Coil element and method of manufacturing a coil element

Abstract

The base portion (30) has a base portion (36) and a standing portion (38). The base portion (36) is provided with a terminal member (40). In addition, the base portion (36) is placed with the coil (20) or the core (10). The standing portion (38) is arranged in a standing manner so as to cross the surface of the base portion (36) in the standing direction. Furthermore, the base portion (36) and the standing portion (38) of the base portion (30) are formed integrally. In addition, the end surface of each of the plurality of coils (20) opposes the facing surface (38a) of the side surface of the standing portion (38).

Description

Technical Field

[0001] This invention relates to a coil element and a method for manufacturing the coil element. Background Technology

[0002] Some coil elements are manufactured by arranging multiple coils and multiple cores in a base portion formed of resin or the like. Regarding this technology, Patent Document 1 discloses a coil element (composite element (100)) formed by arranging E-type cores (20A, 20B) and coils (30A, 30B) on a resin base (10). Specifically, the first coil (30A) is arranged to fit into a metal terminal (14A). This metal terminal (14A) consists of a bottom portion (14A1), a side portion (14A2) rising from the bottom portion (14A1), and a pressing portion (14A3). The second coil (30B) is also arranged to fit into a metal terminal (14C).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2020-174112 Summary of the Invention

[0006] The problem the invention aims to solve

[0007] In the case where the coils (30A, 30B) are arranged on the resin base (10) of Patent Document 1, the coils (30A, 30B) need to be arranged in a manner that the coils (30A, 30B) are fitted with the metal terminals (14A, 14C) and aligned with a predetermined position in the resin base (10). This requires the coils (30A, 30B) to be arranged in the desired position, which may make the manufacture of the coil element difficult. For example, the process of aligning the coils (30A, 30B) in the resin base (10) before arranging the coils (30A, 30B) on the resin base (10) increases the manufacturing time.

[0008] The present invention was made in view of the aforementioned problems and provides a coil element that is easy to manufacture.

[0009] Solution for solving the problem

[0010] The coil element of the present invention includes: two or more cores; two or more coils, each arranged in a spiral around at least a portion of the multiple cores; and a base portion holding the coils and the cores and having terminal members disposed thereon, the base portion comprising: a base portion for disposing the terminal members and for mounting the coils or the cores; and an upright portion disposed uprightly in a manner intersecting the surface of the base portion in an uprighting direction, the base portion and the upright portion being integrally formed, and one end face of each of the multiple coils facing an opposing face that is a side face of the upright portion.

[0011] In the method for manufacturing a coil element according to the present invention, the coil element has: two or more cores; two or more coils arranged in a spiral around at least a portion of the cores; and a base portion holding the coils and the cores and having terminal members disposed thereon. The base portion includes: a base portion for disposing the terminal members and for mounting the coils and the cores; and an erect portion erected in a manner intersecting the surface of the base portion in an erection direction. The base portion and the erect portion are integrally formed. The method for manufacturing the coil element includes a coil mounting step in which the coil is mounted on the base portion by moving it toward the opposing surface with one end face of the coil facing the opposing surface that is the side face of the erect portion.

[0012] When manufacturing the coil element of the present invention, the coil is positioned on the base portion with its end face facing the side of the raised portion. In this case, the coil is positioned on the base portion by moving it along the coil's axial direction, but by positioning the raised portion on the base portion, it is possible to prevent the coil from accidentally moving to a position further inward than the side of the raised portion. That is, the coil's position alignment is assisted by the raised portion. In other words, the process of aligning the coil on the base portion before positioning it on the base portion can be further reduced. In addition, since the raised portion and the base portion are formed integrally, it is not necessary to adjust the position of the raised portion on the base portion.

[0013] The effects of the invention

[0014] According to the coil element of the present invention, by aligning the end face of the coil with the side surface of the raised portion, the coil can be easily aligned at the base portion. Furthermore, since the raised portion and the base portion are integrally formed, the process of aligning the raised portion to the base portion is eliminated. Therefore, a coil element that is easy to manufacture can be provided. Attached Figure Description

[0015] The above-described objectives, as well as other objectives, features, and advantages, become more apparent from the preferred embodiments described below and the accompanying drawings.

[0016] Figure 1 This is a perspective view showing an example of a coil element according to the first embodiment of the present invention.

[0017] Figure 2 This is an exploded perspective view of the coil element according to the first embodiment.

[0018] Figure 3 This is a right view of the coil element according to the first embodiment. The outlines of the coil, adhesive, and part of the base portion, which are not visible due to the core, are shown in dashed lines.

[0019] Figure 4 This is a front view of the coil element according to the first embodiment. The outline of the coil, which is not visible due to the core, and the outline of the bottom surface of the recess in the core are shown by dashed lines.

[0020] Figure 5 This is a top view of the coil element according to the first embodiment.

[0021] Figure 6 (a) is a perspective view of the base portion and terminal component of the first embodiment. Figure 6 (b) is a perspective view of the base and terminal components of the first embodiment viewed from other directions.

[0022] Figure 7 This is a perspective view of the manufacturing process of the coil element according to the first embodiment. Detailed Implementation

[0023] The various constituent elements of the coil element of the present invention do not need to exist independently, and the following situations are allowed: multiple constituent elements form a single component; a constituent element is formed by multiple components; a constituent element is part of other constituent elements; a part of a constituent element is repeated by a part of other constituent elements.

[0024] Furthermore, although the manufacturing method of the present invention is sometimes described using multiple steps described sequentially, the order of these steps does not limit the order or timing of their execution. Therefore, when implementing the manufacturing method of the present invention, the order of these multiple steps can be changed without any obstruction to the content, and some or all of the timing of the execution of the multiple steps may overlap.

[0025] Hereinafter, embodiments of the present invention will be described based on the accompanying drawings. Furthermore, in each drawing, corresponding constituent elements will be labeled with common reference numerals, and repetitive descriptions will be omitted where appropriate.

[0026] Furthermore, in this embodiment, the directions of front-back, left-right, up-down, and back-forward are defined as shown in the illustration. However, this is a convenient definition for simply illustrating the relative relationships of the constituent elements and does not limit the direction during manufacturing or use of the product implementing the present invention. In this embodiment, the up-down direction is the direction orthogonal to the surface of the mounting substrate when the coil element is placed on the mounting substrate. When the coil element is placed on a horizontal mounting substrate, the up-down direction is consistent with the vertical direction, but when the coil element is placed on an inclined mounting substrate, the up-down direction becomes an inclined direction relative to the vertical direction. Sometimes the front-back direction and the left-right direction are referred to as the lateral direction. In this embodiment, the front-back direction is consistent with the axial direction of the coil. In addition, sometimes the left-right direction is referred to as the width direction of the coil element, and sometimes the up-down direction is referred to as the height direction of the coil element or the components in the coil element.

[0027] Furthermore, in this invention, a plane refers to a shape that is physically formed with a plane as its target, and of course, it does not need to be a geometrically perfect plane.

[0028] <First Implementation>

[0029] (Coil element)

[0030] Figure 1 This is a perspective view showing an example of the coil element 1 according to the first embodiment of the present invention.

[0031] First, an overview of the coil element 1 in this embodiment will be described.

[0032] The coil element 1 has two or more cores 10 (first core 11 and second core 12), two or more coils 20 (first coil 21 and second coil 22), and a base portion 30. The two or more coils 20 are arranged in a spiral configuration around at least a portion of the cores 10. The base portion 30 holds the coils 20 and the cores 10. Additionally, a terminal member 40 is disposed on the base portion 30.

[0033] The base portion 30 includes a base portion 36 and an upright portion 38. The base portion 36 is provided with a terminal member 40. In addition, the base portion 36 carries a coil 20 or a core 10. The upright portion 38 is arranged upright so as to intersect the surface of the base portion 36 in the upright direction (vertical direction). Moreover, the base portion 30 is formed in such a way that the base portion 36 and the upright portion 38 are integrally formed.

[0034] In addition, one end face (inner end face 21a, 22a) of each of the plurality of coils 20 is opposite to the opposing surface 38a (first opposing surface 38a1 and second opposing surface 38a2) which is the side of the upright part 38.

[0035] When manufacturing the coil element 1 of the present invention, the coil 20 is disposed on the base portion 30 with the inner end face 21a of the coil 20 facing the side surface (opposing face 38a) of the upright portion 38. In this case, the coil 20 is disposed on the base portion 30 by moving it axially along the coil 20, but by providing the upright portion 38 on the base portion 30, it is possible to prevent the coil 20 from accidentally moving to a position further inward than the side surface of the upright portion 38. That is, the alignment of the coil 20 is assisted by the upright portion 38. For example, as will be explained later, when the coil 20 is inserted into the base portion 30, the coil 20 is inserted into the base portion 30 until the inner end faces 21a and 22a of the coil 20 abut against the side surface of the upright portion 38, and the position of the coil 20 is naturally determined by the position of the upright portion 38. Even when the coil 20 is inserted into the base portion 30 until the inner end faces 21a and 22a of the coil 20 are about to abut against the side of the upright portion 38, the presence of the upright portion 38 prevents the coil 20 from being accidentally inserted into the base portion 30 to the inside. That is, the process of aligning the coil 20 in the base portion 30 before placing it in the base portion 30 can be further reduced. Furthermore, since the upright portion 38 is integrally formed with the base portion 36, there is no need to adjust the position of the upright portion 38 at the base portion 36. Therefore, a coil element 1 that is easy to manufacture can be provided.

[0036] Next, the coil element 1 of this embodiment will be described in detail.

[0037] Coil element 1 is an electronic component having a coil 20. An electronic component is a component that can form part of an electronic circuit. Examples of coil element 1 include transformers, antennas, or inductors. In this embodiment, coil element 1 is configured and mounted on a mounting substrate such that the mounting surface of the terminal member 40 (described later) is in contact with a mounting substrate (not shown).

[0038] The coil 20 is a component formed by arranging conductive material in a spiral shape. In this embodiment, the coil 20 is a flat wound coil formed by arranging a flat wire with a flat cross-section (rectangular or elliptical) in a spiral shape. The coil 20 can also be formed from a circular wire with a circular cross-section. The manufacturing method of the coil 20 is not limited; it can be any type of coil formed by arranging conductive material in a spiral shape. That is, the coil 20 can also be formed by arranging conductive material in a spiral shape with the core portion being hollow. In this case, the core 10 can be inserted into the hollow portion of the coil after it has been formed. The inner surface of the winding portion 28 (the circumferential surface of the flat wire) and the core 10 (especially the circumferential surface of the leg portion 13, described later) can be separate or in contact. Alternatively, the coil 20 can also be formed by winding conductive material (coil wire) around the core 10. In this case, the coil wire in the coil 20 can be crimped or abutted against the core 10 (especially the leg portion 13). The coil wire can also be embedded in the core 10.

[0039] In this embodiment, the coil element 1 has two coils 20 (a first coil 21 and a second coil 22). In this embodiment, the helical direction (left-hand thread direction = counterclockwise) of the first coil 21 relative to its axial direction is opposite to the helical direction (right-hand thread direction = clockwise) of the second coil 22 relative to its axial direction. Alternatively, the helical direction of the first coil 21 relative to its axial direction and the helical direction of the second coil 22 relative to its axial direction can also be the same.

[0040] In the helical shape of coil 20, the direction in which the central axis of the helical shape extends is called the axial direction of coil 20, or simply the axial direction. In this embodiment, the axial direction of the first coil 21 and the axial direction of the second coil 22 are both aligned with the front-back direction.

[0041] like Figure 2 As shown, the coil 20 in this embodiment has a winding portion 28 and two lead-out portions 26 (first lead-out portion 26a and second lead-out portion 26b).

[0042] The winding portion 28 is the spiral-shaped part of the coil 20.

[0043] Lead-out portion 26 is the portion of coil 20 that extends from winding portion 28. Lead-out portion 26 is also one end of the conductive material (flat wire) forming coil 20. In this embodiment, both ends of the flat wire extend from winding portion 28, and coil 20 has two leads 26 (first lead-out portion 26a and second lead-out portion 26b).

[0044] In this embodiment, such as Figure 3 As shown, lead-out section 26 (first lead-out section 26a (refer to...) Figure 2 The first and second leads (26b) extend downward from both ends of the coil 20 (winding portion 28) along the axial direction. That is, the base end portion 26d (the portion near the base end and also the portion inside the base portion 30), which is part of the lead portion 26, extends in the vertical direction. Furthermore, the base end portion 26d only needs to extend in a direction having a vertical component larger than the horizontal component. That is, the base end portion 26d can extend parallel to the vertical direction or extend obliquely relative to the vertical direction.

[0045] Furthermore, the lead-out portion 26 is bent at the midway bend 26c. The top portion 26e, which is part of the lead-out portion 26 (the portion on the top side and also the portion on the outside of the base portion 30), extends in a generally horizontal direction (particularly in the front-back direction). More specifically, the lead-out portion 26 (top portion 26e) extends along the surface of the base portion 36 (the bottom surface of the end-positioned recess 36i, which will be described later) in the axial direction (front-back direction) of the coil 20.

[0046] As mentioned above, and in addition... Figure 4 As shown, the coil 20 (winding portion 28) is arranged in a spiral around at least a portion of the core 10. In this embodiment, the leg 13 of the core 10, which will be described later, is disposed in the center of the winding portion 28.

[0047] Core 10 is a component formed of magnetic material. In this embodiment, core 10 is a so-called PQ core, as described later. Core 10 can be a so-called I core, E core, U core, or other shaped core. Furthermore, in this embodiment, multiple cores 10 have the same shape, but alternatively, multiple cores 10 may have different shapes.

[0048] In this embodiment, multiple cores 10 are combined to form a closed magnetic circuit. Specifically, in this embodiment, the first core 11 and the second core 12 are arranged such that the end faces of their respective legs 13 (described later) are close to each other and the end faces of their respective sidewall portions 16 are close to each other.

[0049] Moreover, in this embodiment, such as Figure 4 As shown, the end face of the sidewall portion 16 of the first core 11 contacts the end face of the sidewall portion 16 of the second core 12. Additionally, the end face of the leg portion 13 of the first core 11 contacts the end face of the leg portion 13 of the second core 12. Alternatively, a gap may be formed between the end faces of the sidewall portion 16 of the first core 11 and the sidewall portion 16 of the second core 12, and also between the end faces of the leg portion 13 of the first core 11 and the leg portion 13 of the second core 12.

[0050] In this embodiment, such as Figure 2 As shown, the core 10 has a rectangular parallelepiped shape. The core 10 has a sidewall portion 16, an outer side arrangement portion 15, a hollow portion 14, and a leg portion 13. The core 10 covers at least a portion of the peripheral surface 24 of the coil 20. The sidewall portion 16 is the portion that covers (encloses) a portion of the peripheral surface 24 of the coil 20 (winding portion 28). In this embodiment, one sidewall portion 16 is arranged on each side of the core 10 in the left-right direction, for a total of two. The sidewall portion 16 is arranged around a portion of the peripheral surface of the winding portion 28 facing laterally (towards the left-right direction).

[0051] The outer configuration portion 15 is the portion that is axially disposed on the outside of the base portion 30. The main surface of the outer configuration portion 15 is opposite to one end face (outer end face) of the coil 20.

[0052] The hollow portion 14 is formed by dividing the space between the sidewall portion 16 and the outer placement portion 15. The hollow portion 14 can also be described as the internal space of the core 10. In other words, the core 10 has a recess that opens to the side and has the outer placement portion 15 as its bottom. The internal space of this recess can also be called the hollow portion 14. The coil 20 (particularly the winding portion 28) is housed in the hollow portion 14. The coil 20 may be entirely disposed in the hollow portion 14, or only a portion of the coil 20 may be disposed in the hollow portion 14 while another portion of the coil 20 is disposed outside the hollow portion 14 (e.g., outside the core 10). Furthermore, in this embodiment, a portion of the raised portion 38 is disposed in the hollow portion 14 of the core 10.

[0053] The leg 13 is a columnar portion that protrudes from the outer placement portion 15 toward the front-back direction (towards the inner side of the base portion 30). The leg 13 is disposed inside the winding portion 28 in the coil 20.

[0054] like Figure 4 As shown, the base portion 30 is a component that holds the coil 20 and the core 10. The base portion 30 is formed of an insulating material. In this embodiment, the base portion 30 is formed of resin.

[0055] The base portion 30 directly or indirectly holds the coil 20 and the core 10. Holding the coil 20 and the core 10 means directly or indirectly supporting the coil 20 or the core 10. In this embodiment, the base portion 30 directly holds the core 10. Specifically, the core 10 is directly mounted on the base portion 30 (particularly the base portion 36), and the core 10 is supported on the base portion 30. Alternatively, the core 10 may be indirectly held on the base portion 30 via other components. On the other hand, in this embodiment, the base portion 30 indirectly holds the coil 20. Specifically, the coil 20 is held on the base portion 30 via the terminal member 40 described later. In detail, the coil 20 is mounted on the terminal member 40 connected (linked) to the base portion 30, and connected (fixed) to the terminal member 40. Alternatively, the terminal member 40 may be mounted on the base portion 30 and directly held on the base portion 30.

[0056] The base portion 36 houses either the coil 20 or the core 10, or both the coil 20 and the core 10. Figure 4As shown, in this embodiment, the core 10 is mounted on the base portion 36. More specifically, the base portion 36 has two raised platforms 36j at its two ends in the left-right direction. The core 10 is mounted on the upper surface of the raised platform 36j. The coil 20 is disposed on the terminal member 40 (described later) and indirectly supported on the base portion 36 via the terminal member 40.

[0057] like Figure 2 As shown, in this embodiment, the base portion 36 is a generally flat plate-shaped portion extending in the horizontal direction. In other words, the base portion 36 is a component that includes the lower surface portion of the base portion 30.

[0058] like Figure 2 As shown, the erecting portion 38 and the base portion 36 are erected intersecting each other along the erecting direction (vertical direction). Here, the surface of the base portion 36 intersecting the extending direction of the erecting portion 38 can be an imaginary upper surface (upward-facing main surface) of the base portion 36, which is generally flat and extends horizontally. The erecting portion 38 can be erected orthogonally to the surface of the base portion 36, or it can be erected in an inclined direction. In this embodiment, the erecting direction of the erecting portion 38 is the vertical direction.

[0059] In this embodiment, the upright portion 38 is formed to protrude upward from the center of the base portion 36. Specifically, the upright portion 38 is disposed at the center of the base portion 36 in the front-rear direction. Alternatively, the upright portion 38 may also be disposed at the periphery of the base portion 36.

[0060] Furthermore, in this embodiment, the upright portion 38 is a flat plate portion having a main surface facing the front-back direction. Alternatively, the upright portion 38 may also have a cylindrical shape.

[0061] The base portion 30 is formed in such a way that the base portion 36 and the upright portion 38 are integrally formed, meaning that the base portion 36 and the upright portion 38 are formed from the same material without any joint. More specifically, in this embodiment, the base portion 36 and the upright portion 38 are formed simultaneously by flowing resin into a mold.

[0062] Terminal member 40 is an electrode member electrically connected to coil 20 (particularly the end of its lead 26). Terminal member 40 serves as an input electrode or output electrode of coil element 1. Terminal member 40 is formed of a conductive material such as metal. Examples of metals forming terminal member 40 include phosphor bronze.

[0063] In this embodiment, the terminal member 40 is formed by bending a flat plate made of a conductive material. Alternatively, the terminal member 40 may be formed by flowing molten metal into a molding die or the like to create a shape with a bent portion.

[0064] The terminal member 40 is disposed on the base portion 30 in such a way that it is hooked onto a part of the base portion 30 (a part of the base portion 36) as described later. Alternatively, the terminal member 40 may be embedded in the base portion 30 or fixed by means of a suitable adhesive or the like.

[0065] In this embodiment, the coil element 1 is mounted on the mounting substrate by grounding the lower surface of the terminal member 40 (the lower surface of the first hook portion 42 described later) to the mounting substrate.

[0066] like Figure 3 As shown, the inner end faces 21a and 22a of each of the plurality of coils 20 are respectively opposed to the first opposing surface 38a1 or the second opposing surface 38a2. The end face of the coil 20 refers to the imaginary surface of the axial end portion of the coil 20 facing the axial direction. The inner end faces 21a and 22a of the coil 20 are the end faces of the coil 20 facing the center side (the side of the upright portion 38) of the base portion 30.

[0067] On the other hand, the first opposing surface 38a1 and the second opposing surface 38a2 are part of the side surfaces (lateral surfaces) of the upright portion 38. In this embodiment, the first opposing surface 38a1 and the second opposing surface 38a2 are respectively the front-to-back facing surfaces (main surfaces) of the upright portion 38.

[0068] The opposing surface 38a can be a plane or a curved surface. The opposing surface 38a of the upright part 38 is opposite to the inner end surfaces 21a and 22a of the coil 20, which is not limited to two parallel planes. The opposing surface 38a of the upright part 38 and the inner end surfaces 21a and 22a of the coil 20 can overlap in a specified direction (e.g., the front-back direction).

[0069] In this embodiment, the first opposing surface 38a1 and the second opposing surface 38a2 are arranged along each other. That is, the first opposing surface 38a1 and the second opposing surface 38a2 are arranged substantially parallel to each other. In this case, the axial direction of the first coil 21 is substantially parallel to the axial direction of the second coil 22.

[0070] Furthermore, in this embodiment, the inner end face 21a of the first coil 21 and the inner end face 22a of the second coil 22 are positioned opposite each other across the raised portion 38. That is, the inner end face 21a of the first coil 21 is opposite to the inner end face 22a of the second coil 22 in the axial direction (front-back direction) of the first coil 21. In other words, when viewed in the front-back direction, at least a portion of the inner end face 21a of the first coil 21 overlaps with at least a portion of the inner end face 22a of the second coil 22. More specifically, in this embodiment, the axis of the first coil 21 and the axis of the second coil 22 are arranged on the same straight line.

[0071] In addition, in this embodiment, the opposing surface 38a of the upright portion 38 can abut against the inner end surfaces 21a and 22a of the coil, or they can be separated.

[0072] The shape of the upright part 38 is not limited to the shape described above, nor is the arrangement relationship between the upright part 38 and the two coils 20 limited to the above.

[0073] Instead of this embodiment, the first opposing surface 38a1 and the second opposing surface 38a2 can also be configured to intersect each other. For example, if the erected portion 38 has a prism shape, adjacent side surfaces can be either the first opposing surface 38a1 or the second opposing surface 38a2. In this case, the two coils 20 are arranged in a manner that intersects their respective axes (e.g., at 90 degrees). Alternatively, a portion of one side-facing main surface of the erected portion 38 can be designated as the first opposing surface 38a1, and the other portion as the second opposing surface 38a2. In this case, the two coils 20 are arranged laterally.

[0074] Alternatively, instead of having the two coils 20 arranged coaxially in this embodiment, the axes of the two coils 20 can be offset in the left-right or up-down direction.

[0075] like Figure 3 As shown, in this embodiment, a locking part 32 is provided in the base part 30. The locking part 32 is arranged such that it is sandwiched between the first core 11 (its sidewall part 16) and the second core 12 (its sidewall part 16) in the axial direction.

[0076] When the first coil 21 and the second coil 22 are arranged in the base portion 30 of this embodiment, the first coil 21 and the second coil 22 are inserted into the base portion 30 from one side of the axial direction to the other side (facing forward or facing backward). Since the locking portion 32 is arranged axially between the first coil 21 and the second coil 22, the first coil 21 and the second coil 22 will abut against the locking portion 32 when inserted into the base portion 30 along the axial direction, thus stopping the insertion. That is, during the process of inserting the coil 20 into the base portion 30, the first coil 21 and the second coil 22 can be positioned by the locking portion 32.

[0077] The locking part 32 is a portion or component capable of locking the axial movement of the first core 11 and the second core 12 respectively. That is, in the axial direction, the locking part 32 overlaps with at least a portion of the first core 11 and at least a portion of the second core 12 respectively.

[0078] In this embodiment, the locking part 32 is formed adjacent to the raised platform 36j of the base part 36 and the erecting part 38. More specifically, the base part 36 protrudes from the erecting part 38 in the left and right directions and from the raised platform 36j upwards.

[0079] Instead of this embodiment, the locking portion 32 may also be formed on other parts of the base portion 30. For example, the locking portion 32 may be formed on the upper part of the upright portion 38 in a manner that protrudes outward in the left-right direction from the upright portion 38. Alternatively, the locking portion 32 may be formed to protrude upward from the outer part in the left-right direction of the base portion 36.

[0080] In this embodiment, the core 10 (particularly the sidewall portion 16) has a recess (receiving recess 17) that can engage with the locking portion 32. The receiving recess 17 is formed by recessing the end of the core 10 (the end closest to the inner side in the front-rear direction of the base portion 30) outward in the front-rear direction of the base portion 30. Here, the outer side in the predetermined direction (particularly the front-rear direction) of the base portion 30 refers to the peripheral side of the base portion 30 in that predetermined direction, and the inner side in the predetermined direction of the base portion 30 refers to the center side of the base portion 30 in that predetermined direction. In this embodiment, a receiving recess 17 that opens inward to the base portion 30 is formed at the lowermost end of the core 10. Furthermore, the receiving recess 17 in this embodiment also opens downward.

[0081] At least a portion of the locking portion 32 is disposed inside the receiving recess 17. In this embodiment, a portion of the locking portion 32 is disposed in the receiving recess 17 of the first core 11, and another portion is disposed in the receiving recess 17 of the second core 12. As a result, the locking portion 32 is disposed entirely in the space formed by the receiving recess 17 of the first core 11 and the receiving recess 17 of the second core 12.

[0082] As described above, the core 10 (first core 11 and second core 12) has a receiving recess 17 that can fit into the locking part 32, thereby enabling the first core 11 to abut against the second core 12, and enabling the locking part 32 to be arranged between the first core 11 and the second core 12 in a manner that does not interfere with the first core 11 and the second core 12.

[0083] A portion of the surface of the core 10 is a contact surface 17a that divides the receiving recess 17. The contact surface 17a refers to the surface of the core 10 that divides the receiving recess 17 and is opposite to the locking part 32 in the axial (front-back direction). The contact surface 17a can abut against the locking part 32 or be separated from the locking part 32 in the front-back direction.

[0084] Here, the contact surface 17a is the surface facing the inside of the base portion 30 in the front-back direction, and it can be a curved surface or a flat surface. In addition, the surface of the locking portion 32 opposite to the contact surface 17a can be a curved surface or a flat surface.

[0085] like Figure 3As shown, in this embodiment, the contact surface 17a of the first core 11 is separated from the locking portion 32 in the front-rear direction, and the contact surface 17a of the second core 12 is also separated from the locking portion 32 in the front-rear direction. More specifically, the front-rear separation distance between the contact surface 17a of the first core 11 and the locking portion 32 is the same as the front-rear separation distance between the contact surface 17a of the second core 12 and the locking portion 32. That is, the first core 11 and the second core 12 are disposed at the center of the base portion 30.

[0086] Instead of this embodiment, the first core 11 and the second core 12 may not be arranged at equal distances from the center of the base portion 30, but rather staggered in the front-rear direction. For example, the front-rear separation distance between the contact surface 17a of the first core 11 and the locking portion 32 may be greater than the front-rear separation distance between the contact surface 17a of the second core 12 and the locking portion 32. Alternatively, the contact surface 17a of the first core 11 may be separated from the locking portion 32 in the front-rear direction, while the contact surface 17a of the second core 12 may contact (abut) the locking portion 32. By staggering the first core 11 and the second core 12 in the front-rear direction in this way, manufacturing errors between the coil elements 1 can be reduced in the arrangement positions of the first core 11 and the second core 12.

[0087] The locking part 32 can be located between the first core 11 and the second core 12, or it can be different from the present embodiment. For example, the locking part 32 can also be formed as a protrusion that is separate from the base part 36 and protrudes to the left and right from the standing part 38. Alternatively, the locking part 32 can also be formed as a protrusion that is separate from the standing part 38 and protrudes upward from the base part 36 (e.g., the raised platform part 36j).

[0088] In this embodiment, such as Figure 2 As shown, the base portion 30 also has a top plate portion 34. The top plate portion 34 is configured to sandwich the upright portion 38 together with the base portion 36 in the uprighting direction (vertical direction). That is, the top plate portion 34 is formed adjacent to the upper end of the upright portion. The top plate portion 34 and the upright portion 38 are formed integrally. That is, there is no seam between the top plate portion 34 and the upright portion 38, and the top plate portion 34 and the upright portion 38 are formed of the same material.

[0089] In addition, such as Figure 5 As shown, when viewed from the top plate portion 34 side (upper side) in the standing direction (vertical direction), the top plate portion 34 covers at least a portion of the core 10.

[0090] The top plate portion 34 provides good protection for the core 10. Furthermore, as described later, the upper surface of the top plate portion 34 is flat. Since the upper surface of the top plate portion 34, which forms the upper surface of the coil element 1, is flat, the coil element 1 can be moved by adsorbing this flat surface using an installation machine or similar device.

[0091] In this embodiment, the top plate portion 34 has a flat plate shape that extends laterally. That is, the top plate portion 34 is arranged substantially parallel to the base portion 36. In addition, the extending direction of the top plate portion 34 intersects the erecting direction of the erected portion.

[0092] When viewed from above, the top plate portion 34 covering at least a portion of the core 10 means that at least a portion of the top plate portion 34 overlaps with at least a portion of the core 10 in the upright direction (vertical direction). In this embodiment, the top plate portion 34 covers at least a portion of both the first core 11 and the second core 12.

[0093] In this embodiment, the upper surface (main surface) of the top plate portion 34 is a flat surface. Furthermore, the top plate portion 34 has a rectangular shape when viewed in the vertical direction. Additionally, the rectangular shape of the top plate portion 34 when viewed in the vertical direction has a smaller shape and size than the rectangular shape of the base portion 36 when viewed in the vertical direction.

[0094] like Figure 6 (a) and Figure 6 As shown in (b), a first groove 38a3 is formed on the opposing surface 38a of the upright portion 38. The first groove 38a3 extends in the upright direction (vertical direction). The first groove 38a3 is formed across the interior of the region (opposing region 38a4) in the opposing surface 38a that is opposite to the inner end faces 21a and 22a of the coil and the periphery of the opposing region 38a4.

[0095] By forming the first groove portion 38a3 described above, the coil element 1 can be assembled well. Specifically, when the core 10 is placed on the base portion 30 where the coil 20 is already placed, the air pressure in the hollow portion 14 of the core 10 sometimes becomes high because the coil 20 is inserted into the internal space (hollow portion 14) of the core 10. By providing the first groove portion 38a3 on the upright portion 38, even when the coil 20 is inserted into the hollow portion 14 of the core 10, the air in the hollow portion 14 can be discharged to the outside of the hollow portion 14 through the first groove portion 38a3. As a result, poor assembly of the coil element 1 is effectively suppressed.

[0096] Furthermore, when using coil element 1, since coil 20 carries heat, hot air sometimes gets trapped inside the core 10 (hollow portion 14). By providing the first groove portion 38a3, this hot air can be discharged to the outside of the hollow portion 14 through the first groove portion 38a3.

[0097] The first groove 38a3 is a recess formed by the indentation of the opposing surface 38a of the upright portion 38 in the axial direction toward the upright portion 38.

[0098] In this embodiment, a hole (core insertion hole 38b) is formed in the center of the upright portion 38. The leg 13 of the core 10 is inserted into this core insertion hole 38b. In this embodiment, the first groove portion 38a3 is divided into an upper groove portion 38c and a lower groove portion 38d in the vertical direction, separated by the core insertion hole 38b. Figure 6 As shown in (b), the upper groove portion 38c extends from the core insertion hole 38b to the junction of the raised portion 38 and the top plate portion 34 (the upper end of the raised portion 38). Figure 6 As shown in (a), the lower groove portion 38d extends from the core insertion hole 38b to the junction of the upright portion 38 and the base portion 36 (the lower end of the upright portion 38). In this embodiment, the upper groove portion 38c and the lower groove portion 38d are arranged on the same straight line, but are not limited thereto. The lower groove portion 38d may also be arranged in a way that avoids the center line of the upper groove portion 38c.

[0099] The extension direction of the first groove portion 38a3 only needs to have an upright direction component that is larger than the lateral component. That is, the first groove portion 38a3 can extend parallel to the upright direction or extend in a direction that is slightly inclined relative to the upright direction. In addition, in this embodiment, the first groove portion 38a3 extends from the lower end to the upper end of the upright portion 38 through the core insertion hole 38b, but it is not limited to this. For example, the upright portion 38 may only have an upper groove portion 38c or only have a lower groove portion 38d.

[0100] The opposing region 38a4 is the area in the opposing surface 38a that overlaps axially with the inner end faces 21a and 22a of the coil 20. The first groove portion 38a3 may terminate at the periphery of the opposing region 38a4, or it may extend to the outside of the opposing region 38a4 and terminate thereon.

[0101] In the first recessed portion 38a3 of this embodiment, the dimension in the width direction (left-right direction) is smaller than the dimension in the vertical direction, and the first recessed portion 38a3 has a shape that is longer in the vertical direction. Alternatively, in this embodiment, the dimension in the width direction of the first recessed portion 38a3 may also be larger than the dimension in the vertical direction.

[0102] like Figure 6 As shown in (b), in this embodiment, a second groove 34c is formed on the lower surface 34b (the inner surface facing the inside of the base portion 30 and also the inner surface facing the circumference of the coil 20) of the top plate portion 34 on the side (lower side) of the base portion 36 in the standing direction (vertical direction). The second groove 34c extends along the axial direction of the coil 20. One end of the second groove 34c (one end in the axial direction; the inner end 34d in the axial direction) communicates with one end (upper end 38a5) of the first groove portion 38a3.

[0103] By providing a second recess 34c in the top plate portion 34, even when the top plate portion 34 is close to the peripheral surface 24 of the coil 20, the rise in air pressure in the internal space (hollow portion 14) of the core 10 during coil element 1 assembly can be suppressed. In addition, the hot air trapped in the internal space (hollow portion 14) of the core 10 during coil element 1 use can be released through the second recess 34c.

[0104] Here, the lower surface 34b of the top plate portion 34 refers to the downward-facing surface of the top plate portion 34. In this embodiment, the lower surface 34b also includes the surface of the top plate protrusion 34a, which will be described later.

[0105] The second groove 34c is a recess formed by indenting upwards from the lower surface 34b of the top plate portion 34. In this embodiment, the second groove 34c is formed in the top plate protrusion 34a of the top plate portion 34, which will be described later. As a result, a space can be provided between the very close top plate protrusion 34a and the peripheral surface 24 of the coil 20.

[0106] When viewed from above, the second groove 34c can extend to the outer end face (outer end face 21b, 22b, reference) of the end face of the coil 20 in the axial direction. Figure 3 It can be terminated at a position on the outer side of the axial direction, or at a position on the inner side of the axial direction that is closer to the outer end face 21b, 22b.

[0107] In this embodiment, such as Figure 5 As shown, in this embodiment, when viewed from above, the outer end faces 21b and 22b of the coil 20 are positioned axially (front-back direction) outward from the periphery of the top plate portion 34. In this embodiment, the second groove portion 34c (refer to...) Figure 6 (b) It terminates at a position axially inner than the outer end faces 21b and 22b. Specifically, as Figure 6 As shown in (b), the second groove portion 34c preferably extends to the outer end (outer end portion 34c1) of the top plate portion 34 (top plate protrusion 34a) in the axial direction. Instead of this embodiment, when the outer end faces 21b and 22b of the coil 20 are positioned axially inward than the periphery of the top plate portion 34 when viewed from above, the second groove portion 34c may extend to the outer end of the top plate portion 34 in the axial direction, or it may terminate midway in the axial direction without extending to that end.

[0108] Here, "the end of one slot communicating with the end of another slot" means that the hollow space of one slot (especially its end) communicates with the hollow space of another slot (especially its end). Furthermore, "the end of one slot communicating with the end of another slot" is not limited to the ends being directly adjacent to each other, but also includes an open space between the ends of one slot and the end of another slot, through which the ends of one slot communicate indirectly. An open space is a hollow space that allows the ends of one slot to communicate spatially with the ends of another slot. In particular, the open space is preferably a space along the extension line of one slot in its extension direction or a space along the extension line of the other slot in its extension direction, and is an open space without a base portion.

[0109] In this embodiment, the inner end portion 34d of the second groove portion 34c is directly connected to the upper end portion 38a5 of the first groove portion 38a3. That is, in the top plate portion 34, the second groove portion 34c extends to the upper end portion of the upright portion 38, and the inner end portion 34d of the second groove portion 34c is adjacent to the upper end portion 38a5 of the first groove portion 38a3.

[0110] Instead, the inner end portion 34d of the second groove portion 34c can also communicate with the upper end portion 38a5 of the first groove portion 38a3 (upper groove portion 38c) via an open space. For example, unlike the shape of the top plate protrusion 34a in this embodiment, sometimes the top plate protrusion 34a is only provided on the outer side of the top plate portion 34 in the axial direction, and not on the inner side of the top plate portion 34 in the axial direction. In this case, the inner side of the top plate portion 34 without the top plate protrusion 34a is recessed upwards than the top plate protrusion 34a to form an open space. When the inner end portion 34d of the second groove portion 34c is adjacent to this open space and the upper end portion 38a5 of the first groove portion 38a3 is also adjacent to this open space, it can be said that the inner end portion 34d of the second groove portion 34c communicates with the upper end portion 38a5 of the first groove portion 38a3.

[0111] like Figure 6 As shown in (a), in this embodiment, a third groove 36e is formed on the upper surface of the top plate portion 34 side (upper side) of the base portion 36 in the standing direction (vertical direction). The third groove 36e extends along the axial direction (front-back direction) of the coil 20. One end of the third groove 36e (which is the inner end 36f on the inner side of the base portion 30 in the axial direction, and is also the inner end 36f on the side of the standing portion 38) communicates with one end (lower end 38a6) of the first groove portion 38a3.

[0112] As described above, the hollow portion 14 communicates with the outside via the third recess 36e. Therefore, during the manufacturing process of the coil element 1, when the coil 20 is inserted into the internal space (hollow portion 14) of the core 10, an unexpected increase in air pressure in the hollow portion 14 can be prevented. Furthermore, if the temperature of the hollow portion 14 of the core 10 rises when using the coil element 1, supplying air to the hollow portion 14 via the third recess 36e can lower the temperature of the hollow portion 14.

[0113] The upper surface of the base portion 36 facing upwards is the surface of the base portion 36 facing upwards. In the base portion 36 of this embodiment, which has a base protrusion 36g, this upper surface also includes the surface of the base protrusion 36g (particularly the protruding end face 36h). In this embodiment, a third groove portion 36e is formed on the base protrusion 36g. As a result, a space for air to pass through can be provided at the location where the peripheral surface 24 of the coil 20 is most likely to be close to the base portion 36, thus separating the coil 20 from the base portion 36.

[0114] In this embodiment, the inner end portion 36f of the third groove portion 36e is directly connected to the lower end portion 38a6 of the first groove portion 38a3 (lower groove portion 38d). That is, in the base portion 36, the third groove portion 36e extends to the lower end portion of the upright portion 38, and the inner end portion 36f of the third groove portion 36e is adjacent to the lower end portion 38a6 of the first groove portion 38a3.

[0115] Instead of this embodiment, the inner end portion 36f of the third groove portion 36e may also be indirectly connected to the lower end portion 38a6 of the first groove portion 38a3 (lower groove portion 38d). For example, the inner end portion 36f of the third groove portion 36e may also be connected to the lower end portion 38a6 of the first groove portion 38a3 (lower groove portion 38d) via an open space.

[0116] In this embodiment, such as Figure 4 As shown, when viewed from the outside in the axial direction, the coil 20 is exposed from the core 10. This facilitates cooling of the coil 20, which generates heat during use. Specifically, the upper end of the winding portion 28 of the coil 20 is exposed from the upper end of the core 10. Additionally, the lower end of the winding portion 28 of the coil 20 is exposed from the lower end of the core 10. By exposing both the upper and lower ends of the winding portion 28, external air flows into the hollow portion 14 from below the core 10 and exits from above the core 10 to the outside of the hollow portion 14. This facilitates cooling of the winding portion 28 disposed in the hollow portion 14. Alternatively, when viewed from the outside in the axial direction, only the upper end, only the lower end, or other portions of the winding portion 28 may be exposed from the core 10.

[0117] In this embodiment, such as Figure 5As shown, when viewed from the top plate portion 34 side (upper side) in the standing direction (vertical direction), the hollow portion 14 is exposed from the top plate portion 34. That is, in this embodiment, the hollow portion 14 can be seen from above.

[0118] By opening the top of the hollow section 14, hot air can be discharged from the internal space (hollow section 14) of the core 10.

[0119] In this embodiment, a portion of the hollow portion 14 does not overlap with the top plate portion 34 in the vertical direction. Furthermore, no other components of the coil element 1 are disposed above this portion of the hollow portion 14. Therefore, when viewed from above, the hollow portion 14 is exposed above the top plate portion 34.

[0120] like Figure 2 As shown, in the core 10 of this embodiment, the sidewall portion 16 is not disposed above the hollow portion 14, and the hollow portion 14 is open at the top. Therefore, in this embodiment, a portion of the hollow portion 14 that does not overlap with the top plate portion 34 in the vertical direction can be seen from above.

[0121] In this embodiment, such as Figure 5 As shown, a portion of the hollow section 14 is positioned axially outward from the top plate 34. In other words, when viewed from above, the axially outer portion of the hollow section 14 is exposed from the top plate 34. That is, the outer portion of the hollow section 14 communicates with the space above the coil element 1. As a result, air flowing into the hollow section 14 from the third groove 36e via the first groove 38a3 moves axially from the inside to the outside and is released from the opening 14a on the outside of the hollow section 14 (the opening of the hollow section 14 divided by the core 10 and the top plate 34) to the outside of the coil element 1. That is, the air flowing into the hollow section 14 circulates sufficiently within the hollow section 14 before being released to the outside. As a result, the interior of the hollow section 14 is sufficiently cooled.

[0122] In this embodiment, such as Figure 4 As shown, protrusions (top plate protrusion 34a and base protrusion 36g) are formed in the top plate portion 34 and the base portion 36, respectively. The protruding end faces 34a1 and 36h of the protrusions extend along a portion of the circumferential surface 24 of the coil 20 in the axial direction (front-back direction) of the coil 20.

[0123] During the manufacturing process of coil element 1, the protruding end faces 34a1 and 36h serve as guides, making it easy for coil 20 to be inserted into the hollow portion 14 of core 10.

[0124] In this embodiment, the top plate protrusion 34a is a portion that protrudes downward from the flat plate portion of the top plate portion 34 toward the side where the coil 20 is disposed. The top plate protrusion 34a is formed in the center portion in the left-right direction of the top plate portion 34. That is, the top plate protrusion 34a protrudes downward from both ends of the top plate portion 34 in the left-right direction.

[0125] In this embodiment, the base protrusion 36g is a portion that protrudes upward from the flat plate portion of the base portion 36 toward the side where the coil 20 is disposed. The base protrusion 36g is formed in the center portion in the left-right direction of the base portion 36. That is, the base protrusion 36g protrudes upward beyond the bottom surface of the end-positioning recess 36i described later. In addition, the base protrusion 36g is disposed between two end-positioning recesses 36i in a pair.

[0126] The protruding end faces 34a1 and 36h are the surfaces of the protrusions facing the protruding direction of the protrusion. That is, the protruding end face 34a1 is the lower surface of the top plate protrusion 34a, and the protruding end face 36h is the upper surface of the base protrusion 36g.

[0127] The term "protruding end faces 34a1, 36h along a portion of the circumferential surface of the coil 20" means that the approximate concave-convex shape (position and depth of the concave-convex shape) of the protruding end faces 34a1, 36h corresponds to the arcuate shape of the circumferential surface 24 of the coil 20. Since the protruding end faces 34a1 and 36h of the protrusion are along the arcuate shape of the circumferential surface 24 of the coil 20, they are recessed in the direction opposite to the protruding direction of the protrusion. The protruding end face 34a1 of the top plate protrusion 34a and the protruding end face 36h of the base protrusion 36g are recessed upwards or downwards, respectively. The grooves on the protruding end faces 34a1, 36h extend axially (front-back direction). Furthermore, the bottom surface of this groove (also referred to as the top surface in the protruding end face 34a1) is positioned above the end of the protruding end face 34a1 in the left-right direction. This groove prevents the coil 20 from easily shifting in the left-right direction when it is inserted into the base portion 30.

[0128] The protruding end faces 34a1 and 36h can be curved surfaces or surfaces formed by adjacent flat surfaces. In this embodiment, the protruding end face 34a1 of the top plate protrusion 34a is a curved surface. The protruding end face 36h of the base protrusion 36g includes a bottom surface that divides the third recess 36e and a pair of wall surfaces, which are flat surfaces.

[0129] In this embodiment, such as Figure 4 As shown, a top plate arrangement recess 18 is formed on the upper side (top side) of the top plate portion 34 in the upright direction (vertical direction) of the core 10. The top plate arrangement recess 18 is a recessed portion facing the lower side (base portion 36) in the upright direction (vertical direction). Figure 5As shown, the top plate is provided with a recess 18 that extends along the axial direction (front-back direction) of the coil 20.

[0130] At least a portion of the top plate portion 34 is disposed within the top plate configuration recess 18.

[0131] According to the above structure, during the manufacturing process of coil element 1, the core 10 is axially guided to be inserted into base portion 30 in such a way that the top plate portion 34 fits into the top plate placement recess 18.

[0132] like Figure 5 As shown, in this embodiment, the top plate arrangement recess 18 extends between the two ends of the core in the front-rear direction. Furthermore, the top plate portion 34 is disposed across both the top plate arrangement recess 18 in the first core 11 and the top plate arrangement recess 18 in the second core 12. Alternatively, the top plate portion 34 may be disposed only in the top plate arrangement recess 18 provided in either core 10.

[0133] like Figure 4 As shown, in this embodiment, only the lower part of the top plate portion 34 is disposed in the top plate placement recess 18, and the upper part of the top plate portion 34 is disposed outside the top plate placement recess 18 (the space above the top plate placement recess 18). Thus, the top plate portion 34 can protect the core 10.

[0134] Alternatively, a portion of the upper surface of the top plate portion 34 may be disposed in the top plate recess 18 instead of this embodiment.

[0135] In this embodiment, such as Figure 4 As shown, the terminal member 40 has two hook portions (first hook portion 42 and second hook portion 44) with hook shapes. The protruding direction of the hook shape of the first hook portion 42 is opposite to the protruding direction of the hook shape of the second hook portion 44.

[0136] A portion of the base portion 36 is configured to be clamped by the first hook portion 42 in the upright direction (vertical direction). The end portion of the coil 20 is configured to be clamped by the second hook portion 44 in the upright direction (vertical direction).

[0137] In this embodiment, the two hooks fix the coil 20 and the base 30, and assist in preventing the terminal component 40 from falling off.

[0138] Here, a hook shape refers to a shape having a protruding shape (letter U-shape) formed by bending the tip back towards the base. In other words, a part having a hook shape can hook onto other components in such a way that the tip side and the base side of that part clamp onto other components.

[0139] The protruding direction of the hook shape refers to the direction towards the tip of the curved protruding shape at a portion having the hook shape. Alternatively, the hook shape can be described as opening in the direction opposite to the protruding direction. In this embodiment, the protruding direction of the first hook portion 42 is outward in the left-right direction, and the protruding direction of the second hook portion 44 is inward in the left-right direction.

[0140] In this embodiment, when viewed in the front-to-back direction, the terminal member 40 has an overall S-shape (including a reversed S-shape). That is, the openings of the two hook shapes are offset in the vertical direction. Alternatively, the openings of the two hook shapes may be arranged at the same height in the vertical direction and face each other. Specifically, the overall shape of the terminal member 40 when viewed in the front-to-back direction may also be a downward or upward C-shape.

[0141] When other components besides terminal member 40 (a portion of base portion 36 or the end portion of coil 20 (the end of lead-out portion 26)) are clamped by hooks in the vertical direction, it means that the component is disposed in the vertical direction between the tip portion and the base portion of terminal member 40 that form a hook shape. Terminal member 40 can contact these other components, and terminal member 40 (especially the tip portion or base portion of terminal member 40 that form a hook shape) can also be separated from these other components.

[0142] In this embodiment, the terminal member 40 is disposed on the base portion 36. Specifically, the first hook portion 42 of the terminal member 40 is hooked onto a portion of the base portion 36 (including a portion of the bottom surface of the base portion 36). Furthermore, the protruding end of the second hook portion 44 is received in a terminal receiving recess 36k formed in the base protrusion 36g (see reference). Figure 6 (a) The protruding end of the hook is the top portion of the hook in the protruding direction of the hook. Terminal receiving recess 36k (refer to) Figure 6 (a) is a recessed portion formed on the side of the base protrusion 36g, which is recessed inward in the left-right direction. The protruding end of the hook is sandwiched between a pair of wall portions that divide the terminal receiving recess 36k in the front-back direction. The terminal receiving recess 36k can suppress the offset of the terminal member 40 in the front-back direction.

[0143] like Figure 6As shown in (a), in this embodiment, a notch 36a is formed in a portion of the base portion 36 that is held by the first hook portion 42. This notch 36a is formed by the base portion 36 being recessed inward in the rear-to-rear direction. By forming this notch 36a, the protrusion 43, which will be described later, can be accommodated in the notch 36a. Alternatively, by forming the notch 36a, the bonding state of the lead-out portion 26 and the terminal member 40, which is joined by solder 70, can be confirmed visually (including by image recognition based on the device).

[0144] In addition, such as Figure 6 As shown in (a), the terminal member 40 of this embodiment has a protrusion 43. The protrusion 43 is a flat plate portion that protrudes axially outward from the hook-shaped base end side of the first hook portion 42. In this embodiment, the protrusion 43 extends slightly obliquely with respect to the lateral direction. Specifically, the protrusion 43 is obliquely downward toward the axially outward direction. Therefore, the protrusion 43 is disposed in the notch portion 36a. Specifically, the protrusion 43 is clamped by the wall portion forming the notch portion 36a in the left-right direction. As a result, the offset of the terminal member 40 relative to the base portion 36 in the left-right direction can be more effectively suppressed. As a result, the terminal member 40 is well fixed to the base portion 36.

[0145] The protrusion dimension (the dimension in the protrusion direction, the dimension along the surface of the protrusion 43) of the protrusion 43 may be the same as, larger than, or smaller than the depth dimension (the dimension in the axial direction) of the notch 36a.

[0146] In addition, Figure 6 (a) and Figure 6 In (b), for convenience, the protrusion 43 is shown with a larger tilt angle. In the actual coil element 1, the protrusion 43 may also extend in a direction with a larger lateral component.

[0147] Instead of this embodiment, the protrusion 43 may also extend axially without tilting. In this case, the protrusion 43 may not be housed in the notch 36a.

[0148] In this embodiment, such as Figure 4 As shown, a pair of end-position recesses 36i (first end-position recess 36i1 and second end-position recess 36i2) are formed on the surface of the base portion 36. The end-position recesses 36i are grooves for the lead-out portions 26 to be respectively positioned.

[0149] like Figure 7As shown, the axial dimensions (dimensions L1 and L2) of each of the pair of end-positioned recesses 36i are greater than the portions of the leads (first lead 26a, second lead 26b) at both ends of the coil 20 that are positioned in the end-positioned recesses 36i (top portion 26e (see reference)). Figure 3 Either of the axial (front-to-back) dimensions (dimensions L3 and L4) is larger.

[0150] As described above, by giving the end-positioning recess 36i a sufficient length, the coil 20 can be positioned on the base portion 36 regardless of the length of the lead-out portion 26. Specifically, depending on the helical direction of the coil 20, there are cases where the first lead-out portion 26a is longer in the axial direction than the second lead-out portion 26b, and cases where the first lead-out portion 26a is shorter in the axial direction than the second lead-out portion 26b. By giving the pair of end-positioning recesses 36i the aforementioned dimensional relationship, each lead-out portion 26 can be positioned on the end-positioning recess 36i regardless of the helical direction of the coil 20.

[0151] The end-positioning recess 36i is a recess formed by the downward indentation of the upper surface of the base portion 36, and is the portion for which the lead-out portion 26 is disposed. In this embodiment, the bottom of the end-positioning recess 36i is disposed below the raised platform portion 36j and the base protrusion 36g. Furthermore, a portion of the end-positioning recess 36i is disposed between the raised platform portion 36j and the base protrusion 36g. The end-positioning recess 36i includes not only the space between the raised platform portion 36j and the base protrusion 36g, but also a space on the outer side in the front-rear direction beyond that space. In other words, in this embodiment, the end-positioning recess 36i also includes a space for the terminal member 40 to be disposed.

[0152] Furthermore, in this embodiment, the end-position recess 36i opens outward in the axial direction. Therefore, as will be described later, the coil can be inserted into the base portion 30 along the axial direction while the lead-out portion 26 is positioned in the end-position recess 36i.

[0153] In this embodiment, the bottom outer side of the end-positioning recess 36i (the area where the terminal member 40 is positioned) is configured to be recessed downwards compared to the bottom inner side of the end-positioning recess 36i (the area where the terminal member 40 is not positioned). Therefore, when the terminal member 40 is positioned at this bottom outer side, the height difference between the surface of the terminal member 40 and the bottom inner side of the end-positioning recess 36i is smaller, allowing for a more stable positioning of the coil 20 within the end-positioning recess 36i.

[0154] In this embodiment, one end (inner end) of the first end recess 36i1 and the second end recess 36i2 extends to the base end of the erected portion 38 (the junction between the erected portion 38 and the base portion 36). In addition, the other end (outer end) of the first end recess 36i1 and the second end recess 36i2 extends to the outer end of the base portion 36 in the front-rear direction.

[0155] The first end-position recess 36i1 and the second end-position recess 36i2 are disposed separately in the left-right direction and are disposed along each other. That is, the extending direction of the first end-position recess 36i1 is substantially parallel to the extending direction of the second end-position recess 36i2. In this embodiment, the extending direction of the first end-position recess 36i1 and the extending direction of the second end-position recess 36i2 are axial (front-back direction, depth direction of the paper).

[0156] In this embodiment, the axial dimensions (dimensions L1 and L2) of the end-position recess 36i are the lengths from the base end of the upright portion 38 (the junction between the upright portion 38 and the base portion 36) to the outer end of the base portion 36. In this embodiment, the axial dimension (dimension L1) of the first end-position recess 36i1 is the same as the axial dimension (dimension L2) of the second end-position recess 36i2. Alternatively, the axial dimension (dimension L1) of the first end-position recess 36i1 may be greater than or less than the axial dimension (dimension L2) of the second end-position recess 36i2.

[0157] A portion of the lead-out portion 26 disposed at the end-positioned recess 36i is a portion of the lead-out portion 26 disposed along the bottom of the end-positioned recess 36i. That is, in this embodiment, the end-positioned recess 36i is the top portion 26e (see reference 26e). Figure 3 ).

[0158] like Figure 4 As shown, in this embodiment, the core 10 is fixed to the top plate portion 34 by an adhesive 50. More specifically, the upper surface of the core 10 (the bottom surface of the top plate mounting recess 18) is separated from the lower surface 34b of the top plate portion 34 in the vertical direction. The adhesive 50 is disposed between the upper surface of the core 10 and the lower surface 34b of the top plate portion 34 in the vertical direction, and is fixed to the upper surface of the core 10 and the lower surface of the top plate portion 34, respectively.

[0159] In this way, the core 10 is bonded to the top plate portion 34 by the adhesive 50, thereby securing the core 10 securely to the base portion 30. Furthermore, by distributing the adhesive 50 between the core 10 and the top plate portion 34, wear of the core 10 or the top plate portion 34 due to friction during the transfer of the coil element 1 (including electronic devices and products on which the coil element 1 is mounted) can be suppressed.

[0160] Examples of adhesives include epoxy resins.

[0161] In this embodiment, adhesive 50 is applied to each of the four corners of the top plate portion 34.

[0162] like Figure 1 As shown, the coil element 1 in this embodiment also has a strip portion 60.

[0163] The belt portion 60 is configured to wrap around the first core 11 and the second core 12. The belt portion 60 keeps the first core 11 and the second core 12 in an adjacent or contacting state.

[0164] like Figure 4 As shown, in this embodiment, the lead-out portion 26 is brazed to the terminal member 40 using a brazing material (solder 70). Thus, the lead-out portion 26 is electrically connected to the terminal member 40.

[0165] In this embodiment, solder 70 covers the top of the second hook portion 44 of the terminal member 40. Furthermore, in this embodiment, the top portion of the second hook portion 44 is separated from the lead-out portion 26 in the vertical direction, and a portion of the solder 70 is disposed between the top portion of the second hook portion 44 and the lead-out portion 26.

[0166] The connection method between the terminal member 40 and the lead-out portion 26 is not limited to the method described above. The terminal member 40 and the lead-out portion 26 may also be electrically connected by simply abutting against each other.

[0167] (Manufacturing method of coil components)

[0168] Hereinafter, a method for manufacturing the coil element 1 of this embodiment (hereinafter, sometimes referred to as this method) will be described.

[0169] Figure 7 This is a perspective view of coil element 1 used to illustrate the manufacturing process of this method.

[0170] First, a brief overview of this method will be provided.

[0171] This method includes a coil mounting process. Furthermore, this embodiment of the method also includes a terminal component arrangement process, a coil arrangement process, and a clamping process. Each process will be described in detail later.

[0172] Next, this method will be explained in detail.

[0173] The terminal member 40 is formed by bending a flat plate portion extending along the length direction. The terminal member 40 has a hook portion (first hook portion 42) with a hook shape at one end. That is, the flat plate portion is bent in such a way that one end in the length direction has a hook shape to form the first hook portion 42.

[0174] In addition, such as Figure 7 As shown, in this embodiment, the first hook portion 42 of the terminal member 40 disposed before the base portion 30 is formed such that the hook-shaped base end is disposed substantially parallel to the top end, but the hook-shaped base end of the second hook portion 44 is disposed at an angle relative to the top end. That is, the second hook portion 44 is a hook shape with an opening larger than that of the first hook portion 42.

[0175] The width dimension (left-right direction) of the top portion of the hook shape of the second hook 44 is preferably smaller than the width dimension (depth dimension, L6) of the terminal receiving recess 36k. This allows for suppression of interference between the second hook 44 and the coil 20 during the coil mounting process described later.

[0176] In the terminal component configuration process, the first hook portion 42 is configured such that the base portion 36 is clamped between the first hook portion 42 in the upright direction (vertical direction). Specifically, a portion of the base portion 36 is disposed between the top end and the base end of the hook-shaped first hook portion 42.

[0177] In this embodiment, with the opening of the first hook portion 42 of the terminal member 40 facing the base portion 36, the terminal member 40 is inserted into the base portion 30 in a left-right direction. At this time, the second hook portion 44 (especially the hook-shaped tip of the second hook portion 44) is housed in the terminal housing recess 36k.

[0178] The terminal component configuration process described above is preferably performed before the coil installation process, but is not limited thereto. The terminal component configuration process can also be performed after the coil installation process.

[0179] Furthermore, in the terminal component assembly process, it is preferable that the protrusion 43 extends axially. That is, it is preferable that the protrusion 43 does not extend axially like... Figure 6 (a) that tilt. This is to avoid interference between the protrusion 43 and the base portion 36 when the terminal member 40 is configured. Alternatively, after the terminal member 40 is configured, the protrusion 43 may be pressed downward in such a way that the protrusion 43 extends at an angle relative to the axial direction.

[0180] In the coil mounting process, the coil 20 is mounted on the base portion 30. This mounting is performed by moving the coil 20 along its axial direction as follows: Specifically, the coil 20 is moved with one end face (inner end face 21a, 22a) facing the opposing surface 38a, which serves as the side surface of the upright portion 38. The coil 20 moves toward the opposing surface 38a. That is, the coil 20 is inserted into the base portion 30 along its axial direction toward the upright portion 38.

[0181] By mounting the coil 20 onto the base portion 30 as described above, the coil 20 can be positioned using the upright portion 38. This is because, even if the coil 20 is accidentally inserted too deeply into the base portion 30, the inner end faces 21a and 22a of the coil 20 will abut against the opposing surface 38a of the upright portion 38, thus stopping the insertion of the coil 20.

[0182] Furthermore, inserting the coil 20 into the base portion 30 here means moving the coil 20 in a predetermined direction to arrange the coil 20 within a predetermined space of the base portion 30. The area surrounding this predetermined space does not necessarily need to be covered by the base portion 30. That is, in this embodiment, the coil 20 is inserted into the space defined by the upright portion 38, the top plate portion 34, and the base portion 36, but it is not limited to this. For example, even if the base portion 30 does not have a top plate portion 34, arranging the coil 20 within the space defined by the base portion 36 and the upright portion 38 of the base portion 30 is also described as the coil 20 being inserted into the base portion 30.

[0183] Similarly, core 10 (refer to...) Figure 1 Inserting the base portion 30 means moving the core 10 in a predetermined direction and placing the core 10 in a predetermined space within the base portion 30.

[0184] During the coil installation process, the winding portion 28 is guided by the protruding end face 34a1 of the top plate protrusion 34a and the protruding end face 36h of the base protrusion 36g and inserted into the base portion 30. After insertion, the winding portion 28 is positioned between the protruding end face 34a1 of the top plate protrusion 34a and the protruding end face 36h of the base protrusion 36g.

[0185] Furthermore, during the coil mounting process, the two leads 26a and 26b are axially inserted into the two end-positioning recesses 36i1 and 36i2, respectively. Specifically, the coil 20 is mounted such that its end portion is positioned on a portion of the terminal member 40. In this embodiment, the portion of the terminal member 40 for the end portion of the coil 20 is the hook-shaped base end of the second hook portion 44.

[0186] In the clamping process, the end portion of the coil 20 (particularly the tip portion 26e of the lead-out portion 26) is clamped by the hook-shaped tip portion and the hook-shaped base portion of the second hook portion 44. Specifically, the hook-shaped tip portion of the second hook portion 44 is pressed downwards, bringing it closer to the base portion. Here, clamping means pressing the hook-shaped tip portion of the second hook portion 44 into contact with the end portion of the coil 20. However, after the clamping process, the hook-shaped tip portion of the second hook portion 44 may be pressed into contact with the end portion of the coil 20, may simply abut against it, or may be separated from the end portion. This clamping process is performed after the coil mounting process.

[0187] In addition, the second hook portion 44 described above is formed through this pressing process.

[0188] Through the above-described clamping process, the coil 20 can be fixed to the base portion 36 using the terminal component 40.

[0189] Furthermore, the present invention is not limited to the above-described embodiments, but also includes various modifications and improvements that can achieve the objectives of the present invention.

[0190] The following variations can be appropriately combined.

[0191] Instead of this embodiment, the base portion 30 may not have a top plate portion 34. For example, the base portion 30 may terminate at the upper end of the erected portion 38.

[0192] The above-described embodiments include the following technical concepts.

[0193] (1) A coil element, wherein,

[0194] The coil element has:

[0195] Two or more cores;

[0196] Two or more coils, each arranged in a helical configuration around at least a portion of the plurality of cores; and

[0197] The base portion, which holds the coil and the core, is equipped with terminal components.

[0198] The base portion includes:

[0199] A base portion, which provides for the configuration of the terminal components and for mounting the coil or the core; and

[0200] The upright portion is configured to stand upright in such a way that it intersects the surface of the base portion in the upright direction.

[0201] The base portion and the upright portion are integrally formed.

[0202] One end face of each of the plurality of coils faces the opposite side of the side that forms the upright portion.

[0203] (2) The coil element according to (1), wherein,

[0204] One end face of the first coil faces the other end face of the second coil in the axial direction.

[0205] The base portion is provided with a locking portion, which is configured to be clamped between the first core and the second core in the axial direction.

[0206] (2-1) In coil elements,

[0207] The core has a receiving recess, which is formed by recessing one end of the core on the axially inner side of the base portion toward the axially outer side of the base portion.

[0208] The locking part is located in the storage recess.

[0209] (2-2) In coil elements,

[0210] The core's surface includes a contact surface that divides a receiving recess and is axially opposed to the surface of the locking portion.

[0211] The contact surfaces of the first core and the second core are axially separated from the locking portion, respectively.

[0212] (2-3) In coil elements,

[0213] The axial separation distance between the contact surface of the first core and the locking part is greater than the axial separation distance between the contact surface of the second core and the locking part.

[0214] (2-4) In coil elements,

[0215] The core's surface includes a contact surface that divides a receiving recess and is axially opposed to the surface of the locking portion.

[0216] The contact surface of the first core is axially separated from the locking part.

[0217] The contact surface of the second core contacts the locking part.

[0218] (3) The coil element according to (1) or (2), wherein,

[0219] The core covers the circumference of the coil.

[0220] The base portion also has a top plate portion, which is configured to clamp the erecting portion together with the base portion in the erecting direction.

[0221] The top plate portion and the upright portion are formed as one unit.

[0222] When viewed from the top plate side in the standing direction, the top plate covers at least a portion of the core.

[0223] (4) The coil element according to (3), wherein,

[0224] A first groove extending in the erection direction is formed on the opposing surface of the erected portion.

[0225] The first groove is formed across the interior and periphery of the region opposite to one end face in the opposing surface.

[0226] (5) The coil element according to (4), wherein,

[0227] A second groove extending axially along the coil is formed on the lower surface of the top plate portion on the base portion side facing the erection direction.

[0228] One end of the second groove is connected to one end of the first groove.

[0229] (6) The coil element according to (4) or (5), wherein,

[0230] A third groove extending axially along the coil is formed on the upper surface of the base portion on the side of the top plate portion facing the erection direction.

[0231] One end of the third groove is connected to one end of the first groove.

[0232] (6-1) In coil elements,

[0233] When viewed from the outside in the axial direction, the coil is exposed from the core.

[0234] (7) The coil element according to any one of (3) to (6), wherein,

[0235] The core has a sidewall portion that surrounds a portion of the circumferential surface of the coil.

[0236] The core has a hollow portion, which is formed by the sidewall portion and houses the coil.

[0237] When viewed from the top plate side in the erection direction, the hollow portion is exposed from the top plate.

[0238] (7-1) In coil elements,

[0239] The outer portion of the hollow section along the axial direction is exposed from the top plate.

[0240] (8) The coil element according to any one of (3) to (7), wherein,

[0241] The top plate portion and the base portion are respectively formed with protrusions, and the protruding end face of the protrusions extends axially along a portion of the circumferential surface of the coil.

[0242] (8-1) In coil elements,

[0243] The protruding end face has a groove that is recessed in the direction opposite to the protruding direction of the protrusion.

[0244] The bottom surface of the groove is positioned above the end of the protruding end face in the width direction of the base portion.

[0245] (9) The coil element according to any one of (3) to (8), wherein,

[0246] A top plate mounting recess is formed on the portion of the core on the side of the top plate portion. This top plate mounting recess is a recess that is recessed toward the base portion side in the standing direction.

[0247] The top plate is provided with a recess that extends along the axial direction of the coil.

[0248] At least a portion of the top plate is disposed within the top plate recess.

[0249] (9-1) In coil elements,

[0250] The lower part of the top plate is disposed in the top plate recess, and the upper part of the top plate is disposed in the outer space of the top plate recess and is a space above the top plate recess.

[0251] (10) The coil element according to any one of (1) to (9), wherein,

[0252] The terminal component has two hook-shaped portions.

[0253] The protruding direction of the hook shape of the first hook portion is opposite to the protruding direction of the hook shape of the second hook portion.

[0254] A portion of the base portion is configured to be clamped by the first hook portion.

[0255] The end portion of the coil is configured to be clamped by the second hook portion in the upright direction.

[0256] (10-1) In coil elements,

[0257] The base protrusion has a terminal receiving recess, which is a recess formed on the side of the base protrusion and recessed inward in the width direction of the base portion.

[0258] The protruding end of the hook is disposed in the terminal receiving recess and is axially disposed between a pair of wall portions that divide the terminal receiving recess.

[0259] (11) The coil element according to any one of (1) to (10), wherein,

[0260] The coil has leads that extend downward from both ends of the coil and bend downward, extending axially along the surface of the base portion.

[0261] A pair of end-positioned recesses are formed on the surface of the base portion. These pair of end-positioned recesses are grooves for the lead-out portions to be respectively positioned.

[0262] The axial dimension of each of the pair of end-positioned recesses is larger than the axial dimension of any of the portions of the two end-positioned leads disposed in the end-positioned recesses.

[0263] (11-1) In coil elements,

[0264] A pair of end-configured recesses extend from the base portion to the base of the upright portion.

[0265] (12) A method for manufacturing a coil element, wherein,

[0266] The coil element has:

[0267] Two or more cores;

[0268] Two or more coils arranged in a spiral around at least a portion of the core; and

[0269] The base portion, which holds the coil and the core, is equipped with terminal components.

[0270] The base portion includes:

[0271] A base portion, which provides for the configuration of the terminal components and for the mounting of the coil and the core; and

[0272] The upright portion is configured to stand upright in such a way that it intersects the surface of the base portion in the upright direction.

[0273] The base portion and the upright portion are integrally formed.

[0274] The method for manufacturing the coil element includes a coil mounting step, in which the coil is mounted on the base by moving it toward the opposing surface with one end face of the coil facing the opposing surface that is the side of the upright portion.

[0275] (13) The method for manufacturing the coil element according to (12), wherein,

[0276] The terminal component is formed by bending a flat plate extending along its length.

[0277] The terminal component has a hook at one end.

[0278] In the coil mounting process, the coil is mounted such that its end portion is positioned on a portion of the terminal member.

[0279] The manufacturing method also includes:

[0280] In the terminal component configuration process, the hook is configured such that it clamps the base portion in the upright direction; and

[0281] A clamping process is performed after the coil installation process, in which the end portion of the coil is clamped by the other end of the terminal member and the portion thereof.

[0282] (14) In coil elements,

[0283] The coil element also contains an adhesive.

[0284] The upper surface of the core and the lower surface of the top plate are separated in the vertical direction.

[0285] The adhesive is disposed between the upper surface of the core and the lower surface of the top plate in the upright direction, and is fixed to the upper surface of the core and the lower surface of the top plate, respectively.

[0286] Explanation of reference numerals in the attached figures

[0287] 1. Coil element; 10. Core; 11. First core; 12. Second core; 13. Leg; 14. Hollow part; 14a. Opening; 15. Outer part; 16. Side wall part; 17. Receiving recess; 17a. Contact surface; 18. Top plate recess; 20. Coil; 21. First coil; 21a. Inner end face; 22. Second coil; 22a. Inner end face; 24. Peripheral surface; 26. Lead-out part; 26a. First lead-out part; 26b. Second lead-out part; 26c. Bending part; 26d. Base end; 26e. Top end; 28. Winding part; 30. Base part; 32. Locking part; 34. Top plate part; 34a. Top plate protrusion; 34a1. Protruding end face; 34b. Lower surface; 34c. Second groove part; 34 d. Inner end portion; 36. Base portion; 36e. Third groove portion; 36f. Inner end portion; 36g. Base protrusion portion; 36h. Protruding end face; 36i. End configuration recess; 36i1. First end configuration recess; 36i2. Second end configuration recess; 36j. Platform portion; 36k. Terminal storage recess; 38. Erect portion; 38a. Opposing surface; 38a1. First opposing surface; 38a2. Second opposing surface; 38a3. First groove portion; 38a4. Opposing area; 38a5. Upper end portion; 38a6. Lower end portion; 38b. Core insertion hole; 38c. Upper groove portion; 38d. Lower groove portion; 40. Terminal component; 42. First hook portion; 44. Second hook portion; 50. Adhesive; 60. Strip portion; 70. Solder.

Claims

1. A coil element, wherein, The coil element has: Two or more cores; Two or more coils, each arranged in a helical configuration around at least a portion of the plurality of cores; and The base portion, which holds the coil and the core, is equipped with terminal components. The base portion includes: A base portion, which provides for the configuration of the terminal components and for mounting the coil or the core; and The upright portion is configured to stand upright in such a way that it intersects the surface of the base portion in the upright direction. The base portion and the upright portion are integrally formed. One end face of each of the plurality of coils faces the opposite side of the side that forms the upright portion.

2. The coil element according to claim 1, wherein, One end face of the first coil faces the other end face of the second coil in the axial direction. The base portion is provided with a locking portion, which is configured to be clamped between the first core and the second core in the axial direction.

3. The coil element according to claim 1 or 2, wherein, The core covers the circumference of the coil. The base portion also has a top plate portion, which is configured to clamp the erecting portion together with the base portion in the erecting direction. The top plate portion and the upright portion are formed as one unit. When viewed from the top plate side in the standing direction, the top plate covers at least a portion of the core.

4. The coil element according to claim 3, wherein, A first groove extending in the erection direction is formed on the opposing surface of the erected portion. The first groove is formed across the interior and periphery of the region opposite to one end face in the opposing surface.

5. The coil element according to claim 4, wherein, A second groove extending axially along the coil is formed on the lower surface of the top plate portion on the base portion side facing the erection direction. One end of the second groove is connected to one end of the first groove.

6. The coil element according to claim 4 or 5, wherein, A third groove extending axially along the coil is formed on the upper surface of the base portion on the side of the top plate portion facing the erection direction. One end of the third groove is connected to one end of the first groove.

7. The coil element according to any one of claims 3 to 6, wherein, The core has a sidewall portion that surrounds a portion of the circumferential surface of the coil. The core has a hollow portion, which is formed by the sidewall portion and houses the coil. When viewed from the top plate side in the erection direction, the hollow portion is exposed from the top plate.

8. The coil element according to any one of claims 3 to 7, wherein, The top plate portion and the base portion are respectively formed with protrusions, and the protruding end face of the protrusions extends axially along a portion of the circumferential surface of the coil.

9. The coil element according to any one of claims 3 to 8, wherein, A top plate mounting recess is formed on the portion of the core on the side of the top plate portion. This top plate mounting recess is a recess that is recessed toward the base portion side in the standing direction. The top plate is provided with a recess that extends along the axial direction of the coil. At least a portion of the top plate is disposed within the top plate recess.

10. The coil element according to any one of claims 1 to 9, wherein, The terminal component has two hook-shaped portions. The protruding direction of the hook shape of the first hook portion is opposite to the protruding direction of the hook shape of the second hook portion. A portion of the base portion is configured to be clamped by the first hook portion. The end portion of the coil is configured to be clamped by the second hook portion in the upright direction.

11. The coil element according to any one of claims 1 to 10, wherein, The coil has leads that extend downward from both ends of the coil and bend downward, extending axially along the surface of the base portion. A pair of end-positioned recesses are formed on the surface of the base portion. These pair of end-positioned recesses are grooves for the lead-out portions to be respectively positioned. The axial dimension of each of the pair of end-positioned recesses is larger than the axial dimension of any of the portions of the two end-positioned leads disposed in the end-positioned recesses.

12. A method for manufacturing a coil element, wherein, The coil element has: Two or more cores; Two or more coils arranged in a spiral around at least a portion of the core; and The base portion, which holds the coil and the core, is equipped with terminal components. The base portion includes: A base portion, which provides for the configuration of the terminal components and for the mounting of the coil and the core; and The upright portion is configured to stand upright in such a way that it intersects the surface of the base portion in the upright direction. The base portion and the upright portion are integrally formed. The method for manufacturing the coil element includes a coil mounting step, in which the coil is mounted on the base by moving it toward the opposing surface with one end face of the coil facing the opposing surface that is the side of the upright portion.

13. The method for manufacturing a coil element according to claim 12, wherein, The terminal component is formed by bending a flat plate extending along its length. The terminal component has a hook at one end. In the coil mounting process, the coil is mounted such that its end portion is positioned on a portion of the terminal member. The manufacturing method also includes: In the terminal component configuration process, the hook is configured such that it clamps the base portion in the upright direction; and A clamping process is performed after the coil installation process, in which the end portion of the coil is clamped by the other end of the terminal member and the portion thereof.

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