Coil component and method for manufacturing the same

Abstract

To provide a coil component having improved productivity and a method for manufacturing the same.SOLUTION: A coil component 1 includes a coil component body 2 including at least two coils 6 and a core 5, a box type case 3 for housing the coil component body 2, and a sealing resin 4 which is filled into the box type case 3. The core 5 has a comb-shaped block 51 for interconnecting a plurality of parallel leg parts 52, and a yoke part 53 for connecting the leg parts 52 in a seamless manner. The two coils 6 are wound around bobbins 7, and are mounted on each of two leg parts 52 extending so as to be adjacent to each other while making the bobbins 7 contact each other. When a gap 9a between one side wall 32 and the coil component body 2 is represented by Ga, a gap 9b between the two coils 6 is represented by Gb, and a gap 9c between the other side wall 32 and the coil component body 2 is represented by Gc, the box type case 3 satisfies Ga>Gb / 2 and Gc>Gb / 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coil component and a method for manufacturing the same. [Background technology]

[0002] When a current is passed through a coil, the coil generates a magnetic flux according to the number of turns, and therefore the coil is used as an electromagnetic component that converts electrical energy into magnetic energy and stores and releases the energy, for example, as a choke coil or a reactor.

[0003] This coil component includes a coil component main body having a core and a coil, a box-shaped case, and a sealing resin. The box-shaped case has one end closed and the other open, and the bottom surface is surrounded by four side walls. The coil component main body is housed in the sealing resin filled in the box-shaped case. The sealing resin protects the coil component main body electrically, chemically, and mechanically from the external environment. Therefore, the coil component main body is prevented from short-circuiting, corrosion, and damage, and vibration is also suppressed, and it also has excellent heat dissipation properties. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-131567 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-055096 Summary of the Invention [Problem to be solved by the invention]

[0005] There are two possible methods for embedding the coil component body in the sealing resin. The first method is to house the coil component body in a box-shaped case, then pour the sealing resin into the gap between the box-shaped case and the coil component body, and then allow the sealing resin to harden. The second method is to pour the sealing resin into the box-shaped case, then submerge the coil component body in the sealing resin, and then allow the sealing resin to harden.

[0006] In either method, the high viscosity of the sealing resin means that it takes time for the sealing resin to penetrate into each part of the coil component body and into the gap between the coil component body and the box-shaped case. Therefore, if the sealing resin is poured too quickly or the coil component body settles too quickly, the sealing resin may leak out of the box-shaped case. In other words, it tends to take a long time to embed the coil component body in the sealing resin, which is one factor that reduces production efficiency in the coil component production process.

[0007] The present invention has been proposed to solve the above-mentioned problems, and its object is to provide a coil component and a manufacturing method thereof that can shorten the time required to embed the coil component body in sealing resin and improve productivity. [Means for solving the problem]

[0008] In order to achieve the above object, a coil component according to an embodiment of the present invention includes at least two coils, bobbins around which the corresponding coils are wound in a one-to-one correspondence with the coils, a core having a plurality of split cores connected in a ring shape, a coil component main body including the coils and the cores, a box-shaped case that houses the coil component main body, and a sealing resin filled in the box-shaped case, wherein at least one of the split cores has a plurality of parallel legs and a yoke portion that connects the legs together seamlessly, the two coils are attached to the two legs that extend adjacent to each other, and the bobbins are abutted against each other, the box-shaped case has two side walls that extend parallel to the legs, and where Ga is the gap between one of the side walls and the coil component main body, Gb is the gap between the two coils, and Gc is the gap between the other side wall and the coil component main body, Ga > Gb / 2 and Gc > Gb / 2.

[0009] The bobbin may have a winding shaft around which the coil is wound and flanges extending from both ends of the winding shaft, and the flanges of the bobbins may abut against adjacent bobbins.

[0010] The coil and the core may be secured together by tape along the annular circumference of the core.

[0011] Furthermore, in order to achieve the above object, a manufacturing method of a coil component according to an embodiment of the present invention is a manufacturing method of a coil component in which a coil component main body is accommodated in a box-shaped case, the coil component main body including at least two coils, bobbins each corresponding to one of the coils and around which the corresponding coil is wound, and a core having a plurality of split cores and formed by connecting the split cores in an annular shape, at least one of the split cores having a plurality of parallel leg portions and a yoke portion connecting the leg portions in a seamless, uninterrupted manner, and the two coils are attached separately to the two adjacently extending leg portions. The coil component main body is accommodated in the box-shaped case such that the bobbins are brought into contact with each other and the two side walls of the box-shaped case are parallel to the legs, and where Ga is a gap between one of the side walls and the coil component main body, Gb is a gap between the two coils, and Gc is a gap between the other side wall and the coil component main body, Ga > Gb / 2 and Gc > Gb / 2. The sealing resin is filled in after the coil component main body is accommodated in the box-shaped case, or the coil component main body is submerged in the sealing resin after the box-shaped case has been filled with the sealing resin. [Effects of the Invention]

[0012] According to the present invention, the pouring speed of the sealing resin or the settling speed of the coil component body can be increased, thereby improving the productivity of coil components. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 2 is a cross-sectional view of the coil component. [Figure 2] 10A and 10B are schematic diagrams showing a process of pouring a sealing resin into a box-shaped case. [Figure 3] FIG. 2 is a schematic diagram showing expansion occurring within a coil component. [Figure 4] FIG. 10 is a schematic diagram showing a crack that occurs when the bobbin is not in contact. [Figure 5] FIG. 10 is a cross-sectional view showing a coil component around which a tape is wound. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, coil components according to embodiments of the present invention will be described with reference to the drawings. In each drawing, thickness, dimensions, positional relationships, ratios, shapes, and the like may be emphasized for ease of understanding, but the present invention is not limited to such emphasis.

[0015] FIG. 1 is a cross-sectional view of a coil component. The coil component 1 includes a coil component body 2, a box-shaped case 3, and a sealing resin 4. The coil component body 2 is housed in the box-shaped case 3. The sealing resin 4 is poured into the box-shaped case 3 and solidifies, sealing the coil component body 2 inside the box-shaped case 3 with the resin. The coil component body 2 includes a core 5 and a plurality of coils 6. The core 5 is an annular body having an annular surface 5a, and each coil 6 is fitted into each of the legs 52 arranged in parallel within the core 5.

[0016] The core 5 includes a magnetic material such as a powder magnetic core, a ferrite magnetic core, a metal composite core, or a laminated steel plate. A powder magnetic core is an annealed compact made by compacting magnetic powder. The magnetic powder is primarily composed of iron, and examples thereof include pure iron powder, iron-based permalloy (Fe-Ni alloy), Si-containing iron alloy (Fe-Si alloy), sendust alloy (Fe-Si-Al alloy), amorphous alloy, nanocrystalline alloy powder, and a mixture of two or more of these powders. A metal composite core is a core made by kneading and molding magnetic powder and resin.

[0017] The annular core 5 is formed by abutting two comb-shaped blocks 51 to form a single annular or polyannular shape. A polyannular shape is a shape in which multiple annular shapes are lined up in a row, sharing a portion of the annular shape, such as a θ shape. The comb-shaped block 51 has multiple legs 52 and one yoke 53, which are seamlessly molded into a single, continuous piece. The yoke 53 is roughly a rectangular parallelepiped. The multiple legs 52 extend from the same surface of the yoke 53, are spaced apart by a predetermined distance, and extend parallel to each other in the same direction. In other words, the yoke 53 magnetically connects the multiple legs 52.

[0018] When two legs 52 extend from the yoke portion 53, the comb-shaped block 51 has a U-shape, and when three legs 52 extend from the yoke portion 53, the comb-shaped block 51 has an E-shape. The two comb-shaped blocks 51 form an annular core 5 by butting their legs 52 together. The two comb-shaped blocks 51 are bonded together with an adhesive 81.

[0019] The coil 6 is a wound body of conductive wire with an insulating coating such as enamel coating. The coil 6 is formed into a cylindrical shape by spirally winding the conductive wire while shifting the winding position for each turn along the winding axis. The conductive wire of the coil 6 is, for example, a rectangular wire, and the coil 6 is, for example, an edgewise coil. The wide surface of the conductive wire of the coil 6 extends in a direction perpendicular to the winding axis of the coil 6. There is no limitation on the type of conductive wire, and other types of wire such as round wire may also be used. A flatwise coil may also be used as the coil 6. Multiple coils 6 may be electrically connected in series or in parallel.

[0020] Each coil 6 is attached to each leg 52. One coil 6 is attached to each leg 52, and the multiple coils 6 are arranged side by side with their circumferential surfaces 61 facing each other. The coils 6 are wound around bobbins 7, electrically insulated via the bobbins 7, and then attached to the legs 52 of the core 5. The bobbins 7 are provided in one-to-one correspondence with each coil 6. That is, the bobbins 7 are resin parts made by molding an insulating material. The material of the bobbins 7 is, for example, epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or a composite of these. A thermally conductive filler may be mixed into the bobbins 7.

[0021] The bobbin 7 has a winding shaft 71 and two flanges 72. The winding shaft 71 is a hollow cylinder or rectangular tube with both ends open, and the coil 6 is wound around the outer periphery of the winding shaft 71. The bobbin 7 is fitted to the core 5 by inserting the legs 52 of the core 5 into the winding shaft 71. The flanges 72 are plates extending from both ends of the winding shaft 71, sharing a common axis with the winding shaft 71, and having a larger diameter than the winding shaft 71. The flanges 72 extend all the way around the circumference of the winding shaft 71. The flanges 72 support the coil 6 from both sides to prevent the coil 6 from becoming unwound.

[0022] With respect to the length of the flange 72, the gap between adjacent leg portions 52 is defined as B. In this case, the radius of the flange 72, i.e., the length from the inner circumferential surface of the winding shaft 71 to the flange edge surface 73 of the flange 72, is half of B. Therefore, when adjacent bobbins 7 are attached to adjacent legs 52, the flanges 72 abut against each other. The bobbins 7 abut against the adjacent bobbins 7 at their flanges 72 in a direction perpendicular to the extension direction of the legs 52.

[0023] In such a coil component body 2, each coil 6 has a conductive wire drawn out, and generates magnetic flux according to the number of turns when current is passed through the conductive wire from a circuit in which the coil component 1 is incorporated. Meanwhile, the core 5 forms a closed magnetic circuit through which the magnetic flux generated by the coil 6 passes with a magnetic permeability higher than that of a vacuum. Therefore, the coil component body 2 is an electromagnetic component that converts core electric energy into magnetic energy and stores and releases it.

[0024] The box-shaped case 3 that houses the coil component body 2 is box-shaped with one end closed and the other end open, and has a rectangular parallelepiped space inside that can house the coil component body 2. The box-shaped case 3 has a rectangular bottom 31 and four side walls 32 rising from each side of the bottom 31. The space of the box-shaped case 3 is defined by the bottom 31 and the side walls 32, and the box-shaped case 3 is open on the side opposite the bottom 31. The box-shaped case 3 is made of metal. Specifically, any material that can provide a magnetic shielding effect, such as aluminum or an aluminum alloy, is sufficient. A lightweight metal with high thermal conductivity, such as an aluminum alloy, is preferred. By housing the coil component body 2, the box-shaped case 3 confines leakage magnetic flux from the coil component body 2.

[0025] When the coil component body 2 is housed in the box-shaped case 3, the box-shaped case 3 is larger than the coil component body 2 so that the coil component body 2 does not come into contact with each side wall 32 of the box-shaped case 3. Here, the gap 9b between adjacent coils 6 is used as a reference. With respect to this reference, the relationship between the gap 9a between the coil component body 2 and one side wall 32 extending parallel to the extension direction of the legs 52 of the core 5 and the gap 9c between the coil component body 2 and the other side wall 32 facing the one side wall 32 and extending parallel to the extension direction of the legs 52 of the core 5 is as follows: In other words, if the distances in the direction perpendicular to the legs 52, in other words, the direction parallel to the extension of the yoke portion 53, are Gb, Ga, and Gc, respectively, in the gap 9b, gap 9a, and gap 9c, respectively, are Gb, Ga, and Gc, respectively, then Ga > Gb / 2 and Gc > Gb / 2.

[0026] Specifically, the gaps 9a and 9c are between the coil circumferential surface 61 of the coil 6 that fits onto the outermost leg portion 52 of the core 5 and the nearby side wall 32. In this coil component 1, the gaps 9a and 9c, which are more than half the gap 9b between adjacent coils 6, are provided between the side wall 32 of the box-shaped case 3 and the coil component main body 2.

[0027] The sealing resin 4 reduces vibration of the coil component body 2 by filling the gap between the coil component body 2 and the box-shaped case 3. The sealing resin 4 also transfers heat from the coil component body 2 to the box-shaped case 3. The sealing resin 4 also electrically, chemically, and mechanically protects the coil component body 2 from the external environment, and suppresses short circuits, corrosion, and damage to the coil component body 2. The sealing resin 4 is, for example, a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins include epoxy resin, urethane resin, silicone resin, and unsaturated polyester resin. Examples of thermoplastic resins include PPS resin.

[0028] 2 is a schematic diagram showing the process of pouring the sealing resin 4 into the box-shaped case 3. As shown in FIG. 2, after the coil component main body 2 is housed in the box-shaped case 3, the sealing resin 4 is poured from between the coil component main body 2 and the side wall 32. Between the coil component main body 2 and the side wall 32, gaps 9a and 9c are formed, each of which is more than half the gap 9b between adjacent coils 6. Because of such a wide opening, the sealing resin 4 does not overflow even if the pouring speed is increased, and the time required to pour the sealing resin 4 can be shortened.

[0029] 3 is a schematic diagram showing expansion that occurs within the coil component 1. The sealing resin 4 thermally expands in accordance with its volume when heated. Because the side wall 32 does not deform, when the sealing resin 4 between the coil component body 2, the side wall 32, and the gap 9a expands, all of this expansion force is directed toward the coil component body 2. Furthermore, because the side wall 32 does not deform, when the sealing resin 4 between the coil component body 2, the side wall 32, and the gap 9b expands, all of this expansion force is directed toward the coil component body 2.

[0030] The expansion force of this gap 9a extends parallel to the side wall 32 through the coil circumferential surface 61 of the coil 6 facing the gap 9a and acts on the leg 52 to which the coil 6 is attached. The leg 52 to which the coil 6 is attached is subjected to an external force in a direction perpendicular to the extension direction of the leg 52. Furthermore, the expansion force of the gap 9c extends parallel to the side wall 32 through the coil circumferential surface 61 of the coil 6 facing the gap 9c and acts on the leg 52 to which the coil 6 is attached. The leg 52 to which the coil 6 is attached is subjected to an external force in a direction perpendicular to the extension direction of the leg 52.

[0031] In response to this, the sealing resin 4 in the gap 9b between the coils 6 also expands, and half of the expansion force of the gap 9b supports the leg 52 that is receiving the external force from the gap 9a. Also, half of the expansion force of the gap 9b supports the leg 52 that is receiving the external force from the gap 9b.

[0032] Here, because the expansion force is proportional to the gap distance, when the distance Ga of the gap 9a between the side wall 32 and the coil component main body 2 is equal to half the distance Gb of the gap 9b between the coils 6, i.e., when Ga = Gb / 2, the expansion force of the gap 9a is completely canceled out by the expansion force of the gap 9b. Also, when the distance Gc of the gap 9c between the side wall 32 and the coil component main body 2 is equal to half the distance Gb of the gap 9b between the coils 6, i.e., when Gc = Gb / 2, the expansion force of the gap 9c is completely canceled out by the expansion force of the gap 9b. However, in order to shorten the time required to pour the sealing resin 4, the gap 9a and the gap 9c are formed to exceed half the gap 9b between the coils 6, and because Ga > Gb / 2 and Gc > Gb / 2, an external force that tilts both legs 52 facing the side wall 32 inward remains.

[0033] However, the bobbins 7 attached to both leg portions 52 are in contact with each other at the flanges 72. Therefore, the legs 52 are prevented from being displaced inward by this external force. On the other hand, FIG. 4 is a schematic diagram showing a case where adjacent bobbins 7 are not in contact with each other. If the adjacent bobbins 7 are not in contact with each other, the bobbins 7 cannot support the legs 52 of the comb-shaped block 51. Therefore, the legs 52 are displaced inward. This distortion generates stress in the center of the yoke portion 53 of the comb-shaped block 51, causing a crack 54 in the center of the yoke portion 53.

[0034] The cracks 54 cause an unnecessary gap length in the magnetic path of the core 5, resulting in deviations from the design inductance characteristics. However, as shown in Fig. 3, in this coil component 1, the occurrence of cracks 54 is prevented by the abutment of the bobbin 7. Therefore, even if the distance Ga of the gap 9a between the side wall 32 and the coil component body 2 and the distance Gb of the gap 9b between the coils 6 are increased to Ga > Gb / 2, and even if the distance Gc of the gap 9c between the side wall 32 and the coil component body 2 and the distance Gb of the gap 9b between the coils 6 are increased to Gc > Gb / 2, the inductance characteristics will not deviate from the design.

[0035] Therefore, the distance Ga of the gap 9a between the side wall 32 and the coil component main body 2 and the distance Gb of the gap 9b between the coils 6 are increased to Ga > Gb / 2, and the distance Gc of the gap 9c between the side wall 32 and the coil component main body 2 and the distance Gb of the gap 9b between the coils 6 are increased to Gc > Gb / 2, thereby increasing the pouring speed of the sealing resin 4.

[0036] Fig. 5 is a cross-sectional view showing a modified example of the coil component 1. As shown in Fig. 5, the coil component body 2 is wrapped with a tape 82 having an adhesive surface on one side. The tape 82 is wrapped around the coil component body 2 so as to surround the outer contour of the coil component body 2 when the coil component body 2 is projected along a direction perpendicular to the annular surface 5a of the core 5. In other words, the tape 82 is wrapped around the coil component body 2 one or more times along the circumference of the ring shape of the core 5 so as to surround the annular surface 5a of the core 5.

[0037] The coil component body 2 wound with this tape 82 is subjected to an external force in the direction of compression, and adjacent bobbins 7 can easily abut the flanges 72 together regardless of the presence of manufacturing errors, and can also easily maintain the abutment of the flanges 72. This further reduces the risk of cracks 54 occurring, and can prevent a decrease in yield while improving the production efficiency of the coil component 1.

[0038] Thus, this coil component 1 includes a coil component body 2 including at least two coils 6 and a core 5, a box-shaped case 3 that houses the coil component body 2, and a sealing resin 4 that fills the box-shaped case 3. The core 5 has a comb-shaped block 51 that has a plurality of parallel legs 52 and a yoke portion 53 that connects the legs 52 in a seamless manner.

[0039] The two coils 6 are wound around bobbins 7 and are attached separately to two adjacent leg portions 52 while the bobbins 7 abut against each other. For example, the bobbins 7 have a winding shaft 71 around which the coil 6 is wound and flange portions 72 that protrude from both ends of the winding shaft 71, and the flange portions 72 abut against adjacent bobbins 7. In addition, the box-shaped case 3 has two opposing side walls 32 that extend parallel to the legs 52, and where Ga is a gap 9a between one side wall 32 and the coil device main body 2, Gb is a gap 9b between the two coils 6, and Gc is a gap 9c between the other side wall 32 and the coil device main body 2, Ga > Gb / 2 and Gc > Gb / 2.

[0040] This makes it possible to create gaps 9a and 9b that are wider than half the distance Gb of gap 9b between two coils 6, while reducing the risk of cracks 54 occurring in yoke portion 53 of comb-shaped block 51. Therefore, in this manufacturing method of coil component 1, when sealing resin 4 is filled after coil component main body 2 is housed in box-shaped case 3, the pouring speed of sealing resin 4 can be increased, and the production efficiency of coil components 1 can be improved without deteriorating the yield of coil components 1.

[0041] Although the core 5 has been described as being formed by connecting two comb-shaped blocks 51, the shape of the other divided blocks is not limited as long as the core 5 is formed by connecting a plurality of divided blocks and at least one of the divided blocks is a comb-shaped block 51. For example, the divided block may be one comb-shaped block 51 and one yoke portion 53, with the legs 52 of the comb-shaped block 51 abutting against the same surface of the yoke portion 53 and fixed with an adhesive. Alternatively, the divided block may be one comb-shaped block 51, separate legs 52 the same number as the legs 52 of the comb-shaped block 51, and one separate yoke portion 53, with the separate legs 52 added to the comb-shaped block 51 and abutting against the same surface of the yoke portion 53 and fixed with an adhesive 81.

[0042] The box-shaped case 3 is not limited to a rectangular parallelepiped shape as long as it includes a pair of opposing side walls 32 that extend parallel to the legs 52. Furthermore, the pair of opposing side walls 32 also need not be truly parallel as long as they extend toward the legs 52, and one or both may extend at an angle relative to the legs 52. Furthermore, it is sufficient that the area of the side walls 32 that faces the legs 52 extends toward the legs 52, and the entire surface of the side walls 32 does not need to be flat.

[0043] The coil device main body 2 may be arranged in the box-shaped case 3 so that the annular surface 5a of the core 5 stands perpendicular to the bottom surface 31, or so that the annular surface 5a of the core 5 faces the bottom surface 31. Either housing method can improve production efficiency without deteriorating yield.

[0044] Although the example in which the coil component body 2 is housed in the box-shaped case 3 and then the sealing resin 4 is poured into the box-shaped case 3 has been described above, the manufacturing method is not limited to this. The coil component body 2 may be submerged after the sealing resin 4 is poured into the box-shaped case 3. Even when the coil component body 2 is submerged later, if the submerging speed is increased, the sealing resin 4 may overflow. However, if the gap 9a between one side wall 32 and the coil component body 2 is Ga, the gap 9b between the two coils 6 is Gb, and the gap 9c between the other side wall 32 and the coil component body 2 is Gc, the submerging speed can be increased and production efficiency can be improved by ensuring that Ga > Gb / 2 and Gc > Gb / 2. Furthermore, the risk of cracks 54 occurring in the yoke portion 53 of the comb-shaped block 51 can be reduced.

[0045] Additionally, the coil 6 and the core 5 are fixed together with tape 82 that runs along the annular circumference of the core 5. This makes it easier to bring adjacent bobbins 7 into contact with each other and to maintain this contact, thereby improving the production efficiency of the coil component 1 and preventing a decrease in yield.

[0046] The above-described embodiments of the present invention are presented as examples, and the present invention is not limited to the above-described embodiments. The above-described embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The embodiments and their modifications are included in the scope of the present invention. [Explanation of symbols]

[0047] 1 Coil parts 2 Coil component body 3 Box-shaped case 31 bottom 32 Side wall 4 Sealing resin 5 cores 5a Annular surface 51 Comb Block 52 Legs 53 York 54 Crack 6 coils 61 Coil circumference 7 Bobbin 71 Reel 72 Tsuba 73 Tsuba-rim surface 81 Adhesive 82 Tape 9a Gap 9b Gap 9c Gap

Claims

1. at least two coils; Each bobbin corresponds to one of the coils and is wound with the corresponding coil; a core having a plurality of split cores connected in an annular shape; a coil component body including the coil and the core; a box-shaped case that houses the coil component body; a sealing resin filled in the box-shaped case; Preparation, At least one of the divided cores has a plurality of parallel legs and a yoke portion connecting the legs in a seamless manner, The two coils are attached separately to the two adjacent leg portions, with the bobbins abutting against each other, The box-shaped case has two side walls extending parallel to the legs, where Ga is a gap between one of the side walls and the coil component body, Gb is a gap between the two coils, and Gc is a gap between the other of the side walls and the coil component body, Ga > Gb / 2 and Gc > Gb / 2. A coil component characterized by:

2. the bobbin has a winding shaft around which the coil is wound and flanges extending from both ends of the winding shaft, and the flanges of the bobbins abut against each other at the adjacent bobbins; The coil component according to claim 1 ,

3. the coil and the core are fixed together with tape along the annular circumference of the core; The coil component according to claim 1 ,

4. A method for manufacturing a coil component in which a coil component main body is accommodated in a box-shaped case, The coil component body includes: at least two coils; Each bobbin corresponds to one of the coils and is wound with the corresponding coil; a core having a plurality of split cores connected in an annular shape; Equipped with At least one of the divided cores has a plurality of parallel legs and a yoke portion connecting the legs in a seamless manner, The two coils are attached separately to the two adjacent leg portions, with the bobbins abutting against each other, The coil component body is housed in the box-shaped case so that the two side walls of the box-shaped case and the leg portions are parallel to each other; In the box-shaped case, when a gap between one of the side walls and the coil component body is Ga, a gap between the two coils is Gb, and a gap between the other of the side walls and the coil component body is Gc, Ga > Gb / 2 and Gc > Gb / 2 are satisfied, the sealing resin is filled after the coil component main body is housed in the box-shaped case, or the coil component main body is submerged in the sealing resin after the sealing resin is filled in the box-shaped case; A method for manufacturing a coil component, comprising:

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