a structure that can prevent external force from concentrating on a specific portion of the coil component during the process of connecting a wire material to a metal terminal and the process of mounting the coil component on a mounting substrate.

[0010] The present invention relates to a coil component, which comprises: a core body, the core body having a winding core portion extending in an axial direction and a first flange portion and a second flange portion respectively arranged at opposite ends of the winding core portion in the axial direction; a metal terminal, the metal terminal is installed on the first flange portion and is composed of a metal plate; and at least one wire rod, which is connected to the metal terminal and wound around the winding core portion.

[0011] The first flange portion comprises: a mounting surface, which is directed toward the mounting substrate side during installation; a top surface, which is directed toward the opposite side of the mounting surface; an inner end surface, which connects the mounting surface and the top surface and is directed toward the core portion side during installation to position the end of the core portion in the axial direction; an outer end surface, which is directed toward the opposite side of the inner end surface during installation; and a first side surface and a second side surface, which connect the inner end surface and the outer end surface and are directed in opposite directions to each other.

[0012] In order to solve the above-mentioned technical problems, the present invention is characterized by having the following structure.

[0013] The metal terminal comprises: 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.

[0014] The mounting surface facing portion includes: a mounting connection portion that can be connected to a conductor on the mounting substrate side during mounting; and a wire connecting portion that can be connected to a wire.

[0015] The installation connection part and the wire connection part are separated from each other.

[0016] The mounting connection portion is connected to one of the outer end surface facing portion and the side surface facing portion via the bent portion, and the wire connection portion is connected to the other of the outer end surface facing portion and the side surface facing portion via the bent portion.

[0017] According to the present invention, not only the installation connection part and the wire connection part are separated from each other, but also, on the one hand, the installation connection part is connected to any one of the outer end surface opposing part and the side surface opposing part, and on the other hand, the wire connection part is connected to any other of the outer end surface opposing part and the side surface opposing part, so that the load applied to the installation connection part can be applied to any one of the outer end surface opposing part and the side surface opposing part, and the load applied to the wire connection part can be applied to any other of the outer end surface opposing part and the side surface opposing part, and these loads can be dispersed advantageously. Therefore, the wire connection part can be made less susceptible to loads such as heat and stress that affect the installation connection part, and the installation connection part can be made less susceptible to loads such as heat and stress that affect the wire connection part.

[0018] In addition, the metal terminal not only has a mounting surface opposing portion opposing the mounting surface and an outer end surface opposing portion opposing the outer end surface, but also has a side surface opposing portion opposing at least one of the first side surface and the second side surface, so that the surface-to-surface opposition between the metal terminal and the first flange portion is achieved at least in three places.

[0019] As can be seen from the above, loads such as heat and stress exerted on the metal terminal can be favorably dispersed, so that the metal terminal can be less likely to come off from the first flange portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] 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.

[0021] Figure 2 Yes means Figure 1 The illustrated perspective view is of the installed state of the coil component 1 .

[0022] Figure 3 is used for Figure 2 A perspective view illustrating typical external forces acting on the coil component 1 in the mounted state shown.

[0023] Figure 4 This is a perspective view showing the appearance of a coil component 1 a according to a second embodiment of the present invention, with mounting surfaces 7 and 8 facing upward.

[0024] Figure 5 This is a perspective view showing the appearance of a coil component 1 b according to a third embodiment of the present invention, with mounting surfaces 7 and 8 facing upward.

[0025] Figure 6 It is along Figure 5 Cross-sectional view along line VI-VI. DETAILED DESCRIPTION

[0026] Reference Figure 1 to Figure 3 A coil component 1 according to a first embodiment of the present invention will be described.

[0027] 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 (i.e., a first flange 3 and a second flange 4) respectively provided at the ends of the winding core 2 in the L direction 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 quadrilateral in the figure, but in addition, it can also be a polygon such as a hexagon, a circle, an ellipse, or a combination thereof.

[0028] 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 during installation; an inner end surface 11, which connects the mounting surface 7 with the top surface 9 and faces the side of the winding core 2 during installation to position 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; and a first side surface 15 and a second side surface 17, which connect the inner end surface 11 with the outer end surface 13 and face opposite directions to each other.

[0029] 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 with the top surface 10 and faces the core portion 2 side when installed to position 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 with the outer end surface 14 and face opposite directions to each other.

[0030] 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 direction perpendicular to the L direction and extending in the mounting surfaces 7, 8 and the top surfaces 9, 10 (W direction) 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.

[0031] The coil component 1 constitutes, for example, a winding-type inductor and includes a wire 21 wound around a winding core 2 of a core body 5. The wire 21 includes: a core wire, which is made of a metal with good conductivity, such as copper, silver or gold; and an insulating coating, which is made of an electrically insulating resin such as polyamide-imide, polyurethane or polyester-imide that covers the core wire. Although 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.

[0032] 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.

[0033] 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 a point-symmetrical shape. As the metal plate forming the metal terminals 23 and 24, for example, a plate having Ni plating and Sn plating applied to a base material formed of phosphor bronze can be used.

[0034] 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.

[0035] In the first metal terminal 23, 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 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.

[0036] Similarly, in the second metal terminal 24, 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.

[0037] like Figure 2 As shown, the coil component 1 is mounted on the conductive pads 37 and 38 provided on the mounting substrate 6 in a state where the metal terminals 23 and 24 are connected via solder. At this time, soldering is performed on the mounting surfaces of the metal terminals 23 and 24 facing the central portions 65 and 66. Figure 2 In the mounted state shown, the mounting surface facing central portions 65 and 66 become "mounting connection portions" that can be connected to the conductive pads 37 and 38 on the mounting substrate 6 side. Figure 2 The middle figure shows a fillet 39 formed by solder connecting the conductive pad 37 and the first metal terminal 23 .

[0038] In addition, in the first metal terminal 23, the first end of the wire 21 is connected to 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, and in the second metal terminal 24, the second end of the wire 21 is connected to 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. Therefore, the first mounting surface opposing end 61 and the second mounting surface opposing end 63, and the first mounting surface opposing end 62 and the second mounting surface opposing end 64 become "wire connecting portions" to which the wire 21 can be connected. In addition, the wire is not connected to all of the first mounting surface opposing end 61 and the second mounting surface opposing end 63, and the first mounting surface opposing end 62 and the second mounting surface opposing end 64, which become "wire connecting portions". Therefore, the so-called "wire connecting portion" should be understood as a portion to which the wire can be connected.

[0039] For the connection between the wire 21 and the metal terminals 23 and 24, for example, thermal compression is applied. As shown in the figure, after the first end of the wire 21 is connected to the first mounting surface opposing end 61 of the first metal terminal 23, and the second end of the wire 21 is connected to the second mounting surface opposing end 64 of the second metal terminal 24, the excess portion of the end of the wire 21 is cut off and removed, but, for example, the edges of the first mounting surface opposing end 61 and the second mounting surface opposing end 64 on the side of the outer end faces 13 and 14 can be advantageously used for the cutting.

[0040] 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 with the top surface 10 of the second flange portion 4. The top plate 40 is joined to the core 5 by an adhesive. As an adhesive, for example, a thermosetting epoxy resin can be used. In order to improve the heat shock resistance of the adhesive, an inorganic filler such as a silica filler can also be added to the adhesive. As a coating method for the adhesive, a printing method of coating the adhesive at the top plate 40, a method of dipping the top surfaces 9, 10 of the flange portions 3, 4 of the core 5 in the adhesive, a method of distributing the adhesive to both the top plate 40 and the core 5, etc. can be adopted.

[0041] As the material of the top plate 40, for example, magnetic bodies such as ferrite, resin containing ferrite powder or metal magnetic powder, or non-magnetic bodies such as aluminum oxide can be 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. It is also possible to replace the top plate 40 and implement coating by resin. In addition, it is also possible to have no top plate 40, and it is also possible to have no resin coating.

[0042] According to the structure described above, the following effects are achieved.

[0043] If you refer to Figure 1 to Figure 3 To explain, when the coil component 1 is in the installed state, the external forces in the positive and negative directions in the L direction among the external forces affecting 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.

[0044] 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 affecting 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.

[0045] In addition, when the coil component 1 is in the installed state, the external force affecting 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.

[0046] As described above, the metal terminals 23 and 24 can be subjected to external forces in at least the five directions described above, so as not to be separated from the flange portions 3 and 4 .

[0047] In this embodiment, a structure is provided that makes it more difficult for the metal terminals 23 and 24 to be separated from the flanges 3 and 4. That is, a limiting portion is further provided, which is used to limit 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, and at least in the direction in which the outer end surface opposing portions 27 and 28 are separated from the outer end surfaces 13 and 14.

[0048] Regarding 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 affecting the core body 5, the external force is usually not generated when the coil component 1 is mounted on the mounting substrate, 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 affecting the core body 5.

[0049] More specifically, with respect to the first metal terminal 23, the limiting portion is provided by a first protrusion 41 disposed 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 accommodating the first protrusion 41.

[0050] In addition, with respect to the second metal terminal 24, the limiting portion is provided by a first protrusion 43 and a notch portion 44, wherein the first protrusion 43 is arranged on at least one of the first side surface 16 and the second side surface 18 of the second flange portion 4, and the notch portion 44 is located at 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 accommodates the first protrusion 43.

[0051] 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, the area of ​​the outer end surface facing portion 27 and the mounting surface facing portion 25 of the first metal terminal 23, which are relatively heavily subjected to external force, can be ensured to be larger. The same can be said to be applicable to the notch portion 44 in 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.

[0052] 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.

[0053] 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 preventing the metal terminals 23 and 24 from detaching from the flange portions 3 and 4 can be further improved.

[0054] The limiting portion obtained by the combination of the first protrusions 41, 43 and the notch portions 42, 44 as described above can not only limit the movement of the mounting surface opposing portions 25, 26 in the direction away from the mounting surfaces 7, 8, but also can limit the movement of the outer end surface opposing portions 27, 28 in the direction away from the outer end surfaces 13, 14.

[0055] 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 mounting surface 7 along the top surface 9 of the first flange portion 3, and a second rising 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 rising wall 45, and a second opposing wall 48 opposite to the second rising wall 46.

[0056] 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 mounting surface 8 along the top surface 10 of the second flange portion 4, 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.

[0057] 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 .

[0058] In this way, if the first upright walls 45, 49 extend in a straight line parallel to the inner end faces 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 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 reliably suppressing the metal terminals 23, 24 from detaching from the flange portions 3, 4.

[0059] In addition, when the first side surface 15 and the second side surface 17 of the first flange portion 3 are observed respectively, the first protrusion 41 is arranged at 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 located at a position 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 of 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 offset to the inner end surface 11 side and the top surface 9 side.

[0060] Similarly, when the first side surface 16 and the second side surface 18 of the second flange portion 4 are observed respectively, the first protrusion 43 is arranged at 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 44 is located at a position 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 of 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 offset to the inner end surface 12 side and the top surface 10 side.

[0061] According to the arrangement of the first protrusions 41, 43 and the notches 42, 44 as described above, it is possible to obtain a larger area for each of the first protrusions 41, 43. In addition, since 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, it is easy to form the core 5 having the first protrusions 41, 43.

[0062] In addition, it is preferred that the first flange portion 3 further includes a second protrusion 53, which is opposite to at least a portion of 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 further includes a second protrusion 54, which is opposite to at least a portion of 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.

[0063] According to such second protrusions 53 and 54, the metal terminals 23 and 24 can be more reliably suppressed from being separated from the flanges 3 and 4 by the external force in the rotation direction generated around the axis toward the W direction and the external force in the rotation direction generated around the axis toward the L direction. In addition, the external force in the rotation direction generated around the axis toward the W direction is generated, 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.

[0064] 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 .

[0065] With regard to the resistance to the external force in the above-mentioned rotational direction, it is particularly effective to arrange the second protrusion 53 so as 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 closer to the top surface 9, and to arrange the second protrusion 54 so as 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 closer to the top surface 10.

[0066] In addition, although 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, 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 possible to prevent the tip of a tweezer or the like from 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.

[0067] According to the coil component 1 described above, the mounting surface facing central portions 65, 66, which are the "mounting connection portions", and the mounting surface facing end portions 61 to 64, which are the "wire connection portions", are separated from each other. Furthermore, the mounting surface facing end portions 61 to 64 are connected to the outer end surface facing portions 27, 28 via the side surface facing portions 29 to 32.

[0068] Therefore, the mounting surface facing ends 61 to 64 are less susceptible to loads such as heat and stress that affect 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 that affect the mounting surface facing ends 61 to 64. Therefore, the connection reliability between the mounting substrate 6 and the metal terminals 23 and 24, and the connection reliability between the metal terminals 23 and 24 and the wire 21 can be improved.

[0069] In addition, as stress affecting the mounting surface opposing ends 61 to 64, there is, for example, stress affecting a specific end of the mounting surface opposing ends 61 to 64 when the wire 21 is hot-pressed to a specific end of the mounting surface opposing ends 61 to 64. If the mounting surface opposing ends 61 to 64, which become "wire connecting portions", are directly connected to the outer end surface opposing portions 27 and 28 via the bent portions, the mounting surface opposing ends 61 to 64 may move in a manner inclined in the T direction with the ridgeline formed by the outer end surfaces 13 and 14 of the flange portions 3 and 4 and the mounting surfaces 7 and 8 as a fulcrum due to the above stress. In particular, the movement of the mounting surface opposing ends 61 to 64 is large on the inner end surfaces 11 and 12 side which is relatively far from the above fulcrum.

[0070] Here, since the wire 21 extends from the inner end surfaces 11 and 12, the wire 21 may be poorly connected or may be cut by the edge portions of the mounting surface opposing ends 61 to 64. In particular, when the lead-out direction of the wire 21 and the direction in which the edge portions of the mounting surface opposing ends 61 to 64 extend are orthogonal to each other, the wire 21 is more likely to be cut.

[0071] In comparison, when the mounting surface opposing ends 61 to 64 that become the "wire connecting portions" extend from the side surface opposing portions 29 to 32, since the ridges where the side surfaces 15 to 18 intersect with the mounting surfaces 7 and 8 serve as fulcrums, the distance from the fulcrum to the inner end surfaces 11 and 12 of the mounting surface opposing ends 61 to 64 is relatively short, thereby reducing the amount of deflection of the mounting surface opposing ends 61 to 64 during hot pressing, and making it less likely that poor connection of the wire 21 will occur.

[0072] Furthermore, if the mounting surface facing ends 61 to 64 that serve as “wire connecting portions” extend from the side surface facing portions 29 to 32 , the metal terminals 23 and 24 can be less likely to be detached from the flange portions 3 and 4 .

[0073] Figure 4 and Figure 5 1a and 1b in accordance with the second embodiment of the present invention and the third embodiment of the present invention. Figure 1 Quite a picture. Figure 6 It is along Figure 5 A cross-sectional view of the line VI-VI. Figures 4 to 6 In, with Figure 1 Corresponding elements are denoted by the same reference numerals, and duplicate description is omitted.

[0074] and Figure 1 Compared with the coil component 1 shown, Figure 4 The coil component 1a shown is different in the form of the mounting surface opposing ends 61 to 64 in each of the metal terminals 23a and 24a. More specifically, in terms of the height from the mounting surfaces 7 and 8 of the flange portions 3 and 4, the mounting surface opposing ends 61 to 64 that are "wire connecting portions" are substantially formed with a gradient in which the height decreases from the outer end surfaces 13 and 14 sides to the inner end surfaces 11 and 12 sides.

[0075] According to this structure, when the wire 21 is connected to a specific end of the mounting surface opposing end portions 61 to 64, the wire 21 can be smoothly guided and led out, and the possibility that the wire 21 will be undesirably cut off by the end edge on the inner end surface 11, 12 side of the mounting surface opposing end portions 61 to 64 after the wire 21 is connected can be reduced.

[0076] Furthermore, all of the mounting surface facing ends 61 to 64 that become the "wire connecting portion" may be formed with a gradient that decreases from the outer end faces 13 and 14 to the inner end faces 11 and 12. According to this structure, since the wire 21 can remain thick after crimping, the wire 21 is less likely to break.

[0077] Figure 5 and Figure 6 The coil component 1b shown is characterized in that, in the metal terminals 23b, 24b, the mounting surface facing center portions 65, 66 as "mounting connection portions" are higher than the mounting surface facing end portions 61 to 64 as "wire connection portions" in terms of height from the mounting surfaces 7, 8 of the flange portions 3, 4. Figure 6 , the positional relationship between the mounting surface facing center portion 66 and the mounting surface facing end portions 62 , 64 with respect to the mounting surface 8 of the second flange portion 4 is well shown.

[0078] The end of the wire 21 connected to a specific end of the mounting surface facing end 61 to 64 is compressed by thermal compression, but the height difference can absorb the thickness of the connected end of the wire 21. It is preferred that the gap 69 between the mounting surface facing central portion 65, 66 and the mounting surface 7, 8 of the flange portion 3, 4 caused by the height difference (see Figure 6) is, for example, 200 μm or less, and the gaps between the mounting surface facing ends 61 to 64 and the mounting surfaces 7 and 8 of the flange portions 3 and 4 are narrower than the gap 69.

[0079] As mentioned above, although this invention was demonstrated in connection with the embodiment shown in figure, other various embodiments are possible within the scope of this invention.

[0080] For example, in addition to constituting a single coil as in the illustrated embodiment, the coil component to which the present invention is directed may also be a component constituting a common mode choke coil, a component constituting a transformer, a balun (balanced-unbalanced converter), etc. Therefore, the number of wires may also be changed according to the function of the coil component, and accordingly, the number of metal terminals provided on each flange portion may also be changed. Typically, there is also a case where two metal terminals are arranged in the W direction on one flange portion.

[0081] As described above, in the case where two metal terminals are arranged side by side in the W direction on one flange portion, each metal terminal has the following form, that is, it has: a mounting surface facing portion, which faces an area smaller than half of the width direction dimension of the mounting surface; an outer end surface facing portion, which faces an area smaller than half of the width direction dimension of the outer end surface; and a side surface facing portion, which faces one of the first side surface and the second side surface. In addition, the mounting surface facing portion has: a mounting connection portion, which can be connected to a conductor on the mounting substrate side during mounting; and a wire connecting portion, which can connect a wire, but the mounting surface facing center portion that becomes the mounting connection portion is smaller than half of the width direction dimension of the mounting surface facing center portion shown in the figure, and has one mounting surface facing end portion as a wire connecting portion.

[0082] In addition, in the present invention, when the metal terminals 23 and 24 are mounted on the flanges 3 and 4, fixation by an adhesive is not essential. However, the present invention does not exclude the use of an adhesive.

[0083] In addition, the mounting surface opposing central portion 65 is located between the first mounting surface opposing end portion 61 and the second mounting surface opposing end portion 63, and the mounting surface opposing central portion 66 is located between the first mounting surface opposing end portion 62 and the second mounting surface opposing end portion 64, but a wire 21 may also be connected to the mounting surface opposing central portions 65, 66 to connect the first mounting surface opposing end portions 61, 62 or the second mounting surface opposing end portions 63, 64 to the conductive pads on the mounting substrate.

[0084] In addition, in the illustrated embodiment, the first metal terminal 23 and the second metal terminal 24 have the same structure, but it is also possible that either the first metal terminal 23 or the second metal terminal 24, for example, only the first metal terminal 23, has the characteristic structure of the present invention. In this case, the second metal terminal 24 can be composed of a metal plate that does not have the characteristic structure of the present invention, or can be composed of a conductor film obtained by firing a conductive paste, for example.

[0085] Furthermore, when configuring the coil component according to the present invention, it is possible to partially replace or combine the structures of the different embodiments described in this specification.

[0086] The embodiments of the present invention are as follows.

[0087] <1>

[0088] A coil component, comprising:

[0089] A core body having a winding core portion extending in an axial direction, and a first flange portion and a second flange portion respectively provided at ends of the winding core portion in opposite directions in the axial direction;

[0090] a metal terminal mounted on the first flange portion and composed of a metal plate; and

[0091] at least one wire connected to the metal terminal and wound around the winding core,

[0092] The first flange portion has:

[0093] A mounting surface, which faces the mounting substrate side during mounting;

[0094] A top surface, which faces the opposite side of the mounting surface when installed;

[0095] an inner end surface, which connects the mounting surface and the top surface and faces the winding core portion during mounting so as to position an end portion of the winding core portion in the axial direction;

[0096] an outer end surface, which faces the opposite side of the inner end surface when installed; and

[0097] a first side surface and a second side surface, the first side surface and the second side surface connecting the inner end surface and the outer end surface and facing in opposite directions to each other,

[0098] The above metal terminal has:

[0099] A mounting surface facing portion, the mounting surface facing portion facing the mounting surface;

[0100] an outer end surface facing portion, the outer end surface facing portion facing the outer end surface; and

[0101] a side surface opposing portion, the side surface opposing portion being opposed to at least one of the first side surface and the second side surface,

[0102] The mounting surface facing portion has:

[0103] A mounting connection portion that can be connected to a conductor on the mounting substrate side during mounting; and

[0104] A wire connecting portion, which can be used for connecting the wires,

[0105] The installation connection part and the wire connection part are separated from each other.

[0106] The mounting connection portion is connected to any one of the outer end surface facing portion and the side surface facing portion via a bent portion.

[0107] The wire connecting portion is connected to the other of the outer end surface facing portion and the side surface facing portion via a bent portion.

[0108] <2>

[0109] In the coil component described in <1>,

[0110] The mounting connection portion is connected to the outer end surface facing portion via the bent portion.

[0111] The wire connecting portion is connected to the side surface facing portion via a bent portion.

[0112] <3>

[0113] In the coil component described in <1> or <2>,

[0114] The side surface facing portion is connected to the outer end surface facing portion via a bent portion.

[0115] <4>

[0116] In the coil component described in any one of <1> to <3>,

[0117] The metal terminal has a first side surface facing portion facing the first side surface and a second side surface facing portion facing the second side surface as the side surface facing portions.

[0118] The mounting surface facing portion includes a first wire connecting portion and a second wire connecting portion as the wire connecting portion.

[0119] When the direction in which the first side surface and the second side surface are opposed to each other is set as the width direction, the first wire connecting portion and the second wire connecting portion are arranged at respective ends in the width direction of the mounting surface via the mounting connecting portion.

[0120] At least one of the first wire connecting portion and the second wire connecting portion is connected to the wire.

[0121] <5>

[0122] In the coil component described in any one of <1> to <4>,

[0123] The mounting connection portion is higher than the wire connection portion in terms of height from the mounting surface of the first flange portion.

[0124] <6>

[0125] In the coil component described in any one of <1> to <5>,

[0126] The wire connecting portion has a height from the mounting surface of the first flange portion that is formed to have a gradient that becomes lower from the outer end surface side toward the inner end surface side.

[0127] <7>

[0128] In the coil component described in any one of <1> to <6>,

[0129] The invention further comprises a limiting portion for limiting the movement of the metal terminal relative to the first flange at least in a direction in which the mounting surface opposing portion is separated from the mounting surface and the movement of the metal terminal relative to the first flange at least in a direction in which the outer end surface opposing portion is separated from the outer end surface,

[0130] The limiting portion is provided by the first protrusion and the notch, wherein:

[0131] The first protrusion is provided on at least one of the first side surface and the second side surface of each of the pair of flange portions.

[0132] The notch portion is located at least one of the first side surface facing portion and the second side surface facing portion of the metal terminal and receives each of the first protrusions.

[0133] <8>

[0134] In the coil component described in <7>,

[0135] The pair of flange portions further include a second protrusion respectively, and the second protrusion 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.

[0136] <9>

[0137] In the coil component described in <8>,

[0138] The second protrusion faces an end edge of the side surface facing portion of the metal terminal that is closer to the top surface.

[0139] <10>

[0140] In the coil component described in any one of <1> to <9>,

[0141] further comprising a second metal terminal mounted on the second flange portion and made of a metal plate,

[0142] The second metal terminal has the same structure as the above-mentioned metal terminal.

[0143] Description of reference numerals:

[0144] 1, 1a, 1b…coil component; 2…winding core portion; 3…first flange portion; 4…second flange portion; 5…core body; 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…first metal terminal; 24, 24a, 24b…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…second side surface opposing portion ; 37, 38…conductive pad; 39…rounded corner; 41, 43…first protrusion; 42, 44…notch; 45, 49…first upright wall; 46, 50…second upright wall; 47, 51…first opposing wall; 48, 52…second opposing wall; 53, 54…second protrusion; 55, 56…first bent portion; 57, 58…second bent portion; 61, 62…first mounting surface opposite end portion (wire connecting portion); 63, 64…second mounting surface opposite end portion (wire connecting portion); 65, 66…mounting surface opposite center portion (mounting connecting portion); 67, 68…third bent portion; 69…gap.

Claims

1. A coil component, wherein: have: a core body having a winding core portion extending in an axial direction, and a first flange portion and a second flange portion respectively provided at ends of the winding core portion in opposite directions from each other in the axial direction; a metal terminal mounted on the first flange portion and composed of a metal plate; and at least one wire connected to the metal terminal and wound around the winding core, The first flange portion has: A mounting surface, which faces the mounting substrate side during mounting; 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 winding core portion during mounting to position an end portion of the winding 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, the first side surface and the second side surface connecting the inner end surface and the outer end surface and facing in opposite directions to each other, The metal terminal has: a mounting surface facing portion, the mounting surface facing portion facing the mounting surface; an outer end surface facing portion, the outer end surface facing portion facing the outer end surface; and a side surface opposing portion, the side surface opposing portion being opposed to at least one of the first side surface and the second side surface, 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 connecting portion, the wire connecting portion being capable of being connected to the wires, The installation connection portion and the wire connection portion are separated from each other, The mounting connection portion is connected to any one of the outer end surface facing portion and the side surface facing portion via a bent portion. The wire connecting portion is connected to the other of the outer end surface facing portion and the side surface facing portion via a bent portion.

2. The coil component according to claim 1, wherein The mounting connection portion is connected to the outer end surface facing portion via a bent portion, The wire connecting portion is connected to the side surface opposing portion via a bent portion.

3. The coil component according to claim 1 or 2, wherein: The side surface facing portion is connected to the outer end surface facing portion via a bent portion.

4. The coil component according to any one of claims 1 to 3, wherein The metal terminal has a first side surface facing portion facing the first side surface and a second side surface facing portion facing the second side surface as the side surface facing portions, The mounting surface facing portion has a first wire connecting portion and a second wire connecting portion as the wire connecting portion, When the direction in which the first side surface and the second side surface are opposed to each other is set as the width direction, the first wire connecting portion and the second wire connecting portion are arranged at respective ends in the width direction of the mounting surface via the mounting connecting portion. At least one of the first wire connecting portion and the second wire connecting portion is connected to the wire.

5. The coil component according to any one of claims 1 to 4, wherein The mounting connection portion is higher than the wire connection portion in terms of height from the mounting surface of the first flange portion.

6. The coil component according to any one of claims 1 to 5, wherein: The wire connecting portion has a gradient in which the height from the mounting surface of the first flange portion becomes lower from the outer end surface side toward the inner end surface side.

7. The coil component according to any one of claims 1 to 6, wherein: The invention further comprises a limiting portion for limiting the movement of the metal terminal relative to the first flange portion at least in a direction in which the mounting surface opposing portion moves away from the mounting surface and the movement of the metal terminal relative to the first flange portion at least in a direction in which the outer end surface opposing portion moves away from the outer end surface, The limiting portion is provided by a first protrusion and a notch, wherein: The first protrusion is provided on 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 least one of the first side surface facing portion and the second side surface facing portion of the metal terminal and receives each of the first protrusions.

8. The coil component according to claim 7, wherein 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.

9. The coil component according to claim 8, wherein The second protrusion faces an end edge of the side surface facing portion of the metal terminal that is closer to the top surface.

10. The coil component according to any one of claims 1 to 9, wherein further comprising a second metal terminal mounted on the second flange portion and made of a metal plate, The second metal terminal has the same structure as the metal terminal.

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