Electronic component and coil component

Abstract

The invention provides an electronic component and a coil component which can easily, objectively and rapidly detect foreign matters with a predetermined size or more through visual observation or a camera. The electronic component is provided with a terminal or an electrode, and at least the surface of the component on which the terminal or the electrode is mounted is provided with a detection pattern having a pattern having a width or interval smaller than the size of a foreign matter to be detected.

Description

Technical Field

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

[0002] As shown in Patent Document 1 below, a surface-mounted coil component has been developed. In such a coil component, foreign matter adhesion during the manufacturing process sometimes becomes a problem. Specifically, foreign matter such as solder balls, ferrite core fragments (debris) sometimes adhere to the surface of the coil component.

[0003] To prevent products from leaving the factory with foreign matter attached, visual inspection or photography can be used to check for foreign matter attachment. When foreign matter is detected, if a specified number or more foreign matter of a specified size or larger is detected within a specified number of fields of view, the product with foreign matter detected under these conditions needs to be sent to a cleaning process or similar operation.

[0004] However, in most cases it is difficult to objectively and quickly detect foreign objects larger than a specified size by visual inspection or a camera. The challenges associated with such foreign object detection are not limited to coil components, but also apply to electronic components that widely have terminals or electrodes.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2015-216302 Summary of the Invention

[0008] The technical problem that the invention aims to solve

[0009] The present invention was made in view of the following actual situation, and its object is to provide an electronic component and a coil component that can easily and quickly detect foreign objects larger than a specified size by visual inspection or a camera.

[0010] Means for solving technical problems

[0011] To achieve the above objectives, one aspect of the present invention relates to an electronic component having terminals or electrodes, wherein at least on the surface of the component on which the terminals or electrodes are mounted, there is a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

[0012] To achieve the above objectives, one aspect of the present invention relates to an electronic component having a terminal block on which terminals are mounted, wherein the surface of the terminal block has a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

[0013] The terminal may also have a wiring portion and a mounting portion.

[0014] The detection pattern may also be provided on the surface of the terminal block located near the wiring portion or the mounting portion.

[0015] Alternatively, it may also have a cover having a terminal block covering portion that covers at least a portion of the terminal block.

[0016] The detection pattern may also be present on at least the surface of the cover near the terminal.

[0017] Based on the electronic component including such a coil component, when a foreign object is present on the detection pattern, it is easy to determine whether the size of the foreign object is larger than the width or spacing of the detection pattern by observing the foreign object against the background of the detection pattern. Therefore, based on this electronic component (including the coil component), foreign objects larger than a specified size can be easily and objectively detected quickly and by visual inspection or by a foreign object detection device (camera).

[0018] For example, the pattern width or spacing of the detection pattern is 0.1–5 mm, or 0.1–3 mm, or 0.1–1 mm, or 0.1–0.5 mm. The size of the foreign object to be detected varies depending on its size (smaller objects are mostly 0.1 mm or larger, while larger objects vary depending on their type, but those exceeding 5 mm are relatively rare). Therefore, the pattern width or spacing of the detection pattern is preferably within the above-mentioned range, but it may deviate from this range depending on the size of the foreign object to be detected.

[0019] Furthermore, depending on the location of the pattern, it can also be used as a positioning scale when installing other components such as cores, and the pattern can also be used to improve the positioning accuracy of mounting components such as cores.

[0020] Preferably, the detection pattern is a repeating pattern of raised and recessed areas formed on the surface of the component. It can also be a pattern without raised or recessed areas, but compared to that, a pattern formed by repeated raised and recessed areas allows for a more three-dimensional observation of foreign objects on the pattern due to differences in reflected light from the illumination light, thus further improving the detection accuracy of foreign objects.

[0021] The adhesive can also be applied within a specified range and brought into contact with the surface of the component on which the detection pattern is formed. By retaining the adhesive in the recessed areas of the pattern, which consists of a repeating pattern of raised and recessed areas, improved bond strength can be expected. Furthermore, depending on the direction of the pattern, wetting and spreading of the adhesive can be effectively prevented, making it easy to apply the adhesive effectively within the specified bonding area. However, if wetting and spreading are significantly greater than anticipated, the bonding effect may be reduced due to adhesive sagging or lack of height. Attached Figure Description

[0022] Figure 1This is a perspective view of a coil component involved in one embodiment.

[0023] Figure 2 yes Figure 1 An exploded perspective view of the coil component shown.

[0024] Figure 3 It means Figure 1 A three-dimensional view of the structure of the winding frame of the coil component shown.

[0025] Figure 4 It means Figure 1 A perspective view of the structure of the coil component's cover.

[0026] Figure 5 It means Figure 1 A perspective view of the structure of the coil component's core and the fixing tape.

[0027] Figure 6 It means Figure 1 The front view of the coil component before the core is installed.

[0028] Figure 7 yes Figure 1 The front view of the coil component shown.

[0029] Figure 8 It means Figure 1 A bottom view of the structure of the coil portion of the coil component shown.

[0030] Figure 9 It means Figure 1 A top view of the structure of the coil portion of the coil component shown.

[0031] Figure 10A It was formed in Figure 1 A magnified 3D view of the main part of the detection pattern on the surface of the winding frame shown.

[0032] Figure 10B It means Figure 10A The enlarged perspective view of the main part of the detected pattern in the deformed example of the detected pattern shown.

[0033] Figure 10C It means Figure 10A The enlarged perspective view of the main part of the detected pattern in the deformed example of the detected pattern shown.

[0034] Figure 10D It means Figure 10A The enlarged perspective view of the main part of the detected pattern in the deformed example of the detected pattern shown.

[0035] Figure 11A It means in such Figure 10AThe image shows an embodiment of a detection pattern in which a foreign object is detected.

[0036] Figure 11B It means that in the absence of such Figure 10A The photograph shows a comparative example of a foreign object present on the surface of a winding frame used for detecting patterns.

[0037] Figure 12 This is a perspective view of the coil component involved in other embodiments.

[0038] Figure 13 This is a perspective view of a chip component, which is an example of an electronic component involved in an implementation method.

[0039] Explanation of symbols:

[0040] 1, 1a…coil components

[0041] 1b…Chip Components

[0042] 2…core

[0043] 21…Midfoot

[0044] 22…outer foot

[0045] 23…base

[0046] 23a…concave part

[0047] 3, 3a…winding frame

[0048] 30…Cylinder section

[0049] 31… Through hole

[0050] 32…End flange portion

[0051] 33…Intermediate flange portion

[0052] 34, 34A…protrusion (second engaging part)

[0053] 34a… Inclined surface

[0054] 34b… Hook

[0055] 36…Terminal block

[0056] 37…Reinforcing Ribs

[0057] 38…lead path

[0058] 5…cover

[0059] 51…end opening

[0060] 51a…Main opening

[0061] 51b…Secondary opening

[0062] 52…end wall

[0063] 52a… Opening edge

[0064] 53…up the wall

[0065] 54…sidewall

[0066] 54a…side opening

[0067] 55… Claw section (first locking section)

[0068] 56…Central opening

[0069] 57…Terminal block covering section

[0070] 58…Connecting Covering Part

[0071] 59…Side end covering part

[0072] 8… wires

[0073] 80…coil section

[0074] 81…lead section

[0075] 9…terminal

[0076] 91… Wiring section

[0077] 92… Installation Department

[0078] 94…Terminal Electrode

[0079] 10, 10a… Adhesive

[0080] 11… Tape

[0081] 100… Pattern for inspection

[0082] Slots 102, 102a, 102b, 102c... Detailed Implementation

[0083] The embodiments are described below. The description is based on the accompanying drawings, but the illustrations are merely schematic and illustrative for understanding the invention, and the appearance or size ratio may differ from the actual product. Furthermore, specific descriptions are given based on the embodiments, but the invention is not limited to these embodiments. For example, at least some of the various embodiments shown below may be combined to form new embodiments.

[0084] First Implementation Method

[0085] like Figure 1As shown, the coil component 1 involved in this embodiment is used, for example, as a transformer that applies high voltage in the power circuit of an EV (Electric Vehicle), PHV (Plug-in Hybrid Vehicle), or on-board charger for commuting (vehicles), or power circuit of household or industrial electrical equipment, or power circuit of computer equipment.

[0086] like Figure 1 as well as Figure 2 As shown, the coil component 1 includes a core (magnetic core) 2, a winding frame 3, and a cover 5. Furthermore, in the accompanying drawings, the X-axis, Y-axis, and Z-axis are perpendicular to each other, with the Z-axis corresponding to the height (thickness) of the coil component 1. Additionally, the X-axis is parallel to the spool of the coil section, which will be described later.

[0087] like Figure 2 as well as Figure 3 As shown, the winding frame 3 has a cylindrical portion 30 and a pair of terminal blocks 36, 36 integrally formed with the cylindrical portion 30 in such a way that they are located on opposite sides of each other in the X-axis direction of the cylindrical portion 30.

[0088] In this embodiment, the pair of terminal blocks 36, 36 have the same structure, but they do not necessarily have to be the same. For example, the number of terminals 9 installed on one terminal block 36 may be different from the number of terminals 9 installed on the other terminal block 36. In addition, for example, the shape of the terminals 9 installed on one terminal block 36 may be different from the shape of the terminals 9 installed on the other terminal block 36, and the shapes of the terminal blocks may also be different from each other.

[0089] The winding frame 3 has a core portion for winding the conductor 8, and a first end flange portion 32 and a second end flange portion 32 located on both sides of the core portion in the X-axis direction. Furthermore, an intermediate flange portion 33 is integrally formed on the outer circumference of the core portion of the winding frame 30 located between the first end flange portion 32 and the second end flange portion 32. A through hole 31 for the core foot is formed in the winding frame 30, through which the core portion having the first end flange portion 32, the intermediate flange portion 33, and the second end flange portion 32 passes in the X-axis direction.

[0090] In this embodiment, cores 2 and 2 have the same shape and have an E-shaped cross-section in the XY section, forming a so-called E-shaped core. That is, each core 2 and 2 has: a base 23 extending along the Y-axis direction; a pair of outer legs 22 and 22 protruding from both ends of the base 23 in the Y-axis direction toward the X-axis direction; and a middle leg 21 protruding from the center in the Y-axis direction toward the X-axis direction between these outer legs 22 and 22.

[0091] In this embodiment, each of the middle legs 21, 21 is inserted into the core foot through hole 31 of the winding frame 3 from both sides in the X-axis direction. Inside the core foot through hole 31 of the winding frame 3, the front ends of the middle legs 21, 21 can contact and abut, or they can be arranged face-to-face with a predetermined gap. Furthermore, by forming a gap, the leakage flux characteristics can be adjusted according to the width of the gap.

[0092] like Figure 2 As shown, the middle legs 21, 21 have a generally quadrangular prism shape that matches the inner circumferential surface shape of the through hole 31 for the core legs, but their shape is not particularly limited and can vary depending on the shape of the through hole 31 for the core legs. Furthermore, the outer legs 22, 22 have a shape that matches the Y-axis direction end face shape of the flanges 32, 33, and their outer surfaces have a plane parallel to the XZ plane (a plane including the X and Z axes). In this embodiment, the material of each core 2, 2 can be a soft magnetic material such as metal or ferrite, but is not particularly limited.

[0093] Terminal blocks 36, 36 extend outward from the Z-axis direction and outward from the X-axis direction of the end flanges 32, 32 (viewed from the center of the winding frame 3, outward / the same applies below). Preferably, the upper surface of the terminal block 36 along the Z-axis is lower than the bottom surface of the through hole 31 by the amount of thickness of the terminal block covering portion 57 of the cover 5 (described later). Preferably, the upper surface of the terminal block covering portion 57 is flush with the bottom surface of the through hole 31. This is to facilitate guiding the middle leg portion 21 of the core 2 from the upper surface of the terminal block covering portion 57 to the bottom surface of the through hole 31.

[0094] Furthermore, the width of the terminal blocks 36, 36 in the Y-axis direction is greater than the width of the end flanges 32, 32 in the Y-axis direction, and they protrude from both end faces of the end flanges 32 in the Y-axis direction with a predetermined width. Preferably, the predetermined width of the terminal blocks 36, 36 protruding from both end faces of the end flanges 32 in the Y-axis direction along the Y-axis is approximately the same as the width of the outer foot portion 22 of the core 2 in the Y-axis direction. The upper surfaces of the terminal blocks 36, 36 are respectively covered by the terminal block covering portions 57, 57 of the cover 5, and the cores 2, 2 are disposed thereon.

[0095] In each terminal block 36, multiple terminals 9 are arranged and embedded along the Y-axis. For example... Figure 3 As shown, each terminal 9 has a wiring portion 91 and a mounting portion 92, which are embedded in the terminal block 36 of the winding frame 3 in such a way that they are embedded in the interior of the terminal block 36.

[0096] The wiring portion 91 is connected to any one of the lead portions 81 among the plurality of wires 8. The mounting portion 92 is, for example, a portion that is connected to a circuit pattern of a circuit board or the like (not shown), and the coil portion 80 formed by the wires 8 is connected to an external circuit of the circuit board or the like through each terminal 9.

[0097] like Figure 3 As shown, in this embodiment, a plurality of wires 8 are wound around the outer periphery of the core portion located between the first end flange portion 32 and the middle flange portion 33, and between the middle flange portion 33 and the second end flange portion 32, and the coil portion 80 and the coil portion 80 constitute one or more transformers.

[0098] The conductor 8 can be made of a single wire or a stranded wire such as Litz wire. The diameter of the conductor 8 is not particularly limited, but is preferably in the range of 0.1 to 0.4 mm. The conductor 8 can be made of conductive wire such as metal wire, but it can also be an insulated conductor.

[0099] like Figure 8 As shown, a pair of lead portions 81, 81 at both ends of each conductor 8 constituting each coil portion 80 are guided to each terminal 9 through lead passages 38 formed between reinforcing ribs 37 on the bottom surface of the terminal block 36, as shown. Figure 9 As shown, it is connected to the wiring section 91 of terminal 9.

[0100] The winding frame 3, including the cylindrical portion 30 and the terminal block 36, is integrally molded from plastics such as PPS, PET, PBT, LCP, and nylon, but it can also be made of other insulating components. However, in this embodiment, the winding frame 3 is preferably made of plastic with a thermal conductivity of 1 W / m·K or higher, such as PPS or nylon.

[0101] like Figure 2 and Figure 4 As shown, the cover 5 is composed of a different component than the winding frame 3. The cover 5 may also be composed of an insulating component of the same material as the winding frame 3, but it is preferable to be composed of an insulating component with better elasticity than the winding frame 3, such as LCP, nylon, etc.

[0102] The cover 5 includes: terminal block covering portions 57, 57 that respectively cover the upper surfaces of a pair of terminal blocks 36 along the Z-axis; and connecting covering portions 58, 58 that extend along the X-axis to connect the two ends of each terminal block covering portion 57, 57 in the Y-axis direction. The upper surfaces of the terminal block covering portions 57, 57 and the connecting covering portions 58, 58 are flush, and the base portions 23, 23 and the outer feet portions 22, 22 of each core 2, 2 are disposed on them. At both ends of the terminal block covering portions 57, 57 and the connecting covering portions 58, 58 in the Y-axis direction, side end covering portions 59 that respectively cover the upper part of the two end faces of each terminal block 36, 36 along the Y-axis are integrally provided.

[0103] A central opening 56 is formed in the center of the cover 5 surrounded by terminal block covering portions 57, 57 and connecting covering portions 58, 58. The upper part of the bobbin portion 30 of the winding frame 3 is inserted from below along the Z-axis through the central opening 56.

[0104] The end walls 52 are formed integrally upward along the Z-axis from the edges of the openings at both ends of the central opening 56 of the cover 5 along the X-axis. Each end wall 52 has an end opening 51 that intersects with and communicates with the central opening 56 at its central portion along the Y-axis. The cover 5 has an upper wall 53 for connecting the upper ends of the end walls 52 located on both sides along the X-axis along the Z-axis.

[0105] Additionally, the cover 5 has side walls 54, 54 integrally connected to the upper portions of the two ends of each end wall 52 located on both sides along the X-axis along the Y-axis. Each side wall 54, 54 is cut off below along the Z-axis in a manner that does not directly connect to the connecting covering portion 58, and each side wall 54, 54 of the cover 5 has a side opening 54a that reaches the central opening 56.

[0106] like Figure 4 As shown, each end opening 51 is divided into a continuous main opening 51a and a secondary opening 51b by claw portions 55, 55 protruding from the opening edges 52a on both sides of the end opening 51 along the Y-axis toward the inside of the end opening 51. The width of the main opening 51a along the Y-axis is narrower than the width of the secondary opening 51b along the Y-axis, and the width of the end opening 51 between the claw portions 55, 55 on both sides along the Y-axis is narrower than the width of the main opening 51a along the Y-axis.

[0107] By making the width of the secondary opening 51b along the Y-axis longer than the width of the main opening 51a along the Y-axis, the claw portion 55 can be easily flexibly deformed, and the adhesive 10 can easily enter the interior of the secondary opening 51b. The upper end of the secondary opening 51b extends by cutting off a portion of the upper wall 53 near the intersection of the end wall 52 and the upper wall 53.

[0108] like Figure 2 and Figure 3 As shown, on each end flange 32 of the winding frame 3, above the end face along the X-axis and above the Z-axis, a protrusion 34 serving as a second engaging portion is integrally provided above the through hole 31. The protrusion 34 is formed to protrude outward from the end face along the X-axis of each end flange 32.

[0109] The length of the protrusion 34 along the Y-axis is shorter than the width along the Y-axis between the claws 55, 55 on both sides of the end opening 51, and is equal to or slightly longer than the length along the Y-axis of the main opening 51a. This is to allow the protrusion 34 to enter the interior of the main opening 51a and to allow the inclined surface 34a of the protrusion 34 to abut against the claws 55, 55.

[0110] like Figure 3 As shown, the protrusion 34 has an inclined surface 34a, which serves as... Figure 2 The claw portion 55 of the first engaging portion shown flexes and deforms along the X-axis and is guided toward the hook portion 34b; and the hook portion 34b engages the claw portion 55. The hook portion 34b is formed below along the Z-axis of the inclined surface 34a, forming the lower surface of the protrusion 34. The inclined surface 34a forms the upper surface of the protrusion 34. Figure 6 As shown, at the position of the hook portion 34b where the protrusion 34 is formed, the claw portions 55, 55 are formed on the opening edge 52a of the end wall 52 in such a way that the claw portions 55, 55 are engaged with the hook portion 34b from both sides along the Y-axis.

[0111] Face to face along the X-axis Figure 4 The width between the end walls 52 shown is perpendicular to the width of the end walls 52 facing each other along the X-axis. Figure 3 The width between the end faces of the end flanges 32 of the winding frame 3 shown is approximately the same or slightly wider. Furthermore, the protrusion height of the protrusions 34 formed on the end faces of each end flange 32 is set to be such that... Figure 1 As shown, after the cover 5 is assembled onto the winding frame 3, the protrusion 34 protrudes from the secondary opening 51b of the cover 5 along the X-axis to that height.

[0112] Therefore, when the cover 5 covers the winding frame 3 from above along the Z-axis, the claw 55 abuts against the inclined surface 34a of the protrusion 34, flexes and deforms along the X-axis, and is guided to the hook 34b. At the moment when it passes the maximum protrusion position of the protrusion 34, the shape of the claws 55, 55 returns to normal, and the claws 55, 55 are locked in place by the hook 34b from both sides along the Y-axis in a single contact manner.

[0113] In this embodiment, such as Figure 3 As shown, a detection pattern 100 is formed on the surface of the terminal block 36 located near the wiring portion 91 or the mounting portion 92. Furthermore, the vicinity of the wiring portion 91 or the mounting portion 92 includes the surface of components such as the terminal block 36 located inside a sphere of radius r, centered on the portion of the wiring portion 91 or the mounting portion 92 that protrudes from the surface of the terminal block 36. The radius r is determined, for example, by the range of foreign matter such as solder balls that may scatter when connecting the lead portion 81 of the wire to the wiring portion 91, and is not particularly limited, but is, for example, within a range of 10 mm.

[0114] In this embodiment, in addition to the surface of the terminal block 36 near the wiring portion 91 or the mounting portion 92, the detection pattern 100 is continuously formed on almost the entire surface of the terminal block 36. For example, the detection pattern 100 is continuously formed on the upper surface and back surface of the terminal block 36 that are approximately perpendicular to the Z-axis, and on the side surface that is approximately perpendicular to the Y-axis. Furthermore, the detection pattern 100 is also formed on the outer surface of the end flange portion 32 of the winding frame 3. In the accompanying drawings, the detection pattern 100 is indicated by a shading line.

[0115] In addition, in this embodiment, such as Figure 2 As shown, the detection pattern 100 is also formed on the outer surface of the cover 5, the outer surface of the core 2, etc. Furthermore, in this embodiment, the detection pattern 100 is not formed on the outer surface of the tape 11, but it can also be formed. However, when the detection pattern 100 is formed on the outer surface of the tape 11, it may not be a raised, repeating pattern as described later, but rather a flat image pattern without raised or recessed areas.

[0116] In this embodiment, for example, Figure 10A As shown, the detection pattern 100 is composed of a raised, repeating pattern obtained by forming grooves 102 of depth D1 in a stripe pattern with a predetermined interval width W2 on the surface 101 of a component such as a terminal block 36. The width (pattern width) W1 of the groove 102 is not particularly limited, and is, for example, 0.1 to 5 mm, 0.1 to 3 mm, 0.1 to 1 mm, or 0.1 to 0.5 mm. The width (pattern width) W1 of the groove 102 is preferably uniform along the length direction of the groove 102, but it can also be different.

[0117] Furthermore, the spacing W2 of the grooves 102 can be the same as or different from the width W1 of the grooves 102, without particular limitation. For example, it can be 0.1–5 mm, 0.1–3 mm, 0.1–1 mm, or 0.1–0.5 mm. The depth D1 of the groove is not particularly limited and can be 0, but it is preferably greater than 0 and more than 1 / 20 of the width W1 of the groove, and most preferably less than 0.1 mm.

[0118] The size of the foreign object to be detected varies. Smaller foreign objects are mostly those 0.1 mm or larger, while larger foreign objects vary depending on their type, but those exceeding 5 mm are relatively rare. Therefore, the pattern width or spacing for detecting patterns is preferably within the range described above, but it may deviate from this range depending on the size of the foreign object to be detected.

[0119] The groove 102 can be continuous along its length, but for example, Figure 10B As shown, the groove 102a can also be an intermittent groove separated by a gap L1 in a direction perpendicular to the width gap W2. The gap L1 can be the same as or different from the gap W2. The shape of the end of the groove 102a in the length direction can be as follows: Figure 10B The image shown is a semicircle, but it can also be a straight line, a polygon, an ellipse, or other shapes.

[0120] Additionally, slot 102b can also be like... Figure 10C The slot shown is a rectangular slot, or a triangular slot, or a polygonal slot with more than one pentagon, or as shown in the image. Figure 10DThe groove shown can be circular, elliptical, a combination of polygons and quadrilaterals, or other shapes. Furthermore, as foreign matter, there are no particular limitations; examples include, in addition to solder rods, core fragments, terminal burrs, terminal plating shavings, solder shavings, wire shavings, resin molding burrs, etc.

[0121] Next, an example of a method for manufacturing the coil component 1 according to this embodiment will be described. For example... Figure 3 As shown, the coil component 1 is assembled by winding the wire 8 into the core portion of the winding frame 3. Figure 2 The components shown are used for manufacturing.

[0122] First, prepare Figure 3 , Figure 8 as well as Figure 9 The winding frame 3 is shown. The winding frame 3 can be formed, for example, by injection molding, such that inspection patterns 100 are formed at necessary locations on the outer surface of the winding frame 3, and for example, patterns are formed on the inner circumferential surface of the mold cavity. Figure 10A The raised pattern shown is a reversed pattern of raised and recessed design. The cover 5 is also formed, for example, by injection molding, and the detection pattern 100 is formed on the outer surface in the same way as the winding frame 3.

[0123] Next, multiple wires 8 are wound around the core portion of the bobbin portion 30 of the winding frame 3 to form a coil portion 80, and the two ends of the wires 8, namely the lead portion 81, are connected to the wiring portion 91 of the terminal 9. There is no particular limitation on the method for connecting the lead portion 81 to the wiring portion 91 of the terminal 9, and methods such as riveting, heat pressing, laser welding, and welding can be exemplified.

[0124] Next, from Figure 3 The winding frame 3 shown is installed above the winding frame 3. Figure 4 The cover shown is 5. At this time, with... Figure 2 The upper part of the cylindrical portion 30 of the winding frame 3 is inserted into the central opening 56 of the cover 5 to combine the cover 5 and the winding frame 3. At this time, the protrusion 34 of the winding frame 3 passes through the main opening 51a of the end opening 51 from the central opening 56. The inclined surface 34a of the protrusion 34 abuts against the claw portion 55. The claw portion 55 flexes and elastically deforms along the inclined surface 34a outward along the X-axis, and then engages with the hook portion 34b of the protrusion 34.

[0125] As a result, the main opening 51a of the end opening 51 of the cover 5 is self-aligned with the through hole 31 of the winding frame 3. The protrusion 34 of the winding frame 3 protrudes from the secondary opening 51b to the outside of the cover 5. In addition, the claw portion 55 has a shape that does not narrow the opening cross-section of the through hole 31 of the winding frame 3.

[0126] Next, with the cover 5 installed on the winding frame 3, the cores 2 and 2 are installed in two directions along the X-axis relative to the cover 5. That is, the middle legs 21 and 21 of the cores 2 and 2 are inserted into the through hole 31 of the winding frame 3 through the main opening 51a of the cover 5, and the cores 2 and 2 are installed on the cover 5 such that the outer legs 22 and 22 of the cores 2 and 2 are provided on the upper surface of the connecting cover portion 58 of the cover 5.

[0127] Alternatively, the front ends of the middle legs 21, 21, which enter the interior of the through hole 31, can have a gap between each other, and the gap can also be zero. In addition, it is preferable that the front ends of the outer legs 22 are in contact with each other.

[0128] Next, tape 11 can be installed around the cores 2, 2 combined with the cover 5 to reinforce the cores 2, 2 to the cover 5 and the winding frame 3. Furthermore, the tape 11 is preferably an insulating tape, such as one made of plastic or rubber. To form a detection pattern 100 on the outer surface of the tape 11, for example, a raised detection pattern can be formed by stamping, or a flat detection pattern without raised areas can be formed by printing.

[0129] Next, as Figure 1 As shown, adhesive 10 is applied in such a way that it covers at least a portion of the protrusion 34 of the winding frame 3 protruding from the secondary opening 51b of the cover 5, at least a portion of the claw portion 55 of the cover 5, and a portion of the core 2 (preferably a portion of the boundary between the middle foot portion 21 and the base 23).

[0130] Preferably, the portion of the claw 55 of the cover 5 closest to the protrusion 34 is included within the fixing range using the adhesive 10. Additionally, it is also preferable that the area near the boundary between the main opening 51a and the secondary opening 51b is included within the fixing range using the adhesive 10. The adhesive 10 is not particularly limited; for example, epoxy-based adhesives, silicone-based adhesives, etc., can be used.

[0131] In this embodiment, for example, Figure 1 As shown, there are sufficient gaps between the lower part of the protrusion 34 protruding from the secondary opening 51b and the upper surface of the core 2, as well as between the claws 55, 55, so that even the adhesive 10 with low flowability can easily enter these gaps. Furthermore, the adhesive can also easily enter the interior of the secondary opening 51b located around the protrusion 34. Therefore, the bonding strength between the core 2 and the winding frame 3 and the cover 5 using the adhesive is improved, and the strength relative to the vibration load on the coil component 1 is also improved. In addition, in this embodiment, due to the improved strength, the wall thickness of the cover 5 can also be reduced.

[0132] Alternatively, an adhesive 10a, which may be the same as or different from adhesive 10, can be applied to the intersection of the terminal block covering portion 57 of the cover 5 and the tape 11, and then fixed thereto. Furthermore, in the absence of tape 11, adhesive 10a can be used to bond and fix the base 23 of the core 2 to the terminal block covering portion 57 of the cover 5.

[0133] In the coil component 1 of this embodiment, when the cover 5 is mounted on the winding frame 3, the first engaging portion, i.e., the claw portion 55, of the cover 5 engages with the protrusion 34 of the winding frame 3. Therefore, by holding the upper surface of the upper wall 53 of the cover 5 in place, for example by means of a suction nozzle, the cover 5 is also difficult to detach from the winding frame 3 when transporting the winding frame 3 on which the cover 5 is mounted, thus improving assembly operability.

[0134] Furthermore, when the cover 5 is installed on the winding frame 3, the end opening 51 of the cover 5 is automatically positioned with the through hole 31 of the winding frame 3, making it easy to install the core 2 into the end opening 51 and the through hole 31, thus improving assembly operability. Additionally, the cover 5 is fitted and fixed to the winding frame 3 using the claw 55, and for example, the core 2 is bonded to the winding frame 3 using adhesive 10, including the claw 55. As a result, the bonding strength between the cover 5, the winding frame 3, and the core 2 is improved, enhancing the strength and reliability of the coil component 1.

[0135] Furthermore, the cylindrical portion 30 of the winding frame 3 has end flanges 32, 32 at its ends along the X-axis, and the end flanges 32, 32 have protrusions 34 that serve as second engaging portions, respectively engaging with the claw portions 55, 55 of the cover 5. With this configuration, assembly operability is further improved, and the strength and reliability of the coil component 1 are further improved.

[0136] Furthermore, the protrusion 34 has an inclined surface 34a that guides the deformation of the claw portion 55 and a hook portion 34b for the claw portion 55 to engage. When the cover 5 is installed on the winding frame 3, the claw portion 55 of the cover 5 is guided by the inclined surface 34a of the protrusion 34 and elastically deforms. Afterward, it returns to its original shape and engages with the hook portion 34b in a one-touch manner, and the cover 5 is fitted into the winding frame 3 in a one-touch manner. Therefore, the assembly operability is further improved, and the strength and reliability of the coil component 1 are further improved.

[0137] Furthermore, in this embodiment, the claw portion 55 is disposed on the end wall 52 where the end opening 51 is formed. With this configuration, the claw portion 55 becomes easily elastically deformable, making it easy to fit the cover 5 into the winding frame 3 with a single contact. Therefore, assembly operability is further improved, and the strength and reliability of the coil component 1 are further improved.

[0138] Furthermore, in this embodiment, the claw portion 55 protrudes from the opening edge 52a of the end wall 52 toward the inside of the end opening 51, and the claw portion 55 is disposed on both sides of the through hole 31 in the width direction. With this configuration, the first engaging portion formed by the pair of claw portions 55 becomes easily elastically deformable, and the cover 5 can be easily engaged with the winding frame 3 with a single contact.

[0139] Alternatively, in other embodiments, a single claw 55 may be provided at one end opening 51 facing each other along the X-axis, and a single claw 55 may also be provided at the other end opening. In this case, it is preferable that the single claw 55 provided at one end opening 51 and the single claw 55 provided at the other end opening 51 facing each other along the X-axis are arranged diagonally opposite each other when viewed from the Z-axis direction.

[0140] Furthermore, in this embodiment, the claw portions 55, 55, and the end opening 51 are divided into a main opening 51a and a secondary opening 51b, forming a structure in which the middle leg 21 is inserted into the main opening 51a. With this configuration, the alignment of the main opening 51a of the cover 5 with the through hole 31 of the winding frame 3 becomes more reliable, and it is easier to insert the middle leg 21 of the core 2 into the main opening 51a and the through hole 31.

[0141] Furthermore, in this embodiment, the winding frame 3 has a terminal block 36 for mounting a terminal 9 that is connected to a lead portion 81 extending from the coil portion 80 of the conductor 8, and the cover 5 has a terminal block covering portion 57 that covers the terminal block 36. Through the terminal block covering portion 57 of the cover 5, the insulation distance from the terminal 9 to the core 2 is increased, and the withstand voltage is improved.

[0142] In this embodiment, for example, Figure 11A As shown, when foreign objects such as solder balls are present on the detection pattern 100, it is easy to determine whether the size of the foreign object is larger than the width or spacing of the detection pattern by observing the foreign object against the background of the detection pattern 100. Therefore, according to this coil component 1, foreign objects larger than a specified size can be easily and quickly detected objectively by visual inspection or by an external inspection device (camera).

[0143] In addition, depending on the position or type of the pattern used for detection, it can also be used as a scale for positioning when installing other components such as cores. The pattern 100 can also be used to improve the positioning accuracy of mounting components such as cores 2.

[0144] Furthermore, in this embodiment, the detection pattern 100 is a repeated pattern formed on the surface of the core 2 and other components. Therefore, due to the difference in reflected light generated by the illumination light, foreign objects on the pattern can be observed more three-dimensionally, and the detection accuracy of foreign objects is further improved.

[0145] In addition, in this embodiment, for example, Figure 1As shown, the adhesives 10 and 10a applied within a specified range come into contact with the surfaces of the components, namely the core 2 and the cover 5, on which the detection pattern 100 is formed. Since the detection pattern 100, composed of a repeating pattern of raised and recessed areas, retains the adhesive in the recessed portions, it is expected to improve the bonding strength. Furthermore, depending on the direction of the pattern, wetting and spreading of the adhesives 10 and 10a can be effectively prevented, making it easy to effectively apply the adhesive within the specified bonding area. Moreover, if wetting and spreading are significantly greater than anticipated, the bonding effect may be reduced because the adhesive may sag or lack height.

[0146] Second Implementation Method

[0147] Figure 12 The coil component 1a of this embodiment shown below differs from the coil component 1 of the first embodiment described above in the following parts. The description of the common parts is the same as that of the first embodiment, and therefore is omitted.

[0148] In this embodiment, the structure of the protrusion 34A, which serves as the second engaging portion, differs from that in the first embodiment described above. For example... Figure 12 As shown, in this embodiment, the protrusion 34A of the end flange 32 formed on at least one side of the winding frame 3a has a structure that is separated along the Y-axis and has an inverted L-shaped shape when viewed from the X-axis direction, and has an inclined surface and a hook portion respectively.

[0149] On the inner side of each protrusion 34A in the Y-axis direction, a stop portion extending downward along the Z-axis is integrally formed with the protrusion 34A. Furthermore, when viewed from the X-axis direction, these stop portions are separated along the Y-axis, but they can also be continuous, single stop portions. That is, protrusions 34A separated along the Y-axis can also be continuous with each other.

[0150] By providing a stop portion at each protrusion 34A, the relative movement of the protrusion 34A and the claw portion 55 in the Y-axis direction is restricted, and it is also possible to prevent the winding frame 3a and the cover 5 from shifting significantly in the Y-axis direction.

[0151] Furthermore, in the first embodiment described above, the alignment of the cover 5 and the winding frame 3a (and the winding frame 3 as well) along the Z-axis is achieved through the inner surface of the terminal block covering portion 57 of the cover 5 and the upper surface of the terminal block 36 of the winding frame 3 (see reference). Figure 3 This can be achieved through contact, etc. Alternatively, the alignment of the cover 5 and the winding frame 3a (and the winding frame 3 as well) along the Z-axis is achieved through the inner surface of the magnetic surface 53 of the cover 5 and the upper part of the flanges 32 and 33 of the winding frame 3 (see reference). Figure 3 This can be achieved through contact, etc.

[0152] Furthermore, the alignment of the cover 5 and the winding frame 3a (and the winding frame 3 as well) along the X-axis is achieved by the inner surface of the end wall 52 of the cover 5 and the end face of the end flange 32 of the winding frame 3 (see reference). Figure 3 This can be achieved through contact, etc. Alternatively, the alignment of the cover 5 and the winding frame 3a (and the winding frame 3 as well) along the X-axis is achieved by the inner surface of the claw portion 55 of the cover 5 and the end face of the end flange portion 32 of the winding frame 3 (see reference). Figure 3 This is achieved through contact, etc. Similarly, in the first embodiment, the claw 55 may be slightly curved inward along the X-axis compared to the end wall 52. This is to facilitate contact between the claw 55 and the end face of the end flange 32 of the winding frame 3 (see reference). Figure 3 )touch.

[0153] In this embodiment, a detection pattern 100 is formed on the surface of at least the winding frame 3a, core 2, and cover 5 of the terminal block 36 located near the wiring section 91 or mounting section 92, producing the same effect as in the above embodiment.

[0154] Third Implementation Method

[0155] As Figure 13 The chip component 1b of the electronic component shown in this embodiment has a different internal structure from the coil component 1 or 1a of the first or second embodiment described above, but they share the common feature that the detection pattern 100 is formed on the surface of the insulating component. In the following description, the different parts will be described in particular, while the description of the common parts is the same as in the first or second embodiment and is therefore omitted.

[0156] As a chip component 1b, such as a capacitor chip, inductor chip, rheostat chip, or other electronic component, the detection pattern 100 described above is formed on the insulating surface of the chip body at both ends, where a pair of terminal electrodes 94, 94 are formed along the X-axis. The detection pattern 100 can be formed, for example, by laser processing, stamping, printing, etc., and can be formed before or after the formation of the terminal electrodes 94.

[0157] Similar to the embodiments described above, in this embodiment, when a foreign object is detected on the detection pattern 100, by observing the foreign object against the background of the detection pattern, it is easy to determine whether the size of the foreign object is larger than the width or spacing of the detection pattern. Therefore, according to this chip component 1b, foreign objects larger than a specified size can be easily and quickly detected objectively through visual inspection or an external inspection using a foreign object detection device (camera).

[0158] In addition, in this embodiment, by setting the detection pattern 100 to, for example, a repeating pattern with concave and convex shapes along the X-axis, when the terminal electrodes 94, 94 are formed by impregnation with electrode paste, the wetting and spreading of the paste can be suppressed, and the positioning of the electrodes can also be expected.

[0159] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the invention. For example, in Figure 13 In the embodiment shown, the detection pattern 100 is formed on the entire surface of the chip body located between the terminal electrodes 94, 94, but the pattern 100 may also be formed only on the surface of the chip body located near the terminal electrodes 94, 94.

Claims

1. An electronic component, wherein, The electronic component has terminals or electrodes. At least on the surface of the component on which the terminal or electrode is mounted, there is a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

2. The electronic component according to claim 1, wherein, The pattern width or spacing of the detected pattern is 0.1 to 5 mm.

3. The electronic component according to claim 1 or 2, wherein, The detected pattern is a repeating pattern of raised and recessed areas formed on the surface of the component.

4. The electronic component according to claim 3, wherein, The adhesive applied within a specified range comes into contact with the surface of the component on which the detection pattern is formed.

5. A coil component, wherein, The coil component has a terminal block on which terminals are mounted. The surface of the terminal block has a detection pattern with a width or spacing smaller than the size of the foreign object to be detected.

6. The coil component according to claim 5, wherein, The terminal has a wiring portion and a mounting portion. The detection pattern is provided on the surface of the terminal block located near the wiring portion or the mounting portion.

7. The coil component according to claim 5 or 6, wherein, It also includes: a cover having a terminal block covering portion that covers at least a portion of the terminal block, The detection pattern is present on at least the surface of the cover near the terminal.

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