Coil component

Abstract

To provide a coil component in which the adhesion strength between an elementary body and an external terminal is improved.SOLUTION: In a coil component 1, an area through which an external terminal electrode 60A and an elementary body 10 are brought into contact with each other is increased due to convex parts 61a, 61b of the external terminal electrode 60A, the external terminal electrode 60A and the elementary body 10 are more strongly adhered. Thereby, the adhesion strength between the external terminal electrode 60A and the elementary body 10 can be improved. As a result, it is possible to prevent the external terminal electrode 60A from peeling off from the elementary body 10.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a coil component.

Background Art

[0002] Conventionally, a coil component having a coil provided in a body has been known. Patent Document 1 below discloses a four-terminal coil component having two coils provided in a body.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the coil component as described above, generally, an external terminal electrically connected to an end of the coil is provided on the body surface. If the adhesion strength between the body and the external terminal is low, the external terminal may peel off from the body, so it is necessary to obtain sufficient adhesion strength.

[0005] An object of the present invention is to provide a coil component in which the adhesion strength between the body and the external terminal is improved.

Means for Solving the Problems

[0006] The coil component according to one aspect of the present invention includes a base body having a first end face and a second end face parallel to each other, an insulating substrate provided in the base body, exposed on the first end face, and an exposed region exposed on the first end face extending along a first direction, a first coil portion provided on the insulating substrate and having a first end portion exposed on the first end face, and a first external terminal provided on the first end face, covering a part of the exposed region of the insulating substrate and covering the first end portion of the first coil portion, and the first external terminal has a first convex portion protruding toward the exposed region of the insulating substrate along the first direction.

[0007] In the above coil component, due to the first convex portion of the first external terminal, the contact area between the first external terminal and the base body increases, so that the two are more firmly adhered to each other. Therefore, the adhesion strength between the first external terminal and the base body can be improved.

[0008] The coil component according to another aspect of the present invention is such that the first external terminal has a pair of the first convex portions, and the pair of the first convex portions protrude in opposite directions along the first direction.

[0009] The coil component according to another aspect of the present invention is such that the first convex portion is offset from the center position of the first external terminal with respect to a second direction orthogonal to the first direction on the first end face.

[0010] The coil component according to another aspect of the present invention is such that the outer shape of the first external terminal has a corner portion formed by a curve.

[0011] The coil component according to another aspect of the present invention is such that the insulating substrate includes a glass cloth.

[0012] The coil component according to another aspect of the present invention is such that the surface roughness of the insulating substrate in the exposed region is smaller than the surface roughness of the first end face of the base body.

[0013] The coil component according to another aspect of the present invention is such that the base body further has a pair of magnetic layers sandwiching the insulating substrate from a second direction orthogonal to the first direction on the first end face, and with respect to the second direction, the thickness of the insulating substrate is thinner than the thickness of the magnetic layer.

[0014] The coil component according to another aspect of the present invention has a base body made of a metal magnetic powder-containing resin.

[0015] The coil component according to another aspect of the present invention further has a mounting surface orthogonal to the first end face and the second end face, and a top face facing the mounting surface, and the first external terminal is spaced apart from the edge of the top face at the first end face.

[0016] The coil component according to another aspect of the present invention has the first external terminal having a plurality of regions arranged in a second direction orthogonal to the first direction at the first end face, and the plurality of regions include a first region including a first convex portion, a second region adjacent to the first region on the mounting surface side, and a third region adjacent to the first region on the top face side, and in the first direction, the length of the second region is longer than the length of the third region.

[0017] The coil component according to another aspect of the present invention has an insulating substrate protruding from the base body at the first end face.

[0018] The coil component according to another aspect of the present invention further includes a second coil portion provided on the insulating substrate and having a second end portion exposed at the first end face, and a second external terminal provided adjacent to the first external terminal in the first direction at the first end face, covering a part of the exposed region of the insulating substrate and covering the second end portion of the second coil portion, and the second external terminal has a second convex portion protruding toward the exposed region of the insulating substrate along the first direction, and at the first end face, the first convex portion of the first external terminal and the second convex portion of the second external terminal face each other.

Advantages of the Invention

[0019] According to the present invention, there is provided a coil component in which the adhesion strength between the base body and the external terminal is improved.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Mode for Carrying Out the Invention

[0021] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description, the same reference numerals are used for the same elements or elements having the same function, and redundant descriptions are omitted.

[0022] The coil component 1 according to the embodiment is, as an example, a balun coil. The balun coil is used, for example, when mounting a near-field communication circuit (NFC circuit) on a cellular terminal. By the balun coil performing conversion between the unbalanced signal of the antenna and the balanced signal of the NFC circuit, connection between the unbalanced circuit and the balanced circuit is realized. The coil component 1 can be used for a common mode filter or a transformer.

[0023] As shown in FIG. 1, the coil component 1 includes a body 10, a coil structure 20 embedded in the body 10, and a pair of external terminal electrodes 60A, 60B, 60C, 60D provided on the surface of the body 10.

[0024] The base body 10 has a rectangular parallelepiped outer shape and has six surfaces 10a to 10f. As an example, the base body 10 is designed with dimensions of a long side of 2.0 mm, a short side of 1.25 mm, and a height of 0.50 mm to 0.65 mm (0.65 mm as an example). Among the surfaces 10a to 10f of the base body 10, the end face 10a (the first end face) and the end face 10b (the second end face) are parallel to each other, the upper surface 10c (the mounting surface) and the lower surface 10d (the top surface) are parallel to each other, and the side surface 10e and the side surface 10f are parallel to each other. The lower surface 10d faces the upper surface 10c. The upper surface 10c, the lower surface 10d, the side surface 10e, and the side surface 10f are orthogonal to the end face 10a and the end face 10b. The upper surface 10c of the base body 10 is a surface that faces parallel to the mounting surface of the mounting substrate on which the coil component 1 is mounted. In the following description, the opposing direction of the side surfaces 10e and 10f is also referred to as the width direction of the base body 10, and the opposing direction of the upper surface 10c and the lower surface 10d is also referred to as the height direction of the base body 10.

[0025] The base body 10 is composed of a metal magnetic powder-containing resin 12, which is a kind of magnetic material. The metal magnetic powder-containing resin 12 is a bound powder in which metal magnetic powder particles are bound by a binder resin. The metal magnetic powder of the metal magnetic powder-containing resin 12 is composed of, for example, an iron-nickel alloy (Permalloy alloy), carbonyl iron, amorphous, non-crystalline or crystalline FeSiCr-based alloy, Sendust, etc. The binder resin is, for example, a thermosetting epoxy resin. In the present embodiment, the content of the metal magnetic powder in the bound powder is 80 to 92 vol% in volume percentage and 95 to 99 wt% in mass percentage. From the viewpoint of magnetic properties, the content of the metal magnetic powder in the bound powder may be 85 to 92 vol% in volume percentage and 97 to 99 wt% in mass percentage. The magnetic powder of the metal magnetic powder-containing resin 12 may be a powder having one kind of average particle size or a mixed powder having a plurality of kinds of average particle sizes.

[0026] As shown in FIGS. 2 and 3, the resin 12 containing metal magnetic powder of the base body 10 integrally covers a coil structure 20 described later. Specifically, the resin 12 containing metal magnetic powder covers the coil structure 20 from above and below and also covers the outer periphery of the coil structure 20. Further, the resin 12 containing metal magnetic powder fills the inner peripheral region of the coil structure 20. As shown in FIGS. 4 and 5, the resin 12 containing metal magnetic powder has a pair of magnetic portions 12a, 12b (magnetic layers) sandwiching the coil structure 20 from the height direction of the base body 10, and a plurality of magnetic portions 12c interposed between the magnetic portion 12a and the magnetic portion 12b. Also, as shown in FIG. 4, the maximum value W 10a ,W 10b and the minimum value W 20a ,W 20b are the thicknesses of the magnetic portions 12a, 12b along the height direction of the base body 10. The maximum value W 10a ,W 10b is the thickness of the magnetic portions 12a, 12b in a portion where the coil structures 40A and 40B described later are not interposed, for example, the thickness of the magnetic portions 12a, 12b at the corner portions defined by the end faces 10a, 10b and the side faces 10e, 10f. The maximum value W 10a of the thickness of the magnetic portion 12a and the maximum value W 10b of the thickness of the magnetic portion 12b are, for example, 235 μm to 315 μm. Also, the minimum value W 20a , the minimum value W 20b are, for example, the thicknesses of the magnetic portions 12a, 12b in a portion where the coil structures 40A and 40B described later are interposed. The minimum value W 20a of the thickness of the magnetic portion 12a and the minimum value W 20b of the thickness of the magnetic portion 12b are, for example, 80 μm to 270 μm.

[0027] The coil structure 20 is embedded in the metal magnetic powder-containing resin 12. The coil structure 20 includes an insulating substrate 30, an upper coil structure 40A provided above the insulating substrate 30, and a lower coil structure 40B provided below the insulating substrate 30. Note that the plurality of magnetic portions 12c described above are located in the same layer as the insulating substrate 30. The plurality of magnetic portions 12c fill the portion excluding the insulating substrate 30 in the layer where the insulating substrate 30 is provided. Specifically, a part of the magnetic portion 12c fills the inner peripheral region of the insulating substrate 30, and another part of the magnetic portion 12c fills the outer peripheral region of the insulating substrate 30.

[0028] The insulating substrate 30 has a flat plate shape and extends between the end faces 10a and 10b of the base body 10, and is designed to be orthogonal to the end faces 10a and 10b. Further, the insulating substrate 30 extends parallel to the upper surface 10c and the lower surface 10d of the base body 10. As shown in FIG. 3, the insulating substrate 30 has an elliptical annular coil forming portion 31 extending along the long side direction of the base body 10, and a pair of frame portions 34A and 34B extending along the short side direction of the base body 10 and sandwiching the coil forming portion 31 from both sides. The insulating substrate 30 is exposed from the end face 10a of the base body 10 in the frame portion 34A, and the frame portion 34A forms an exposed region R A exposed at the end face 10a. Similarly, the insulating substrate 30 is exposed from the end face 10b of the base body 10 in the frame portion 34B, and the frame portion 34B forms an exposed region R B exposed at the end face 10b. An elliptical opening 32 extending along the long side direction of the base body 10 is provided in the central portion of the coil forming portion 31.

[0029] The insulating substrate 30 is made of a non-magnetic insulating material. In this embodiment, the insulating substrate 30 has a structure in which a glass cloth is impregnated with an epoxy resin. The resin constituting the insulating substrate 30 is not limited to an epoxy resin, and may be a BT resin, polyimide, aramid, or the like. The constituent material of the insulating substrate 30 may be ceramic or glass. The constituent material of the insulating substrate 30 may be a printed circuit board material that is mass-produced. The constituent material of the insulating substrate 30 may be a resin material used for a BT printed circuit board, an FR4 printed circuit board, or an FR5 printed circuit board.

[0030] The thickness W of the insulating substrate 30 30 can be designed, for example, in the range of 10 μm to 60 μm as shown in FIG. 4. The thickness W of the insulating substrate 30 30 is, for example, 25 μm. The thickness W of the insulating substrate 30 30 is, for example, the minimum value W of the thickness of the magnetic portion 12a 20a and the minimum value W of the thickness of the magnetic portion 12b 20b and can be designed to be thinner. Note that the maximum value W of the thickness of the magnetic portion 12a 10a , the maximum value W of the thickness of the magnetic portion 12b 10b , and the thickness W of the insulating substrate 30 30 When added together, they have the same length as the height of the element body 10.

[0031] The upper coil structure 40A is provided on the upper surface 30a of the substrate in the coil forming portion 31 of the insulating substrate 30. As shown in FIGS. 2 and 3, the upper coil structure 40A includes a first planar coil 41, a second planar coil 42, and an upper insulator 50A. The first planar coil 41 and the second planar coil 42 are wound adjacent to each other in parallel on the upper surface 30a of the insulating substrate 30. In this embodiment, the thickness W of the upper coil structure 40A 40A is designed to be thicker than the thickness W of the insulating substrate 30 30 . As shown in FIG. 4, the thickness W of the upper coil structure 40A 40A is, for example, 90 μm to 175 μm, and as an example, 110 μm. Note that the minimum value W of the thickness of the magnetic portion 12a 20aand the thickness W of the coil structure 40A 40A When added together, it becomes the same thickness as the maximum value W of the thickness of the magnetic portion 12a 10a .

[0032] The first planar coil 41 is a substantially oval spiral air-core coil wound around the opening 32 of the coil forming portion 31 within the same layer on the upper surface 30a of the insulating substrate 30. The number of turns of the first planar coil 41 may be 1 turn or a plurality of turns. In the present embodiment, the number of turns of the first planar coil 41 is 3 to 4. The first planar coil 41 has an outer end portion 41a and an inner end portion 41b. The outer end portion 41a is provided on the frame portion 34A and is exposed from the end surface 10a of the element body 10. The inner end portion 41b is provided at the edge of the opening 32. On the insulating substrate 30, a first through conductor 41c extending in the thickness direction of the insulating substrate 30 is provided at a position overlapping the inner end portion 41b of the first planar coil 41. The first planar coil 41 is made of, for example, Cu and can be formed by electrolytic plating.

[0033] Similar to the first planar coil 41, the second planar coil 42 is a substantially oval spiral air-core coil wound around the opening 32 of the coil forming portion 31 within the same layer on the upper surface 30a of the insulating substrate 30. The second planar coil 42 is wound on the inner peripheral side of the first planar coil 41 so as to be adjacent to the first planar coil 41. The number of turns of the second planar coil 42 may be one turn or a plurality of turns. In the present embodiment, the number of turns of the second planar coil 42 is the same as the number of turns of the first planar coil 41. The second planar coil 42 has an outer end portion 42a and an inner end portion 42b. The outer end portion 42a of the second planar coil 42 is provided on the frame portion 34A, similar to the outer end portion 41a of the first planar coil 41, and is exposed from the end surface 10a of the element body 10. The inner end portion 42b of the second planar coil 42 is provided at the edge of the opening 32 and is adjacent to the inner end portion 41b of the first planar coil 41. An insulating substrate 30 is provided with a second through conductor 42c extending in the thickness direction of the insulating substrate 30 at a position overlapping the inner end portion 42b of the second planar coil 42. Similar to the first planar coil 41, the second planar coil 42 is made of, for example, Cu and can be formed by electrolytic plating.

[0034] The upper insulator 50A is provided on the upper surface 30a of the insulating substrate 30 and is a thick film resist patterned by known photolithography. The upper insulator 50A defines the plating growth regions of the first planar coil 41 and the second planar coil 42. In the present embodiment, as shown in FIG. 4, the upper insulator 50A integrally covers the first planar coil 41 and the second planar coil 42. More specifically, it covers the side surfaces and the upper surface of the first planar coil 41 and the second planar coil 42. As shown in FIGS. 5 and 6, a part of the upper insulator 50A extends from the inside of the element body 10 through between the outer end 41a and the outer end 42a to the end surface 10a of the element body 10 and is exposed on the end surface 10a. Also, as shown in FIGS. 5 and 6, a part of the upper insulator 50A extends from the inside of the element body 10 along the upper surface 30a of the substrate to the end surface 10b and is exposed on the end surface 10b. The thickness of the upper insulator 50A is thicker than the thicknesses of the first planar coil 41 and the second planar coil 42. The upper insulator 50A is made of, for example, an epoxy resin.

[0035] The lower coil structure 40B is provided on the lower surface 30b of the coil forming portion 31 of the insulating substrate 30. The lower coil structure 40B includes, as shown in FIGS. 2 and 3, a first planar coil 41, a second planar coil 42, and a lower insulator 50B. The first planar coil 41 and the second planar coil 42 are wound adjacent to each other in a parallel state on the lower surface 30b of the insulating substrate 30. In the present embodiment, the thickness W 40B of the lower coil structure 40B 30 is designed to be thicker than the thickness W 40B of the insulating substrate 30. As shown in FIG. 4, the thickness W 20b of the lower coil structure 40B 40B is, for example, 90 μm to 175 μm, and is 110 μm as an example. The sum of the minimum value W 10b of the thickness of the magnetic portion 12b and the thickness W

[0036] The first planar coil 41 and the second planar coil 42 of the lower coil structure 40B have symmetry with the first planar coil 41 and the second planar coil 42 of the upper coil structure 40A. More specifically, the first planar coil 41 and the second planar coil 42 of the lower coil structure 40B have a shape obtained by inverting the first planar coil 41 and the second planar coil 42 of the upper coil structure 40A around an axis parallel to the short side of the base body 10.

[0037] The outer end portion 41a of the first planar coil 41 of the lower coil structure 40B is provided on the frame portion 34B and is exposed from the end face 10b of the base body 10. The inner end portion 41b of the first planar coil 41 of the lower coil structure 40B overlaps with the first through conductor 41c provided on the insulating substrate 30. Therefore, the inner end portion 41b of the first planar coil 41 of the lower coil structure 40B is electrically connected to the inner end portion 41b of the first planar coil 41 of the upper coil structure 40A via the first through conductor 41c. The first planar coil 41 of the lower coil structure 40B is made of, for example, Cu and can be formed by electrolytic plating.

[0038] The outer end portion 42a of the second planar coil 42 of the lower coil structure 40B is provided on the frame portion 34B and is exposed from the end face 10b of the base body 10. The inner end portion 42b of the second planar coil 42 of the lower coil structure 40B overlaps with the second through conductor 42c provided on the insulating substrate 30. Therefore, the inner end portion 42b of the second planar coil 42 of the lower coil structure 40B is electrically connected to the inner end portion 42b of the second planar coil 42 of the upper coil structure 40A via the second through conductor 42c. The second planar coil 42 of the lower coil structure 40B is made of, for example, Cu and can be formed by electrolytic plating.

[0039] The lower insulator 50B is provided on the lower surface 30b of the insulating substrate 30 and is a thick film resist patterned by known photolithography. The lower insulator 50B, similar to the upper insulator 50A, defines the plating growth regions of the first planar coil 41 and the second planar coil 42. In the present embodiment, as shown in FIG. 4, the lower insulator 50B integrally covers the first planar coil 41 and the second planar coil 42. More specifically, it covers the side surfaces and the upper surfaces of the first planar coil 41 and the second planar coil 42. A part of the lower insulator 50B, similar to the upper insulator 50A, extends from the inside of the element body 10 through between the outer end 41a and the outer end 42a to the end face 10b of the element body 10 and is exposed on the end face 10b. Also, a part of the lower insulator 50B extends from the inside of the element body 10 to the end face 10a along the lower surface 30b of the substrate and is exposed on the end face 10a. The thickness of the lower insulator 50B is thicker than the thicknesses of the first planar coil 41 and the second planar coil 42. The thickness of the lower insulator 50B may be the same as the thickness of the upper insulator 50A. The lower insulator 50B is made of, for example, an epoxy resin.

[0040] The base body 10 is provided with a pair of coil parts C1 and C2 that constitute a double coil structure. The first coil part C1 is composed of a first planar coil 41 of an upper coil structure 40A provided on the upper surface 30a of the insulating substrate 30, a first planar coil 41 of a lower coil structure 40B provided on the lower surface 30b of the insulating substrate 30, and a first through conductor 41c that connects the first planar coils 41 on both sides. In the first coil part C1, the outer end 41a of the first planar coil 41 of the upper coil structure 40A constitutes the first end, and the outer end 41a of the first planar coil 41 of the lower coil structure 40B constitutes the second end. The second coil part C2 is composed of a second planar coil 42 of the upper coil structure 40A provided on the upper surface 30a of the insulating substrate 30, a second planar coil 42 of the lower coil structure 40B provided on the lower surface 30b of the insulating substrate 30, and a second through conductor 42c that connects the second planar coils 42 on both sides. In the second coil part C2, the outer end 42a of the second planar coil 42 of the upper coil structure 40A constitutes the first end, and the outer end 42a of the second planar coil 42 of the lower coil structure 40B constitutes the second end.

[0041] The two pairs of external terminal electrodes 60A, 60B, 60C, and 60D are provided in pairs on the mutually parallel end faces 10a and 10b of the base body 10.

[0042] Of the pair of external terminal electrodes 60A and 60B provided on the end face 10a, the external terminal electrode 60A (the first external terminal) is connected to the outer end portion 41a of the first planar coil 41 of the upper coil structure 40A and covers the outer end portion 41a. The external terminal electrode 60B (the second external terminal) is connected to the outer end portion 42a of the second planar coil 42 of the upper coil structure 40A and covers the outer end portion 42a. As shown in FIG. 7, the pair of external terminal electrodes 60A and 60B are adjacent to each other in the width direction of the base body 10 and are provided so as to be spaced apart from each other. When viewed from the end face 10a side, the external terminal electrode 60A is biased toward the side face 10f side and covers up to the vicinity of the side face 10f on the end face 10a. The external terminal electrode 60A is spaced apart from the edge of the lower face 10d on the end face 10a. Further, the external terminal electrode 60B is biased toward the side face 10e side and covers up to the vicinity of the side face 10e on the end face 10a. The external terminal electrode 60B is spaced apart from the edge of the lower face 10d on the end face 10a.

[0043] Of the pair of external terminal electrodes 60C and 60D provided on the end face 10b, the external terminal electrode 60C is connected to the outer end portion 41a of the first planar coil 41 of the lower coil structure 40B, and the external terminal electrode 60D is connected to the outer end portion 42a of the second planar coil 42 of the lower coil structure 40B. As shown in FIG. 8, the pair of external terminal electrodes 60C and 60D are adjacent to each other in the width direction of the base body 10 and are provided so as to be spaced apart from each other. The external terminal electrode 60C is biased toward the side face 10f side and covers up to the vicinity of the side face 10f on the end face 10b. The external terminal electrode 60C is spaced apart from the edge of the lower face 10d on the end face 10b. Further, the external terminal electrode 60D is biased toward the side face 10e side and covers up to the vicinity of the side face 10e on the end face 10b. The external terminal electrode 60D is spaced apart from the edge of the lower face 10d on the end face 10b.

[0044] The external terminal electrode 60A on the end face 10a and the external terminal electrode 60C on the end face 10b are provided at positions corresponding to each other in the long side direction of the base body 10. Similarly, the external terminal electrode 60B on the end face 10a and the external terminal electrode 60D on the end face 10b are provided at positions corresponding to each other in the long side direction of the base body 10.

[0045] The external terminal electrodes 60A, 60B, 60C, and 60D are all bent in an L shape and continuously cover the end faces 10a, 10b and the upper face 10c. In the present embodiment, the external terminal electrodes 60A, 60B, 60C, and 60D are made of resin electrodes, for example, resin containing Ag powder.

[0046] Subsequently, with reference to FIG. 7, the configuration of the end face 10a of the element body 10 will be described.

[0047] As described above, the insulating substrate 30 is exposed in the exposed region R on the end face 10a of the element body 10. A is exposed in. The exposed region R A extends between the side faces 10e and 10f of the element body 10 along the first direction (i.e., the width direction of the element body 10 on the end face 10a) parallel to the upper face 10c and the lower face 10d on the end face 10a. The exposed region R A is located at a substantially central position of the end face 10a with respect to the second direction (i.e., the facing direction with the upper face 10c and the lower face 10d, the height direction of the element body 10 on the end face 10a) orthogonal to the first direction.

[0048] The external terminal electrode 60A is located on the side face 10f side on the end face 10a and covers a part of the exposed region R. A The external terminal electrode 60A has a substantially rectangular shape when viewed from the end face 10a side, and more specifically, has a rectangular shape with rounded corners (i.e., rounded corners). Therefore, the outer shape of the external terminal electrode 60A does not have sharp corners. More specifically, the external terminal electrode 60A is composed of three regions arranged in the second direction. The three regions each have a rectangular shape extending in the first direction. Among the three regions, the first region R a1 is located on the exposed region R. A The second region R a2 is adjacent to the first region R a1 on the upper face 10c side. The third region R a3 is adjacent to the first region R a1and is adjacent on the lower surface 10d side. The first region R along the first direction a1 The length (i.e., the width of the first region R a1 is denoted as) W a1 is longer than the length (i.e., the width of the second region R a2 along the first direction). Further, the length of the second region R a2 is denoted as) W a2 is longer than the length (i.e., the width of the third region R a2 along the first direction). The length W of the first region R a2 is, for example, 500 μm to 600 μm, the length W of the second region R a3 is, for example, 400 μm to 500 μm, and the length W of the third region R a3 is, for example, 300 μm to 400 μm. When the second region R a3 is wide, the solder formation region near the mounting substrate expands during solder mounting, so the mounting strength and the stability of the electrical connection are enhanced. a1 The first region R located on the exposed region R a1 is located substantially at the center of the end face 10a in the second direction. The second region R of the external terminal electrode 60A a2 reaches the edge of the upper surface 10c on the end face 10a. On the other hand, the third region R of the external terminal electrode 60A a2 does not reach the edge of the lower surface 10d on the end face 10a, and the lower end of the third region R a3 is spaced apart from the edge of the lower surface 10d along the second direction. Therefore, the height of the second region R along the second direction a3 is higher than the height of the third region R a2 and the center position La of the external terminal electrode 60A in the second direction is located closer to the upper surface 10c side than the center position of the end face 10a. In other words, the first region R of the external terminal electrode 60A

[0049] is biased closer to the lower surface 10d side than the center position La of the external terminal electrode 60A in the second direction. A is located substantially at the center of the end face 10a in the second direction. The second region R of the external terminal electrode 60A a1 reaches the edge of the upper surface 10c on the end face 10a. On the other hand, the third region R of the external terminal electrode 60A a2 reaches the edge of the upper surface 10c on the end face 10a. On the other hand, the third region R of the external terminal electrode 60A a3 does not reach the edge of the lower surface 10d on the end face 10a, and the lower end of the third region R a3 is spaced apart from the edge of the lower surface 10d along the second direction. Therefore, the height of the second region R along the second direction a2 is higher than the height of the third region R a3 and the center position La of the external terminal electrode 60A in the second direction is located closer to the upper surface 10c side than the center position of the end face 10a. In other words, the first region R of the external terminal electrode 60A a1 is biased closer to the lower surface 10d side than the center position La of the external terminal electrode 60A in the second direction.

[0050] The first region R of the external terminal electrode 60A a1 As described above, the second region R a2 and the third region R a3 have a greater length along the first direction compared to them. Specifically, among the first region R of the external terminal electrode 60A a1 the parts that do not contact the second region R a2 and the third region R a3 constitute a pair of convex portions 61a, 61b (first convex portions) that protrude in the first direction compared to the second region R a2 and the third region R a3 . The pair of convex portions 61a, 61b protrude toward the exposed region R of the insulating substrate 30 along the first direction A . The pair of convex portions 61a, 61b protrude in opposite directions from each other. Specifically, the convex portion 61a protrudes in a direction approaching the side surface 10e along the first direction (rightward in FIG. 7). The convex portion 61b protrudes in a direction approaching the side surface 10f along the first direction (leftward in FIG. 7). In this embodiment, since the first region R a1 is biased toward the lower surface 10d side rather than the center position La of the external terminal electrode 60A in the second direction, the convex portions 61a, 61b of the first region R a1 are also biased toward the lower surface 10d side rather than the center position La of the external terminal electrode 60A in the second direction. The protruding length of the convex portions 61a, 61b is, for example, 10 μm to 100 μm.

[0051] The external terminal electrode 60B is located on the side surface 10e side of the end surface 10a and covers a part of the exposed region R A . The external terminal electrode 60B has a substantially rectangular shape when viewed from the end surface 10a side, and more specifically, has a rectangular shape with rounded corners (that is, rounded). Therefore, the outer shape of the external terminal electrode 60B does not have sharp corners. More specifically, the external terminal electrode 60B is composed of three regions arranged in the second direction, similar to the external terminal electrode 60A. The three regions each have a rectangular shape extending in the first direction. Among the three regions, the first region R b1 is located on the exposed region R A . The second region R b2 is adjacent to the first region Rb1 is adjacent to the upper surface 10c side. The third region R b3 is adjacent to the first region R b1 on the lower surface 10d side. The length of the first region R b1 along the first direction (i.e., the width of the first region R b1 ) W b1 is longer than the length of the second region R b2 along the first direction (i.e., the width of the second region R b2 ) W b2 . Furthermore, the length W b2 of the second region R b2 is longer than the length of the third region R b3 along the first direction (i.e., the width of the third region R b3 ) W b3 . The length W b1 of the first region R b1 is, for example, 500 μm to 600 μm, the length W b2 of the second region R b2 is, for example, 400 μm to 500 μm, and the length W b3 of the third region R b3 is, for example, 300 μm to 400 μm.

[0052] The exposed region R A The first region R located on b1 is located at approximately the center of the end face 10a with respect to the second direction. The second region R of the external terminal electrode 60B b2 reaches the edge of the upper surface 10c on the end face 10a. On the other hand, the third region R of the external terminal electrode 60B b3 does not reach the edge of the lower surface 10d on the end face 10a, and the lower end of the third region R b3 is separated from the edge of the lower surface 10d along the second direction. Therefore, the height of the second region R b2 along the second direction is higher than the height of the third region R b3 , and the central position Lb of the external terminal electrode 60B with respect to the second direction is located closer to the upper surface 10c side than the central position of the end face 10a. In other words, the first region R of the external terminal electrode 60B b1With respect to the second direction, it is offset toward the lower surface 10d side from the center position Lb of the external terminal electrode 60B. In the present embodiment, the center position La of the external terminal electrode 60A and the center position Lb of the external terminal electrode 60B are at the same height position with respect to the second direction.

[0053] The first region R of the external terminal electrode 60B b1 As described above, is the second region R b2 and the third region R b3 has a greater length along the first direction as compared therewith. Specifically, in the first region R of the external terminal electrode 60B b1 among them, the portions that do not contact the second region R b2 and the third region R b3 constitute a pair of convex portions 62a, 62b (second convex portions) that protrude in the first direction as compared with the second region R b2 and the third region R b3 . The pair of convex portions 62a, 62b protrude toward the exposed region R A of the insulating substrate 30 along the first direction. The pair of convex portions 62a, 62b protrude in opposite directions to each other. Specifically, the convex portion 62a protrudes in a direction approaching the side surface 10f along the first direction (leftward in FIG. 7). The convex portion 62b protrudes in a direction approaching the side surface 10e along the first direction (rightward in FIG. 7). In the present embodiment, since the first region R b1 is offset toward the lower surface 10d side from the center position Lb of the external terminal electrode 60B with respect to the second direction, the convex portions 62a, 62b of the first region R b1 are also offset toward the lower surface 10d side from the center position Lb of the external terminal electrode 60B with respect to the second direction. Further, the convex portion 62a of the external terminal electrode 60B and the convex portion 61a of the external terminal electrode 60A face each other in the exposed region R A of the end surface 10a. Specifically, the convex portion 62a of the external terminal electrode 60B protrudes in the exposed region R A so as to approach the external terminal electrode 60A. The convex portion 61a of the external terminal electrode 60A protrudes in the exposed region R A so as to approach the external terminal electrode 60B. The protruding lengths of the convex portions 62a, 62b are, for example, 10 μm to 100 μm.

[0054] Next, while referring to FIG. 8, the configuration of the end face 10b of the base body 10 will be described.

[0055] On the end face 10b of the base body 10, the insulating substrate 30 is exposed in the exposed region R B as shown in FIG. 8. As shown in FIG. 8, the exposed region R B extends between the side faces 10e and 10f of the base body 10 along the first direction (i.e., the width direction of the base body 10 on the end face 10b) parallel to the upper surface 10c and the lower surface 10d on the end face 10b, in the same manner as the exposed region R A on the end face 10a. The exposed region R B is located at a substantially central position of the end face 10b with respect to the second direction (i.e., the facing direction with the upper surface 10c and the lower surface 10d, the height direction of the base body 10 on the end face 10b) orthogonal to the first direction.

[0056] The external terminal electrode 60C is located on the side face 10f side on the end face 10b and covers a part of the exposed region R B . The external terminal electrode 60C has a substantially rectangular shape when viewed from the end face 10b side, and more specifically, has a rectangular shape with rounded corners (i.e., rounded). Therefore, the outer shape of the external terminal electrode 60C does not have sharp corners. More specifically, the external terminal electrode 60C is composed of three regions arranged in the second direction. The three regions each have a rectangular shape extending in the first direction. Among the three regions, the first region R c1 is located on the exposed region R B . The second region R c2 is adjacent to the first region R c1 on the upper surface 10c side. The third region R c3 is adjacent to the first region R c1 on the lower surface 10d side. The length (i.e., the width of the first region R c1 ) W c1 of the first region R c1 along the first direction is longer than the length (i.e., the width of the second region R c2 ) W c2 of the second region R c2 along the first direction. Further, the length W c2 of the second region Rc2 is the third region R along the first direction c3 has a length (i.e., the width of the third region R c3 is longer than W). The length W of the first region R c3 is, for example, 500 μm to 600 μm, and the length W of the second region R c1 is, for example, 400 μm to 500 μm, and the length W of the third region R c1 is, for example, 300 μm to 400 μm. c2 The first region R located on the exposed region R c2 is located substantially at the center of the end face 10b with respect to the second direction. The second region R of the external terminal electrode 60C c3 reaches the edge of the upper surface 10c on the end face 10b. On the other hand, the third region R of the external terminal electrode 60C c3 does not reach the edge of the lower surface 10d on the end face 10b, and the lower end of the third region R

[0057] is separated from the edge of the lower surface 10d along the second direction. Therefore, the height of the second region R along the second direction B is higher than the height of the third region R, and the center position Lc of the external terminal electrode 60C with respect to the second direction is located closer to the upper surface 10c side than the center position of the end face 10b. In other words, the first region R of the external terminal electrode 60C c1 is biased toward the lower surface 10d side with respect to the center position Lc of the external terminal electrode 60C in the second direction. c2 The first region R of the external terminal electrode 60C c3 has a greater length along the first direction compared to the second region R c3 and the third region R as described above. Specifically, among the first region R of the external terminal electrode 60C c2 the portions that do not contact the second region R c3 and the third region R c1 are larger than the second region R

[0058] The first region R of the external terminal electrode 60C c1 is, as described above, larger in length along the first direction compared to the second region R c2 and the third region R c3 Specifically, among the first region R of the external terminal electrode 60C c1 the portions that do not contact the second region R c2 and the third region R c3 are larger than the second region R c2 and the third region R c3A pair of convex portions 63a and 63b that protrude in the first direction as compared with are configured. The pair of convex portions 63a and 63b protrude toward the exposed region R of the insulating substrate 30 along the first direction B . The pair of convex portions 63a and 63b protrude in opposite directions to each other. Specifically, the convex portion 63a protrudes in a direction approaching the side surface 10e along the first direction (leftward in FIG. 8). The convex portion 63b protrudes in a direction approaching the side surface 10f along the first direction (rightward in FIG. 8). In the present embodiment, since the first region R c1 is biased toward the lower surface 10d side rather than the center position Lc of the external terminal electrode 60C with respect to the second direction, the convex portions 63a and 63b of the first region R c1 are also biased toward the lower surface 10d side rather than the center position Lc of the external terminal electrode 60C with respect to the second direction. The protruding lengths of the convex portions 63a and 63b are, for example, 10 μm to 100 μm.

[0059] The external terminal electrode 60D is located on the side surface 10e side of the end surface 10b and covers a part of the exposed region R B . The external terminal electrode 60D has a substantially rectangular shape when viewed from the end surface 10b side, and more specifically, has a rectangular shape with rounded corners (that is, rounded). The outer shape of the external terminal electrode 60D does not have sharp corners. More specifically, the external terminal electrode 60D is composed of three regions arranged in the second direction, similar to the external terminal electrode 60C. The three regions each have a rectangular shape extending in the first direction. Among the three regions, the first region R d1 is located on the exposed region R B . The second region R d2 is adjacent to the first region R d1 on the upper surface 10c side. The third region R d3 is adjacent to the first region R d1 on the lower surface 10d side. The length of the first region R d1 along the first direction (that is, the width of the first region R d1 ) W d1 is longer than the length of the second region R d2 along the first direction (that is, the width of the second region R d2 ) W d2 . Further, the second region R d2The length W d2 is the length of the third region R d3 along the first direction (i.e., the width of the third region R d3 is greater than W d3 of the first region R d1 The length W d1 is, for example, 500 μm to 600 μm, and the length W d2 of the second region R d2 is, for example, 400 μm to 500 μm, and the length W d3 of the third region R d3 is, for example, 300 μm to 400 μm.

[0060] The exposed region R B The first region R located on it d1 is located substantially at the center of the end face 10b in the second direction. The second region R of the external terminal electrode 60D d2 reaches the edge of the upper surface 10c on the end face 10b. On the other hand, the third region R of the external terminal electrode 60D d3 does not reach the edge of the lower surface 10d on the end face 10b, and the lower end of the third region R d3 is spaced apart from the edge of the lower surface 10d along the second direction. Therefore, the height of the second region R along the second direction d2 is higher than the height of the third region R d3 , and the central position Ld of the external terminal electrode 60D in the second direction is located closer to the upper surface 10c side than the central position of the end face 10b. In other words, the first region R of the external terminal electrode 60D d1 is biased toward the lower surface 10d side with respect to the central position Ld of the external terminal electrode 60D in the second direction. In the present embodiment, the central position Lc of the external terminal electrode 60C and the central position Ld of the external terminal electrode 60D in the second direction are at the same height position.

[0061] The first region R of the external terminal electrode 60D d1 is, as described above, larger in length along the first direction than the second region R d2 and the third region R d3 . That is, among the first region R of the external terminal electrode 60D d1 the second region R d2 and the third region R d3The portion not in contact forms the second region R d2 and the third region R d3 and constitutes a pair of convex portions 64a and 64b that protrude in the first direction as compared with them. The pair of convex portions 64a and 64b protrude toward the exposed region R B of the insulating substrate 30 along the first direction. The pair of convex portions 64a and 64b protrude in opposite directions to each other. Specifically, the convex portion 64a protrudes in a direction approaching the side surface 10f along the first direction (rightward in FIG. 8). The convex portion 64b protrudes in a direction approaching the side surface 10e along the first direction (leftward in FIG. 8). In the present embodiment, since the first region R d1 is biased toward the lower surface 10d side than the center position Ld of the external terminal electrode 60D in the second direction, the convex portions 64a and 64b of the first region R d1 are also biased toward the lower surface 10d side than the center position Ld of the external terminal electrode 60D in the second direction. Further, the convex portion 64a of the external terminal electrode 60D and the convex portion 63a of the external terminal electrode 60C face each other in the exposed region R B of the end surface 10b. Specifically, the convex portion 64a of the external terminal electrode 60D protrudes in the exposed region R B so as to approach the external terminal electrode 60C. The convex portion 63a of the external terminal electrode 60C protrudes in the exposed region R B so as to approach the external terminal electrode 60D. The protruding lengths of the convex portions 64a and 64b are, for example, 10 μm to 100 μm.

[0062] The cross sections of the end surfaces 10a and 10b will be described with reference to FIG. 9. Since the cross section of the end surface 10b is the same as or similar to the cross section of the end surface 10a, the description thereof will be omitted.

[0063] As shown in FIG. 9, on the end surface 10a, a protruding portion 35A in which the frame portion 34A of the insulating substrate 30 protrudes from the end surface 10a is provided. The protruding length W 35A of the protruding portion 35A is, for example, 10 μm to 30 μm. That is, among the three regions R a1 , R a2 , R a3 , the first region R a1The insulating substrate 30 corresponding to it protrudes. The thickness of the external terminal electrode 60A is not uniform with respect to the end face 10a. As shown in FIG. 9, there are three regions R a1 , R a2 , R a3 which are different from each other. Specifically, the thickness of the external terminal electrode 60A is the minimum thickness T1 at the lower end portion near the lower surface 10d of the second region R a2 , and is the maximum thickness T2 near the center in the second direction of the third region R a3 . The thickness of the external terminal electrode 60A increases monotonically from the lower end portion of the second region R a2 to near the center of the third region R a3 , and then decreases monotonically until it reaches the upper surface 10c. However, since the exposed region R A of the frame portion 34A protrudes in the direction orthogonal to the end face 10a at the end face 10a, in the exposed region R A , the thickness T3 of the external terminal electrode 60A is shortened by the length W 35A by which the protruding portion 35A protrudes. The minimum thickness T1 is, for example, 10 μm, and the maximum thickness T2 is, for example, 40 μm.

[0064] The protruding portion 35A of the end face 10a is generated by the metal magnetic powder-containing resin 12 on the end face 10a retreating from the end face 10a at the manufacturing stage of the element body 10. More specifically, a plurality of element bodies 10 formed integrally are cut, and the respective element bodies 10 are separated from each other. A flat end face 10a is formed as the surface generated by the cutting. Then, surface treatment such as barrel polishing (including etching treatment, etc.) is performed on each element body 10, and the metal magnetic powder-containing resin 12 that is relatively easily polished on the end face 10a is polished. By this polishing, the regions other than the exposed region R A on the end face 10a retreat in the direction perpendicular to the end face 10a, so that a part of the frame portions 34A and 34B protrudes from the end face 10a relatively, and becomes the protruding portion 35A. Note that the surface roughness of the exposed region R A after polishing on the end face 10a is smaller than the surface roughness of the magnetic portions 12a and 12b.

[0065] In this embodiment, the convex portions 61a and 61b of the external terminal electrode 60A increase the contact area between the external terminal electrode 60A and the element body 10, so that the two are more firmly adhered to each other. Therefore, the adhesion strength between the external terminal electrode 60A and the element body 10 can be improved. Note that the external terminal electrodes 60B, 60C, and 60D can similarly improve the adhesion strength with the element body 10. From the above, it is possible to suppress the external terminal electrodes 60A, 60B, 60C, and 60D from peeling off from the element body 10.

[0066] Also, in this embodiment, the outer shapes of the external terminal electrodes 60A, 60B, 60C, and 60D are formed of curves and have a shape without corners. Here, when there are sharp corners in the outer shape, if stress is applied from the outside to the external terminal electrodes 60A, 60B, 60C, and 60D, the external terminal electrodes 60A, 60B, 60C, and 60D are likely to peel off starting from the corners. Therefore, according to the configuration of this embodiment, it is possible to suppress the external terminal electrodes 60A, 60B, 60C, and 60D from peeling off from the element body 10.

[0067] Also, in this embodiment, the frame portion 34A of the insulating substrate 30 protrudes from the element body 10 at the end face 10a. And the frame portion 34B of the insulating substrate 30 protrudes from the element body 10 at the end face 10b. Thereby, the surface area of the end face 10a increases at the protruding portion 35A, and thereby the contact area with the external terminal electrodes 60A, 60B, 60C, and 60D increases, and the two are more firmly adhered to each other. Therefore, the adhesion strength between the external terminal electrode 60A and the element body 10 can be improved. From the above, it is possible to suppress the external terminal electrodes 60A, 60B, 60C, and 60D from peeling off from the element body 10.

[0068] As described above, the embodiments of the present invention have been described. However, the present invention is not necessarily limited to the above-described embodiments, and various modifications are possible without departing from the gist thereof. For example, the number of coils is not limited to two, and may be three or more. The number of terminals at the end faces 10a and 10b is not limited to two, and may be one or three or more. The first region R a1,R b1 ,R c1 ,R d1 is offset from the center positions La, Lb, Lc, Ld of the external terminal electrodes 60A, 60B, 60C, 60D toward the lower surface 10d side, but may coincide with the center positions La, Lb, Lc, Ld or may be offset toward the upper surface 10c side. The upper insulator 50A and the lower insulator 50B are exposed at the end faces 10a, 10b, but may not be exposed. The center positions La, Lb may be located at the same height as each other or at different heights. The center positions Lc, Ld may be located at the same height as each other or at different heights. In the external terminal electrodes 60A, 60B, 60C, 60D, the number of convex portions is not limited to two, and may be one or three or more.

Explanation of Reference Numerals

[0069] 1... coil component, 10... element body, 10a... end face (first end face), 10b... end face (second end face), 10d... lower surface (mounting surface), 12... metal magnetic powder-containing resin, 12a, 12b... magnetic portions (magnetic layers), 30... insulating substrate, 41... first planar coil, 42... second planar coil, 41a... outer end portion (first end portion), 42a... outer end portion (second end portion), 50A... upper insulator, 50B... lower insulator, 60A to 60D... external terminal electrodes, 61a, 61b... convex portions (first convex portions), 62a, 62b... convex portions (second convex portions), R A ,R B ... exposed region, C1... first coil portion, C2... second coil portion, R a1 ,R b1 ,R c1 ,R d1 ... first region, R a2 ,R b2 ,R c2 ,R d2 ... second region, R a3 ,R b3 ,R c3 ,R d3 ... third region, W 30 ... thickness of insulating substrate, W 10a ,W 20a ,W 10b ,W 20b ... thickness of magnetic layer.

Claims

1. A base body having a first end face and a second end face parallel to each other, an insulating substrate provided in the base body, exposed on the first end face, and having an exposed area exposed on the first end face extending along a first direction, a first coil portion provided on the insulating substrate and having a first end portion exposed on the first end face, a first external terminal provided on the first end face, covering a part of the exposed area of the insulating substrate and covering the first end portion of the first coil portion, the first external terminal has a first convex portion protruding toward the exposed area of the insulating substrate along the first direction, the first convex portion is offset from the center position of the first external terminal with respect to a second direction orthogonal to the first direction on the first end face, a coil component.

2. the first external terminal has a pair of the first convex portions, the pair of the first convex portions protrude in opposite directions to each other along the first direction, the coil component according to claim 1.

3. the coil component according to claim 1 or 2, wherein an outer shape of the first external terminal has a corner portion formed by a curve.

4. the coil component according to any one of claims 1 to 3, wherein the insulating substrate includes a glass cloth.

5. the coil component according to any one of claims 1 to 4, wherein a surface roughness of the insulating substrate in the exposed area is smaller than a surface roughness of the first end face of the base body.

6. the base body further has a pair of magnetic layers sandwiching the insulating substrate from a second direction orthogonal to the first direction on the first end face, the coil component according to any one of claims 1 to 5, wherein a thickness of the insulating substrate is thinner than a thickness of the magnetic layer with respect to the second direction.

7. the coil component according to any one of claims 1 to 6, wherein the base body is made of a metal magnetic powder-containing resin.

8. the base body further has a mounting surface orthogonal to the first end face and the second end face, and a top surface facing the mounting surface, the coil component according to any one of claims 1 to 7, wherein the first external terminal is spaced apart from an edge of the top surface on the first end face.

9. the first external terminal has a plurality of regions arranged in a second direction orthogonal to the first direction on the first end face, the plurality of regions include a first region including the first convex portion, a second region adjacent to the first region on the mounting surface side, and a third region adjacent to the first region on the top surface side. The coil component according to claim 8, wherein, with respect to the first direction, the length of the second region is longer than the length of the third region.

10. The coil component according to any one of claims 1 to 9, wherein the insulating substrate protrudes from the element body at the first end face.

11. A second coil part provided on the insulating substrate and having a second end portion exposed at the first end face; A second external terminal provided adjacent to the first external terminal in the first direction at the first end face, covering a part of the exposed region of the insulating substrate and covering the second end portion of the second coil part; The second external terminal has a second convex portion protruding toward the exposed region of the insulating substrate along the first direction; The coil component according to any one of claims 1 to 10, wherein, at the first end face, the first convex portion of the first external terminal and the second convex portion of the second external terminal face each other.

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