Coil component

Abstract

The present application provides a coil component capable of narrow-adjacent mounting without generation of short-circuit failure. The coil component (1) has: a bulk (2) containing magnetic particles and a resin, and having a first face (30a); a coil (10) located inside the bulk (2); and a terminal electrode (40a) to which a lead-out portion (12a) of the coil (10) is connected, and which is in contact with an electrode contact portion (36a) of the first face (30a). The bulk (2) has a raised portion (38) raised at least around the terminal electrode (40a) with respect to the electrode contact portion (36a). The raised portion (38) is located at an outer edge portion of the first face (30a).

Description

Technical Field

[0001] This disclosure relates to a coil component. Background Technology

[0002] Currently, a coil component with a coil arranged inside the body is known. For example, the coil component in Patent Document 1 has a body, a coil located inside the body, and terminal electrodes connected to the leads of the coil, and functions as an inductor.

[0003] In recent years, with the miniaturization and integration of coil components, there has been a trend towards narrowing the spacing between adjacent coil components on a substrate. In the coil component of Patent Document 1, by forming terminal electrodes on the mounting surface of the substrate, it is easy to mount many coil components on a substrate with narrow configuration spacing in a narrow adjacent mounting.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 11-251177 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] When the terminal electrode is formed on the mounting surface of the substrate, it is desirable to take measures to prevent short circuits between adjacent coil components or between the coil component and the conductive pattern.

[0009] This disclosure provides a coil component capable of narrow adjacent mounting without the occurrence of short-circuit defects.

[0010] Technical solutions for solving the problem

[0011] One embodiment of the coil component of this disclosure has:

[0012] The base body comprises magnetic particles and resin, and has a first surface;

[0013] A coil, which is located inside the body; and

[0014] The terminal electrode connects to the lead-out portion of the coil and contacts the electrode contact portion on the first surface.

[0015] The substrate has a raised portion, which is formed at least around the terminal electrode and protrudes relative to the electrode contact portion.

[0016] The raised portion is located at the outer edge of the first surface.

[0017] In a coil component according to one embodiment of this disclosure, the body has a raised portion formed at least around the terminal electrode and protruding relative to the electrode contact portion. Therefore, when the terminal electrode is bonded to the mounting substrate (conductive pattern) using a conductive bonding material, the raised portion serves to prevent the conductive bonding material from flowing out of the terminal electrode (electrode contact portion) around the terminal electrode. Additionally, the raised portion serves to prevent the conductive bonding material from flowing into the terminal electrode around the terminal electrode.

[0018] In particular, in a coil component according to one embodiment of this disclosure, a raised portion is located at the outer edge of the first surface. Therefore, the raised portion at the outer edge of the first surface prevents conductive bonding material from flowing out from the terminal electrode to the outside of the outer edge of the first surface. As a result, conductive bonding material is less likely to flow from one coil component to another between adjacent coil components, preventing short circuits. Furthermore, the raised portion at the outer edge of the first surface prevents conductive bonding material from flowing into the terminal electrode from the outside of the outer edge of the first surface. Therefore, conductive bonding material is less likely to flow from one coil component to another between adjacent coil components, preventing short circuits.

[0019] In addition, the conductive bonding material between the coil component and the adjacent conductive pattern is not easily flowed in or out, which can prevent the occurrence of short circuits.

[0020] Furthermore, the volume of the body is increased by forming a raised portion containing magnetic particles and resin at the outer edge of the first surface. As a result, the inductance characteristics of the coil component are improved, and the shielding effect against external magnetic fields is enhanced. Attached Figure Description

[0021] Figure 1A This is a perspective view of an example of the coil component of the first embodiment.

[0022] Figure 1B This is a perspective view of an example of a coil component that schematically represents the surface shape of an outer casing.

[0023] Figure 1C Viewed from the first side Figure 1B A three-dimensional view of the coil component shown.

[0024] Figure 1D yes Figure 1C A perspective view of a modified example of the coil component shown.

[0025] Figure 2A It is along Figure 1A The cross-sectional view of the outer casing along line IIA-IIA is shown.

[0026] Figure 2B It is along Figure 1AThe cross-sectional view of the outer casing along line IIB-IIB is shown.

[0027] Figure 2C yes Figure 2A A cross-sectional view of an example of a modified coil component shown.

[0028] Figure 2D yes Figure 2C A cross-sectional view of an example of a modified coil component shown.

[0029] Figure 2E yes Figure 2C A cross-sectional view of an example of a modified coil component shown.

[0030] Figure 3 This is a perspective view of an example of a core equipped with a coil and terminal electrodes.

[0031] Figure 4A It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0032] Figure 4B It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0033] Figure 5A It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0034] Figure 5B It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0035] Figure 6A It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0036] Figure 6B It means Figure 1C A bottom view showing the change in the shape of the raised portion.

[0037] Figure 7 It means Figure 1A A perspective view of an example of a method for manufacturing a coil component.

[0038] Figure 8 It means Figure 7 A perspective view of an example of a process following the one shown.

[0039] Figure 9 It means Figure 8 A perspective view of an example of a process following the one shown.

[0040] Figure 10 It is along Figure 9 The sectional view of the mold shown along line XX.

[0041] Figure 11 It means Figure 9 A perspective view of an example of a process following the one shown.

[0042] Figure 12A It means Figure 11 A perspective view of an example of a process following the one shown.

[0043] Figure 12B It means Figure 11 A perspective view of an example of a process following the one shown.

[0044] Figure 13A This is a perspective view of an example of the coil component according to the second embodiment.

[0045] Figure 13B Viewed from the first side Figure 13A A three-dimensional view of the coil component shown.

[0046] Figure 14 It means Figure 13A A perspective view of an example of a method for manufacturing a coil component.

[0047] Figure 15 It means Figure 14 A perspective view of an example of a process following the one shown.

[0048] Figure 16 It means Figure 15 A perspective view of an example of a process following the one shown.

[0049] Figure 17 It is along Figure 16 The cross-sectional view of the mold along line XVII-XVII shown.

[0050] Figure 18 It means Figure 16 A perspective view of an example of a process following the one shown.

[0051] Figure 19 It means Figure 18 A perspective view of an example of a process following the one shown.

[0052] Figure 20A yes Figure 1A A perspective view of a modified example of the coil component shown.

[0053] Figure 20B Viewed from the first side Figure 20A A three-dimensional view of the coil component shown.

[0054] Figure 21yes Figure 1A A perspective view of a modified example of the coil component shown.

[0055] Figure 22 yes Figure 1A A perspective view of a modified example of the coil component shown.

[0056] Figure 23 It means in Figure 4A , Figure 5A and Figure 6A Bottom view of the changes in the shape of the raised portion shown in each of (a-1). Detailed Implementation

[0057] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. Furthermore, the illustrations are merely schematic and illustrative for the purpose of understanding the present disclosure, and their appearance or size ratios may differ from the actual product. Additionally, the present disclosure is not limited to the embodiments described below.

[0058] (First Implementation)

[0059] Figure 1A The coil component 1 shown in the first embodiment functions as an inductor, for example, and is mounted in the power supply of various electrical devices. The coil component 1 has a body 2, a coil 10, and terminal electrodes 40a and 40b. The coil component 1 is a surface-mount type coil component.

[0060] The base body 2 has a core 20 and an outer casing 30 covering the core 20 and the coil 10. The base body 2 is hexahedral, but it can also be an octahedron or other polyhedron. The base body 2 has a first surface 30a on which terminal electrodes 40a and 40b are disposed, a second surface 30b opposite to the first surface 30a, and one or more connecting surfaces connecting the first surface 30a and the second surface 30b. In this embodiment, the base body 2 is hexahedral. Therefore, the base body 2 has a third surface 30c, a fourth surface 30d adjacent to the third surface 30c, a fifth surface 30e adjacent to the fourth surface 30d, and a sixth surface 30f adjacent to the fifth surface 30e as connecting surfaces connecting the first surface 30a and the second surface 30b.

[0061] exist Figure 1AIn this diagram, the X-axis corresponds to the direction opposite to the fourth surface 30d and the sixth surface 30f. The Y-axis corresponds to the direction opposite to the third surface 30c and the fifth surface 30e. The Z-axis is perpendicular to the X-axis and Y-axis, and corresponds to the direction opposite to the first surface 30a and the second surface 30b. Hereinafter, for each of the X-axis, Y-axis, and Z-axis, the direction away from the center of the substrate 2 is defined as the outer side, and the direction closer to the center of the substrate 2 is defined as the inner side. Furthermore, the positive direction of the Z-axis (from the first surface 30a towards the second surface 30b) is defined as the upper side (above), and the negative direction of the Z-axis (from the second surface 30b towards the first surface 30a) is defined as the lower side (below). However, the upper side of the Z-axis direction is not necessarily the same as the upper side of the vertical direction. Similarly, the lower side of the Z-axis direction is not necessarily the same as the lower side of the vertical direction.

[0062] In this disclosure, “equal,” “identical,” “equivalent,” or “same” does not only refer to the state in which the physical quantities of the multiple objects being compared are strictly equal, identical, equivalent, or the same, but also includes the state in which there is an error of ±Δ% (without particular limitation, e.g., Δ=7, 5, or 3) or less between the physical quantities of the multiple objects being compared.

[0063] Furthermore, in this disclosure, "parallel" does not only refer to the concept of strict parallelism; it also includes states where an error of ±Δθ° (without particular limitation, e.g., Δθ=3) or less occurs relative to strict parallelism. Similarly, "perpendicular" or "orthogonal" does not only refer to the concept of strict perpendicularity or orthogonality; it also includes states where an error of ±Δθ° (without particular limitation, e.g., Δθ=3) occurs relative to strict perpendicularity or orthogonality.

[0064] There is no particular limitation on the length of the base body 2 in the X-axis direction, for example, it is 0.6mm to 6.5mm. There is no particular limitation on the length of the base body 2 in the Y-axis direction, for example, it is 0.6mm to 6.5mm. There is no particular limitation on the length of the base body 2 in the Z-axis direction, for example, it is 0.5mm to 5.0mm.

[0065] like Figure 1C As shown, the second surface 30b, the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f are constituted by the outer casing 30. On the other hand, the first surface 30a is constituted by the outer end surface 22a of the core 20 and a portion of the outer casing 30 located around the outer end surface 22a, forming the mounting surface of the body 2. The mounting surface is the surface opposite to the mounting substrate when the coil component 1 is mounted onto the mounting substrate (not shown). The body 2 may also not have the core 20, for example, it may be constituted only by the outer casing 30. In this case, the first surface 30a does not include the outer end surface 22a of the core 20 and is constituted by the outer casing 30.

[0066] The base body 2 is not limited to a polyhedron; from the viewpoint of effective magnetic flux, it can also be a cylinder or other prism. In this disclosure, the prism also includes solids such as a frustum where the first face 30a and the second face 30b are not identical. When the base body 2 is a cylinder or a frustum, the base body 2 has a connecting surface that connects the first face 30a and the second face 30b.

[0067] The base body 2 is formed, for example, by flowing the outer material constituting the outer body 30 into the cavity of a mold in which the core 20 is provided, and then compressing and curing it. The outer material is composed of a composite material containing magnetic particles (magnetic fillers) and resin. The base body 2 can also be formed by resin molding, transfer molding, injection molding, dry molding, etc.

[0068] There are no particular limitations on the particle size of the magnetic particles constituting the outer casing material, for example, 1 μm to 50 μm. There are no particular limitations on the magnetic material (magnetic filler) constituting the outer casing material, for example, ferrite or metallic magnetic materials. There are no particular limitations on the resin constituting the outer casing material, for example, epoxy resin or phenolic resin. There are no particular limitations on the specific permeability of the outer casing 30, for example, 1 to 20000.

[0069] like Figure 1B As shown, the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f refer to inclined surfaces that form an acute angle with respect to the first surface 30a. The inclination angle θ1 of the third surface 30c relative to the first surface 30a is not particularly restricted; for example, it can be 60° ≤ θ1 < 90°. The inclination angle θ1 can also be, for example, 75° ≤ θ1 ≤ 85°. However, the third surface 30c may not be an inclined surface, and the inclination angle θ1 of the third surface 30c relative to the first surface 30a can also be 90°. The same applies to each of the inclination angles θ2 of the fourth surface 30d relative to the first surface 30a, θ3 of the fifth surface 30e relative to the first surface 30a, and θ4 of the sixth surface 30f relative to the first surface 30a. Furthermore, inclination angles θ1, θ2, θ3, and θ4 can all be equal or different.

[0070] By setting at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f as an inclined surface, the orientation of the outer casing 30 can be identified based on its external shape. Furthermore, by setting at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f as an inclined surface, miniaturization of the outer casing 30 can be achieved.

[0071] In this embodiment, the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f are all inclined surfaces, but any one, two, or three of these surfaces can also be inclined surfaces. For example, the third surface 30c and the fifth surface 30e, which are opposite to each other, can be inclined surfaces, while the fourth surface 30d and the sixth surface 30f, which are opposite to each other, are not inclined surfaces. Alternatively, the fourth surface 30d and the sixth surface 30f can be inclined surfaces, while the third surface 30c and the fifth surface 30e are not inclined surfaces. When inclined surfaces are formed on the outer body 30 in this way, it is easier to perform the mold release operation when the outer body 30 is formed using a mold.

[0072] A protrusion 32 is formed on the first ridge portion 35a located between the second surface 30b and the third surface 30c. A protrusion 32 is also formed on the second ridge portion 35b located between the second surface 30b and the fourth surface 30d. A protrusion 32 is also formed on the third ridge portion 35c located between the second surface 30b and the fifth surface 30e. A protrusion 32 is also formed on the fourth ridge portion 35d located between the second surface 30b and the sixth surface 30f.

[0073] exist Figure 1B In the example shown, the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d are respectively formed with concave and convex shapes 32, which are formed around the outer periphery of the second surface 30b. However, the concave and convex shapes 32 may also be formed only in any one, two, or three of these ridge portions.

[0074] In the first ridge portion 35a, the protrusions and recesses 32 are formed continuously or discontinuously from one end of the first ridge portion 35a in the X-axis direction to the other end. However, the protrusions and recesses 32 may also be formed locally in a part of the first ridge portion 35a (e.g., the central part or end in the X-axis direction). The same applies to the protrusions and recesses 32 formed in the third ridge portion 35c.

[0075] In the second ridge portion 35b, the protrusions and recesses 32 are formed continuously or discontinuously from one end of the second ridge portion 35b in the Y-axis direction to the other end. However, the protrusions and recesses 32 may also be formed locally in a part of the second ridge portion 35b (e.g., the central part or end in the Y-axis direction). The same applies to the protrusions and recesses 32 formed in the fourth ridge portion 35d.

[0076] In addition to being formed on the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d, the concave and convex shapes 32 can also be formed on the periphery of these ridge portions. For example, the concave and convex shapes 32 can also be formed on the outer edge of the second surface 30b. In this case, the concave and convex shapes 32 can also be formed to a distance W1 (see reference) from the inner side of the first ridge portion 35a in the Y-axis direction. Figure 1B (The enlarged view) The distance W1 is, for example, 0.5 μm to 300 μm, or 0.5 μm to 40 μm. Alternatively, the concave-convex shape 32 may be formed at a position that is the same distance from W1, located inward from the second ridge portion 35b in the X-axis direction. Alternatively, the concave-convex shape 32 may be formed at a position that is the same distance from W1, located inward from the third ridge portion 35c in the Y-axis direction. Alternatively, the concave-convex shape 32 may be formed at a position that is the same distance from W1, located inward from the fourth ridge portion 35d in the X-axis direction.

[0077] Alternatively, the protrusion 32 may be formed on the upper end of the third surface 30c, the fourth surface 30d, the fifth surface 30e, or the sixth surface 30f. In this case, the protrusion 32 may also be formed to extend downward from the first ridge portion 35a by a distance W2 (see reference). Figure 1B The location of the magnified image (see diagram). The distance W2 is, for example, 10μm to 300μm, or 20μm to 200μm, or 50μm to 100μm. Furthermore, the distance W2 can also be related to the following... Figure 10 The height H3 of the connecting region 72 (the thickness of the connecting portion 90) is the same, and can be, for example, 10μm to 50μm, or 20μm to 40μm. Furthermore, the unevenness 32 can be formed to a position that is equidistant from the second ridge portion 35b in the negative Z-axis direction, at the same distance from W2. Additionally, the unevenness 32 can be formed to a position that is equidistant from the third ridge portion 35c in the negative Z-axis direction, at the same distance from W2. Furthermore, the unevenness 32 can be formed to a position that is equidistant from the fourth ridge portion 35d in the negative Z-axis direction, at the same distance from W2.

[0078] As described later, in the manufacturing method of coil component 1, a process is performed to monolithically form a molded body comprising multiple substrates 2. In this process, the molded body is not cut with a cutting tool, but broken. At this time, the resin constituting the substrate 2 (outer body 30) is peeled off along the magnetic particles constituting the substrate 2 (outer body 30) at the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d. As a result, unevenness 32 is formed at the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d. Therefore, at least a portion of the unevenness 32 has a shape that reflects the shape of the magnetic particles (a shape along the surface shape of the magnetic particles), and the unevenness 32 is different from so-called burrs. That is, the unevenness 32 is not located on the outer side of the imaginary surface that extends the flat area of ​​each of the third surface 30c to the sixth surface 30f, but is located on the inner side (coil 10 side). In this way, the coil component 1 can be monolithically manufactured without producing external burrs in the manufacturing method of coil component 1.

[0079] A curved portion 31 is formed on the fifth ridge section 35e located between the third surface 30c and the fourth surface 30d. A curved portion 31 is also formed on the sixth ridge section 35f located between the fourth surface 30d and the fifth surface 30e. A curved portion 31 is formed on the seventh ridge section 35g located between the fifth surface 30e and the sixth surface 30f. A curved portion 31 is also formed on the eighth ridge section 35h located between the sixth surface 30f and the third surface 30c. The curved portion 31 bends on a cross section perpendicular to the direction orthogonal to the first surface 30a (Z-axis direction). Figure 1B In the example shown, curved portions 31 are formed in the fifth ridge portion 35e, the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h, respectively, but curved portions 31 may also be formed in any one, two, or three of these ridge portions.

[0080] In the fifth ridge portion 35e, the bend 31 is formed continuously or intermittently from one end to the other in the extending direction of the fifth ridge portion 35e. However, the bend 31 may also be formed locally in a portion of the fifth ridge portion 35e (e.g., the central portion or end portion in the extending direction of the fifth ridge portion 35e). The same applies to the bends 31 formed in the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h. By forming the bend 31 in at least one of the fifth ridge portion 35e, the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h, it is possible to prevent magnetic flux from concentrating around the periphery of these ridge portions and improve the inductance characteristics of the coil component 1.

[0081] The degree of curvature (radius of curvature) of the curved portion 31 can also increase as it moves toward the side facing the Z-axis. Figure 1B In the example shown, the radius of curvature of the bent portion 31 decreases towards the second surface 30b, but the radius of curvature of the bent portion 31 can also decrease towards the first surface 30a. However, the radius of curvature of the bent portion 31 is an indicator of the curvature of the outer peripheral surface (planar curve) of the outer body 30 at the position of the fifth ridge portion 35e (or the sixth ridge portion 35f, the seventh ridge portion 35g, or the eighth ridge portion 35h) in a section perpendicular to the Z-axis of the outer body 30. By increasing the radius of curvature of the bent portion 31 towards one side in the Z-axis direction at at least one of the fifth ridge portion 35e, the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h, magnetic flux concentration on one side of the extension direction of these ridge portions can be prevented, thereby improving the inductance characteristics of the coil component 1.

[0082] An arbitrary pattern based on the raised / recessed pattern 33 can also be formed on the second surface 30b. The raised / recessed pattern 33 is formed by a plurality of protrusions and / or a plurality of recesses. These protrusions and / or recesses can also be formed regularly along the X-axis and / or Y-axis at a predetermined interval. Alternatively, the raised / recessed pattern 33 can also be an aggregate of randomly arranged protrusions and / or recesses. The height of the plurality of protrusions forming the raised / recessed pattern 33 can be constant or different. The depth of the plurality of recesses forming the raised / recessed pattern 33 can be constant or different. There are no particular limitations on the height of the plurality of protrusions forming the raised / recessed pattern 33 or the depth of the plurality of recesses forming the raised / recessed pattern 33, for example, from 0.1 μm to 40 μm.

[0083] The raised pattern 33 is formed from one end of the second surface 30b along the X-axis to the other end. Additionally, the raised pattern 33 is formed from one end of the second surface 30b along the Y-axis to the other end. However, the raised pattern 33 may also be formed locally on the second surface 30b. The degree of raisedness (e.g., surface roughness) of the raised pattern 33 is less than that of the raised pattern 32, but it may be equal to or greater than the degree of raisedness of the raised pattern 32.

[0084] By forming an embossed pattern 33 on the second surface 30b, the orientation of the outer casing 30 can be identified based on its external shape. The embossed pattern 33 can also be formed in a slit shape on the second surface 30b. Alternatively, the embossed pattern 33 can also be formed on the first surface 30a.

[0085] like Figure 1A As shown, core 20 has a core portion 21 and a flange portion 22. Core 20 is a T-shaped core, formed from a composite material containing magnetic material and resin. Core 20 is formed, for example, by powder molding, injection molding, or machining. The material constituting core 20 may be the same as or different from the material constituting outer casing 30. The specific permeability of core 20 may be the same as or different from the specific permeability of outer casing 30. For example, core 20 may also be made of a material with a higher specific permeability than outer casing 30.

[0086] The core 21 has a cylindrical shape and protrudes from the center of the flange 22. The axial direction of the core 21 corresponds to the Z-axis direction. Additionally, the axial direction of the core 21 corresponds to the winding direction of the coil 10. The core 21 may also protrude at a position radially offset from the center of the flange 22. The core 21 is located inside the outer casing 30. The shape of the core 21 may be, for example, a quadrangular prism, an octagonal prism, or other polygonal prisms.

[0087] The flange portion 22 has a flat rectangular parallelepiped shape (flat plate shape) and is formed at one end of the core portion 21 along its axial direction. The flange portion 22 has an outer end face 22a, an inner end face 22b, and a side face 22c. The inner end face 22b is the face that connects to the core portion 21. The outer end face 22a is the face opposite to the inner end face 22b. The side face 22c is the face that connects the outer end face 22a and the inner end face 22b. The flange portion 22 is arranged parallel to the second surface 30b of the outer body 30. The top view shape of the flange portion 22 may also be circular, octagonal, or other polygonal. Furthermore, either the core portion 21 or the flange portion 22 may be omitted from the core 20.

[0088] like Figure 1C As shown, the outer end face 22a of the flange portion 22 protrudes from the first surface 30a, but can also be covered by the outer casing 30. A terminal electrode 40a is provided on one side of the outer end face 22a in the X-axis direction, and a terminal electrode 40b is provided on the other side of the outer end face 22a in the X-axis direction. (As shown...) Figure 1C As shown by the dashed lines, the flange portion 22 has an electrode contact portion 36a located on one side of the outer end face 22a in the X-axis direction and an electrode contact portion 36b located on the other side of the outer end face 22a in the X-axis direction. The electrode contact portion 36a is the contact surface between the terminal electrode 40a and the first surface 30a, and the terminal electrode 40a contacts the electrode contact portion 36a. The electrode contact portion 36b is the contact surface between the terminal electrode 40b and the first surface 30a, and the terminal electrode 40b contacts the electrode contact portion 36b.

[0089] The coefficient of thermal expansion of the core 20 (at least one of the core portions 21 in the flange portion 22) may be equal to or different from the coefficient of thermal expansion of the outer body 30. The coefficient of thermal expansion of the core 20 (at least one of the flange portion 22 and the core portion 21) may be less than or greater than the coefficient of thermal expansion of the outer body 30.

[0090] When the core 21 is formed of annealed metal, its coefficient of thermal expansion is, for example, 10 ppm / K or more and 20 ppm / K or less. When the core 21 is formed of a composite material containing magnetic material and resin, its coefficient of thermal expansion is, for example, 20 ppm / K or more and 60 ppm / K or less. The coefficient of thermal expansion of the outer casing 30 is, for example, 15 ppm / K. The difference between the coefficient of thermal expansion of the core 21 and the outer casing 30 can be, for example, 2 ppm / K or more, or 5 ppm / K or more. The difference between the coefficient of thermal expansion of the core 21 and the outer casing 30 can be, for example, 45 ppm / K or less, or 10 ppm / K or less. In this case, cracks can be prevented from forming on the outer casing 30 around the core 21 due to the coefficient of thermal expansion of the core 21.

[0091] As a method for making the coefficient of thermal expansion of the core 21 smaller than that of the outer casing 30, an annealing process for the core 21 is illustrated. When the core 21 contains magnetic particles and resin, annealing the core 21 reduces the resin content, thereby reducing the coefficient of thermal expansion of the core 21.

[0092] Alternatively, the core 21 can be formed from a material different from that of the outer casing 30, making its coefficient of thermal expansion smaller than that of the outer casing 30. Alternatively, if both the core 20 and the outer casing 30 contain magnetic particles and resin, the coefficient of thermal expansion of the core 21 can be made smaller than that of the outer casing 30 by making the resin proportion in the core 20 smaller than that in the outer casing 30. Alternatively, the core 20 (core 21 and / or flange 22) can be formed from sintered ferrite or other ceramic materials, making its coefficient of thermal expansion smaller than that of the outer casing 30.

[0093] like Figure 1A As shown, the coil 10 has a winding portion 11 wound in a coil shape and lead-out portions 12a and 12b extending from the winding portion 11. The winding portion 11 is located inside the body 2 (outer body 30) and is provided on the outer peripheral surface of the core portion 21. The winding portion 11 is formed, for example, by winding a wire around the core portion 21. However, if the coil 10 is an air-core coil, the winding portion 11 can also be embedded in the core portion 21. As the wire forming the winding portion 11, conductive core wires such as flat wires, round wires, stranded wires, Litz wires, and braided wires made of copper or the like can be used, or insulated wires formed by covering these conductive core wires with an insulating coating can be used. Specifically, known windings such as AIW, UEW, PEW, and USTC can be used. There is no particular limitation on the wire diameter; in the case of round wires, it is, for example, 50 μm to 2 mm. In the case of flat wires, for example, the wire thickness is 20μm to 2mm, and the wire width is 40μm to 2mm. Figure 2A As shown, the number of layers in the winding direction of the winding section 11 is, for example, three layers, and the number of layers in the radial direction is, for example, three layers.

[0094] like Figure 1A As shown, leads 12a and 12b respectively constitute one end and the other end of the wire forming coil 10, and are separated along the X-axis direction. Lead 12a is led out from one end of winding portion 11 in the Z-axis direction toward the third surface 30c of outer casing 30 inside outer casing 30. Similarly, lead 12b is led out from the other end of winding portion 11 in the Z-axis direction toward the third surface 30c of outer casing 30 inside outer casing 30.

[0095] like Figure 3As shown, terminal electrodes 40a and 40b are formed on flange 22 and separated along the X-axis. Terminal electrodes 40a and 40b have exposed portions 42 and embedded portions 44 and 46. Exposed portions 42 are disposed on outer end face 22a and extend along the Y-axis. The shape of exposed portions 42 is not particularly limited, but may be rectangular in plan view, for example. At least a portion of exposed portions 42 is exposed from first surface 30a (see reference). Figure 1C Embedded portions 44 and 46 are disposed on side 22c and are opposite each other along the Y-axis. Embedded portion 44 extends upward from one end of the exposed portion 42 along its long side. Embedded portion 46 extends upward from the other end of the exposed portion 42 along its long side. Lead-out portion 12a is connected to terminal electrode 40a, and lead-out portion 12b is connected to terminal electrode 40b. Lead-out portion 12a is connected to embedded portion 44 of terminal electrode 40a. Lead-out portion 12b is connected to embedded portion 44 of terminal electrode 40b. Terminal electrodes 40a and 40b are, for example, composed of a laminated electrode film consisting of a base electrode film and a plating film formed on the base electrode film. The base electrode film is not particularly limited, and may be, for example, a conductive paste film containing metals such as Sn, Ag, Ni, Cu, Pd, or their alloys. The plating film is not particularly limited, and may be, for example, a metal such as Sn, Au, Ni, Pt, Ag, Pd, Cu, or their alloys.

[0096] like Figure 2A As shown, the thickness of terminal electrode 40a decreases towards its outer edge and increases towards its center in its cross-section. The cross-sectional shape of terminal electrode 40a is convex, projecting downwards. The same applies to the cross-sectional shape of terminal electrode 40b. However, the cross-sectional shapes of terminal electrodes 40a and 40b are not limited to... Figure 2A The shape shown. For example, the cross-sectional shape of terminal electrodes 40a and 40b can also be rectangular.

[0097] like Figure 2B As shown, the thickness of terminal electrode 40a decreases towards its outer edge and increases towards its center in its longitudinal section. The longitudinal section shape of terminal electrode 40a is a convex shape protruding downwards. The same applies to the longitudinal section shape of terminal electrode 40b. However, the longitudinal section shapes of terminal electrodes 40a and 40b are not limited to... Figure 2B The shape shown. For example, the longitudinal cross-sectional shape of terminal electrodes 40a and 40b can also be rectangular.

[0098] The thickness T of terminal electrodes 40a and 40b is, for example, 3 μm to 100 μm. The thickness of terminal electrode 40a is equal to the thickness of terminal electrode 40b, but they may also be different. Lead-out portion 12a is connected to terminal electrode 40a, for example, by thermoforming, soldering, or conductive adhesive. Lead-out portion 12b is connected to terminal electrode 40b, for example, by thermoforming, soldering, or conductive adhesive.

[0099] like Figure 1C As shown, the outer periphery of the exposed portion 42 of the terminal electrode 40a has a first side 41a1, a second side 41a2, a third side 41a3, and a fourth side 41a4. The third side 41a3 connects the first side 41a1 and the second side 41a2 and extends linearly (straight-line) along the Y-axis. However, as described later, the third side 41a3 may also extend non-linearly. The fourth side 41a4 connects the first side 41a1 and the second side 41a2 and extends linearly (straight-line) along the Y-axis. The first side 41a1 and the second side 41a2 extend parallel to each other along the X-axis and are opposite each other along the extension direction (Y-axis direction) of the third side 41a3.

[0100] The outer periphery of the exposed portion 42 of the terminal electrode 40b has a first side 41b1, a second side 41b2, a third side 41b3, and a fourth side 41b4. The third side 41b3 connects the first side 41b1 and the second side 41b2 and extends linearly (straight-line) along the Y-axis. However, as described later, the third side 41b3 may also extend non-linearly. The fourth side 41b4 connects the first side 41b1 and the second side 41b2 and extends linearly (straight-line) along the Y-axis. The first side 41b1 and the second side 41b2 extend parallel to each other along the X-axis and are opposite each other along the extension direction (Y-axis direction) of the third side 41b3.

[0101] The first side 41a1, the second side 41a2, and the third side 41a3 are located at the outer edge of the first surface 30a. Similarly, the first side 41b1, the second side 41b2, and the third side 41b3 are also located at the outer edge of the first surface 30a. Here, the outer edge of the first surface 30a includes the outer periphery of the first surface 30a and a peripheral portion of the outer periphery. The peripheral portion of the outer periphery of the first surface 30a is the region between a first position on the outer periphery of the first surface 30a and a second position located a predetermined length away from the first position in the X-axis or Y-axis direction (wherein, in the case of a circular or elliptical shape, this is radial). Here, "inner" refers to the direction towards the center of the first surface 30a. Furthermore, the predetermined length is, for example, a length of 30% or less equivalent to the length of the first surface 30a in the X-axis or Y-axis direction (wherein, in the case of a circular or elliptical shape, this is the diameter, major axis, or minor axis).

[0102] The outer edge of the first surface 30a has a first outer edge 2b1, a second outer edge 2b2, a third outer edge 2b3, and a fourth outer edge 2b4. The first outer edge 2b1 and the second outer edge 2b2 extend linearly (straight-line) along the X-axis from the terminal electrode 40a toward the terminal electrode 40b. The third outer edge 2b3 and the fourth outer edge 2b4 connect the first outer edge 2b1 and the second outer edge 2b2 and extend linearly (straight-line) along the Y-axis. However, as will be described later, the third outer edge 2b3 and the fourth outer edge 2b4 may also extend non-linearly. The first outer edge 2b1 and the second outer edge 2b2 extend parallel to each other along the X-axis and are opposite each other along the extension direction (Y-axis direction) of the third outer edge 2b3 and the fourth outer edge 2b4.

[0103] The body 2 has a raised portion 38. The raised portion 38 is formed at least around the terminal electrodes 40a and / or 40b. The raised portion 38 protrudes relative to the electrode contact portion 36a. In particular, the raised portion 38 protrudes relative to the outer edge of the electrode contact portion 36a (particularly along the first outer edge 2b1, second outer edge 2b2, and third outer edge 2b3 of the first surface 30a). Additionally, the raised portion 38 protrudes relative to the electrode contact portion 36b. In particular, the raised portion 38 protrudes relative to the outer edge of the electrode contact portion 36b (particularly along the first outer edge 2b1, second outer edge 2b2, and fourth outer edge 2b4 of the first surface 30a). The raised portion 38 has a portion that does not overlap with the flange portion 22 in the Z-axis direction (viewed from the Z-axis direction) (non-repeating portion) and a portion that overlaps with the flange portion 22 in the Z-axis direction (viewed from the Z-axis direction) (repeating portion).

[0104] Here, the outer edge of the electrode contact portion 36a includes the outer periphery of the electrode contact portion 36a and a peripheral portion of the outer periphery of the electrode contact portion 36a. The peripheral portion of the outer periphery of the electrode contact portion 36a is the region between a first position on the outer periphery of the electrode contact portion 36a and a second position located a predetermined length away from the first position in the X-axis or Y-axis direction (wherein, in the case that the shape of the electrode contact portion 36a is circular or elliptical). The predetermined length is, for example, a length of less than 30% of the length of the electrode contact portion 36a in the X-axis or Y-axis direction (wherein, in the case that the shape of the electrode contact portion 36a is circular or elliptical). The outer edge of the electrode contact portion 36b is defined in the same way as the outer edge of the electrode contact portion 36a.

[0105] The raised portion 38 is located below the average height of the electrode contact portion 36a. Specifically, the raised portion 38 is located below the average height of the outer edge of the electrode contact portion 36a (particularly along the first outer edge 2b1, second outer edge 2b2, and third outer edge 2b3 of the first surface 30a). Furthermore, the raised portion 38 is located below the average height of the electrode contact portion 36b. Specifically, the raised portion 38 is located below the average height of the outer edge of the electrode contact portion 36a (particularly along the first outer edge 2b1, second outer edge 2b2, and fourth outer edge 2b4 of the first surface 30a). Here, the average height position refers to the position where the height of the electrode contact portion 36a or 36b is averaged when there are unevenness or irregularity.

[0106] The raised portion 38 is located at the outer edge of the first surface 30a. For example... Figure 2A and Figure 2B As shown, the raised portion 38 is located at the outer edge of the first surface 30a (in this embodiment, at...). Figure 2A The middle part is the outer side of the outer end face 22a of the flange portion 22 in the X-axis direction. Figure 2B The raised portion 38 protrudes below the height of the electrode contacts 36a and 36b (especially the height of the outer edges of the electrode contacts 36a and 36b) in the Y-axis direction of the outer end face 22a. In addition, the raised portion 38 extends along the outer periphery of the outer end face 22a in a manner that surrounds the outer end face 22a and is adjacent to the terminal electrodes 40a and 40b.

[0107] exist Figure 2A In the example shown, the raised portion 38 covers the outer edge of the terminal electrode 40a in the X-axis direction. Additionally, in Figure 2B In the example shown, the raised portion 38 covers the outer edge of the terminal electrode 40a in the Y-axis direction. However, as... Figure 1D and Figure 2D As shown, the raised portion 38 may not cover the terminal electrodes 40a and 40b. Figure 1D and Figure 2D In the example shown, the raised portion 38 is adjacent to the terminal electrodes 40a and 40b without overlapping them. The raised portion 38 contacts the terminal electrodes 40a and 40b along the X-axis, but can also be separated from the terminal electrodes 40a and 40b.

[0108] The raised portion 38 is formed by extending a portion of the outer body 30 to a position lower than the height of the outer end face 22a (electrode contacts 36a and 36b, especially the outer edges of electrode contacts 36a and 36b) at the outer edge of the first surface 30a. For example, during the molding of the base body 2, inside the mold, a portion of the outer material constituting the outer body 30 is wound from the outside of the side surface 22c of the flange 22 to a position lower than the height of the outer end face 22a. The raised portion 38 is formed by compressing and curing the outer material wound to a position lower than the height of the outer end face 22a. Figure 2C As shown by the dashed line, the Z-axis boundary of the raised portion 38 and the rest of the outer casing 30 (the main body: at least the portion covering the core 20 and coil 10) is formed at the height position of the outer end face 22a (the height position of the electrode contact portion 36a or 36b, especially the height position of the outer edge of the electrode contact portion 36a or 36b). Figure 2A As shown, the height Ha from the second surface 30b to the lower end of the raised portion 38 is higher than the height Hb from the second surface 30b to the electrode contact portion 36a or 36b (especially the outer edge of the electrode contact portion 36a or 36b).

[0109] exist Figure 2A In the example shown, the raised portion 38 does not directly cover the outer edge of the outer end face 22a. However, as Figure 2C As shown, the raised portion 38 can also directly cover at least a portion of the outer edge of the outer end face 22a. Figure 2C In the example shown, a portion of the raised portion 38 is located on the outer edge of the outer end face 22a and overlaps with the outer end face 22a.

[0110] Here, the outer edge of the outer end face 22a of the flange portion 22 includes the outer periphery of the outer end face 22a and a peripheral portion of the outer periphery of the outer end face 22a. The peripheral portion of the outer periphery of the outer end face 22a is the region between a first position on the outer periphery of the outer end face 22a and a second position located a predetermined length away from the first position in the X-axis or Y-axis direction (wherein, in the case that the shape of the outer end face 22a is circular or elliptical). Here, "inner" refers to the direction toward the center of the outer end face 22a. In addition, the predetermined length is, for example, a length of 30% or less relative to the length of the outer end face 22a in the X-axis or Y-axis direction (wherein, in the case that the shape of the outer end face 22a is circular or elliptical).

[0111] Figure 2CThe raised portion 38 shown is formed as follows. For example, during the molding of the base body 2, inside the mold, a portion of the outer material constituting the outer body 30 wraps around from the outside of the side 22c of the flange portion 22 to a position lower than the height of the outer end face 22a, and further wraps around the outer end face 22a. By compressing and curing the outer material wrapped around the outer end face 22a, a shape is formed. Figure 2C The raised portion 38 is shown.

[0112] exist Figures 2A to 2C In any of the figures, the raised portion 38 is in contact with the outer periphery of the outer end face 22a along the X-axis or Y-axis direction (radial direction of the flange portion 22). However, the raised portion 38 may not be in contact with the outer periphery of the outer end face 22a. For example, Figure 2A and Figure 2B The raised portion 38 shown can also be located at a position that separates from the outer periphery of the outer end face 22a in the X-axis direction or the Y-axis direction.

[0113] As in Figure 2C The enlarged view schematically shows that the surface roughness of the raised portion 38 is greater than that of the terminal electrode 40a. Furthermore, the surface roughness of the raised portion 38 is greater than that of the core 20, and the surface roughness of the core 20 is greater than that of the terminal electrode 40a. Figure 2C In the enlarged view, for ease of understanding, only the surface of the raised portion 38 on the surface of the outer casing 30 is shown to have unevenness, but the surface roughness of the raised portion 38 is the same as the surface roughness of the portion other than the raised portion 38. The unevenness of the surface of the raised portion 38 is formed, for example, by at least a portion of the magnetic particles (magnetic filler) contained in the raised portion 38 being exposed to the surface of the raised portion 38. Alternatively, the unevenness of the surface of the raised portion 38 is formed, for example, by the resin on the surface layer of the raised portion 38 undulating along the surface shape of the magnetic particles contained in the raised portion 38. On the surface of the raised portion 38, the exposed proportion of magnetic particles is greater than the exposed proportion of resin.

[0114] At least a portion of the magnetic particles (magnetic filler) contained in the raised portion 38 are exposed on the surface of the raised portion 38, and the adhesion of the surface of the raised portion 38 to the conductive bonding material is lower than that of the surface of the terminal electrode 40a to the conductive bonding material. Therefore, the conductive bonding material is more difficult to adhere to the surface of the raised portion 38 compared to the surface of the terminal electrode 40a.

[0115] like Figure 2C As shown in the enlarged view, the raised portion 38 may also contain magnetic particles (magnetic fillers) having an average particle size equal to or greater than that of the terminal electrode 40a. When such magnetic particles are contained in the raised portion 38, the surface roughness of the raised portion 38 is likely to be greater than the surface roughness of the terminal electrodes 40a and 40b.

[0116] exist Figure 2A In the example shown, the height (average height, or maximum height) Hc of the raised portion 38 from the electrode contact portion 36a is lower than the thickness (maximum thickness) T of the terminal electrode 40a. However, the height (maximum height) Hc of the raised portion 38 from the electrode contact portion 36a can also be equal to the thickness (maximum thickness) T of the terminal electrode 40a. The thickness (maximum thickness) T of the terminal electrode 40a is not particularly limited, but is 10 μm or more. The same applies to the thickness (maximum thickness) of the terminal electrode 40b. On the other hand, the height (average height, or maximum height) Hc of the raised portion 38 from the electrode contact portion 36a is higher than the thickness (average thickness, or maximum thickness) of the outer edge portion of the terminal electrode 40a (particularly along the first outer edge portion 2b1, the second outer edge portion 2b2, and the third outer edge portion 2b3 of the first surface 30a). However, the height (average height, or maximum height) Hc of the raised portion 38 from the electrode contact portion 36a can also be equal to the thickness (average thickness, or maximum thickness) of the outer edge portion of the terminal electrode 40a (particularly along the first outer edge portion 2b1, the second outer edge portion 2b2, and the third outer edge portion 2b3 of the first surface 30a). Figure 1C The thickness (average thickness or maximum thickness) of the first outer edge portion 2b1, the second outer edge portion 2b2, and the third outer edge portion 2b3 of the first surface 30a is the same. The height (average height or maximum height) of the raised portion 38 from the electrode contact portion 36b is also the same.

[0117] Here, the outer edge of terminal electrode 40a includes the outer periphery of terminal electrode 40a and a peripheral portion of the outer periphery of terminal electrode 40a. The peripheral portion of the outer periphery of terminal electrode 40a is the region between a first position on the outer periphery of terminal electrode 40a and a second position located a predetermined length away from the first position in the X-axis or Y-axis direction (wherein, in the case of a circular or elliptical shape, it is radial). The predetermined length is, for example, a length equivalent to 30% or less of the length of terminal electrode 40a in the X-axis or Y-axis direction (wherein, in the case of a circular or elliptical shape, it is the diameter, major axis, or minor axis). The outer edge of terminal electrode 40b is defined in the same way as the outer edge of terminal electrode 40a.

[0118] The height Hc of the raised portion 38 from the electrode contact portion 36a can also be generally or partially smaller than the thickness (maximum thickness) T of the terminal electrode 40a. Additionally, the height Hc of the raised portion 38 from the electrode contact portion 36a can also generally or partially be greater than the outer edge of the terminal electrode 40a (especially along the...). Figure 1C The thickness (average thickness or maximum thickness) of the first outer edge portion 2b1, the second outer edge portion 2b2 and the third outer edge portion 2b3 of the first surface 30a.

[0119] The height Hc of the raised portion 38 from the electrode contact portion 36a does not need to be constant, and may be distributed accordingly. For example, the height Hc of the raised portion 38 from the electrode contact portion 36a may increase as it approaches the outer periphery of the first surface 30a, or may decrease as it approaches the terminal electrode 40a or 40b. Alternatively, the height Hc of the raised portion 38 from the electrode contact portion 36a may decrease as it approaches the outer periphery of the first surface 30a, or may increase as it approaches the terminal electrode 40a or 40b.

[0120] The surface of the raised portion 38 does not necessarily have to be a flat surface; it can also be an inclined surface that is tilted relative to the electrode contact portions 36 and / or 36b. The surface of the raised portion 38 can be a convex surface that protrudes entirely or partially away from the electrode contact portion 36a, or it can be a concave surface that is recessed in the direction toward the electrode contact portion 36a. Alternatively, the surface of the raised portion 38 can also be a surface that is both concave and convex, either entirely or partially.

[0121] like Figure 1C As shown, the raised portion 38 extends along the outer edge of the first surface 30a and is located at the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4. However, the raised portion 38 may also be located at any one, two, or three of the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4. For example, the raised portion 38 may be located at the first outer edge 2b1 and / or the second outer edge 2b2 but not at the third outer edge 2b3 and / or the fourth outer edge 2b4. Alternatively, the raised portion 38 may be located at the third outer edge 2b3 and / or the fourth outer edge 2b4 but not at the first outer edge 2b1 and / or the second outer edge 2b2. Alternatively, the raised portion 38 may be located at the first outer edge 2b1 and the third outer edge 2b3 but not at the second outer edge 2b2 and the fourth outer edge 2b4. Alternatively, the raised portion 38 may be located in the second outer edge portion 2b2 and the fourth outer edge portion 2b4 instead of the first outer edge portion 2b1 and the third outer edge portion 2b3.

[0122] The raised portion 38 is formed along the X-axis over the entire area of ​​the first outer edge portion 2b1, but may also be formed partially over a portion of the first outer edge portion 2b1 (e.g., the central portion of the first outer edge portion 2b1 in the X-axis direction, or the end portion of the first outer edge portion 2b1 in the X-axis direction). Similarly, the raised portion 38 is formed along the X-axis over the entire area of ​​the second outer edge portion 2b2, but may also be formed partially over a portion of the second outer edge portion 2b2 (e.g., the central portion of the second outer edge portion 2b2 in the X-axis direction, or the end portion of the second outer edge portion 2b2 in the X-axis direction).

[0123] For example, the raised portion 38 may be formed only around the terminal electrodes 40a and / or 40b. That is, the raised portion 38 may be formed only around the first edge 41a1 of the terminal electrode 40a and / or the first edge 41b1 of the terminal electrode 40b on the first outer edge 2b1, but not around the inter-electrode region 37 (outer side of the inter-electrode region 37 in the Y-axis direction). Here, "outer side" refers to the direction away from the center of the first surface 30a. Alternatively, the raised portion 38 may be formed only around the second edge 41a2 of the terminal electrode 40a and / or the second edge 41b2 of the terminal electrode 40b on the second outer edge 2b2, but not around the inter-electrode region 37 (outer side of the inter-electrode region 37 in the Y-axis direction).

[0124] Furthermore, the raised portion 38 is formed along the Y-axis over the entire area of ​​the third outer edge portion 2b3, but it may also be formed partially over a portion of the third outer edge portion 2b3 (e.g., the central portion of the third outer edge portion 2b3 in the Y-axis direction, or the end portion of the third outer edge portion 2b3 in the Y-axis direction). Similarly, the raised portion 38 is formed along the Y-axis over the entire area of ​​the fourth outer edge portion 2b4, but it may also be formed partially over a portion of the fourth outer edge portion 2b4 (e.g., the central portion of the fourth outer edge portion 2b4 in the Y-axis direction, or the end portion of the fourth outer edge portion 2b4 in the Y-axis direction).

[0125] The raised portion 38 extends continuously from one end of the first outer edge portion 2b1 along the X-axis to the other end, but it can also be formed intermittently. Similarly, the raised portion 38 extends continuously from one end of the second outer edge portion 2b2 along the X-axis to the other end, but it can also be formed intermittently. The raised portion 38 does not necessarily have to extend elongatedly along the X-axis. For example, multiple island-shaped raised portions 38 can be discretely arranged on the first outer edge portion 2b1 and / or the second outer edge portion 2b2.

[0126] Furthermore, the raised portion 38 extends continuously from one end of the third outer edge portion 2b3 along the Y-axis to the other end, but it can also be formed intermittently. Similarly, the raised portion 38 extends continuously from one end of the fourth outer edge portion 2b4 along the Y-axis to the other end, but it can also be formed intermittently. The raised portion 38 does not necessarily need to extend elongatedly along the Y-axis. For example, multiple island-shaped raised portions 38 can be discretely arranged on the third outer edge portion 2b3 and / or the fourth outer edge portion 2b4.

[0127] The raised portion 38 overlaps with the outer edge portion (peripheral portions of the first side 41a1, second side 41a2, and third side 41a3) of the terminal electrode 40a, and the outer edge portion of the terminal electrode 40a is covered by the raised portion 38. Therefore, the area of ​​the portion on the surface of the terminal electrode 40a that facilitates the adhesion of conductive bonding material can be adjusted. Similarly, the raised portion 38 overlaps with the outer edge portion (peripheral portions of the first side 41b1, second side 41b2, and third side 41b3) of the terminal electrode 40b, and the outer edge portion of the terminal electrode 40b is covered by the raised portion 38. Therefore, the area of ​​the portion on the surface of the terminal electrode 40b that facilitates the adhesion of conductive bonding material can be adjusted.

[0128] like Figure 1D As shown, the raised portion 38 can extend along the outer periphery of the terminal electrode 40a at the outer edge of the first surface 30a without covering the terminal electrode 40a. Alternatively, the raised portion 38 can also extend along the outer periphery of the terminal electrode 40b at the outer edge of the first surface 30a without covering the terminal electrode 40b. Figure 1C In the example shown, the raised portion 38 is adjacent to the outer periphery of the terminal electrode 40a without overlapping with the terminal electrode 40a. Similarly, the raised portion 38 is adjacent to the outer periphery of the terminal electrode 40b without overlapping with the terminal electrode 40b.

[0129] exist Figure 2E In the example shown, the flange 22 has a chamfered portion 23. The chamfered portion 23 is formed at the ridge between the outer end face 22a and the side face 22c. At the location of the chamfered portion 23, the outer end face 22a is inclined relative to the inner end face 22b, and the thickness of the flange 22 decreases as it approaches the outer periphery of the outer end face 22a. Furthermore, at the location of the chamfered portion 23, the terminal electrode 40a is inclined along the outer end face 22a. Therefore, the thickness of the terminal electrode 40a decreases as it approaches the outer periphery of the outer end face 22a. The same applies to the thickness of the terminal electrode 40b. Thus, with the flange 22 having the chamfered portion 23, a portion of the outer material constituting the outer casing 30 can easily wrap around from the outside of the side face 22c of the flange 22 to a position lower than the height of the outer end face 22a, and further wrap around the terminal electrode 40a. Therefore, the raised portion 38 can indirectly cover at least a portion of the chamfered portion 23 while covering the outer edge of the terminal electrode 40a.

[0130] Terminal electrodes 40a and / or 40b may not be formed on the chamfered portion 23, and the chamfered portion 23 may be exposed from the terminal electrodes 40a and / or 40b. In this case, a portion of the outer material constituting the outer body 30 wraps around the chamfered portion 23 from the outside of the side 22c of the flange portion 22. Therefore, the raised portion 38 can directly cover at least a portion of the chamfered portion 23.

[0131] like Figure 1CAs shown, the raised portion 38 extends along the first side 41a1 of the terminal electrode 40a at the first outer edge 2b1, and along the second side 41a2 at the second outer edge 2b2. However, the raised portion 38 may also extend along either the first side 41a1 or the second side 41a2. In this case, the extending direction of the raised portion 38 may also be inclined relative to the first side 41a1 or the second side 41a2. Alternatively, the raised portion 38 may not be formed around the first side 41a1 or the second side 41a2. The raised portion 38 extends continuously along the first side 41a1 and the second side 41a2, but it may also extend intermittently.

[0132] Additionally, the raised portion 38 extends along the first edge 41b1 of the terminal electrode 40b at the first outer edge 2b1, and along the second edge 41b2 at the second outer edge 2b2. However, the raised portion 38 may also extend along either the first edge 41b1 or the second edge 41b2. In this case, the extending direction of the raised portion 38 may also be inclined relative to the first edge 41b1 or the second edge 41b2. Alternatively, the raised portion 38 may not be formed around the first edge 41b1 or the second edge 41b2. The raised portion 38 extends continuously along the first edge 41b1 and the second edge 41b2, but it may also extend intermittently.

[0133] The raised portion 38 extends along the third side 41a3 of the terminal electrode 40a at the fourth outer edge 2b4. Additionally, the raised portion 38 extends along the third side 41b3 of the terminal electrode 40b at the third outer edge 2b3. However, the raised portion 38 may also extend along either the third side 41a3 or the third side 41b3. In this case, the extending direction of the raised portion 38 may also be inclined relative to the third side 41a3 or the third side 41b3. Alternatively, the raised portion 38 may not be formed around the third side 41a3 or the third side 41b3. The raised portion 38 extends continuously along the third side 41a3 and the third side 41b3, but it may also extend intermittently.

[0134] The raised portion 38 may extend along the first side 41a1 and / or the second side 41a2 of the terminal electrode 40a but not along the third side 41a3. Alternatively, the raised portion 38 may extend along the first side 41b1 and / or the second side 41b2 of the terminal electrode 40b but not along the third side 41b3. Or, the raised portion 38 may also extend along the third side 41a3 of the terminal electrode 40a but not along the first side 41a1 and / or the second side 41a2. Alternatively, the raised portion 38 may also extend along the third side 41b3 of the terminal electrode 40b but not along the first side 41b1 and / or the second side 41b2.

[0135] like Figures 4A to 6BAs shown, the outer end face 22a of the flange portion 22, the terminal electrodes 40a and 40b, the first surface 30a, and the raised portion 38 can adopt various top-view shapes. Figure 4A (a-1)~(a-4), Figure 5A (a-1) to (a-4) and Figure 6A In (a-1) to (a-4), the top view shape of the outer end face 22a is rectangular. Similarly, the top view shapes of the terminal electrodes 40a and 40b are rectangular. Specifically, the first side 41a1 and the second side 41a2 of the terminal electrode 40a extend parallel to each other and are opposite each other along the extension direction of the third side 41a3. Furthermore, the first side 41b1 and the second side 41b2 extend parallel to each other and are opposite each other along the extension direction of the third side 41b3. The third sides 41a3 and 41b3 extend linearly.

[0136] exist Figure 4A (b-1)~(b-4) Figure 5A (b-1) to (b-4) and Figure 6A In (b-1) to (b-4), the top view shape of the outer end face 22a is a polygon (for example, an octagon). Additionally, the top view shapes of the terminal electrodes 40a and 40b are polygons (for example, trapezoids). That is, the first side 41a1 and the second side 41a2 of the terminal electrode 40a are inclined relative to the third side 41a3. Similarly, the first side 41b1 and the second side 41b2 of the terminal electrode 40b are inclined relative to the third side 41b3. The third sides 41a3 and 41b3 extend linearly.

[0137] exist Figure 4B (c-1)~(c-4) Figure 5B (c-1) to (c-4) and Figure 6B In (c-1) to (c-4), the top view shape of the outer end face 22a is approximately rectangular (a rectangle with rounded corners) or approximately elliptical. Additionally, the top view shapes of the terminal electrodes 40a and 40b are approximately semi-circular or approximately semi-elliptical. That is, at least a portion (in one example, all) of the third side 41a3 is curved in an arc. Furthermore, at least a portion (in one example, all) of the third side 41b3 is curved in an arc. The third sides 41a3 and 41b3 extend non-linearly.

[0138] exist Figure 4B (d-1)~(d-4) Figure 5B (d-1) to (d-4) and Figure 6BIn (d-1) to (d-4), the top view shape of the outer end face 22a is elliptical or circular. Additionally, the top view shapes of the terminal electrodes 40a and 40b are semi-circular or semi-elliptical. That is, the first side 41a1, the second side 41a2, and the third side 41a3 are continuous in an arc shape. Furthermore, the first side 41b1, the second side 41b2, and the third side 41b3 are continuous in an arc shape. The third side 41a3 is integral with the first side 41a1 and the second side 41a2 and extends non-linearly. Furthermore, the third side 41b3 is integral with the first side 41b1 and the second side 41b2 and extends non-linearly.

[0139] exist Figure 4A (a-1) and (b-1) and Figure 4B In (c-1) and (d-1), the top view of the first surface 30a is rectangular. That is, the first outer edge 2b1 and the second outer edge 2b2 of the first surface 30a extend parallel to each other and are opposite to each other along the extension directions of the third outer edge 2b3 and the fourth outer edge 2b4. The raised portion 38 has an annular shape and is formed on the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 while surrounding the outer periphery of the outer end face 22a of the flange portion 22. Figure 4A (a-1) and (b-1) and Figure 4B In (c-1) and (d-1), the outer periphery of the raised portion 38 has a rectangular shape when viewed from above. On the other hand, Figure 4A The inner periphery of the raised portion 38 of (a-1) has a rectangular shape when viewed from above. Figure 4A The top view of the inner periphery of the raised portion 38 of (b-1) is a polygon (for example, an octagon). Figure 4B The inner periphery of the raised portion 38 of (c-1) has a roughly rectangular or roughly elliptical shape when viewed from above. Figure 4B The top view of the inner periphery of the raised portion 38 of (d-1) is elliptical.

[0140] exist Figure 4A (a-2) and (b-2) and Figure 4B In (c-2) and (d-2), the top view shape of the first surface 30a is polygonal (for example, an octagon). That is, the third outer edge 2b3 and the fourth outer edge 2b4 are bent at least at one location (for example, two locations). The raised portion 38 has an annular shape and is formed on the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 while surrounding the outer periphery of the outer end face 22a. Figure 4A (a-2) and (b-2) and Figure 4B In (c-2) and (d-2), the top view shape of the outer periphery of the raised portion 38 is polygonal (for example, an octagon). On the other hand, Figure 4AThe inner periphery of the raised portion 38 of (a-2) has a rectangular shape when viewed from above. Figure 4A The top view of the inner periphery of the raised portion 38 of (b-2) is a polygon (for example, an octagon). Figure 4B The top view of the inner periphery of the raised portion 38 of (c-2) is approximately rectangular or approximately elliptical, and the top view of the inner periphery of the raised portion 38 of (d-2) in Figure 4C is elliptical.

[0141] exist Figure 4A (a-3) and (b-3) and Figure 4B In (c-3) and (d-3), the top view of the first surface 30a is approximately rectangular or approximately elliptical. That is, the third outer edge 2b3 and the fourth outer edge 2b4 are generally curved in an arc shape. However, the third outer edge 2b3 and the fourth outer edge 2b4 may also be partially curved in an arc shape. In addition, the first outer edge 2b1 and the second outer edge 2b2 extend parallel to each other. The raised portion 38 has an annular shape and is formed on the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 while surrounding the outer periphery of the outer end face 22a. Figure 4A (a-3) and (b-3) and Figure 4B In (c-3) and (d-3), the outer periphery of the raised portion 38 has a generally rectangular or generally elliptical shape when viewed from above. On the other hand, Figure 4A The inner periphery of the raised portion 38 of (a-3) has a rectangular shape when viewed from above. Figure 4A The top view of the inner periphery of the raised portion 38 of (b-3) is a polygon (for example, an octagon). Figure 4B The inner periphery of the raised portion 38 of (c-3) has a roughly rectangular or roughly elliptical shape when viewed from above. Figure 4B The inner periphery of the raised portion 38 of (d-3) is elliptical when viewed from above.

[0142] exist Figure 4A (a-4) and (b-4) and Figure 4B In (c-4) and (d-4), the top view of the first surface 30a is elliptical. That is, the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 are continuously elliptical. Alternatively, the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 can also be continuously circular. The raised portion 38 has an annular shape and is formed on the first outer edge 2b1, the second outer edge 2b2, the third outer edge 2b3, and the fourth outer edge 2b4 while surrounding the outer periphery of the outer end face 22a. Figure 4A (a-4) and (b-4) and Figure 4B In (c-4) and (d-4), the outer periphery of the raised portion 38 has an elliptical shape when viewed from above. On the other hand, Figure 4A The inner periphery of the raised portion 38 of (a-4) has a rectangular shape when viewed from above. Figure 4A The top view of the inner periphery of the raised portion 38 of (b-4) is a polygon (for example, an octagon). Figure 4B The inner periphery of the raised portion 38 of (c-4) has a roughly rectangular or roughly elliptical shape when viewed from above. Figure 4B The inner periphery of the raised portion 38 of (d-4) is elliptical when viewed from above.

[0143] like Figure 5A , Figure 5B , Figure 6A and Figure 6B As shown, the raised portion 38 may not have a ring shape. Figure 5A and Figure 5B In the example shown, the raised portion 38 at least located at the first outer edge 2b1 and the raised portion 38 at least located at the second outer edge 2b2 are opposite each other along the Y-axis. At both ends of the flange portion 22 in the X-axis direction, the side surface 22c is not covered by the outer body 30 and is exposed to the outside. In addition, at one end of the flange portion 22 in the X-axis direction, at least a portion of the third side 41a3 of the terminal electrode 40a is not adjacent to the raised portion 38 and is exposed to the outside. In addition, at the other end of the flange portion 22 in the X-axis direction, at least a portion of the third side 41b3 of the terminal electrode 40b is not adjacent to the raised portion 38 and is exposed to the outside.

[0144] In addition, Figure 6A and Figure 6B In the example shown, the raised portion 38 at least located at the third outer edge 2b3 and the raised portion 38 at least located at the fourth outer edge 2b4 are opposite each other along the X-axis. At both ends of the flange portion 22 in the Y-axis direction, the side surface 22c is not covered by the outer body 30 and is exposed to the outside. Additionally, in Figure 6A (a-1) to (a-4) and Figure 6B In (c-1) to (c-4), at both ends of the flange portion 22 in the Y-axis direction, the first side 41a1 and the second side 41a2 of the terminal electrode 40a are not adjacent to the raised portion 38 and are exposed to the outside. Similarly, the first side 41b1 and the second side 41b2 of the terminal electrode 40b are not adjacent to the raised portion 38 and are exposed to the outside.

[0145] Next, refer to Figures 7 to 12B The manufacturing method of coil component 1 will be explained. First, as follows... Figure 7 As shown, a plurality of cores 20 having a plurality of coils 10 are prepared. In this embodiment, from the viewpoint of preventing the position of the plurality of coils 10 from deviating, the plurality of coils 10 are fixed on the plurality of cores 20 respectively, but the plurality of cores 20 are not necessary.

[0146] The coil 10 is mounted on the core 20 by embedding the winding portion 11 into the core portion 21 or by winding a wire around the core portion 21. The lead-out portion 12a of the coil 10 is connected to a terminal electrode 40a formed from the outer end face 22a of the flange portion 22 to the side face 22c, and the lead-out portion 12b of the coil 10 is connected to a terminal electrode 40b formed from the outer end face 22a to the side face 22c (see reference). Figure 3 ).

[0147] Terminal electrodes 40a and 40b are not particularly limited and can be formed by paste coating, plating, sputtering, or screen printing. Terminal electrode 40a is formed on the outer end face 22a. Figure 2A Thus, an electrode contact portion 36a is formed on the outer end face 22a. A terminal electrode 40b is formed on the outer end face 22a. Figure 2A Thus, an electrode contact portion 36b is formed on the outer end face 22a.

[0148] Next, the partition 50 is prepared and attached to the base 130 via the adhesive sheet 120. For example, a double-sided adhesive sheet can be used as the adhesive sheet 120. In this case, by exposing the adhesive sheet 120 to a heated atmosphere, the partition 50 can be peeled off from the adhesive sheet 120, allowing the partition 50 to detach from the base 130. However, an adhesive or the like can be used instead of the adhesive sheet 120 to bond the partition 50 to the base 130. Alternatively, the partition 50 can be fixed to the base 130 mechanically or magnetically.

[0149] The partition 50 may be made of metal, but it may also be made of heat-resistant resin or the like. The partition 50 has partition walls 51 and multiple partition spaces 52. Each partition space 52 is a bottomless cylindrical space surrounded by partition walls 51. The multiple partition spaces 52 are arranged in a matrix along the X and Y axes, but they may also be arranged randomly. The cross-sectional shape of the partition space 52 perpendicular to the axial direction (Z-axis direction) corresponds to the shape of the outer end face 22a of the flange 22, and is quadrilateral, but it may also be other polygons or circles, etc. The partition 50 has 20 partition spaces 52, but the number of partition spaces 52 is not particularly limited.

[0150] Next, the multiple coils 10 are respectively arranged in the multiple partition spaces 52 by distributing the multiple cores 20 having multiple coils 10 in the multiple partition spaces 52. In this embodiment, each coil 10 is disposed in each of the multiple partition spaces 52. However, it is not necessary to distribute the coils 10 in all partition spaces 52, and it is also possible not to distribute the coils 10 in any partition space 52. One axial side of the partition space 52 is closed by the adhesive sheet 120. On the other hand, the other axial side of the partition space 52 is open. Therefore, when the cores 20 and coils 10 are disposed in the partition space 52, the outer end face 22a of the cores 20 is fixed (bonded) to the adhesive sheet 120 inside the partition space 52.

[0151] Next, as Figure 8 As shown, with multiple cores 20 bonded to the adhesive sheet 120, the separator 50 is housed inside the mold (lower mold) 60. Here, the mold 60 has a main body 61 and a cavity 62 formed in the main body 61. The cavity 62 is a space (recess) surrounded by an inner wall 63 and a bottom surface 64. If necessary, a release film 110 is disposed on the bottom surface 64 of the cavity 62. Figure 8 In the example shown, the release film 110 is configured to adhere tightly to the inner wall 63 and bottom surface 64 of the cavity 62. The outer edge of the release film 110 may also be positioned further outward than the opening edge of the cavity 62. After the release film 110 is placed in the cavity 62, an outer material 80 is filled into the cavity 62. As the outer material 80, a flowable material is used. For example, a composite magnetic material comprising an adhesive resin composed of a thermoplastic or thermosetting resin and magnetic particles (magnetic filler) is used as the outer material 80.

[0152] When the partition 50 is housed inside the mold 60 (cavity 62), the partition 50 is directed towards... Figure 8 The arrow in the image indicates the direction of movement. Therefore, as... Figure 9 As shown, multiple cores 20 and multiple coils 10 can be housed in the cavity 62. The mold 60 is heated before and after the separator 50 is housed in the cavity 62. This reduces the connection strength between the adhesive sheet 120 and the separator 50, allowing the separator 50 to... Figure 8 The pedestal 130 is shown disengaged.

[0153] like Figure 10 As shown, inside the cavity 62, the top of the core 21 faces the bottom surface 64 of the cavity 62 and is positioned apart from the bottom surface 64. Additionally, the outer end face 22a of the flange 22 faces the opening surface of the cavity 62. In this embodiment, the core 20 and the coil 10 are arranged in the partition space 52 such that the surfaces of the terminal electrodes 40a and 40b are exposed from the partition portion 50.

[0154] The partition 50 also has a plurality of first openings 53 and a plurality of second openings 54. The first openings 53 are formed on one side of the partition space 52 and open toward the bottom surface 64 of the cavity 62. The second openings 54 open in the Z-axis direction on the side opposite to the first openings 53. The second openings 54 are formed on the other side of the partition space 52 and open toward the opening surface of the cavity 62. The partition wall 51 has a first end 51a close to the bottom surface 64 of the cavity 62 and a second end 51b in the Z-axis direction opposite to the first end 51a.

[0155] When the partition 50 is housed in the cavity 62, the outer material 80 filling the cavity 62 enters the plurality of partition spaces 52. Furthermore, in the partition spaces 52, the winding portion 11 is covered by the outer material 80, and the core portion 21 is also covered by the outer material 80. Additionally, at least a portion of the flange portion 22 is covered by the outer material 80. A portion of the outer material 80 enters the space on the outer side of the side surface 22c of the flange portion 22 in the X-axis direction and / or Y-axis direction. Figure 10 As shown, the outer material 80 can also enter the outer space of the side 22c in the X-axis direction and / or Y-axis direction until it reaches at least the same height position as the surface of the terminal electrodes 40a and 40b (especially the same height position as the surface of the outer edge of the terminal electrodes 40a and 40b).

[0156] The partition 50 is housed inside the mold 60 such that the position of the second end 51b of the partition wall 51 is equal to the position of the opening surface of the cavity 62. Because the height H1 of the partition wall 51 is lower than the depth H2 of the cavity 62, the first end 51a of the partition wall 51 is positioned at a distance H3 from the bottom surface 64. By housing the partition 50 inside the cavity 62, multiple partitioned areas 70 are formed inside the cavity 62 at positions corresponding to the multiple partitioned spaces 52, defined (divided) by the partition 50 (partition wall 51).

[0157] The partition region 70 extends from the opening surface of the cavity 62 to the bottom surface 64 of the cavity 62 in the Z-axis direction, and the height (depth) of the partition region 70 is H2. On the other hand, the partition space 52 extends from the opening surface of the cavity 62 in the Z-axis direction to a position corresponding to the first end 51a of the partition wall 51, and the height (depth) of the partition space 52 is H1. Therefore, the partition region 70 includes the partition space 52. In other words, the partition region 70 is a region formed by virtually extending the partition space 52 to the position of the bottom surface 64 along the inner wall surface 51c of the partition wall 51.

[0158] Therefore, the process of arranging the core 20 and coil 10 in the partition space 52 is equivalent to the process of arranging the core 20 and coil 10 in the partition region 70. Furthermore, the process of filling the partition space 52 with the outer material 80 is equivalent to the process of filling the partition region 70 with the outer material 80.

[0159] In this embodiment, such as Figure 8 As shown, with the coil 10 arranged in the partition space 52, by housing the partition portion 50 in the cavity 62, Figure 10 The coil 10 is arranged in the partition region 70 shown. However, the method of arranging the coil 10 in the partition region 70 is not limited to this. For example, the coil 10 may be arranged in the partition region 70 after the partition portion 50 is arranged in the cavity 62 and the partition region 70 is formed in the cavity 62.

[0160] By distributing the partition 50 inside the cavity 62, a connecting region 72 is formed inside the cavity 62 in addition to the partition region 70. The connecting region 72 is the area held by the bottom surface 64 of the cavity 62 at the first end 51a of the partition wall 51. The connecting region 72 has a gap formed between the first end 51a and the bottom surface 64, connecting adjacent partition regions 70 to each other. The height H3 of the connecting region 72 (the height of the gap) is, for example, 10μm≤H3≤50μm, or 20μm≤H3≤40μm.

[0161] Adjacent partition regions 70 and another partition region 70 are connected via a connecting region 72. The connecting region 72 extends along the bottom surface 64 and connects the Z-axis ends of adjacent partition regions 70 (partition spaces 52) and the Z-axis ends of another partition region 70 (partition spaces 52). Therefore, the outer material 80 fills the partition regions 70 and also fills at least a portion of the connecting region 72 that connects the adjacent partition regions 70. The outer material 80 can be filled in the connecting region 72 without gaps, or it can be filled with gaps. Although detailed illustrations are omitted, Figure 8 The release film 110 shown spans Figure 10 The multiple partitioned regions 70 shown are configured via a connecting region 72.

[0162] The inner wall surface 51c of partition 51 is an inclined surface that is tilted relative to the bottom surface 64 of mold 60, and also inclined relative to the axial direction (Z-axis direction) of partition space 52. The inclination angle θ5 of the inner wall surface 51c relative to the first end 51a of partition 51 (which is the same as the inclination angle of the inner wall surface 51c relative to the bottom surface 64 of mold 60) is... Figure 1AThe third surface 30c of the outer casing 30 shown corresponds to the inclination angle θ1 relative to the first surface 30a. However, the inner wall surface 51c may not be an inclination surface, and the inclination angle θ5 of the inner wall surface 51c relative to the bottom surface 64 of the mold 60 may also be 90°. Figure 10 In the direction perpendicular to the axial direction (X-axis direction) of the partition space 52 shown, the distance L between the opposing inner wall surfaces 51c increases as they separate from the bottom surface 64 of the cavity 62 (as they move towards the opening surface of the cavity 62). The aforementioned distance L is related to... Figure 1A The length of the outer body 30 in the X-axis direction corresponds to that shown. The minimum value of the distance L mentioned above can also be less than the length of the outer end face 22a of the flange portion 22 in the X-axis direction (wherein, in the case that the outer end face 22a is circular, it is the diameter).

[0163] The cross-sectional area of ​​the partition space 52 perpendicular to the axial direction increases towards the bottom surface 64 away from the cavity 62 (as it moves towards the opening surface of the cavity 62). The aforementioned cross-sectional area and... Figure 1A The cross-sectional area of ​​the outer casing 30 perpendicular to the Z-axis corresponds to that shown. Furthermore, the opening area of ​​the second opening 54 is larger than the opening area of ​​the first opening 53.

[0164] Next, fill to Figure 10 The outer material 80 in the cavity 62 shown is compressed and cured. More specifically, an upper mold (not shown) is prepared, and the outer material 80 is compressed and cured at a predetermined mold temperature for a predetermined time using a mold (lower mold) 60 and the upper mold. Thus, the outer material 80 filling the partition region 70 is compressed and cured, forming an outer body 30 inside the partition region 70. Additionally, the outer material 80 filling the connecting region 72 is compressed and cured, forming a connecting portion 90 inside the connecting region 72. As described above, since the multiple partition regions 70 are connected via the connecting region 72, the multiple outer bodies 30 are connected via the connecting portion 90. Thus, in this embodiment, a molded body 100 can be formed having multiple outer bodies 30 formed in the multiple partition regions 70 and a connecting portion 90 formed in the connecting region 72 and connected to the multiple outer bodies 30. In other embodiments, the filling of the partition region 70 with the outer material 80 and the compression and curing of the outer material 80 can be performed simultaneously.

[0165] Next, as Figure 11As shown, the partition 50, on which the molded body 100 is formed, is removed from the mold 60 (cavity 62). Then, the plurality of outer parts 30 are broken off from the connecting part 90 and removed from the partition 50. For example, a clamp can be used to press the connecting part 90 toward the first end 51a from the first end 51a toward the second end 51b of the partition wall 51, breaking off the plurality of outer parts 30 from the connecting part 90. As described above, the opening area of ​​the second opening 54 is larger than the opening area of ​​the first opening 53. Therefore, the outer parts 30 can be easily removed from the partition region 70 via the second opening 54. Alternatively, the connecting part 90 can be pressed against the opening edge of the first opening 54 to break off the outer parts 30 from the connecting part 90. Or, a cutting tool can be used to cut the outer parts 30 from the connecting part 90.

[0166] By breaking off multiple outer components 30 from the connecting portion 90, the multiple outer components 30 (base body 2) connected to the connecting portion 90 can be made into single pieces, resulting in... Figure 12A The diagram shows a single piece of multiple outer casings 30. In each outer casing 30, a fracture surface with an uneven shape is formed, for example, at the location where the connecting portion 90 is attached. This fracture surface is formed at... Figure 1B The outer casing 30 is shown with its first ridge portion 35a, second ridge portion 35b, third ridge portion 35c, and fourth ridge portion 35d, featuring uneven surfaces 32. This breakage surface also extends to the second surface 30b, third surface 30c, fourth surface 30d, fifth surface 30e, and sixth surface 30f of the outer casing 30. When the outer casing 30 is broken from the connecting portion 90, the resin peels off along the magnetic particles, thus preventing the magnetic particles from being cut and the formation of new surfaces. This prevents oxidation of the magnetic particles, suppressing rust formation on the surface of the outer casing 30 even without the use of a rust inhibitor. Furthermore, as a result of suppressing rust-induced deterioration of the outer casing 30, it is possible to prevent a decrease in the soft magnetic properties of the coil component 1.

[0167] exist Figure 10 In the middle, the outer material 80 of the space outside the side surface 22c of the flange portion 22 in the X-axis direction and / or Y-axis direction (the space between the side surface 22c and the inner wall surface 51c of the partition 51) becomes, after compression and curing, a Figure 2A The raised portion 38 is shown. Here, at the location where the terminal electrodes 40a and 40b are formed (electrode contacts 36a and 36b), from... Figure 2A The position shown is towards Figure 2C In the case of the positional change shown, the outer material 80, which is wrapped around the space outside the side surface 22c of the flange 22 in the X-axis or Y-axis direction (the space between the side surface 22c and the inner wall surface 51c of the partition 51), is wrapped around to the outer edge of the outer end face 22a of the flange 22. In this state, by compressing and curing the outer material 80, such as... Figure 2CAs shown, a raised portion 38 can also be formed on the outer edge of the outer end face 22a. In this way, the size, shape, and forming range of the raised portion 38 can be adjusted according to conditions such as the position of the terminal electrodes 40a and 40b, the pressure when the outer casing material 80 is compressed, the type of magnetic particles and resin constituting the outer casing material 80, the size of the partition space 52, and the arrangement of the core 20 within the partition space 52.

[0168] In the release film 110 ( Figure 8 When a pear skin pattern is formed on the surface of a pear skin pattern, the pear skin pattern is transferred to... Figure 1B On the second surface 30b of the outer casing 30 shown, a raised pattern 33 can be formed.

[0169] Figure 11 The thickness of the connecting part 90 shown (and) Figure 10 The connection area 72 shown (corresponding to the height H3) is relatively thin, for example, 10 μm or more and 50 μm or less (or 20 μm or more and 40 μm or less), so that multiple outer parts 30 can be easily broken off from the connection part 90. Figure 12B As shown, when multiple outer components 30 are broken off from the connecting portion 90, a flow channel with multiple holes is formed in the connecting portion 90. Thus, the coil component 1 can be obtained.

[0170] like Figure 1C As shown, in the coil component 1 of this embodiment, the body 2 has a raised portion 38 formed at least around the terminal electrode 40a and raised relative to the electrode contact portion 36a. Therefore, when the terminal electrode 40a is bonded to the conductive pattern (not shown) of the mounting substrate by a conductive bonding material, the raised portion 38 serves to prevent the conductive bonding material from flowing out of the terminal electrode 40a around the terminal electrode 40a. In addition, the raised portion 38 serves to prevent the conductive bonding material from flowing into the terminal electrode 40a around the terminal electrode 40a.

[0171] In this embodiment, in particular, the raised portion 38 is located at the outer edge of the first surface 30a. Therefore, the raised portion 38 prevents conductive bonding material from flowing out from the terminal electrode 40a to the outer side of the outer edge of the first surface 30a at the outer edge of the first surface 30a. As a result, conductive bonding material is less likely to flow from one coil component 1 to another between adjacent coil components 1, preventing short circuits. Furthermore, the raised portion 38 prevents conductive bonding material from flowing into the terminal electrode 40a from the outer side of the outer edge of the first surface 30a at the outer edge of the first surface 30a. Therefore, conductive bonding material is less likely to flow from one coil component 1 to another between adjacent coil components 1, preventing short circuits.

[0172] In addition, conductive bonding material is not easily flowed in or out between the coil component 1 and the adjacent conductive pattern, which can prevent the occurrence of short circuits.

[0173] Furthermore, at the outer edge of the first surface 30a, a raised portion 38 containing magnetic particles and resin is formed, increasing the volume of the body 2. This improves the inductance characteristics of the coil component 1 and enhances its shielding effect against external magnetic fields.

[0174] In addition, such as Figure 2C As shown, the surface roughness of the raised portion 38 is greater than that of the terminal electrode 40a. Therefore, due to the unevenness of the surface of the raised portion 38, the conductive bonding material is less likely to adhere to the surface of the raised portion 38 compared to the surface of the terminal electrode 40a. Thus, the raised portion 38 can effectively prevent the conductive bonding material from flowing out of the terminal electrode 40a and can effectively prevent the conductive bonding material from flowing into the terminal electrode 40a.

[0175] Furthermore, the adhesion of the surface of the raised portion 38 to the conductive bonding material is lower than that of the surface of the terminal electrode 40a to the conductive bonding material. Here, for example, when the terminal electrode 40a is connected to the mounting substrate by solder, the adhesion to the conductive bonding material refers to the solder wettability. In this case, the conductive bonding material is less likely to adhere to the surface of the raised portion 38 and more likely to remain on the surface of the terminal electrode 40a compared to the surface of the terminal electrode 40a. Therefore, the conductive bonding material is less likely to flow on the surface of the raised portion 38, and the raised portion 38 can effectively prevent the conductive bonding material from flowing out of the terminal electrode 40a. In addition, the raised portion 38 can effectively prevent the conductive bonding material from flowing into the terminal electrode 40a.

[0176] Furthermore, the height of the raised portion 38 from the electrode contact portion 36a is equal to or greater than the thickness of the outer edge of the terminal electrode 40a. Therefore, the raised portion 38 functions as a stopper relative to the conductive bonding material that will flow out of the terminal electrode 40a or into the terminal electrode 40b. As a result, the conductive bonding material is less likely to cross the raised portion 38, and the raised portion 38 effectively prevents the conductive bonding material from flowing out of the terminal electrode 40a. Additionally, the raised portion 38 effectively prevents the conductive bonding material from flowing into the terminal electrode 40b.

[0177] Furthermore, the raised portion 38 includes magnetic particles with an average particle size equal to or greater than the thickness of the outer edge of the terminal electrode 40a. Therefore, the height of the raised portion 38 from the electrode contact portion 36a can be increased by using magnetic particles with an average particle size equal to or greater than the thickness of the terminal electrode 40a. Consequently, the raised portion 38 effectively blocks conductive bonding material that is about to flow out of or into the terminal electrode 40a. Therefore, conductive bonding material is less likely to further cross the raised portion 38, and the raised portion 38 can effectively prevent conductive bonding material from flowing out of the terminal electrode 40a. Additionally, the raised portion 38 can effectively prevent conductive bonding material from flowing into the terminal electrode 40b.

[0178] In addition, such as Figure 1C As shown, the raised portion 38 extends along the outer periphery of the terminal electrode 40a, overlapping with the outer edge of the terminal electrode 40a. Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a and also prevents conductive bonding material from flowing into the terminal electrode 40a in the vicinity of the terminal electrode 40a. Furthermore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a and also prevents conductive bonding material from flowing into the terminal electrode 40a in the region along the outer periphery of the terminal electrode 40a. Thus, the raised portion 38 can effectively prevent conductive bonding material from flowing out of the terminal electrode 40a and effectively prevent conductive bonding material from flowing into the terminal electrode 40a.

[0179] Furthermore, the outer periphery of the terminal electrode 40a has a first side 41a1, a second side 41a2, and a third side 41a3 located at the outer edge of the first surface 30a. The third side 41a3 connects the first side 41a1 and the second side 41a2 and extends linearly or non-linearly. The raised portion 38 extends along at least one of the first side 41a1 and the second side 41a2 (both in this embodiment). Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a in the region along the first side 41a1 and the second side 41a2, and also prevents conductive bonding material from flowing into the terminal electrode 40a. For example, on a mounting substrate, when the first side 41a1 of the terminal electrode 40a of one coil component 1 and the second side 41a2 of the terminal electrode 40a of another coil component 1 are adjacent to each other across the raised portion 38, it is possible to effectively prevent short circuit defects caused by the inflow and outflow of conductive bonding material between these coil components 1.

[0180] Furthermore, the raised portion 38 extends along at least one of the first side 41a1 and the second side 41a2 (both in this embodiment) and the third side 41a3. Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a and prevents conductive bonding material from flowing into the terminal electrode 40b in the regions along the first side 41a1, the second side 41a2, and the third side 41a3. For example, on the mounting substrate, when the first side 41a1 of the terminal electrode 40a of the first coil component 1 and the second side 41a2 of the terminal electrode 40a of the second coil component 1 are adjacent to each other across the raised portion 38, short-circuit defects caused by the inflow and outflow of conductive bonding material can be effectively prevented between these coil components 1. Additionally, on the mounting substrate, when the third side 41a3 of the terminal electrode 40a of the first coil component 1 and the third side 41b3 of the terminal electrode 40b of the third coil component 1 are adjacent to each other across the raised portion 38, short-circuit defects caused by the inflow and outflow of conductive bonding material can be effectively prevented between these coil components 1.

[0181] Furthermore, the raised portion 38 extends along the third side 41a3. Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a and also prevents conductive bonding material from flowing into the terminal electrode 40a in the region along the third side 41a3 of the terminal electrode 40a. For example, on a mounting substrate, when the third side 41a3 of the terminal electrode 40a of one coil component 1 and the third side 41b3 of the terminal electrode 40b of another coil component 1 are adjacent to each other across the raised portion 38, it is possible to effectively prevent short-circuit defects caused by the inflow and outflow of conductive bonding material between these coil components 1.

[0182] Furthermore, the first side 41a1 and the second side 41a2 extend parallel to each other and are opposite each other along the extension direction of the third side 41a3. Therefore, for example, a raised portion 38 can be formed along the outer periphery of the terminal electrode 40a, which is composed of quadrilaterals, at the outer edge of the first surface 30a.

[0183] Additionally, for example, in Figure 4A In (b-1) to (b-4), the first side 41a1 and the second side 41a2 are inclined relative to the third side 41a3. Therefore, for example, a raised portion 38 can be formed along the outer periphery of the terminal electrode 40a, which is composed of polygons, at the outer edge of the first surface 30a.

[0184] Additionally, for example, in Figure 4B In (c-1) to (c-4), at least a portion (in this embodiment, all) of the third side 41a3 is curved in an arc shape. Additionally, for example, in... Figure 4BIn (d-1) to (d-4), the first side 41a1, the second side 41a2, and the third side 41a3 are continuous in an arc shape. Therefore, a raised portion 38 can be formed along the outer periphery of the terminal electrode 40a having a curved shape at the outer edge of the first surface 30a.

[0185] In addition, such as Figure 1C As shown, the outer edge of the first surface 30a has a first outer edge 2b1 and a second outer edge 2b2 extending from the terminal electrode 40a toward the terminal electrode 40b, and a third outer edge 2b3 and a fourth outer edge 2b4 connecting the first outer edge 2b1 and the second outer edge 2b2 and extending linearly or non-linearly. A raised portion 38 is located on at least one of the first outer edge 2b1 and the second outer edge 2b2 (both in this embodiment). Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a from the first outer edge 2b1 and the second outer edge 2b2, and also prevents conductive bonding material from flowing into the terminal electrode 40a. For example, on a mounting substrate, when the first outer edge 2b1 of one coil component 1 and the second outer edge 2b2 of another coil component 1 are adjacent to each other across the raised portion 38, short-circuit defects caused by the inflow and outflow of conductive bonding material can be effectively prevented between these coil components 1.

[0186] Furthermore, the raised portion 38 is located at least one of the first outer edge portion 2b1 and the second outer edge portion 2b2 (both in this embodiment) and at least one of the third outer edge portion 2b3 and the fourth outer edge portion 2b4 (both in this embodiment). Therefore, the raised portion 38 prevents the conductive bonding material from flowing out of the terminal electrode 40a at the first outer edge portion 2b1 and the second outer edge portion 2b2, and also prevents the conductive bonding material from flowing into the terminal electrode 40a. In addition, the raised portion 38 prevents the conductive bonding material from flowing out of the terminal electrode 40a at the third outer edge portion 2b3 and the fourth outer edge portion 2b4, and also prevents the conductive bonding material from flowing into the terminal electrode 40a. For example, on the mounting substrate, when the first outer edge portion 2b1 of the first coil component 1 and the second outer edge portion 2b2 of the second coil component 1 are adjacent to each other across the raised portion 38, it is possible to effectively prevent short circuit failures caused by the inflow and outflow of conductive bonding material between these coil components 1. Furthermore, on the mounting substrate, when the third outer edge 2b3 of the first coil component 1 and the fourth outer edge 2b4 of the third coil component 1 are adjacent to each other across the raised portion 38, it is possible to effectively prevent short circuit defects caused by the inflow and outflow of conductive bonding material between these coil components 1.

[0187] Furthermore, the raised portion 38 is located on at least one of the third outer edge portion 2b3 and the fourth outer edge portion 2b4 (both in this embodiment). Therefore, the raised portion 38 prevents conductive bonding material from flowing out of the terminal electrode 40a and prevents conductive bonding material from flowing into the terminal electrode 40a at the third outer edge portion 2b3 and the fourth outer edge portion 2b4. For example, on a mounting substrate, when the third outer edge portion 2b3 of one coil component 1 and the fourth outer edge portion 2b4 of another coil component 1 are adjacent to each other across the raised portion 38, it is possible to effectively prevent short circuit failures caused by the inflow and outflow of conductive bonding material between these coil components 1.

[0188] Furthermore, the first outer edge portion 2b1 and the second outer edge portion 2b2 extend parallel to each other and are opposite to each other along the extending directions of the third outer edge portion 2b3 and the fourth outer edge portion 2b4. Therefore, for example, it is possible to form raised portions in the first outer edge portion 2b1 and the second outer edge portion 2b2 of the first surface 30a, which is composed of quadrilaterals.

[0189] Additionally, for example, in Figure 4A (a-2) and (b-2) and Figure 4B In (c-2) and (d-2), the third outer edge 2b3 and the fourth outer edge 2b4 are bent at least at one location. In this case, for example, a raised portion 38 can be formed on the third outer edge 2b3 and the fourth outer edge 2b4 of the first surface 30a composed of polygons.

[0190] Additionally, for example, in Figure 4A (a-3) and (b-3) and Figure 4B In (c-3) and (d-3), at least a portion (in this embodiment, all) of the third outer edge 2b3 and at least a portion (in this embodiment, all) of the fourth outer edge 2b4 are curved in an arc shape. Additionally, for example, in Figure 4A (a-4) and (b-4) and Figure 4B In (c-4) and (d-4), the first outer edge portion 2b1, the second outer edge portion 2b2, the third outer edge portion 2b3, and the fourth outer edge portion 2b4 are continuous in a circular or elliptical shape. Therefore, it is possible to form a raised portion 38 in the first outer edge portion 2b1, the second outer edge portion 2b2, the third outer edge portion 2b3, and the fourth outer edge portion 2b4 of the first surface 30a, which has a curved shape.

[0191] In addition, such as Figure 2AAs shown, the body 2 has a core 20 and an outer casing 30. The core 20 has a core portion 21 on which a coil 10 is disposed and a flange portion 22 formed at one axial end of the core portion 21. The outer casing 30 covers the core 20 and the coil 10 and has a raised portion 38. The flange portion 22 has an inner end face 22b connected to the core portion 21 and an outer end face 22a opposite to the inner end face 22b. The outer end face 22a has an electrode contact portion 36a for contact with the terminal electrode 40a. The raised portion 38 is in contact with the outer periphery of the outer end face 22a along the radial direction of the flange portion 22. By constructing the body 2 from the core 20 and the outer casing 30, the inductance characteristics of the coil component 1 can be adjusted according to the type of magnetic material constituting the core 20 and the outer casing 30. In addition, the coil 10 can be fixed to the core portion 21, and the positional deviation of the coil 10 is less likely to occur. Furthermore, by connecting the raised portion 38 to the outer periphery of the outer end face 22a of the flange portion 22, the raised portion 38 can prevent the conductive bonding material from flowing out of the terminal electrode 40a near the outer periphery of the outer end face 22a, and can also prevent the conductive bonding material from flowing into the terminal electrode 40a.

[0192] In addition, such as Figure 2C As shown, the raised portion 38 is located on the outer edge of the outer end face 22a of the flange portion 22. Therefore, the raised portion 38 functions as a stop (anti-detachment) to fix the core 20 to the outer casing 30. As a result, the fixing strength between the core 20 and the outer casing 30 is increased, and the core 20 is not easily detached from the outer casing 30.

[0193] In addition, such as Figure 2E As shown, the flange portion 22 has a side surface 22c connecting the outer end face 22a and the inner end face 22b, and a chamfered portion 23 formed on the ridge portion located between the outer end face 22a and the side surface 22c. The raised portion 38 directly or indirectly covers at least a portion of the chamfered portion 23 (in this embodiment, the entire chamfered portion 23, but it may also be a part of the chamfered portion 23). By forming the chamfered portion 23 on the flange portion 22, during the molding of the base body 2, the outer material constituting the outer body 30 can easily be wrapped around the outer end face 22a through the chamfered portion 23. As a result, the raised portion 38 can be easily formed around the terminal electrode 40a.

[0194] (Second Implementation)

[0195] Figure 13A The coil component 1A of the second embodiment shown has the same structure as the coil component 1 of the first embodiment, except for the points shown below. Components that are repeated with the coil component 1 of the first embodiment are labeled with the same reference numerals, and their detailed descriptions are omitted.

[0196] like Figure 13A and Figure 13BAs shown, the coil component 1A has a body 2A, and the body 2A has an outer casing 30A. In the outer casing 30A, protrusions 32 are formed on the ninth ridge portion 35i, the tenth ridge portion 35j, the eleventh ridge portion 35k, and the twelfth ridge portion 35l. Specifically, the ninth ridge portion 35i is located between the first surface 30a and the third surface 30c, the tenth ridge portion 35j is located between the first surface 30a and the fourth surface 30d, the eleventh ridge portion 35j is located between the first surface 30a and the fifth surface 30e, and the twelfth ridge portion 35l is located between the first surface 30a and the sixth surface 30f of the outer casing 30. The ninth ridge portion 35i, the tenth ridge portion 35j, the eleventh ridge portion 35k, and the twelfth ridge portion 35l form the outer periphery of the first surface 30a. In this embodiment, a raised portion 38 with protrusions 32 is formed on the outer edge of the first surface 30a.

[0197] Terminal electrodes 40aA and 40bA are not embedded in portions 44 and 46. Figure 3 In this respect, it differs from the terminal electrodes 40a and 40b of the first embodiment. Lead-out portions 12a and 12b are led out from the winding portion 11 toward the outer end face 22a. The exposed portion 42 of terminal electrode 40aA is disposed on the outer end face 22a in a manner that covers the lead-out portion 12a. The exposed portion 42 of terminal electrode 40bA is disposed on the outer end face 22a in a manner that covers the lead-out portion 12b. In this embodiment, the terminal electrodes 40a and 40b of the first embodiment may also be provided on the coil member 1 instead of terminal electrodes 40aA and 40bA.

[0198] Next, refer to Figures 14-19 right Figure 13A and Figure 13B The manufacturing method of the coil component 1A shown will be explained. First, as shown... Figure 14 As shown, multiple cores 20 with multiple coils 10 are prepared. Next, the outer end face 22a of the flange portion 22 is bonded to the base 130 via adhesive sheet 120.

[0199] Next, as Figure 15 As shown, the base 130, to which multiple cores 20 are bonded, moves toward the mold (lower mold) 60A filled with outer material 80, in the direction of the arrow in the figure. Furthermore, as... Figure 16 As shown, multiple coils 10 are housed inside the mold 60A. Figure 15 ) and multiple cores 20. Here, as Figure 15 As shown, in addition to the main body 61 and the cavity 62, the mold 60A also has a partition wall 66. The cavity 62 is divided by the partition wall 66, and a plurality of partition spaces 65 are formed inside the cavity 62. The partition space 65 is a bottomed cylindrical space surrounded by the partition wall 66.

[0200] A release film 110 is disposed on the bottom surface 64 of the cavity 62. The release film 110 is configured to fit tightly against the inner wall 63, the bottom surface 64, and the partition wall 66 of the cavity 62. The outer material 80 is filled in the cavity 62 with the release film 110 disposed therein.

[0201] like Figure 16 As shown, the mold 60A is heated before and after the core 20 is housed in the cavity 62. As a result, the connection strength between the adhesive sheet 120 and the outer end face 22a of the flange portion 22 is reduced, allowing the core 20 to detach from the base 130.

[0202] like Figure 17 As shown, when the core 20 is housed in the cavity 62, in the partition space 65, the winding portion 11 is covered by the outer material 80, and the core portion 21 is also covered by the outer material 80. Additionally, at least a portion of the flange portion 22 is covered by the outer material 80. A portion of the outer material 80 extends into the space outside the X-axis and / or Y-axis direction of the side surface 22c of the flange portion 22 (the space between the side surface 22c of the flange portion 22 and the inner wall surface 66a of the partition wall 66). The outer material 80 may also extend into the space outside the X-axis and / or Y-axis direction of the side surface 22c (the space between the side surface 22c of the flange portion 22 and the inner wall surface 66a of the partition wall 66) until it reaches at least the same height as the surfaces of the terminal electrodes 40aA and 40bA (particularly the same height as the surfaces of the outer edges of the terminal electrodes 40aA and 40bA).

[0203] A connecting region 67 is formed at the upper end 66b of the partition wall 66. The outer material 80 filled into the cavity 62 can flow from one adjacent partition space 65 to another partition space 65 through the connecting region 67. The upper end 66b of the partition wall 66 is covered by the outer material 80 filled in the connecting region 67.

[0204] The inner wall surface 66a of the partition 66 is an inclined surface that is inclined relative to the bottom surface 64 of the mold 60A. In the direction perpendicular to the axial direction of the partition space 65 (X-axis direction), the distance L between the opposing inner wall surfaces 66a increases as they separate from the bottom surface 64 of the cavity 62 (as they move toward the opening surface of the cavity 62). In addition, the cross-sectional area of ​​the partition space 65 perpendicular to the axial direction increases as it moves away from the bottom surface 64 of the cavity 62 (as it moves toward the opening surface of the cavity 62).

[0205] Next, the outer material 80 filled into the cavity 62 is compressed and cured. As a result, the outer material 80 filled into the partition space 65 is compressed and cured, forming an outer body 30A inside the partition space 65. Additionally, the outer material 80 filled into the connecting region 67 is compressed and cured, forming a connecting portion 90A in the connecting region 67. As described above, since the multiple partition spaces 65 are connected via the connecting region 67, the multiple outer bodies 30A are connected via the connecting portion 90A. Thus, in this embodiment, a molded body 100A can also be formed, which has multiple outer bodies 30A formed in the multiple partition spaces 65 and a connecting portion 90A formed in the connecting region 67 and connected to the multiple outer bodies 30A.

[0206] Next, as Figure 18 As shown, the molded body 100A is removed from the mold 60A (cavity 62). Next, for example, using a jig, multiple outer parts 30A (base body 2A) are broken off from the connecting portion 90A. By breaking off the multiple outer parts 30A from the connecting portion 90A, the multiple outer parts 30A connected via the connecting portion 90A can be single-pieceed, resulting in... Figure 19 The diagram shows a single piece of multiple outer casings 30A (base body 2A). In each outer casing 30A, a fracture surface with, for example, an uneven shape is formed at the location where the connecting portion 90A is attached. This fracture surface is formed at... Figure 13B The ninth ridge portion 35i, the tenth ridge portion 35j, the eleventh ridge portion 35k, and the twelfth ridge portion 35l of the outer body 30A are shown. This fracture surface can also reach the first surface 30a, the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f of the outer body 30.

[0207] exist Figure 17 In the middle, the outer material 80 of the space outside the side surface 22c of the flange portion 22 in the X-axis direction and / or Y-axis direction (the space between the side surface 22c of the flange portion 22 and the inner wall surface 66a of the partition wall 66) becomes, after compression and curing, a Figure 13B The raised portion 38 is shown. When the outer casing 30A is broken from the connecting portion 90A, at least a portion of the outer periphery of the raised portion 38 breaks off. Therefore, as shown... Figure 13B As shown, a protrusion 32 is formed on the outer periphery of the raised portion 38. Thus, the coil component 1 can be obtained.

[0208] In this embodiment, the same effects as in the first embodiment can be achieved. Furthermore, in this embodiment, the separator 50 is not required in the manufacturing process of the coil component 1A. Figure 7 Therefore, it is not necessary to consider the relationship between the partition 50 and the base 130. Figure 7 The alignment accuracy of coil component 1A is high, making its manufacture easy.

[0209] Furthermore, this disclosure is not limited to the embodiments described above, and various changes can be made within the scope of this disclosure.

[0210] In the above embodiments, such as Figure 3 As shown, core 20 is a T-shaped core, but it can also be a drum-shaped core with flanges 22 formed at both ends of the core 21 in the axial direction.

[0211] In the above embodiments, such as Figure 20A As shown, coil 10 can also be made of flat wire. Coil 10 is a vertically wound flat wire, but it can also be a horizontally wound flat wire. For example... Figure 20B As shown, a portion of the lead-out portion 12a of the coil 10 is exposed from the first surface 30a. Similarly, a portion of the lead-out portion 12b of the coil 10 is exposed from the first surface 30a. The portions of the lead-out portion 12a and the lead-out portion 12b exposed from the first surface 30a function as terminal electrodes.

[0212] exist Figure 20A and 20B In the coil component 1 shown, terminal electrodes 40a and 40b can be omitted. Figure 1A Therefore, the structure and manufacturing process of coil component 1 can be simplified. Furthermore, because coil 10 is formed from flat wire, even if coil 10 is not fixed to core 20, the position of coil 10 inside the body 2 can be prevented from shifting. Additionally, the current flowing to coil 10 can be increased.

[0213] In the above embodiments, such as Figure 21 As shown, the winding direction of the winding section 11 can also be parallel to the first surface 30a. Figure 21 In this configuration, the winding direction of the winding portion 11 corresponds to the Y-axis direction. Viewed from the winding direction, the shape of the winding portion 11 is a rectangle with a long side in the X-axis direction, but it can also be a square, other polygons, a circle, or an ellipse. Lead-out portions 12a and 12b are directly led out from the winding portion 11 toward the first surface 30a and are disposed on the surface of the first surface 30a.

[0214] In the above embodiments, such as Figure 22 As shown, the embedded part 46 can also be omitted from the terminal electrode 40b. The same applies to the terminal electrode 40a.

[0215] exist Figure 4A In (a-1), the terminal electrodes 40a and 40b have a rectangular shape when viewed from above, and the third sides 41a3 and 41b3 extend linearly. However, as... Figure 23 As shown in (a-1)', at least a portion of the third side 41a3 and at least a portion of the third side 41b3 can also be curved in an arc. Figure 23 In the example shown, the intersections of the third side 41a3 with the first side 41a1 and with the second side 41a2 are curved in an arc shape. Similarly, the intersections of the third side 41b3 with the first side 41b1 and with the second side 41b2 are also curved in an arc shape.

[0216] for Figure 5A The terminal electrodes 40a and 40b shown in (a-1) are also the same, as... Figure 23 As shown in (a-1)'', at least a portion of the third side 41a3 and at least a portion of the third side 41b3 can also be curved in an arc shape. Furthermore, for Figure 6A The terminal electrodes 40a and 40b shown in (a-1) are also the same, as... Figure 23 As shown in (a-1), at least a portion of the third side 41a3 and at least a portion of the third side 41b3 can also be curved in an arc shape.

[0217] In the above embodiments, the core 20 may not be a sintered body, or it may be formed using the same material and manufacturing method as the outer body 30.

[0218] This specification discloses the following content. [1]

[0220] A coil component having:

[0221] The base body comprises magnetic particles and resin, and has a first surface;

[0222] The coil, which is located inside the aforementioned body; and

[0223] The terminal electrode is connected to the lead-out portion of the aforementioned coil and contacts the electrode portion of the aforementioned first surface.

[0224] The aforementioned substrate has a raised portion, which is formed at least around the aforementioned terminal electrode and is raised relative to the aforementioned electrode contact portion.

[0225] The aforementioned raised portion is located at the outer edge of the aforementioned first surface. [2]

[0227] According to the coil component described above [1], wherein,

[0228] The surface roughness of the aforementioned raised portion is greater than the surface roughness of the aforementioned terminal electrode. [3]

[0230] According to the coil component described in [1] or [2] above, wherein,

[0231] The aforementioned terminal electrodes can be connected to the mounting substrate via a conductive bonding material.

[0232] The adhesion of the surface of the aforementioned raised portion to the aforementioned conductive bonding material is lower than the adhesion of the surface of the aforementioned terminal electrode to the aforementioned conductive bonding material. [4]

[0234] The coil component according to any one of [1] to [3] above, wherein,

[0235] The height of the aforementioned raised portion from the aforementioned electrode contact portion is at least equal to or greater than the thickness of the outer edge portion of the aforementioned terminal electrode. [5]

[0237] The coil component according to any one of [1] to [4] above, wherein,

[0238] The aforementioned raised portion contains the aforementioned magnetic particles having an average particle size equal to or greater than the thickness of the outer edge portion of the aforementioned terminal electrode. [6]

[0240] According to any one of [1] to [5] above, the coil component, wherein,

[0241] The aforementioned raised portion extends along the outer periphery of the aforementioned terminal electrode in a manner that overlaps with the outer edge of the aforementioned terminal electrode. [7]

[0243] The coil component according to any one of [1] to [6] above, wherein,

[0244] The outer periphery of the aforementioned terminal electrode has a first side, a second side, and a third side located on the outer edge of the aforementioned first surface.

[0245] The third side connects the first and second sides and extends linearly or non-linearly.

[0246] The aforementioned raised portion extends along at least one of the aforementioned first side and the aforementioned second side. [8]

[0248] According to the coil component described above [7], wherein,

[0249] The aforementioned raised portion extends along at least one of the aforementioned first side and the aforementioned second side and the aforementioned third side. [9]

[0251] The coil component according to any one of [1] to [6] above, wherein,

[0252] The outer periphery of the aforementioned terminal electrode has a first side, a second side, and a third side located on the outer edge of the aforementioned first surface.

[0253] The third side connects the first and second sides and extends linearly or non-linearly.

[0254] The aforementioned raised portion extends along the aforementioned third side.

[10]

[0256] The coil component according to any one of [7] to [9] above, wherein,

[0257] The first side and the second side extend in parallel and are opposite each other along the direction of extension of the third side.

[11]

[0259] The coil component according to any one of [7] to [9] above, wherein,

[0260] The first side and the second side mentioned above are inclined relative to the third side mentioned above.

[12]

[0262] The coil component according to any one of [7] to [9] above, wherein,

[0263] At least a portion of the aforementioned third side is curved in an arc shape.

[13]

[0265] The coil component according to any one of [7] to [9] above, wherein,

[0266] The first side, the second side, and the third side are continuous in an arc shape.

[14]

[0268] The coil component according to any one of [1] to

[13] above, wherein,

[0269] The aforementioned terminal electrode is composed of a first terminal electrode and a second terminal electrode. The first terminal electrode is connected to the first lead of the coil, and the second terminal electrode is opposite to the first terminal electrode and is connected to the second lead of the coil.

[0270] The outer edge of the first surface has a first outer edge and a second outer edge extending from the first terminal electrode toward the second terminal electrode, and a third outer edge and a fourth outer edge connecting the first outer edge and the second outer edge and extending linearly or non-linearly.

[0271] The aforementioned raised portion is located on at least one of the aforementioned first outer edge portion and the aforementioned second outer edge portion.

[15]

[0273] According to the coil component described above

[14] , wherein,

[0274] The aforementioned raised portion is located at least one of the aforementioned first outer edge portion and the aforementioned second outer edge portion, and at least one of the aforementioned third outer edge portion and the aforementioned fourth outer edge portion.

[16]

[0276] The coil component according to any one of [1] to

[13] above, wherein,

[0277] The aforementioned terminal electrode is composed of a first terminal electrode and a second terminal electrode. The first terminal electrode is connected to the first lead of the coil, and the second terminal electrode is opposite to the first terminal electrode and is connected to the second lead of the coil.

[0278] The outer edge of the first surface has a first outer edge and a second outer edge extending from the first terminal electrode toward the second terminal electrode, and a third outer edge and a fourth outer edge connecting the first outer edge and the second outer edge and extending linearly or non-linearly.

[0279] The aforementioned raised portion is located on at least one of the aforementioned third outer edge portion and the aforementioned fourth outer edge portion.

[17]

[0281] The coil component according to any one of

[14] to

[16] above, wherein,

[0282] The first outer edge and the second outer edge extend in parallel and are opposite each other along the extending directions of the third outer edge and the fourth outer edge.

[18]

[0284] The coil component according to any one of

[14] to

[16] above, wherein,

[0285] The aforementioned third outer edge and the aforementioned fourth outer edge are bent at least at one location.

[19]

[0287] The coil component according to any one of

[14] to

[16] above, wherein,

[0288] At least a portion of the third outer edge and at least a portion of the fourth outer edge are curved in an arc shape.

[20]

[0290] The coil component according to any one of

[14] to

[16] above, wherein,

[0291] The aforementioned first outer edge, second outer edge, third outer edge, and fourth outer edge are continuous in a circular or elliptical shape. [twenty one]

[0293] The coil component according to any one of [1] to

[20] above, wherein,

[0294] The aforementioned body has a core and an outer casing. The core has a core portion on which the aforementioned coil is disposed and a flange portion formed at one axial end of the core portion. The outer casing covers the core and the aforementioned coil and has the aforementioned raised portion.

[0295] The flange portion has an inner end face that connects to the core portion and an outer end face that is opposite to the inner end face.

[0296] The aforementioned outer end face has an electrode contact portion for contacting the aforementioned terminal electrode.

[0297] The aforementioned raised portion is in contact with the outer periphery of the aforementioned outer end face along the radial direction of the aforementioned flange portion. [twenty two]

[0299] According to the coil component described above

[21] , wherein,

[0300] The aforementioned raised portion is located on the outer edge of the outer end face of the aforementioned flange portion. [twenty three]

[0302] According to the coil component described in

[21] or

[22] above, wherein,

[0303] The flange portion has a side surface and a chamfered portion. The side surface connects the outer end face and the inner end face. The chamfered portion is formed at the ridge portion located between the outer end face and the side surface.

[0304] The aforementioned raised portion directly or indirectly covers at least a portion of the aforementioned chamfered portion.

[0305] Explanation of reference numerals in the attached figures

[0306] 1. 1A: Coil component

[0307] 2. 2A: Body

[0308] 2b1, 2b2, 2b3, 2b4: First outer edge to fourth outer edge

[0309] 10, 10A: Coil

[0310] 11: Winding section

[0311] 12a, 12b: Introduction

[0312] 20: Core

[0313] 21: Core

[0314] 22: Flange portion

[0315] 22a: outer end face

[0316] 22b: Inner end face

[0317] 22c: Side view

[0318] 23: Chamfered section

[0319] 30, 30A: Exterior body

[0320] 30a~30f: Page 1 to Page 6

[0321] 31: Bend

[0322] 32: Concave and convex

[0323] 33: Embossed pattern

[0324] 35a, 35b, 35c, 35d, 35e, 35f, 35g, 35h, 35i, 35j, 35k, 35l: First to twelfth ridge sections

[0325] 36a, 36b: Electrode contact portion

[0326] 37: Interelectrode region

[0327] 38: Raised area

[0328] 40a, 40b: Terminal electrodes

[0329] 41a1, 41a2, 41a3, 41a4: First to fourth sides

[0330] 41b1, 41b2, 41b3, 41b4: First to fourth sides

[0331] 42: Exposed area

[0332] 44, 46: Installation Section

[0333] 50: Divider

[0334] 51: Next door

[0335] 51a: First end

[0336] 51b: Second end

[0337] 51c: Inner wall surface

[0338] 52: Dividing space

[0339] 53: First opening

[0340] 53a: Opening edge

[0341] 54: Second opening

[0342] 55: Bottom wall

[0343] 56: Through hole

[0344] 56a: Opening edge

[0345] 60, 60A: Mold

[0346] 61: Main Body

[0347] 62: Cavity

[0348] 63: Inner wall

[0349] 64: Bottom

[0350] 65: Dividing space

[0351] 66: Next door

[0352] 66b: Upper end

[0353] 66c: Inner wall surface

[0354] 67: Connecting Area

[0355] 70: Dividing areas

[0356] 72: Connecting Area

[0357] 80: Exterior materials

[0358] 90, 90A: Connecting parts

[0359] 100, 100A: Molded body

[0360] 110: Release film

[0361] 120: Adhesive sheet

[0362] 130: Pedestal

Claims

1. A coil component, comprising: The base body comprises magnetic particles and resin, and has a first surface; A coil, which is located inside the body; and The terminal electrode is connected to the lead-out portion of the coil and is in contact with the electrode contact portion of the first surface. The substrate has a raised portion, which is formed at least around the terminal electrode and protrudes relative to the electrode contact portion. The raised portion is located at the outer edge of the first surface.

2. The coil component according to claim 1, wherein, The surface roughness of the raised portion is greater than the surface roughness of the terminal electrode.

3. The coil component according to claim 1 or 2, wherein, The terminal electrodes can be connected to the mounting substrate via a conductive bonding material. The surface of the raised portion has a lower affinity with the conductive bonding material than the surface of the terminal electrode has with the conductive bonding material.

4. The coil component according to claim 1 or 2, wherein, The height of the raised portion from the electrode contact portion is at least equal to or greater than the thickness of the outer edge of the terminal electrode.

5. The coil component according to claim 1 or 2, wherein, The raised portion includes magnetic particles having an average particle size equal to or greater than the thickness of the outer edge of the terminal electrode.

6. The coil component according to claim 1 or 2, wherein, The raised portion extends along the outer periphery of the terminal electrode in a manner that overlaps with the outer edge of the terminal electrode.

7. The coil component according to claim 6, wherein, The outer periphery of the terminal electrode has a first side, a second side, and a third side located on the outer edge of the first surface. The third side connects the first side and the second side, and extends linearly or non-linearly. The raised portion extends along at least one of the first side and the second side.

8. The coil component according to claim 7, wherein, The raised portion extends along at least one of the first side and the second side and the third side.

9. The coil component according to claim 6, wherein, The outer periphery of the terminal electrode has a first side, a second side, and a third side located on the outer edge of the first surface. The third side connects the first side and the second side, and extends linearly or non-linearly. The raised portion extends along the third side.

10. The coil component according to any one of claims 7 to 9, wherein, The first side and the second side extend in parallel and are opposite each other along the direction of extension of the third side.

11. The coil component according to any one of claims 7 to 9, wherein, The first side and the second side are inclined relative to the third side.

12. The coil component according to any one of claims 7 to 9, wherein, At least a portion of the third side is curved in an arc shape.

13. The coil component according to any one of claims 7 to 9, wherein, The first side, the second side, and the third side are continuous in an arc shape.

14. The coil component according to claim 1 or 2, wherein, The terminal electrode consists of a first terminal electrode and a second terminal electrode. The first terminal electrode is connected to a first lead of the coil, and the second terminal electrode is opposite to the first terminal electrode and is connected to a second lead of the coil. The outer edge of the first surface has a first outer edge and a second outer edge extending from the first terminal electrode toward the second terminal electrode, and a third outer edge and a fourth outer edge connecting the first outer edge and the second outer edge and extending linearly or non-linearly. The raised portion is located on at least one of the first outer edge portion and the second outer edge portion.

15. The coil component according to claim 14, wherein, The raised portion is located at least one of the first outer edge portion and the second outer edge portion, and at least one of the third outer edge portion and the fourth outer edge portion.

16. The coil component according to claim 1 or 2, wherein, The terminal electrode consists of a first terminal electrode and a second terminal electrode. The first terminal electrode is connected to a first lead of the coil, and the second terminal electrode is opposite to the first terminal electrode and is connected to a second lead of the coil. The outer edge of the first surface has a first outer edge and a second outer edge extending from the first terminal electrode toward the second terminal electrode, and a third outer edge and a fourth outer edge connecting the first outer edge and the second outer edge and extending linearly or non-linearly. The raised portion is located on at least one of the third outer edge portion and the fourth outer edge portion.

17. The coil component according to claim 14, wherein, The first outer edge and the second outer edge extend in parallel and are opposite to each other along the extending directions of the third outer edge and the fourth outer edge.

18. The coil component according to claim 16, wherein, The third outer edge and the fourth outer edge are each bent at least at one location.

19. The coil component according to claim 16, wherein, At least a portion of the third outer edge and at least a portion of the fourth outer edge are curved in an arc shape.

20. The coil component according to claim 15, wherein, The first outer edge, the second outer edge, the third outer edge, and the fourth outer edge are continuous in a circular or elliptical shape.

21. The coil component according to claim 1 or 2, wherein, The body has a core and an outer casing. The core has a core portion on which the coil is disposed and a flange portion formed at one axial end of the core portion. The outer casing covers the core and the coil and has the raised portion. The flange portion has an inner end face that connects to the core portion and an outer end face that is opposite to the inner end face. The outer end face has an electrode contact portion for contact with the terminal electrode. The raised portion is in contact with the outer periphery of the outer end face along the radial direction of the flange portion.

22. The coil component according to claim 21, wherein, The raised portion is located on the outer edge of the outer end face of the flange portion.

23. The coil component according to claim 21, wherein, The flange portion has a side surface and a chamfered portion. The side surface connects the outer end face and the inner end face. The chamfered portion is formed at a ridge located between the outer end face and the side surface. The raised portion directly or indirectly covers at least a portion of the chamfered portion.

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