Electronic components and coil components

Abstract

To provide electronic components and coil components that can easily detect foreign objects exceeding a predetermined size objectively and quickly using visual inspection or a camera. [Solution] An electronic component having terminals or electrodes, At least the surface of the member to which the terminal or electrode is attached is provided with a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

Description

Technical Field

[0001] The present invention relates to electronic components and coil components.

Background Art

[0002] As shown in Patent Document 1 below, surface-mounted coil components have been developed. In this type of coil component, foreign matter adhesion during the manufacturing process may become a problem. Specifically, foreign matter such as solder balls and pieces of ferrite cores may adhere to the surface of the coil component.

[0003] In order to prevent products from being shipped with foreign matter attached, visual inspection or inspection with a camera for foreign matter adhesion is performed. When detecting foreign matter, when a foreign matter of a predetermined size or more is detected in a predetermined number of fields of view in a predetermined number or more, operations such as sending the product in which the foreign matter is detected under such conditions to a cleaning process or the like become necessary.

[0004] However, it is often difficult to objectively and quickly detect foreign matter of a predetermined size or more visually or with a camera. Such problems associated with the detection of foreign matter are not limited to coil components, but are the same for electronic components having terminals or electrodes widely.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In view of such a situation, the present invention has been made, and an object thereof is to provide an electronic component and a coil component in which it is easy to objectively and quickly detect foreign matter of a predetermined size or more visually or with a camera.

Means for Solving the Problems

[0007] To achieve the above objective, an electronic component according to one aspect of the present invention is: An electronic component having terminals or electrodes, At least the surface of the member to which the terminal or electrode is attached is provided with a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

[0008] To achieve the above objective, a coil component according to one aspect of the present invention is: A coil component having a terminal block to which terminals are attached, The surface of the terminal block is provided with a detection pattern having a width or spacing smaller than the size of the foreign object to be detected.

[0009] The terminal may have a connecting portion and a mounting portion. The detection pattern may be provided on the surface of the terminal block located near the connecting wire portion or the mounting portion.

[0010] Furthermore, the terminal block may have a cover having a terminal block covering portion that covers at least a part of the terminal block. The detection pattern may be provided at least on the surface of the cover that is close to the terminal.

[0011] With electronic components including such coil components, when a foreign object is present on the detection pattern, the foreign object is observed against the detection pattern, making it easy to determine whether the size of the foreign object is large or small compared to the width or spacing of the detection pattern. Therefore, with this electronic component (including the coil component), it becomes easy to objectively and quickly detect foreign objects larger than a predetermined size through visual inspection or by foreign object detection device (camera), etc.

[0012] For example, the pattern width or spacing of the detection pattern may be 0.1 to 5 mm, 0.1 to 3 mm, 0.1 to 1 mm, or 0.1 to 0.5 mm. Regarding the size of foreign objects to be detected, small foreign objects are often 0.1 mm or larger, while larger foreign objects vary depending on the type of foreign object, but those exceeding 5 mm are rare. Therefore, the pattern width or spacing of the detection pattern is preferably within the above range, but may fall outside this range depending on the size of the foreign object to be detected.

[0013] Furthermore, depending on the location where the pattern is formed, it can also be used as a positioning scale when attaching other parts such as cores, and the pattern can also be used to improve the positioning accuracy of mounting members such as cores.

[0014] Preferably, the detection pattern is a repeating pattern of bumps and ridges formed on the surface of the member. A pattern without bumps or ridges is also acceptable, but a pattern formed by repeating bumps or ridges allows for a more three-dimensional observation of foreign objects on the pattern due to differences in reflected light from illumination, further improving the accuracy of foreign object detection.

[0015] The surface of the member on which the detection pattern is formed may come into contact with adhesive applied within a predetermined range. A pattern consisting of repeating indentations and recesses can be expected to improve adhesive strength by retaining the adhesive in the recessed areas. Furthermore, depending on the direction of the pattern, it may be possible to effectively prevent the adhesive from spreading, making it easier to apply the adhesive effectively within the predetermined range to be bonded. However, if the spreading is greater than expected, the adhesive may drip or fail to reach its desired height, potentially reducing the bonding effect. [Brief explanation of the drawing]

[0016] [Figure 1] Figure 1 is a perspective view of a coil component according to one embodiment. [Figure 2] Figure 2 is an exploded perspective view of the coil component shown in Figure 1. [Figure 3] Figure 3 is a perspective view showing the configuration of the bobbin of the coil component shown in Figure 1. [Figure 4] Figure 4 is a perspective view showing the configuration of the cover of the coil component shown in Figure 1. [Figure 5] Figure 5 is a perspective view showing the configuration of the core and the fixing tape of the coil component shown in Figure 1. [Figure 6] Figure 6 is a front view showing the state before the core of the coil component shown in Figure 1 is mounted. [Figure 7] Figure 7 is a front view of the coil component shown in Figure 1. [Figure 8] Figure 8 is a bottom view showing the configuration of the coil portion of the coil component shown in Figure 1. [Figure 9] Figure 9 is a plan view showing the configuration of the coil portion of the coil component shown in Figure 1. [Figure 10A] Figure 10A is an enlarged perspective view of the main part of the detection pattern formed on the surface of the bobbin shown in Figure 1. [Figure 10B] Figure 10B is an enlarged perspective view of the main part of the detection pattern showing a modified example of the detection pattern shown in Figure 10A. [Figure 10C] Figure 10C is an enlarged perspective view of the main part of the detection pattern showing a modified example of the detection pattern shown in Figure 10A. [Figure 10D] Figure 10D is an enlarged perspective view of the main part of the detection pattern showing a modified example of the detection pattern shown in Figure 10A. [Figure 11A] Figure 11A is a photograph of an example showing a state where foreign matter is detected on the detection pattern as shown in Figure 10A. [Figure 11B] Figure 11B is a photograph of a comparative example showing a state where foreign matter exists on the surface of the bobbin without the detection pattern as shown in Figure 10A. [Figure 12] Figure 12 is a perspective view of a coil component according to another embodiment. [Figure 13] Figure 13 is a perspective view of a chip component as an example of an electronic component according to the embodiment.

Embodiments for Carrying Out the Invention

[0017] Embodiments will be described below. While the descriptions will refer to the drawings as necessary, the illustrations are for illustrative purposes only to aid in understanding the present invention, and the appearance and dimensional ratios may differ from the actual product. Furthermore, although the embodiments will be described in detail below, the invention is not limited to these embodiments. For example, at least some of the embodiments shown below may be combined to create new embodiments.

[0018] First Embodiment As shown in Figure 1, the coil component 1 according to this embodiment is used, for example, in an on-board charger for an EV (Electric Vehicle), PHV (Plug-in Hybrid Vehicle), or commuter vehicle, or in a power supply circuit for household or industrial electrical equipment, or in a power supply circuit for computer equipment, and is used as a transformer to which a high voltage is applied.

[0019] As shown in Figures 1 and 2, this coil component 1 has a core (magnetic core) 2, a bobbin 3, and a cover 5. In the drawings, the X, Y, and Z axes are perpendicular to each other, and the Z axis corresponds to the height (thickness) of the coil component 1. The X axis is parallel to the winding axis of the coil section, which will be described later.

[0020] As shown in Figures 2 and 3, the bobbin 3 has a cylindrical portion 30 and a pair of terminal blocks 36, 36 integrally molded to the cylindrical portion 30 so as to be located on mutually opposite sides of the cylindrical portion 30 in the X-axis direction.

[0021] In this embodiment, the pair of terminal blocks 36, 36 have the same configuration, but they do not necessarily have to be the same. For example, the number of terminals 9 mounted on one terminal block 36 may be different from the number of terminals 9 mounted on the other terminal block 36. Also, for example, the shape of the terminals 9 mounted on one terminal block 36 may be different from the shape of the terminals 9 mounted on the other terminal block 36, and the shapes of the terminal blocks themselves may be different.

[0022] The cylindrical portion 30 of the bobbin 3 has a winding core portion around which the wire 8 is wound, and a first end flange portion 32 and a second end flange portion 32 located on both sides of the winding core portion in the X-axis direction. An intermediate flange portion 33 is integrally formed on the outer circumference of the winding core portion of the cylindrical portion 30 located between the first end flange portion 32 and the second end flange portion 32. The cylindrical portion 30 has through holes 31 for core legs that penetrate the winding core portion, which has the first end flange portion 32, the intermediate flange portion 32 and the second end flange portion 32, in the X-axis direction.

[0023] In this embodiment, the cores 2,2 have the same shape and have an E-shaped cross-section in the XY cross-section, thus constituting a so-called E-type core. That is, each core 2,2 has a base portion 23 extending in the Y-axis direction, a pair of outer leg portions 22,22 protruding in the X-axis direction from both ends of the base portion 23 in the Y-axis direction, and a middle leg portion 21 protruding in the X-axis direction from the center in the Y-axis direction between these outer leg portions 22,22.

[0024] In this embodiment, each of the intermediate legs 21, 21 is inserted into the through-hole 31 for the core legs of the bobbin 3 from both sides in the X-axis direction. Inside the through-hole 31 for the core legs of the bobbin 3, the tips of the intermediate legs 21, 21 may be in contact and abutting against each other, or they may be configured to face each other with a predetermined gap in between. By forming a gap, the leakage characteristics can be adjusted according to the width of the gap.

[0025] As shown in Figure 2, the middle leg portions 21, 21 have a roughly rectangular prism shape so as to match the shape of the inner circumferential surface of the through-hole 31 for the core leg, but their shape is not particularly limited and may be changed to match the shape of the through-hole 31 for the core leg. The outer leg portions 22, 22 have a shape that matches the shape of the Y-axis end faces of the flange portions 32, 33, and their outer surfaces have a plane parallel to the XZ plane (a plane containing the X and Z axes). In this embodiment, the material of each core 2, 2 can be a metal, a soft magnetic material such as ferrite, etc., but is not particularly limited.

[0026] The terminal blocks 36, 36 each extend from below the end flanges 32, 32 in the Z-axis direction outward in the X-axis direction (outward when viewed from the center of the bobbin 3 / hereinafter the same). Preferably, the upper surface of the terminal block 36 along the Z-axis is lower than the bottom surface of the through hole 31 by the thickness of the terminal block covering portion 57 of the cover 5, which will be described later. It is preferable that the upper surface of the terminal block covering portion 57 and the bottom surface of the through hole 31 are flush. This is to facilitate the guidance of the middle leg portion 21 of the core 2 from the upper surface of the terminal block covering portion 57 to the bottom surface of the through hole 31.

[0027] Furthermore, the Y-axis width of the terminal blocks 36, 36 is greater than the Y-axis width of the end flanges 32, 32, and they protrude by a predetermined width from both Y-axis faces of the flanges 32. Preferably, the predetermined width by which the terminal blocks 36, 36 protrude along the Y-axis from both Y-axis faces of the flanges 32, 32 is approximately the same as the Y-axis width of the outer leg portion 22 of the core 2. The upper surfaces of the terminal blocks 36, 36 are covered by the terminal block covering portions 57, 57 of the cover 5, respectively, and the cores 2, 2 are arranged on top of them.

[0028] Each terminal block 36, 36 has multiple terminals 9 arranged and embedded along the Y-axis. As shown in Figure 3, each terminal 9 has a connecting portion 91 and a mounting portion 92, and the space between them is insert-molded into the terminal block 36 of the bobbin 3 so that it is embedded inside the terminal block 36.

[0029] One of the lead portions 81 of the multiple wires 8 is connected to the connecting portion 91. The mounting portion 92 is a part that is connected to a circuit pattern such as a circuit board (not shown), and the coil portion 80 formed by the wires 8 is connected to an external circuit such as a circuit board through each terminal 9.

[0030] As shown in Figure 3, in this embodiment, multiple wires 8 are wound around the outer circumference of the core located between the first end flange 32 and the intermediate flange 33, and between the intermediate flange 33 and the second end flange 32, and the coil sections 80 and coil sections 80 constitute one or more transformers.

[0031] Wire 8 may be composed of a single wire or a stranded wire such as Litz wire. The diameter of wire 8 is not particularly limited, but is preferably in the range of 0.1 to 0.4 mm. Wire 8 is composed of a conductive wire such as a metal wire, but may also be an insulated wire.

[0032] As shown in Figure 8, the pair of lead portions 81, 81, which are the ends of each wire 8 constituting each coil portion 80, pass through lead passages 38 formed between reinforcing ribs 37 formed on the bottom surface of the terminal block 36, are led to each terminal 9, and are connected to the connecting portion 91 of the terminal 9, as shown in Figure 9.

[0033] The bobbin 3, including the cylindrical portion 30 and the terminal block 36, is integrally molded from a plastic such as PPS, PET, PBT, LCP, or nylon, but may be composed of other insulating materials. However, in this embodiment, the bobbin 3 is preferably made of a plastic with a high thermal conductivity of, for example, 1 W / m·K or higher, such as PPS or nylon.

[0034] As shown in Figures 2 and 4, the cover 5 is made of a different material from the bobbin 3. While the cover 5 can be made of the same insulating material as the bobbin 3, it is preferable that it be made of an insulating material with better elasticity than the bobbin 3, such as LCP or nylon.

[0035] The cover 5 has terminal block covering portions 57, 57 that cover the upper surfaces of a pair of terminal blocks 36 along the Z axis, and connecting covering portions 58, 58 that extend along the X axis to connect the Y-axis ends of each terminal block covering portion 57, 57. The upper surfaces of the terminal block covering portions 57, 57 and the connecting covering portions 58, 58 are flush, and the base portions 23, 23 and outer leg portions 22, 22 of each core 2, 2 are arranged on them. Side end covering portions 59 are integrally provided at both Y-axis ends of the terminal block covering portions 57, 57 and the connecting covering portions 58, 58, respectively, to cover the upper parts of the Y-axis end faces of each terminal block 36, 36.

[0036] A central opening 56 is formed in the center of the cover 5, which is surrounded by terminal block coverings 57, 57 and connecting coverings 58, 58. The upper part of the cylindrical portion 30 of the bobbin 3 is inserted into this central opening 56 from below along the Z-axis.

[0037] From each opening edge along the X-axis of the central opening 56 of the cover 5, end walls 52 are formed to rise integrally upward along the Z-axis. Along the Y-axis of each end wall 52, an end opening 51 is formed in the center that intersects with and communicates with the central opening 56. The cover 5 has an upper wall 53 to connect the upper ends along the Z-axis of each end wall 52 located on both sides along the X-axis.

[0038] Furthermore, the cover 5 has side walls 54, 54 that are integrated to connect the upper ends of each end wall 52 located on both sides along the X-axis with the upper ends along the Y-axis. Each side wall 54, 54 is notched down along the Z-axis so as not to be directly connected to the connecting covering portion 58, and each side wall 54, 54 of the cover 5 has a side opening 54 that reaches the central opening 56.

[0039] As shown in Figure 4, each end opening 51 is divided into a continuous main opening 51a and a sub-opening 51b by claw portions 55, 55 that protrude inward from each opening edge 52a located on both sides along the Y-axis of the end opening 51. The width of the main opening 51a along the Y-axis is narrower than the width of the sub-opening 51b along the Y-axis, and the width of the space between the claw portions 55, 55 located on both sides along the Y-axis of the end opening 51 is narrower than the width of the main opening 51a along the Y-axis.

[0040] By making the width of the secondary opening 51b along the Y-axis longer than the width of the main opening 51a along the Y-axis, the claw portion 55 becomes easier to bend and elastically deform, and the adhesive 10 becomes easier to penetrate into the interior of the secondary opening 51b. The upper end of the secondary opening 51b extends beyond the intersection of the end wall 52 and the upper wall 53, cutting out a portion of the upper wall 53.

[0041] As shown in Figures 2 and 3, each end flange 32 of the bobbin 3 is integrally provided with a projection 34 as a second engaging portion, located above the through hole 31, on the upper side of the end face along the Z axis, above the end face along the X axis. The projection 34 is formed to protrude outward along the X axis from the end face along the X axis of each end flange 32.

[0042] The length of the protrusion 34 along the Y-axis is shorter than the width along the Y-axis between the claw portions 55, 55 located on both sides of the end opening 51 along the Y-axis, and is equal to or slightly longer than the length of the main opening 51a along the Y-axis. This is so that the protrusion 34 fits inside the main opening 51a and the inclined surface 34a of the protrusion 34 contacts the claw portions 55, 55.

[0043] As shown in Figure 3, the protrusion 34 has an inclined surface 34a that guides the claw portion 55, which serves as the first engaging portion as shown in Figure 2, to the hook portion 34b by bending and deforming it along the X-axis, and a hook portion 34b into which the claw portion 55 engages. The hook portion 34b is formed downward along the Z-axis of the inclined surface 34a and forms the lower surface of the protrusion 34. The inclined surface 34a forms the upper surface of the protrusion 34. As shown in Figure 6, the claw portions 55, 55 are formed on the opening edge 52a of the end wall 52 so that the claw portions 55, 55 engage with the hook portion 34b from both sides along the Y-axis at the position where the hook portion 34b of the protrusion 34 is formed.

[0044] The width between the end walls 52 shown in Figure 4, which face each other along the X-axis, is approximately the same as, or slightly wider than, the width between the end faces of the end flanges 32 of the bobbin 3 shown in Figure 3, which face each other along the X-axis. Furthermore, the protrusion height of the convex portions 34 formed on the end faces of each flange end 32 is set such that, as shown in Figure 1, the convex portions 34 protrude along the X-axis from the sub-opening 51b of the cover 5 after the cover 5 has been assembled to the bobbin 3.

[0045] Therefore, when the cover 5 is placed over the bobbin 3 from above along the Z-axis, the claw portion 55 contacts the inclined surface 34a of the protrusion 34 and is guided to the hook portion 34b while bending and deforming along the X-axis. Once the maximum protruding position of the protrusion 34 has been passed, the shape of the claw portions 55, 55 returns to its original state, and the claw portions 55, 55 lock onto the hook portion 34b from both sides along the Y-axis in a one-touch manner.

[0046] In this embodiment, as shown in Figure 3, a detection pattern 100 is formed on the surface of the terminal block 36 located at least near the connecting portion 91 or the mounting portion 92. The area near the connecting portion 91 or the mounting portion 92 includes the surface of the terminal block 36 or other component located inside a sphere of radius r, centered on the portion where the connecting portion 91 or the mounting portion 92 protrudes from the surface of the terminal block 36. The radius r is determined by, for example, the range over which foreign matter such as solder balls that may be generated when connecting the wire lead portion 81 to the connecting portion 91 may scatter, and is not particularly limited, but is for example within a range of 10 mm.

[0047] In this embodiment, the detection pattern 100 is formed not only on the surface of the terminal block 36 near the connecting portion 91 or the mounting portion 92, but also continuously on almost the entire surface of the terminal block 36. For example, the detection pattern 100 is formed continuously on the top and back surfaces of the terminal block 36 that are approximately perpendicular to the Z axis, and on the side surfaces that are approximately perpendicular to the Y axis. The detection pattern 100 is also formed on the outer surface of the end flange portion 32 of the bobbin 3. In the drawings, the detection pattern 100 is shown by hatching with diagonal lines.

[0048] In this embodiment, the detection pattern 100 is also formed on the outer surface of the cover 5, the outer surface of the core 2, etc., as shown in Figure 2. In this embodiment, the detection pattern 100 is not formed on the outer surface of the tape 11, but it may be formed. However, if the detection pattern 100 is formed on the outer surface of the tape 11, it may be a flat image pattern without irregularities, rather than a repeating pattern of irregularities described later.

[0049] In this embodiment, for example, as shown in Figure 10A, the detection pattern 100 is composed of a repeating pattern of bumps and dips obtained by forming grooves 102 with a depth D1 in a stripe pattern at predetermined intervals width W2 on the surface 101 of a member such as a terminal block 36. The width (pattern width) W1 of the grooves 102 is not particularly limited, but may be, for example, 0.1 to 5 mm, 0.1 to 3 mm, 0.1 to 1 mm, or 0.1 to 0.5 mm. The width (pattern width) W1 of the grooves 102 is preferably uniform along the longitudinal direction of the grooves 102, but may be different.

[0050] Furthermore, the spacing W2 of the grooves 102 may be the same as the width W1 of the grooves 102, but may also be different and is not particularly limited, but may be, for example, 0.1 to 5 mm, 0.1 to 3 mm, 0.1 to 1 mm, or 0.1 to 0.5 mm. The depth D1 of the grooves is not particularly limited and may be 0, but is greater than 0, preferably 1 / 20 or more of the width W1 of the grooves, and preferably 0.1 mm or less at most.

[0051] Regarding the size of foreign objects to be detected, small foreign objects are often 0.1 mm or larger, while larger foreign objects vary depending on the type of foreign object, but those exceeding 5 mm are rare. Therefore, the pattern width or spacing of the detection pattern is preferably within the above range, but it may fall outside this range depending on the size of the foreign object to be detected.

[0052] The groove 102 may be continuous along its longitudinal direction, but it may also be an intermittent groove 102a separated by a vertical spacing L1 from the widthwise spacing W2, for example, as shown in Figure 10B. The spacing L1 may be similar to the spacing W2, but may also be different. The shape of the longitudinal end of the groove 102a may be a semicircle, as shown in Figure 10B, but may also be a straight line, polygon, ellipse, or other shape.

[0053] Furthermore, as shown in Figure 10C, the groove 102b may be a rectangular groove, a triangular groove, a polygonal groove with pentagons or more sides, or, as shown in Figure 10D, a circular groove, an elliptical groove, a groove with a shape combining polygons and squares, or a groove of any other shape. The foreign matter is not particularly limited, and examples include, in addition to solder poles, core fragments, terminal burrs, terminal plating debris, solder debris, wire debris, and resin molding burrs.

[0054] Next, an example of a method for manufacturing the coil component 1 according to this embodiment will be described. The coil component 1 is manufactured by winding a wire 8 around the core of a bobbin 3, as shown in Figure 3, and assembling the components shown in Figure 2.

[0055] First, prepare the bobbin 3 shown in Figures 3, 8, and 9. The bobbin 3 can be molded, for example, by injection molding, and a raised and recessed pattern, such as the reverse pattern of the raised and recessed pattern shown in Figure 10A, is formed on the inner circumferential surface of the mold cavity so that the detection pattern 100 is formed in the necessary locations on the outer surface of the bobbin 3. The cover 5 is also formed, for example, by injection molding, and the detection pattern 100 is formed on its outer surface in the same manner as the bobbin 3.

[0056] Next, multiple wires 8 are wound around the core of the cylindrical portion 30 of the bobbin 3 to form a coil portion 80, and the lead portions 81 at both ends of the wires 8 are connected to the connecting portion 91 of the terminal 9. The method for connecting the lead portions 81 to the connecting portion 91 of the terminal 9 is not particularly limited, but examples include crimping, thermocompression, laser welding, and soldering.

[0057] Next, the cover 5 shown in Figure 4 is attached to the bobbin 3 shown in Figure 3. At this time, the cover 5 is assembled to the bobbin 3 so that the upper part of the cylindrical portion 30 of the bobbin 3 shown in Figure 2 is inserted into the central opening 56 of the cover 5. At this time, the protrusion 34 of the bobbin 3 passes from the central opening 56 through the main opening 51a of the end opening 51, the inclined surface 34a of the protrusion 34 comes into contact with the claw portion 55, the claw portion 55 bends outward along the X axis along the inclined surface 34a and elastically deforms, and then locks into the hook portion 34b of the protrusion 34.

[0058] As a result, the main opening 51a of the end opening 51 formed in the cover 5 and the through hole 31 of the bobbin 3 are aligned in a self-aligning manner. The protrusion 34 of the bobbin 3 is exposed to the outside of the cover 5 through the sub-opening 51b. The protrusion 55 has a shape that does not narrow the opening cross-section of the through hole 31 of the bobbin 3.

[0059] Next, with the cover 5 attached to the bobbin 3, the cores 2, 2 are attached to the cover 5 from both directions along the X-axis. That is, the middle legs 21, 21 of the cores 2, 2 are inserted into the through hole 31 of the bobbin 3 through the main opening 51a of the cover 5, and the outer legs 22, 22 of the cores 2, 2 are placed on the upper surface of the connecting covering portion 58 of the cover 5, thus attaching the cores 2, 2 to the cover 5.

[0060] A gap may be provided between the tips of the middle leg portions 21, 21 that have entered the through hole 31, or there may be no gap. Furthermore, it is preferable that the tips of the outer leg portions 22 are in contact with each other.

[0061] Next, the tape 11 may be attached around the cores 2,2 assembled to the cover 5 to reinforce the fixation of the cores 2,2 to the cover 5 and the bobbin 3. The tape 11 is preferably an insulating tape, and is made of, for example, plastic or rubber. To form the detection pattern 100 on the outer surface of the tape 11, a raised or recessed detection pattern may be formed by, for example, press working, or a flat detection pattern without raised or recessed areas may be formed by printing.

[0062] Next, as shown in Figure 1, adhesive 10 is applied so that at least a portion of the protrusion 34 of the bobbin 3 that protrudes from the sub-opening 51b of the cover 5, at least a portion of the claw portion 55 of the cover 5, and a portion of the core 2 (preferably a portion of the boundary between the middle leg portion 21 and the base portion 23) are covered.

[0063] Preferably, the portion of the cover 5 where the claw portion 55 and the protrusion portion 34 are closest together is included in the fixing range of the adhesive 10. It is also preferable that the area near the boundary between the main opening 51a and the sub-opening 51b is included in the fixing range of the adhesive 10. The adhesive 10 is not particularly limited, but for example, epoxy adhesives and silicone adhesives can be used.

[0064] In this embodiment, as shown in Figure 1 for example, sufficient gaps exist between the lower part of the protrusion 34 protruding from the sub-opening 51b and the upper surface of the core 2, and between the claw portions 55, 55. Therefore, even an adhesive 10 with low fluidity can easily penetrate these gaps. The adhesive can also easily penetrate into the interior of the sub-opening 51b located around the protrusion 34. As a result, the adhesive strength between the core 2, bobbin 3, and cover 5 is improved, and the strength against vibration loads on the coil component 1 is also improved. Furthermore, in this embodiment, because the strength is improved, it becomes possible to reduce the thickness of the cover 5.

[0065] Alternatively, the same or a different adhesive 10a as adhesive 10 may be applied to the intersection of the upper surface of the terminal block covering portion 57 of the cover 5 and the tape 11 to fix them together. If the tape 11 is not provided, the adhesive 10a will bond and fix the base portion 23 of the core 2 and the terminal block covering portion 57 of the cover 5.

[0066] In the coil component 1 according to this embodiment, when the cover 5 is attached to the bobbin 3, the claw portion 55, which is the first engaging portion of the cover 5, fits onto the protrusion 34 of the bobbin 3. Therefore, even when transporting the bobbin 3 with the cover 5 attached by holding the upper surface of the upper wall 53 of the cover 5 with a suction nozzle or the like, the cover 5 is less likely to come off the bobbin 3, improving assembly workability.

[0067] Furthermore, when the cover 5 is attached to the bobbin 3, the end opening 51 of the cover 5 and the through hole 31 of the bobbin 3 are automatically positioned, making it easier to attach the core 2 to the end opening 51 and the through hole 31, thus improving assembly workability. The cover 5 is also fitted and fixed to the bobbin 3 by the claw portion 55, and the core 2 and bobbin 3 are bonded together with adhesive 10, including the claw portion 55. This improves the bonding strength between the cover 5, bobbin 3 and core 2, and improves the strength reliability of the coil component 1.

[0068] Furthermore, the cylindrical portion 30 of the bobbin 3 has end flanges 32, 32 along the X axis, and the end flanges 32, 32 each have protrusions 34 that act as second engaging portions that fit into the claw portions 55, 55 of the cover 5. This configuration further improves assembly workability and enhances the strength and reliability of the coil component 1.

[0069] Furthermore, the protrusion 34 has an inclined surface 34a that deforms and guides the claw portion 55, and a hook portion 34b into which the claw portion 55 engages. When attaching the cover 5 to the bobbin 3, the claw portion 55 of the cover 5 is guided by the inclined surface 34a of the protrusion 34 and elastically deforms, then returns to its original shape and engages with the hook portion 34b in a one-touch manner, and the cover 5 fits onto the bobbin 3 in a one-touch manner. Therefore, assembly workability is further improved, and the strength reliability of the coil component 1 is further enhanced.

[0070] Furthermore, in this embodiment, the claw portion 55 is positioned on the end wall 52, which has an end opening 51. This configuration makes the claw portion 55 more elastically deformable, making it easier to fit the cover 5 onto the bobbin 3 with a single touch. Consequently, assembly workability is further improved, and the strength reliability of the coil component 1 is further enhanced.

[0071] Furthermore, in this embodiment, the claw portion 55 protrudes inward from the opening edge 52a of the end wall 52 into the end opening 51, and the claw portion 55 is arranged on both sides in the width direction of the through hole 31. This configuration makes the first engaging portion, which consists of a pair of claw portions 22, more elastically deformable, making it easier to fit the cover 5 onto the bobbin 3 in a one-touch manner.

[0072] In another embodiment, one end opening 51 facing each other along the X-axis may be provided with a single claw portion 55, and the other end opening may also be provided with a single claw portion 55. In that case, it is preferable that the single claw portion 55 provided on one end opening 51 facing each other along the X-axis and the single claw portion 55 provided on the other end opening 51 are positioned diagonally opposite to each other when viewed from the Z-axis direction.

[0073] In this embodiment, the end opening 51 is divided into a main opening 51a and a sub-opening 51b by the claw portions 55, 55, and the middle leg portion 21 is inserted into the main opening 51a. This configuration makes it easier to align the main opening 51a of the cover 5 with the through hole 31 of the bobbin 3, and makes it easier to insert the middle leg portion 21 of the core 2 into the main opening 51a and the through hole 31.

[0074] Furthermore, in this embodiment, the bobbin 3 has a terminal block 36 to which terminals 9 connected to lead portions 81 drawn out from the coil portion 80 of the wire 8 are attached, and the cover 5 has a terminal block covering portion 57 that covers the terminal block 36. The terminal block covering portion 57 of the cover 5 increases the insulation distance from the terminals 9 to the core 2, improving the dielectric strength.

[0075] In this embodiment, for example, as shown in Figure 11A, when a foreign object such as a solder ball is present on the detection pattern 100, the foreign object is observed against the background of the detection pattern 100, making it easy to determine whether the size of the foreign object is large or small compared to the width or spacing of the detection pattern. Therefore, this coil component 1 makes it easy to objectively and quickly detect foreign objects of a predetermined size or larger through visual inspection or by a foreign object detection device (camera).

[0076] Furthermore, depending on the position and type of the detection pattern 100, it can also be used as a positioning scale when attaching other components such as the core 2, and the pattern 100 can also be used to improve the positioning accuracy of mounting members such as the core 2.

[0077] Furthermore, in this embodiment, since the detection pattern 100 is a repeating pattern of irregularities formed on the surface of a component such as the core 2, foreign objects on the pattern can be observed more three-dimensionally due to differences in reflected light from illumination light, further improving the accuracy of foreign object detection.

[0078] In this embodiment, as shown in Figure 1, for example, adhesives 10 and 10a applied within a predetermined range are in contact with the surfaces of the core 2 and cover 5, which are members on which the detection pattern 100 is formed. With the detection pattern 100 consisting of a repeating pattern of bumps and dips, the adhesive is retained in the dips, and it is expected that the adhesive strength will be improved. Furthermore, depending on the direction of the pattern, it is possible to effectively prevent the wetting and spreading of the adhesives 10 and 10a, making it easier to effectively apply the adhesive within the predetermined range to be bonded. However, if the wetting and spreading is greater than expected, the adhesive may drip or not reach a sufficient height, which may reduce the adhesive effect.

[0079] Second Embodiment The coil component 1a according to this embodiment, shown in Figure 12, differs from the coil component 1 according to the first embodiment described above in the following parts. The description of the common parts is the same as in the first embodiment and will therefore be omitted.

[0080] In this embodiment, the bobbin 3a differs from the first embodiment described above in the configuration of the protrusion 34A as the second engaging portion. As shown in Figure 12, in this embodiment, the protrusion 34A formed on at least one of the end flange portions 32 of the bobbin 3a is configured to be separated along the Y axis, and when viewed from the X axis direction, each has an inverted L shape, and each has an inclined surface and a hook portion.

[0081] Each protrusion 34A has a stopper portion formed integrally with it, extending downward along the Z-axis on the inward side in the Y-axis direction. Although these stopper portions are separated along the Y-axis when viewed from the X-axis direction, they may also be a single continuous stopper portion. In other words, the protrusions 34A separated along the Y-axis may be continuous with each other.

[0082] The presence of a stopper portion on each protrusion 34A restricts the relative movement of the protrusion 34A and the claw portion 55 in the Y-axis direction, thereby preventing the bobbin 3a and the cover 5 from being significantly misaligned in the Y-axis direction.

[0083] As is also the case in the first embodiment described above, the alignment of the cover 5 and the bobbin 3a (and the bobbin 3) along the Z-axis is achieved by the inner surface of the terminal block covering portion 57 of the cover 5 contacting the upper surface of the terminal block 36 of the bobbin 3 (see Figure 3). Alternatively, the alignment of the cover 5 and the bobbin 3a (and the bobbin 3) along the Z-axis is achieved by the inner surface of the magnetic surface 53 of the cover 5 contacting the upper parts of the flange portions 32 and 33 of the bobbin 3 (see Figure 3).

[0084] Furthermore, alignment of the cover 5 and the bobbin 3a (and the bobbin 3) along the X-axis is achieved by the inner surface of the end wall 52 of the cover 5 contacting the end face of the end flange 32 of the bobbin 3 (see Figure 3). Alternatively, alignment of the cover 5 and the bobbin 3a (and the bobbin 3) along the X-axis is achieved by the inner surface of the claw portion 55 of the cover 5 contacting the end face of the end flange 32 of the bobbin 3 (see Figure 3). As in the first embodiment, the claw portion 55 may be bent slightly inward along the X-axis compared to the end wall 52. This is to facilitate contact between the claw portion 55 and the end face of the end flange 32 of the bobbin 3 (see Figure 3).

[0085] In this embodiment as well, the detection pattern 100 is formed on the surface of the bobbin 3a, core 2, and cover 5, including the terminal block 36 located at least near the connecting portion 91 or the mounting portion 92, and provides the same effects as in the embodiment described above.

[0086] Third Embodiment The chip component 1b, an electronic component according to this embodiment shown in Figure 13, differs from the coil component 1 or 1a of the first or second embodiment described above in its internal structure, but it shares the common feature of having a detection mark 100 formed on the surface of an insulating material. In the following description, the differences will be explained in particular, and the description of the common parts will be omitted as it is the same as in the first or second embodiment.

[0087] Examples of chip components 1b include capacitor chips, inductor chips, varistor chips, and other electronic components, and the detection mark 100 described above is formed on the insulating surface of the chip body, which has a pair of terminal electrodes 94, 94 formed at both ends along the X axis. The detection mark 100 can be formed by, for example, laser processing, press processing, printing, etc., and may be formed before or after the formation of the terminal electrodes 94.

[0088] In this embodiment, as in the previously described embodiment, when a foreign object is present on the detection pattern 100, the foreign object is observed against the background of the detection pattern, making it easy to determine whether the size of the foreign object is large or small compared to the width or spacing of the detection pattern. Therefore, this chip component 1b makes it easy to objectively and quickly detect foreign objects of a predetermined size or larger through visual inspection or by a foreign object detection device (camera) or the like.

[0089] Furthermore, in this embodiment, by making the detection pattern 100 a pattern that is a repeating pattern of bumps and dips along the X axis, when forming the terminal electrodes 94, 94 by dipping them in electrode paste, it is possible to suppress the wetting and spreading of the paste and also expect to have the effect of positioning the electrodes.

[0090] It should be noted that the present invention is not limited to the embodiments described above, and can be modified in various ways within the scope of the present invention. For example, in the embodiment shown in Figure 13, the detection pattern 100 is formed on the entire surface of the chip body located between the terminal electrodes 94, 94, but the pattern 100 may be formed only on the surface of the chip body located near the terminal electrodes 94, 94. [Explanation of Symbols]

[0091] 1,1a... Coil components 1b... Chip components 2... Core 21...middle leg 22...Outer leg 23...Base section 23a…recess 3,3a...bobbin 30...Cylinder part 31…Through hole 32...End flange 33...Intermediate flange 34, 34A... Protruding part (second engaging part) 34a…Slope surface 34b...Hook part 36…Terminal block 37…Reinforcement ribs 38… Lead passage 5…cover 51…End opening 51a…Main opening 51b…Sub-opening 52…End wall 52a...Opening edge 53... Upper wall 54…Side wall 54a... Side opening 55...Claw part (first engaging part) 56…Central opening 57…Terminal block covering part 58... Connecting Covering Section 59... Side edge covering 8... Wire 80... Coil section 81... Lead section 9… Terminals 91...Connection section 92…Implementation Section 94...Terminal electrode 10,10a…Adhesive 11… Tape 100...Detection pattern 102,102a,102b,102c...Groove

Claims

1. An electronic component having terminals or electrodes, An electronic component having a detection pattern on the surface of at least the member to which the terminal or electrode is attached, the pattern having a width or spacing smaller than the size of the foreign object to be detected.

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

3. The electronic component according to claim 1 or 2, wherein the detection pattern is a repeating pattern of irregularities formed on the surface of the member.

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

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

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

7. The device further comprises a cover having a terminal block covering portion that covers at least a part of the terminal block, The coil component according to claim 5 or 6, wherein the detection pattern is provided on the surface of the cover, at least near the terminal.

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