Inductor component and method for manufacturing the same

Abstract

Provided is an inductor component which makes it possible to easily perform a wire member assembly operation. An inductor component equipped with a coil which includes a plurality of wire members, wherein: a first end section of a first wire member and a second end section of a second wire member, which are adjacent wire members, are connected to one another; the plurality of wire members constitute the spiral of the coil; a wall section which projects in the centerline direction of the first end section is provided to the end surface of the first end section; the end surface of the first end section faces a peripheral surface of the second end section; and a lateral surface of the wall section in a direction which is perpendicular to the centerline direction of the first end section faces the end surface of the second end section.

Description

Technical Field

[0001] The present invention relates to an inductor component and a method for manufacturing the same.

Background Art

[0002] Conventionally, as an inductor component, there is one described in Japanese Utility Model Publication No. 50-20152 (Patent Document 1). This inductor component includes an annular core and a coil wound around the core. The coil includes a U-shaped first wire member and a linear second wire member, and one end of the first wire member and one end of the second wire member are connected to form one turn of the coil.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in the conventional inductor component, after assembling the first wire member and the second wire member, one end of the first wire member and one end of the second wire member are welded to form one turn of the coil, and further, a plurality of turns need to be connected in series, and high-precision control is required for positioning during welding of the first wire member and the second wire member. Thus, the assembly work of the wire members has been time-consuming.

[0005] Therefore, the present disclosure aims to provide an inductor component and a method for manufacturing the same that can facilitate the assembly work of wire members.

Means for Solving the Problems

[0006] To solve the above problems, an inductor component according to one aspect of the present disclosure includes a coil including a plurality of wire members, In adjacent wire members, a first end portion of a first wire member and a second end portion of a second wire member are connected, and the plurality of wire members form the helix of the coil. A wall portion protruding in the direction of the center line of the first end portion is provided on the end surface of the first end portion. The end surface of the first end portion faces the circumferential surface of the second end portion. The side surface of the wall portion in a direction orthogonal to the direction of the center line of the first end portion faces the end surface of the second end portion.

[0007] Here, the center line of the first end portion is a line passing through the center of gravity of the first end portion in a cross section orthogonal to the extending direction of the first end portion. The center line of the second end portion is a line passing through the center of gravity of the second end portion in a cross section orthogonal to the extending direction of the second end portion. The end surface of the first end portion is the outermost surface located in the direction of the center line of the first end portion. The end surface of the second end portion is the outermost surface located in the direction of the center line of the second end portion. The circumferential surface of the second end portion is the outer surface in the circumferential direction centered on the center line of the second end portion.

[0008] According to the above aspect, since the end surface of the first end portion of the first wire member faces the circumferential surface of the second end portion of the second wire member, when assembling the first wire member to the second wire member, the positioning of the first wire member in the direction of the center line of the first end portion can be easily performed. Further, since the side surface of the wall portion in a direction orthogonal to the direction of the center line of the first end portion faces the end surface of the second end portion, when assembling the first wire member to the second wire member, the positioning of the first wire member in the direction of the center line of the second end portion can be easily performed. Thus, according to the above aspect, since the positioning of the first wire member can be performed by two surfaces, namely, the end surface of the first end portion and the side surface of the wall portion, the assembly work of the first wire member and the second wire member can be facilitated. On the other hand, in the prior art, since the positioning is performed by only one surface, the assembly work of the wire member has been troublesome.

[0009] Preferably, in one embodiment of the inductor component, The coil has a welded portion where a part of the first end portion and a part of the second end portion are welded. The welded portion connects the end face of the second end portion and the side face of the wall portion.

[0010] According to the embodiment, since the first end portion and the second end portion are connected by the welded portion, generation of cracks or the like in the connection portion can be suppressed more than when the first end portion and the second end portion are connected by, for example, solder, and long-term reliability of the connection portion can be ensured. In addition, since the size of the connection portion can be made smaller than when the first end portion and the second end portion are mechanically connected by, for example, caulking, the coil can be miniaturized.

[0011] Preferably, in one embodiment of the inductor component, The welded portion further connects the end face of the first end portion and the circumferential surface of the second end portion.

[0012] According to the embodiment, the cross-sectional area (connection cross-sectional area; joint cross-sectional area) of the connection portion between the first end portion and the second end portion increases, and the mechanical strength can be enhanced. As a result, the reliability of the connection portion can be improved. In addition, since the electrical resistance of the connection portion is reduced, a large current can flow through the coil.

[0013] Preferably, in one embodiment of the inductor component, When viewed from the center line direction of the second end portion, a part of the end face of the second end portion does not overlap with the welded portion.

[0014] According to the embodiment, a part of the end face of the second end portion is not melted by welding. Thereby, swelling of the welded portion in a direction orthogonal to the center line direction of the second end portion is suppressed, and a short circuit that may occur between adjacent first wire members and between adjacent second wire members can be suppressed.

[0015] Preferably, in one embodiment of the inductor component, The first wire member includes at least a conductor portion, The second wire member includes a conductor portion and a coating that covers a part of the outer surface of the conductor portion of the second wire member. The outer surface of the first wire member has a first exposed region where the conductor portion of the first wire member is exposed from the end surface of the first end portion toward the center line direction of the first end portion. The outer surface of the second wire member has a second exposed region where the conductor portion of the second wire member is exposed from the end surface of the second end portion toward the center line direction of the second end portion. The maximum length of the second exposed region in the center line direction of the second end portion is shorter than the maximum length of the first exposed region in the center line direction of the first end portion.

[0016] According to the embodiment, compared with the case where the maximum length of the second exposed region is longer than the maximum length of the first exposed region, the covering area of the coating film of the second wire member can be made larger, so that the insulation between adjacent second wire members can be ensured.

[0017] Preferably, in one embodiment of the inductor component, The outer surface of the conductor portion of the first wire member is not covered with a coating film.

[0018] According to the embodiment, since it is not necessary to cover the conductor portion of the first wire member with a coating film, the first wire member can be easily manufactured.

[0019] In one embodiment of the method for manufacturing an inductor component, In adjacent wire members, a step of assembling the first wire member and the second wire member, in which the end surface of the first end portion of the first wire member is opposed to the peripheral surface of the second end portion of the second wire member, and the side surface of the wall portion provided on the end surface of the first end portion and protruding in the center line direction of the first end portion is opposed to the end surface of the second end portion; And a step of connecting the first end portion of the first wire member and the second end portion of the second wire member.

[0020] According to the embodiment, the assembly work of the first wire member and the second wire member can be facilitated.

[0021] Preferably, in one embodiment of the method for manufacturing an inductor component, In the step of connection, a laser is irradiated onto the wall portion to weld the end face of the second end portion and the side face of the wall portion.

[0022] According to the embodiment, since the first end portion and the second end portion are connected by welding, generation of cracks or the like in the connection portion can be suppressed as compared with the case where the first end portion and the second end portion are connected by, for example, solder, and long-term reliability of the connection portion can be ensured. Further, since the size of the connection portion can be made smaller than the case where the first end portion and the second end portion are mechanically connected by, for example, caulking, the coil can be miniaturized.

[0023] Further, since a laser is irradiated onto the wall portion of the first wire member, it is possible to suppress the laser from irradiating a portion other than the welded portion of the second wire member and damaging the portion by baking or the like. On the other hand, when a laser is irradiated onto a portion between the end face and the peripheral surface with the wall portion not provided on the end face of the first end portion and the end face of the first end portion facing the peripheral surface of the second end portion, the laser passes between the end face and the peripheral surface, and a portion other than the welded portion of the second wire member may be irradiated with the laser and damaged by baking or the like.

[0024] Further, since a laser is irradiated onto the wall portion of the first wire member, the amount of heat of the second wire member generated during laser irradiation can be made smaller than the amount of heat of the first wire member. As a result, heat damage that may occur in the second wire member can be reduced, and breakage of the second wire member can be suppressed. In particular, when the second wire member has a coating, it is possible to suppress the coating from deteriorating and breaking due to heat.

[0025] Preferably, in one embodiment of the method for manufacturing an inductor component In the step of connection, a laser is irradiated onto the wall portion to further weld the end face of the first end portion and the peripheral surface of the second end portion.

[0026] According to the embodiment, the connection strength between the first wire member and the second wire member can be increased.

[0027] Preferably, in one embodiment of the method for manufacturing an inductor component, In the step of connecting, as viewed from the center line direction of the second end portion, the tip of the wall portion in the center line direction of the first end portion has a plurality of separated convex portions, and each of the plurality of convex portions is irradiated with a laser.

[0028] According to the embodiment, the wall portion has a plurality of separated convex portions. Since the volume of each convex portion is smaller than the volume of the wall portion when the plurality of convex portions are integrated, the heat capacity of each convex portion can be made smaller than the heat capacity of the wall portion. Therefore, the laser irradiation time for each convex portion can be shortened, the amount of heat applied to each convex portion can be made smaller, and the amount of heat transmitted to the second wire member can also be made smaller. As a result, breakage of the second wire member can be suppressed. In particular, when the second wire member has a coating, deterioration and breakage of the coating due to heat can be suppressed.

[0029] Preferably, in one embodiment of the method for manufacturing an inductor component, The connecting step is a first laser irradiation step of irradiating a laser to one of the plurality of convex portions, a cooling step of cooling the laser irradiation portion irradiated with the laser, and a second laser irradiation step of irradiating a laser to another one of the convex portions.

[0030] According to the embodiment, the amount of heat transmitted to the second wire member can be made smaller than in the case where the first laser irradiation step and the second laser irradiation step are continuously performed without providing the cooling step. As a result, breakage of the second wire member can be further suppressed. In particular, when the second wire member has a coating, deterioration and breakage of the coating due to heat can be further suppressed.

[0031] Preferably, in one embodiment of the method for manufacturing an inductor component, The connecting step is a first laser irradiation step of irradiating a laser to one of the plurality of convex portions, A second laser irradiation step of irradiating another convex portion with a laser continuously following the first laser irradiation step.

[0032] According to the embodiment, the first wire member and the second wire member can be connected in a short time.

[0033] Preferably, in one embodiment of the method for manufacturing an inductor component In the assembling step, when viewed from the center line direction of the second end portion, a part of the end surface of the second end portion does not overlap with the wall portion.

[0034] According to the embodiment, after irradiating the wall portion with a laser, the laser can be scanned to irradiate the end surface of the second end portion of the second wire member with a laser. Thereby, the melting amount of the first end portion and the melting amount of the second end portion due to laser irradiation can be increased, and the metals of the first wire member and the second wire member can be mixed more. As a result, the mechanical strength of the connection portion can be further increased.

[0035] Also, when viewed from the center line direction of the second end portion, the area of the portion of the end surface of the second end portion facing the side surface of the wall portion can be made smaller than when the entire end surface of the second end portion overlaps with the wall portion. Thereby, the amount of heat transferred to the second wire member can be further reduced, and breakage of the second wire member can be further suppressed. In particular, when the second wire member has a coating, deterioration and breakage of the coating due to heat can be further suppressed.

[0036] Preferably, in one embodiment of the method for manufacturing an inductor component In the assembling step, the following formula is satisfied. y≦(2 / 3)x+(19 / 3) 25≦x≦70 20≦y≦50 However, x = (thickness of the wall portion in the center line direction of the second end portion) / (thickness of the first end portion in the center line direction of the second end portion) × 100 y = (Length of the wall portion in the center line direction of the first end) / (Length of the end face of the second end in the center line direction of the first end) × 100

[0037] Here, the thickness of the wall portion in the center line direction of the second end refers to the maximum thickness of the wall portion in the center line direction of the second end in the cross section including the center line of the first end and the center line of the second end. The thickness of the first end in the center line direction of the second end refers to the maximum thickness of the first end in the center line direction of the second end in the above cross section. The length of the wall portion in the center line direction of the first end refers to the maximum length of the wall portion in the center line direction of the first end in the above cross section. The length of the end face of the second end in the center line direction of the first end refers to the length of the end face in the above cross section.

[0038] According to the above embodiment, since the thickness and length of the wall portion are appropriately controlled, when the wall portion is irradiated with a laser, the amount of heat transferred to the second wire member can be further reduced. Thereby, breakage of the second wire member can be further suppressed. In particular, when the second wire member has a coating, deterioration and breakage of the coating due to heat can be further suppressed.

[0039] Preferably, in one embodiment of the method for manufacturing an inductor component, It is further made to satisfy the following formula. (13 / 15)x - (83 / 3) ≤ y

[0040] According to the above embodiment, since the thickness and length of the wall portion are appropriately controlled, the first wire member can be stably assembled to the second wire member. On the other hand, when (13 / 15)x - (83 / 3) > y, the thickness of the wall portion increases and the length of the wall portion decreases. As a result, since the area of the portion of the outer surface of the second end facing the first end decreases, it may be difficult to stably assemble the first wire member to the second wire member.

[0041] Preferably, in one embodiment of the method for manufacturing an inductor component, In the assembling step, the end face of the first end portion is shaped along the circumferential surface of the second end portion.

[0042] According to the embodiment, even when the first wire member is moved in a direction orthogonal to the center line direction of the first end portion and parallel to the end face of the second end portion to assemble the first wire member to the second wire member, since the end face of the first end portion is shaped along the circumferential surface of the second end portion, the positioning of the first wire member in this direction can be facilitated.

Effect of the Invention

[0043] According to the inductor component and its manufacturing method which are one aspect of the present disclosure, the assembly work of the wire member can be facilitated.

Brief Description of the Drawings

[0044]

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Embodiments for Carrying Out the Invention

[0045] Hereinafter, an inductor component, which is an aspect of the present disclosure, will be described in detail with reference to the illustrated embodiments. Note that the drawings include some schematic ones and may not reflect actual dimensions and ratios.

[0046] (First Embodiment) (Overall Configuration of Inductor Component) FIG. 1 is an upper perspective view showing an inductor component according to an embodiment of the present invention. FIG. 2 is a lower perspective view of the inductor component. FIG. 3 is a lower perspective view showing the inside of the inductor component. FIG. 4 is an exploded perspective view of the inductor component.

[0047] As shown in FIGS. 1 to 4, the inductor component 1 includes a case 2, an inductor element L housed in the case 2, first to fourth electrode terminals 51 to 54 attached to the case 2, and a resin member 90 disposed in the case 2. The inductor component 1 is, for example, a common mode choke coil or the like. The inductor element L is composed of an annular core 3, a first coil 41 and a second coil 42 wound around the core 3, and a core cover 60 attached to the core 3.

[0048] The case 2 has a bottom plate portion 21 and a box portion 22 that covers the bottom plate portion 21. The case 2 is made of a material having strength and heat resistance, and preferably, a material having flame retardancy. The case 2 is composed of, for example, a resin such as PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide), or ceramics.

[0049] The bottom plate portion 21 has a bottom portion 210 including a first main surface 210a and a second main surface 210b facing each other, and a side wall portion 211 provided along the outer periphery of the bottom portion 21 on the first main surface 210a of the bottom portion 210. The bottom plate portion 21 has a recess 215, and the recess 215 is configured to be surrounded by the bottom portion 210 and the side wall portion 211. The side wall portion 211 is provided continuously in the circumferential direction, but may be provided intermittently in the circumferential direction. The bottom portion 210 has a plurality of openings 216 penetrating the first main surface 210a and the second main surface 210b. The plurality of openings 216 are provided at positions corresponding to the first to fourth electrode terminals 51 to 54. In this embodiment, the number of the openings 216 is four, but the increase or decrease in the quantity is free.

[0050] An inductor element L is disposed on the bottom plate portion 21. That is, the core 3 is disposed on the bottom plate portion 21 such that the central axis of the core 3 is orthogonal to the first main surface 210a of the bottom portion 210. The central axis of the core 3 refers to the central axis of the inner diameter hole portion of the core 3. The shape of the case 2 (the bottom plate portion 21 and the box portion 22) is rectangular when viewed from the central axis direction of the core 3. In this embodiment, the shape of the case 2 is rectangular.

[0051] Here, the short side direction of the case 2 when viewed from the central axis direction of the core 3 is defined as the X direction, the long side direction of the case 2 when viewed from the central axis direction of the core 3 is defined as the Y direction, and the height direction of the case 2 which is perpendicular to both the short side direction and the long side direction is defined as the Z direction. The bottom plate portion 21 and the box portion 22 of the case 2 are arranged to face each other in the Z direction, the bottom plate portion 21 is on the lower side, the box portion 22 is on the upper side, the upper side is the forward direction of the Z direction, and the lower side is the reverse direction of the Z direction. That is, in the height direction orthogonal to the first main surface 2,10a, the direction from the first main surface 210a toward the core 3 is defined as the upward direction. When the shape of the bottom plate portion 21 of the case 2 is square, the length of the case 2 in the X direction and the length of the case 2 in the Y direction are the same.

[0052] The box portion 22 is attached to the bottom plate portion 21 so as to cover the inductor element L. That is, the core 3 and the coils 41 and 42 are surrounded by the box portion 22 and are not exposed to the outside. Therefore, the inductor element L can be protected from the outside.

[0053] The first to fourth electrode terminals 51 to 54 are attached to the bottom plate portion 21. The first electrode terminal 51 and the second electrode terminal 52 are located at two corners of the bottom plate portion 21 facing each other in the Y direction, and the third electrode terminal 53 and the fourth electrode terminal 54 are located at two corners of the bottom plate portion 21 facing each other in the Y direction. The first electrode terminal 51 and the third electrode terminal 53 face each other in the X direction, and the second electrode terminal 52 and the fourth electrode terminal 54 face each other in the X direction.

[0054] The core 3 is a toroidal core, and the shape of the core 3 is an oval (track shape) when viewed from the central axis direction. The core 3 includes a pair of longitudinal portions 31 extending along the major axis and facing each other in the minor axis direction, and a pair of short side portions 32 extending along the minor axis and facing each other in the major axis direction when viewed from the central axis direction. Note that the shape of the core 3 may be rectangular, elliptical, or circular when viewed from the central axis direction.

[0055] The core 3 is composed of, for example, a ceramic core such as ferrite, or a magnetic core made of iron-based powder molding or nanocrystalline foil. The core 3 has a first end face 301 and a second end face 302 facing each other in the central axis direction, an inner peripheral surface 303, and an outer peripheral surface 304. The first end face 301 is the lower end face of the core 3 and faces the first main surface 210a of the bottom plate portion 21. The second end face 302 is the upper end face of the core 3 and faces the inner surface of the box portion 22. The core 3 is housed in the case 2 so that the major axis direction of the core 3 coincides with the Y direction.

[0056] The shape of the cross section orthogonal to the circumferential direction of the core 3 when viewed from the central axis direction is rectangular. The first end face 301 and the second end face 302 are arranged perpendicular to the central axis direction of the core 3. The inner peripheral surface 303 and the outer peripheral surface 304 are arranged parallel to the central axis direction of the core 3. In this specification, "perpendicular" includes not only a state of being completely perpendicular but also a state of being substantially perpendicular. Also, "parallel" includes not only a state of being completely parallel but also a state of being substantially parallel.

[0057] The lower part of the core 3 is covered by the core cover 60. That is, a part of the bottom plate portion 21 side of the core 3 is covered by the core cover 60. Note that at least a part of the bottom plate portion 21 side of the core 3 only needs to be covered by the core cover 60, and the entire core 3 may be covered by the core cover 60. The core cover 60 is composed of a super engineering plastic such as LCP, PPA, or PPS, thereby improving the heat resistance, insulation, and processability of the core cover 60.

[0058] The core cover 60 is formed in an annular shape and has an annular recess 61 that covers the lower part of the core 3. By fitting the lower part of the core 3 into the annular recess 61 of the core cover 60, the core cover 60 can be attached to the core 3.

[0059] The resin member 90 is disposed in the recess 215 of the bottom plate portion 21 and contacts the bottom plate portion 21 and the inductor element L. As the material of the resin member 90, for example, a thermosetting epoxy resin can be used.

[0060] The first coil 41 is wound around the core 3 and the core cover 60 between the first electrode terminal 51 and the second electrode terminal 52. One end of the first coil 41 is connected to the first electrode terminal 51. The other end of the first coil 41 is connected to the second electrode terminal 52.

[0061] The second coil 42 is wound around the core 3 and the core cover 60 between the third electrode terminal 53 and the fourth electrode terminal 54. One end of the second coil 42 is connected to the third electrode terminal 53. The other end of the second coil 42 is connected to the fourth electrode terminal 54.

[0062] The first coil 41 and the second coil 42 are spirally wound around the core 3 along the circumferential direction of the core 3 as viewed from the central axis direction of the core 3. Specifically speaking, the first coil 41 is wound along the major axis direction of the core 3 on one longitudinal portion 31 of the core 3, and the second coil 42 is wound along the major axis direction of the core 3 on the other longitudinal portion 31 of the core 3. The winding axes of the first coil 41 and the second coil 42 are parallel. The first coil 41 and the second coil 42 are symmetric with respect to the major axis of the core 3.

[0063] The number of turns of the first coil 41 and the number of turns of the second coil 42 are the same. The winding direction of the first coil 41 with respect to the core 3 and the winding direction of the second coil 42 with respect to the core 3 are opposite. That is, the winding direction from the first electrode terminal 51 to the second electrode terminal 52 of the first coil 41 and the winding direction from the third electrode terminal 53 to the fourth electrode terminal 54 of the second coil 42 are opposite.

[0064] Then, the first to fourth electrode terminals 51 to 54 are connected so that the common-mode current flows from the first electrode terminal 51 to the second electrode terminal 52 in the first coil 41 and from the third electrode terminal 53 to the fourth electrode terminal 54 in the second coil 42, that is, the direction of the current flow is the same. When the common-mode current flows through the first coil 41, a first magnetic flux due to the first coil 41 is generated in the core 3. When the common-mode current flows through the second coil 42, a second magnetic flux is generated in the core 3 in a direction that reinforces the first magnetic flux in the core 3. For this reason, the first coil 41 and the core 3, and the second coil 42 and the core 3 act as inductance components, and noise is removed from the common-mode current.

[0065] The first coil 41 is formed by connecting a plurality of pin members by welding such as laser welding or spot welding. Note that FIG. 3 shows a state where the plurality of pin members are assembled, not a state where the plurality of pin members are actually welded. Also, the connection method of the plurality of pin members is not limited to welding, and other connection methods using, for example, solder or a conductive adhesive member may be adopted. Hereinafter, for the sake of simplicity of explanation, it will be described that welding is adopted as the connection method of the plurality of pin members.

[0066] The plurality of pin members are not printed wiring or conducting wires, but rod-shaped members. The pin members have rigidity. Specifically, in a cross section orthogonal to the circumferential direction of the core 3, the pin members are shorter than the length of one round of the outer circumference of the core passing through the first end face 301, the second end face 302, the inner circumferential face 303, and the outer circumferential face 304 of the core 3, and also have high rigidity itself, so they are difficult to bend.

[0067] The plurality of pin members include bent pin members 410 bent in a substantially U shape, straight pin members 412 extending in a substantially straight line, and outermost straight pin members 411. The straight pin members 412 and the outermost straight pin members 411 correspond to an example of the "first wire member" described in the claims. The bent pin members 410 correspond to an example of the "second wire member" described in the claims.

[0068] The first coil 41 includes, in order from one end to the other end, the outermost straight pin member 411 on one end side (one side), a plurality of sets of bent pin members 410 and straight pin members 412, and the outermost straight pin member 411 on the other end side (the other side). The outermost straight pin member 411 is a straight pin member located at the outermost end in the axial direction of the first coil 41. In this embodiment, the outermost straight pin member 411 and the straight pin member 412 have the same shape. However, it is not limited to this, and the outermost straight pin member 411 and the straight pin member 412 may have different shapes. For example, the length of the outermost straight pin member 411 in the extending direction may be shorter than the length of the straight pin member 412 in the extending direction.

[0069] Regarding the spring index of the bent pin member 410, as shown in FIG. 5, when the bent pin member 410 is arranged along the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3, the spring index Ks of the bent pin member 410 at the curvature radius R1 of the bent pin member 410 located at the corner of the outer peripheral surface 304 of the core 3 and the curvature radius R2 of the bent pin member 410 located at the corner of the inner peripheral surface 303 of the core 3 is smaller than 3.6. The spring index Ks can be expressed as the curvature radius R1, R2 of the bent pin member / the wire diameter r of the bent pin member. Thus, the bent pin member 410 has high rigidity and is difficult to bend.

[0070] The bent pin member 410 and the straight pin member 412 are alternately connected by welding such as laser welding or spot welding. One end of the straight pin member 412 is connected to one end of the bent pin member 410, and the other end of the straight pin member 412 is connected to one end of another bent pin member 410. By repeating this, a plurality of bent pin members 410 and straight pin members 412 are connected, and the connected plurality of bent pin members 410 and straight pin members 412 are arranged spirally around the core 3. That is, one set of the bent pin member 410 and the straight pin member 412 constitutes one turn.

[0071] The bent pin member 410 is arranged parallel to each of the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3. The bent pin member 410 is arranged such that a virtual line connecting both end portions in the extending direction is orthogonal to the axial direction of the first coil 41. In other words, the bent pin member 410 is arranged such that a plane including the center line of the bent pin member 410 is parallel to a plane (XZ plane) orthogonal to the axial direction of the first coil 41. The straight pin member 412 is arranged parallel to the first end face 301 of the core 3. The straight pin member 412 extends in the X direction with a slight inclination in the Y direction. The outermost straight pin member 411 is arranged parallel to the first end face 301 of the core 3. The outermost straight pin member 411 extends in a direction parallel to the straight pin member 412.

[0072] The first electrode terminal 51 is connected to one of the outermost straight pin members 411, and one of the outermost straight pin members 411 is connected to one end of the bent pin member 410 of the adjacent turn to the one of the outermost straight pin members 411. A part of the first electrode terminal 51 enters into the case 2, and the circumferential surface of one of the outermost straight pin members 411 is connected to the first electrode terminal 51. Specifically speaking, a part of the first electrode terminal 51 passes through the opening 216 and is connected to the circumferential surface of one of the outermost straight pin members 411. In short, the first coil 41 and the first electrode terminal 51 are electrically connected via the opening 216.

[0073] The second electrode terminal 52 is connected to the other outermost straight pin member 411, and the other outermost straight pin member 411 is connected to one end of the bent pin member 410 of the adjacent turn to the other outermost straight pin member 411. A part of the second electrode terminal 52 enters into the case 2, and the circumferential surface of the other outermost straight pin member 411 is connected to the second electrode terminal 52. Specifically speaking, a part of the second electrode terminal 52 passes through the opening 216 and is connected to the circumferential surface of the other outermost straight pin member 411. In short, the first coil 41 and the second electrode terminal 52 are electrically connected via the opening 216.

[0074] The second coil 42 is composed of a plurality of pin members, similar to the first coil 41. That is, the second coil 42 includes, in order from one end to the other end, the outermost straight pin member 421 on one end side (one side), a plurality of sets of bent pin members 420 and straight pin members 422, and the outermost straight pin member 421 on the other end side (the other side). The bent pin members 420 and the straight pin members 422 are alternately connected and wound around the core 3. That is, the plurality of bent pin members 420 and straight pin members 422 are connected, and the connected plurality of bent pin members 420 and straight pin members 422 are spirally wound around the core 3.

[0075] The third electrode terminal 53 is connected to one of the outermost straight pin members 421, and one of the outermost straight pin members 421 is connected to one end of the bent pin member 420 of the adjacent turn to the one of the outermost straight pin members 421. A part of the third electrode terminal 53 enters into the case 2, and the circumferential surface of one of the outermost straight pin members 421 is connected to the third electrode terminal 53. Specifically speaking, a part of the third electrode terminal 53 penetrates through the opening 216 and is connected to the circumferential surface of one of the outermost straight pin members 421. In short, the second coil 42 and the third electrode terminal 53 are electrically connected via the opening 216.

[0076] The fourth electrode terminal 54 is connected to the other outermost straight pin member 421, and the other outermost straight pin member 421 is connected to one end of the bent pin member 420 of the adjacent turn to the other outermost straight pin member 421. A part of the fourth electrode terminal 54 enters into the case 2, and the circumferential surface of the other outermost straight pin member 421 is connected to the fourth electrode terminal 54. Specifically speaking, the fourth electrode terminal 54 penetrates through the opening 216 and is connected to the circumferential surface of the other outermost straight pin member 421. In short, the second coil 42 and the fourth electrode terminal 54 are electrically connected via the opening 216.

[0077] As shown in FIG. 3, it is preferable that the first coil 41 and the second coil 42 (pin members 410 to 412, 420 to 422) each include a conductor part and a coating that covers a part of the conductor part. The conductor part is, for example, a copper wire, and the coating is, for example, a polyamideimide resin. The thickness of the coating is, for example, 0.02 to 0.04 mm.

[0078] The outermost straight pin members 411, 421 are composed of conductor parts 411a, 421a without coating. The straight pin members 412, 422 are composed of conductor parts 412a, 422a without coating. The bent pin members 410, 420 are composed of conductor parts 410a, 420a and coatings 410b, 420b.

[0079] At one end and the other end of the bent pin members 410 and 420, the conductor portions 410a and 420a are exposed from the coatings 410b and 420b. That is, the outermost straight pin members 411 and 421, the straight pin members 412 and 422, and the bent pin members 410 and 420 are, for example, welded to each other at the exposed conductor portions 411a, 421a, 412a, 422a, 410a, and 420a. The conductor portions not covered by these coatings, that is, the conductor portions exposed from the coatings (without coatings), can be electrically connected to the outside.

[0080] FIG. 6 is an XZ cross-sectional view passing through the center of the inductor component 1 in the Y direction. In FIG. 6, the box portion 22 is omitted.

[0081] As shown in FIG. 6, in the first coil 41, the ends of adjacent pin members have welded portions welded to each other. The welded portion indicates a portion that melted once during welding and then solidified. Specifically, the first coil 41 has a first welded portion 81 and a second welded portion 82. More specifically, in adjacent turns of the first coil 41, the straight pin member 412 and the bent pin member 410 of one turn form a first welded portion 81 where one conductor portion 412a of the straight pin member 412 and the conductor portion 410a of the bent pin member 410 are welded to each other, and the straight pin member 412 and the bent pin member 410 of the other turn form a second welded portion 82 where the other conductor portion 412a of the straight pin member 412 and the conductor portion 410a of the bent pin member are welded to each other.

[0082] Note that in FIG. 6, the turns composed of the straight pin member 412 and the bent pin member 410 of the first coil 41 are described, but the same applies to the turns composed of the outermost straight pin member 411 and the bent pin member 410. Specifically, the outermost straight pin member 411 is welded to the conductor portion 410a of the bent pin member connected to the conductor portion 411a to form the first welded portion 81 or the second welded portion 82.

[0083] The second coil 42 has a third welding portion 83 and a fourth welding portion 84. Also in the second coil 42, similar to the first coil 41, in adjacent turns, the straight pin member 422 and the bent pin member 420 of one turn are welded at one conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member 420 to form the third welding portion 83, and the straight pin member 422 and the bent pin member 420 of the other turn are welded at the other conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member to form the fourth welding portion 84. Further, the outermost straight pin member 421 is welded at the conductor portion 420a of the bent pin member connected to the conductor portion 421a to form the third welding portion 83 or the fourth welding portion 84. The third welding portion 83 and the fourth welding portion 84 of the second coil 42 have the same configuration as the first welding portion 81 and the second welding portion 82 of the first coil 41, and the description thereof is omitted.

[0084] The core cover 60 exists between the conductor portions and the welding portions exposed from the coating in the coils 41, 42 and the core 3. Thereby, the conductor portions and the welding portions of the coils 41, 42 and the core 3 can be more reliably insulated.

[0085] The core cover 60 is provided over the first end face 301 of the core 3, a part of the inner peripheral surface 303 of the core 3, and a part of the outer peripheral surface 304 of the core 3. The core cover 60 has a first portion 60a facing the inner peripheral surface 303 of the core 3, a second portion 60b facing the outer peripheral surface 304 of the core 3, and a third portion 60c facing the first end face 301 of the core 3.

[0086] The core cover 60 is indirectly connected to the core 3. That is, the core cover 60 is not directly connected to the core 3. Specifically speaking, the core cover 60 is connected to the core 3 via the core support member 310. By connecting the core support member 310 to a part of the core 3, the stress on the core 3 received from the core cover 60 can be reduced, and the deterioration of the magnetic characteristics of the core 3 can be suppressed. That is, the decrease in the inductance value due to magnetostriction can be suppressed. Note that the core cover 60 may be simply fitted into the core 3 without being connected to the core 3 via the core support member 310.

[0087] The core support member 310 is provided between the first end face 301 of the core 3 and the third portion 60c of the core cover 60. Thereby, while reducing the influence of magnetostriction on the core 3, the mounting state of the core cover 60 to the core 3 can be made stable.

[0088] Examples of the material of the core support member 310 include soft resins such as urethane resin and silicone resin. By providing such a soft resin, the influence of magnetostriction can be reduced.

[0089] In FIG. 6, the core support member 310 is provided over the entire area between the first end face 301 of the core 3 and the third portion 60c of the core cover 60, but it may be provided only in a part thereof. Also, in FIG. 6, the core support member 310 is provided between the first end face 301 of the core 3 and the third portion 60c of the core cover 60, but it may be provided between the inner peripheral surface 303 of the core 3 and the first portion 60a of the core cover 60, or between the outer peripheral surface 304 of the core 3 and the second portion 60b of the core cover 60, and it may be provided at a plurality of these locations among them.

[0090] As shown in FIG. 6, the inductor element L is disposed in the recess 215 such that the conductor portions exposed from the coating films of the coils 41 and 42 are located on the first main surface 210a side. The resin member 90 is fixed in the recess 215 to fix the inductor element L to the bottom plate portion 21 and cover at least a part of the conductor portions exposed from the coating films of the coils 41 and 42. Preferably, the resin member 90 covers all of the conductor portions.

[0091] Since the resin member 90 is made of, for example, a thermosetting resin, it is fixed to the inductor element L and the bottom plate portion 21 by curing. The resin member 90 contacts the inner surface of the recess 215, a part of the first portion 60a of the core cover 60, a part of the second portion 60b of the core cover 60, and a part of the third portion 60c of the core cover 60, and covers the conductor portions 411a, 412a, 410a exposed from the coating film 410b of the first coil 41 and the conductor portions 421a, 422a, 420a exposed from the coating film 420b of the second coil 42. Further, the resin member 90 also covers the welding portions 81 to 84 of the coils 41 and 42.

[0092] Since the resin member 90 is fixed in the recess 215 of the bottom plate portion 21, the resin member 90 is stably fixed to the bottom plate portion 21, and thereby, the resin member 90 can stably fix the inductor element L to the bottom plate portion 21. Also, in the manufacturing process of the inductor component 1, when filling the recess 215 with the liquid resin member 90, the liquid resin member 90 can be retained in the recess 215, and the resin member 90 can surely fix the inductor element L to the bottom plate portion 21. Further, since the resin member 90 covers the conductor portions exposed from the coating films of the coils 41 and 42, problems such as an electrical short to the outside can be prevented. Moreover, when the inductor component 1 is subjected to an external force such as vibration or impact, the resin member 90 can absorb the impact and protect the coils 41 and 42.

[0093] (Detailed Configuration of Connection Portion of Wire Member) Next, the detailed configuration of the connection portion between the straight pin member 412 (first wire member) and the bent pin member 410 (second wire member) will be described. FIGS. 7 and 8 are upper perspective views of the connection portion between the straight pin member 412 and the bent pin member 410. FIGS. 7 and 8 show the state immediately after assembling the straight pin member 412 to the bent pin member 410, that is, the state before connecting the bent pin member 410 and the straight pin member 412 by, for example, welding. Further, FIGS. 7 and 8 show the connection portion located on the radially inner side of the connection portion between the straight pin member 412 and the bent pin member 410, which is located on the radially inner side and the radially outer side of the core 3. FIG. 9 is a view of the straight pin member 412 as seen from the direction of the center line 412c of the first end portion 412e1 of the straight pin member 412.

[0094] As shown in FIGS. 7 to 9, the straight pin member 412 has a rectangular cross section. In a cross section orthogonal to the extending direction (X direction), each of the two corner portions on the Z direction side (the side facing the core 3) of the straight pin member 412 has a curved surface C. Thereby, when assembling the straight pin member 412 to the bent pin member 410, it is possible to prevent the corner portion of the straight pin member 412 from hitting the core 3 and damaging the core 3. The size of the cross section of the straight pin member 412 is, for example, the width in the Y direction is 1.8 mm, the height in the Z direction is 2 mm, and the radius of curvature of the curved surface C is 0.5 mm. Note that the cross-sectional shape of the straight pin member 412 is not particularly limited, and may be circular, elliptical, or another polygon other than rectangular. Further, in a cross section orthogonal to the extending direction, each of the two corner portions on the opposite Z direction side of the straight pin member 412 may have a curved surface C, or the curved surface C may not be provided at the corner portion.

[0095] On the end face 412ef of the first end portion 412e1 of the linear pin member 412, a wall portion 412w protruding in the direction of the center line 412c of the first end portion 412e1 is provided. Similarly, on the end face 412ef of the second end portion 412e2 of the linear pin member 412, a wall portion 412w protruding in the direction of the center line 412c of the first end portion 412e1 is provided. Here, the center line 412c of the first end portion 412e1 is a line passing through the center of gravity of the first end portion 412e1 in a cross section orthogonal to the extending direction (X direction) of the first end portion 412e1. The end face 412ef of the first end portion 412e1 is the outermost outer surface in the direction of the center line 412c of the first end portion 412e1. The same applies to the end face 412ef of the second end portion 412e2. The end face 412ef is orthogonal to the direction of the center line 412c of the first end portion 412e1. The shape of the wall portion 412w is not particularly limited, but in this embodiment, it is in the shape of a rectangular parallelepiped. The wall portion 412w can be formed, for example, by pressing a part of the end face of the first end portion 412e1 in the direction of the center line 412c. Alternatively, the wall portion 412w can be formed, for example, by cutting a part of the end face of the first end portion 412e1.

[0096] The position where the wall portion 412w is provided on the end face 412ef is not particularly limited either. However, as in this embodiment, the wall portion 412w is provided at the end portion on the opposite Z-direction side of the end face 412ef, and it is preferable that the end face on the opposite Z-direction side of the wall portion 412w and the end face on the opposite Z-direction side of the portion of the linear pin member 412 excluding the wall portion 412w are flush. Thereby, the linear pin member 412 can be stably assembled to the bent pin member 410, and the end face on the opposite Z-direction side of the linear pin member 412 can be made flat. For example, when laser is irradiated on the end face for welding, welding can be performed well without scattering the laser.

[0097] The bent pin member 410 has a circular cross-section. The diameter of the cross-section of the bent pin member 410 is, for example, 2.0 mm. However, it is not limited to this, and the cross-sectional shape of the bent pin member 410 may be an ellipse, a polygon, or the like. The end face 410ef of the second end portion 410e2 of the bent pin member 410 is flat. The end face 410ef is orthogonal to the center line 410c direction of the second end portion 410e2. Similarly, the end face of the first end portion (not shown) of the bent pin member 410 is flat. The said end face is orthogonal to the center line direction of the first end portion.

[0098] FIG. 10 is a schematic cross-sectional view of the connection portion between the straight pin member 412 and the bent pin member 410. FIG. 11 is a view of the connection portion between the straight pin member 412 and the bent pin member 410 as seen from the direction of the center line 410c of the second end portion 410e2 of the bent pin member 410. FIGS. 10 and 11 show the state after connecting the bent pin member 410 and the straight pin member 412 by welding. In FIG. 11, for the sake of convenience, hatching is applied to the position where the first weld portion 81 exists.

[0099] As shown in FIGS. 10 and 11, the end face 412ef of the first end portion 412e1 of the straight pin member 412 faces the peripheral surface 410cf of the second end portion 410e2 of the bent pin member 410. In this embodiment, a part of the end face 412ef is in contact with the peripheral surface 410cf. Here, the center line 410c of the second end portion 410e2 is a line passing through the centroid of the second end portion 410e2 in a cross-section orthogonal to the extending direction of the second end portion 410e2. The peripheral surface 410cf of the second end portion 410e2 is the outer surface in the circumferential direction centered on the center line of the second end portion 410e2. Note that the end face 412ef may be in contact with the peripheral surface 410cf via, for example, a conductive adhesive member. Among the connection portions of the plurality of pin members, there may be a connection portion where the end face 412ef is not in contact with the peripheral surface 410cf, that is, the end face 412ef and the peripheral surface 410cf are spaced apart with a space therebetween.

[0100] The side surface 412wf of the wall portion 412w in the direction orthogonal to the center line 412c direction of the first end portion 412e1 (the forward Z direction) faces the end surface 410ef of the second end portion 410e2. In this embodiment, the side surface 412wf is in surface contact with the end surface 410ef. In short, in this embodiment, the corner portion of the second end portion 410e2 of the bent pin member 410 is fitted into the space surrounded by the end surface 412ef of the linear pin member 412 and the wall portion 412w. Here, the end surface 410ef of the second end portion 410e2 is the outermost outer surface in the direction of the center line 410c of the second end portion 410e2. Note that the entire surface of the side surface 412wf may be in surface contact with the end surface 410ef, a part of the side surface 412wf may be in surface contact with the end surface 410ef, or the side surface 412wf may be in surface contact with the end surface 410ef via, for example, a conductive adhesive member. Note that among the connection portions of the plurality of pin members, there may be a connection portion where the side surface 412wf is not in surface contact with the end surface 410ef, that is, the side surface 412wf and the end surface 410ef are separated with a space therebetween.

[0101] The first welding portion 81 is continuously provided from the end surface on the reverse Z direction side of the wall portion 412w to a position exceeding the end surface 410ef of the second end portion 410e2. The first welding portion 81 is formed, for example, by irradiating the wall portion 412w with a laser from the reverse Z direction side to melt a part of the first end portion 412e1 and a part of the second end portion 410e2. In this embodiment, the first welding portion 81 is formed by melting a part of the wall portion 412w and a part of the second end portion 410e2. However, it is not limited thereto, and the first welding portion 81 may be formed by melting the entire wall portion 412w and a part of the second end portion 410e2. The first welding portion 81 connects the end surface 410ef of the second end portion 410e2 and the side surface 412wf of the wall portion 412w. Thereby, the first end portion 412e1 of the linear pin member 412 and the second end portion 410e2 of the bent pin member 410 are connected.

[0102] When the first end portion 412e1 of the straight pin member 412 and the second end portion 410e2 of the bent pin member 410 are connected by welding, as shown in FIG. 10, the wall portion 412w includes at least a part of the first weld portion 81. When the boundary between the end face 412ef of the first end portion 412e1 and the peripheral surface 410cf of the second end portion 410e2 is unclear, the end face 412ef is the virtual line VL1 including the clear peripheral surface 410cf on the reverse X-direction side of the second end portion 410e2 in the cross section including the center line 410c and the center line 412c (that is, the cross section shown in FIG. 10). It may be the portion between the peripheral surface on the forward Z-direction side and the peripheral surface on the reverse Z-direction side of the straight pin member 412. Further, in the above cross section, the peripheral surface 410cf on the reverse X-direction side of the second end portion 410e2 may be the portion located on the forward Z-direction side of the virtual line VL2 including the end face 410ef of the second end portion 410e2 among the virtual line VL1. When the boundary between the side face 412wf of the wall portion 412w and the end face 410ef of the second end portion 410e2 is unclear, the end face 410ef may be the portion between the peripheral surface on the forward X-direction side and the peripheral surface on the reverse X-direction side of the second end portion 410e2 among the virtual line VL2 in the above cross section.

[0103] Further, when the boundary between the end face 412ef and the peripheral surface 410cf and the boundary between the side face 412wf and the end face 410ef are unclear, the wall portion 412w is, in the above cross section, the region on the forward X-direction side of the virtual line VL1 and the virtual line VL2 among the first end portion 412e1 and the second end portion 410e2. It may be the portion existing in the overlapping region with the region on the reverse Z-direction side.

[0104] Also, the configuration of the connection portion of the wire member is the same for the connection portion between the straight pin member 412 and the bent pin member 410, which is located on the radially outer side of the core 3. That is, the end face 412ef of the second end portion 412e2 of the straight pin member 412 faces the peripheral surface of the first end portion of the bent pin member 410. The side surface of the wall portion 412w in the direction orthogonal to the center line direction of the second end portion 412e2 (the forward Z direction) faces the end face of the first end portion of the bent pin member 410. The second welding portion 82 connects the end face of the first end portion of the bent pin member 410 and the side surface of the wall portion 412w. Further, the configuration of the connection portion of the wire member is the same for the connection portion between the outermost straight pin member 411 and the bent pin member 410, the connection portion between the straight pin member 422 and the bent pin member 420 in the second coil 42, and the connection portion between the outermost straight pin member 421 and the bent pin member 420.

[0105] Also, when using solder instead of welding, the configuration of the connection portion between the straight pin member 412 and the bent pin member 410 may be, for example, a configuration in which solder is provided so as to cover the wall portion 412w in the configuration shown in FIG. 7. Also, when using a conductive adhesive member instead of welding, the configuration of the connection portion between the straight pin member 412 and the bent pin member 410 may be, for example, a configuration in which at least a conductive adhesive member is provided between the side surface 412wf of the wall portion 412w and the end face 410ef of the bent pin member 410 in the configuration shown in FIG. 7.

[0106] The above inductor component 1 includes coils 41 and 42 including bent pin members 410 and 420, straight pin members 412 and 422, and extreme straight pin members 411 and 421. In adjacent bent pin members 410 and 420 and straight pin members 412 and 422 (extreme straight pin members 411 and 421), a first end portion of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) and a second end portion of the bent pin members 410 and 420 are connected, and the bent pin members 410 and 420, the straight pin members 412 and 422, and the extreme straight pin members 411 and 421 constitute the helix of the coils 41 and 42. A wall portion protruding in the center line direction of the first end portion is provided on an end surface of the first end portion. The end surface of the first end portion faces the peripheral surface of the second end portion. A side surface of the wall portion in a direction orthogonal to the center line direction of the first end portion faces the end surface of the second end portion.

[0107] According to the inductor component 1, since the end surface of the first end portion of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) faces the peripheral surface of the second end portion of the bent pin members 410 and 420, when assembling the straight pin members 412 and 422 (extreme straight pin members 411 and 421) to the bent pin members 410 and 420, the positioning of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) in the center line direction of the first end portion can be easily performed. Further, since the side surface of the wall portion in a direction orthogonal to the center line direction of the first end portion faces the end surface of the second end portion, when assembling the straight pin members 412 and 422 (extreme straight pin members 411 and 421) to the bent pin members 410 and 420, the positioning of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) in the center line direction of the second end portion can be easily performed. Thus, according to the inductor component 1, since the positioning of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) can be performed by two surfaces, i.e., the end surface of the first end portion and the side surface of the wall portion, the assembly work of the straight pin members 412 and 422 (extreme straight pin members 411 and 421) and the bent pin members 410 and 420 can be facilitated. On the other hand, in the prior art, since the positioning is performed by only one surface, the assembly work of the wire member has been troublesome.

[0108] Preferably, as shown in FIG. 10, the first coil 41 has a first welding portion 81 where a part of the first end portion 412e1 of the straight pin member 412 and a part of the second end portion 410e2 of the bent pin member 410 are welded. The first welding portion 81 connects the end face 410ef of the second end portion 410e2 and the side face 412wf of the wall portion 412w.

[0109] According to the above configuration, since the first end portion 412e1 and the second end portion 410e2 are connected by the first welding portion 81, generation of cracks or the like at the connection portion can be suppressed as compared with a case where the first end portion 412e1 and the second end portion 410e2 are connected by, for example, solder, and long-term reliability of the connection portion can be ensured. In addition, since the size of the connection portion can be made smaller than in a case where the first end portion 412e1 and the second end portion 410e2 are mechanically connected by, for example, caulking, the first coil 41 can be miniaturized.

[0110] Note that the above preferable configuration and effects are the same also in a connection portion between the straight pin member 412 and the bent pin member 410, which is located on the outer side in the radial direction of the core 3. Further, the above preferable configuration and effects are the same also in a connection portion between the straight pin member 422 and the bent pin member 420 in the second coil 42.

[0111] Preferably, as shown in FIG. 11, when viewed from the direction of the center line 410c of the second end portion 410e2 of the bent pin member 410, a part of the end face 410ef of the second end portion 410e2 does not overlap the first welding portion 81.

[0112] According to the above configuration, a part of the end face 410ef of the second end portion 410e2 is not melted by welding. Thereby, swelling of the first welding portion 81 in a direction orthogonal to the direction of the center line 410c of the second end portion 410e2 is suppressed, and a short circuit that may occur between the straight pin members 412 adjacent in the Y direction and between the bent pin members 410 adjacent in the Y direction can be suppressed.

[0113] Note that the above preferable configurations and effects are the same in the connection portion between the linear pin member 412 and the bent pin member 410, which is located radially outside the core 3. Also, the above preferable configurations and effects are the same in the connection portion between the linear pin member 422 and the bent pin member 420 in the second coil 42.

[0114] Preferably, as shown in FIG. 7, the outer surface of the conductor portion 412a of the linear pin member 412 is not covered with a coating. According to this configuration, since it is not necessary to cover the conductor portion 412a of the linear pin member 412 with a coating, the linear pin member 412 can be easily manufactured. This preferable configuration and effect are the same for the outer surfaces of the linear pin member 422, the outermost linear pin member 411, and the outermost linear pin member 421.

[0115] (Method for manufacturing an inductor component) Next, a method for manufacturing the inductor component 1 will be described.

[0116] The manufacturing method of the inductor component 1 includes a step of assembling the linear pin members 412 and 422 and the bent pin members 410 and 420, in which the end surfaces of the first ends of the linear pin members 412 and 422 are opposed to the peripheral surfaces of the second ends of the bent pin members 410 and 420, and the side surfaces of the wall portions provided on the end surfaces of the first ends and protruding in the center line direction of the first ends are opposed to the end surfaces of the second ends. And a step of connecting the first ends of the linear pin members 412 and 422 and the second ends of the bent pin members 410 and 420. According to the above configuration, the assembly work of the linear pin members 412 and 422 and the bent pin members 410 and 420 can be facilitated.

[0117] Specifically, as shown in FIG. 3, the first coil 41 and the second coil 42 are wound around the core 3 with the core cover 60 fitted therein such that their winding axes are parallel to each other, and at least a part of the exposed conductor portions 411a, 412a, 410a of the first coil 41 and at least a part of the exposed conductor portions 421a, 422a, 420a of the second coil 42 are arranged on the first end face 301 side of the core 3.

[0118] Regarding the winding method of the first coil 41 and the second coil 42, more specifically, first, a plurality of aligned bent pin members 410, 420 are arranged. Then, the core 3 with the core cover 60 fitted therein is inserted into the recesses of the plurality of aligned bent pin members 410, 420. Then, as shown in FIG. 12A, the end face 412ef of the first end 412e1 of the straight pin member 412 faces the circumferential surface 410cf of the second end 410e2 of the bent pin member 410, and the side face 412wf of the wall portion 412w of the first end 412e1 faces the end face 410ef of the second end 410e2, and the straight pin member 412 is assembled to the bent pin member 410. At this time, since the wall portion 412w is provided on the end face 412ef of the first end 412e1, positioning in the direction of the center line 410c of the second end 410e2 becomes easy. Similarly, the straight pin member 422 is assembled to the bent pin member 420 such that the end face of the first end of the straight pin member 422 faces the circumferential surface of the second end of the bent pin member 420, and the side face of the wall portion of the first end faces the end face of the second end. The same applies to the connection portions between the straight pin members 412, 422 and the bent pin members 410, 420 on the outer side in the radial direction of the core 3.

[0119] Thereafter, with the first end face 301 of the core 3 facing upward, each pin member of the first coil 41 is connected, for example, by welding, and each pin member of the second coil 42 is connected, for example, by welding. Specifically, when welding, for example, as shown in FIG. 12A, the wall portion 412w is irradiated with a laser from above to form a first welded portion 81 as shown in FIG. 12B. Similarly, second to fourth welded portions 82 to 84 are formed at the connection portion between the straight pin member 412 and the bent pin member 410 on the outer side in the radial direction of the core 3 and at the connection portion between the straight pin member 422 and the bent pin member 420 on the side of the second coil 42.

[0120] Here, an example of the laser irradiation method will be described. FIG. 13 is a diagram showing an example of the relationship between the laser irradiation time and the laser output. As shown in FIG. 13, after irradiating the wall portion with a laser, it is preferable to reduce the laser output to a range of 60% to 80% when the melting of the wall portion starts. Thereby, the amount of heat transmitted to the bent pin member can be reduced compared to the case where the laser output is maintained at 100%. When the material of the pin member is Cu, it is easy to reflect the laser (reflectivity: 90% to 95%). When the pin member melts and becomes a liquid, the reflectivity decreases to 60% to 70%, so it becomes easier to absorb the laser. Therefore, the laser output can be reduced.

[0121] The laser may be continuously irradiated on the same portion of the wall portion, or after irradiating the wall portion with the laser, the laser may be scanned outward in the extending direction of the straight pin member. After the start of melting of the wall portion, by shifting (scanning) the laser irradiation position to the end face of the bent pin member, a stable welded portion can be obtained. By melting a part of the bent pin member with the laser, a more reliable electrical and mechanical connection can be realized. In this case, it is preferable to limit the amount of heat input to the bent pin member while ensuring the area of the melted portion. Specifically, it is preferable to at least not melt the portion of the outer periphery of the end face of the bent pin member that is located in the protruding direction of the wall portion. On the other hand, when the entire end face of the bent pin member is melted, the welded portion may bulge and a short circuit may occur between adjacent pin members.

[0122] An example of laser irradiation conditions is given below. Laser output: 1 kW to 4 kW Spot diameter: 20 µm Irradiation time: 20 ms to 400 ms (laser output: 100%) Wavelength: 1000 nm (fundamental wave)

[0123] In addition, as a method of connecting the pin members, when using, for example, solder instead of welding, after assembling the straight pin member 412 to the bent pin member 410 as shown in FIG. 12A, for example, solder may be provided so as to cover the wall portion 412w. Alternatively, as a method of connecting the pin members, when using, for example, a conductive adhesive member instead of welding, for example, after preliminarily attaching the conductive adhesive member to at least a part of the end face 410ef of the bent pin member 410, the straight pin member may be assembled to the bent pin member.

[0124] Thereafter, the core 3 and the coils 41 and 42 are arranged in the recess 215 of the bottom plate portion 21 so that the conductor portions exposed from the coatings in the coils 41 and 42 are located on the first main surface 210a side. At this time, the first end portions and the second end portions of the coils 41 and 42 are connected to the corresponding first to fourth electrode terminals 51 to 54.

[0125] Thereafter, as shown in FIG. 6, the liquid resin member 90 is filled into the recess 215 by, for example, a potting method. At this time, the liquid resin member 90 stays in the recess 215 and spreads wet over the conductor portions exposed from the coatings in the coils 41 and 42 and a part of the core cover 60. Further, the liquid resin member 90 is also filled into the opening 216 of the bottom plate portion 21. Since the liquid resin member 90 does not leak from the opening 216, a tape is attached to the second main surface 210b of the bottom portion 210 so as to close the opening 216.

[0126] Thereafter, heat is applied to cure the liquid resin member 90. As a result, the core 3 and the coils 41 and 42 can be fixed to the bottom plate portion 21 by the resin member 90, and the conductor portions exposed from the coating in the coils 41 and 42 can be covered by the resin member 90. Further, the resin member 90 can fill the opening 216. As the material of the resin member 90, a thermosetting epoxy resin is used. At this time, the elastic modulus is 7 GPa, and as the curing conditions, it is cured by heating at 120° C. for 30 minutes.

[0127] Thereafter, the box portion 22 is covered and housed in the case 2 to manufacture the inductor component 1. By using such a manufacturing method, the number of manufacturing steps of the inductor component 1 can be reduced, and the inductor component 1 can be manufactured more easily.

[0128] Preferably, as shown in FIGS. 12A and 12B, in the connecting step, a laser is irradiated on the wall portion 412w of the straight pin member 412 to weld the end face 410ef of the second end portion 410e2 of the bent pin member 410 and the side face 412wf of the wall portion 412w. The same applies to the connection portion between the straight pin member 422 on the second coil 42 side and the bent pin member 420.

[0129] According to the above configuration, since the first end portions of the straight pin members 412 and 422 and the second end portions of the bent pin members 410 and 420 are connected by welding, for example, compared with the case where the first end portion and the second end portion are connected by solder or the like, the occurrence of cracks or the like in the connection portion can be suppressed, and the long-term reliability of the connection portion can be ensured. Further, since the size of the connection portion can be made smaller than in the case where the first end portion and the second end portion are mechanically connected by caulking or the like, for example, the coils 41 and 42 can be miniaturized.

[0130] In addition, since the walls of the straight pin members 412 and 422 are irradiated with a laser, it is possible to suppress the laser from irradiating portions of the bent pin members 410 and 420 other than the welded portions and prevent these portions from being damaged, such as by burning. On the other hand, when the laser is irradiated on the portion between the end face of the first end and the circumferential surface of the second end in a state where there is no wall portion provided on the end face of the first end and the end face of the first end and the circumferential surface of the second end face each other, the laser passes between the end face and the circumferential surface, and there is a case where the laser irradiates portions of the bent pin members 410 and 420 other than the welded portions, and these portions are damaged, such as by burning.

[0131] In addition, in order to irradiate the walls of the straight pin members 412 and 422 with a laser, the amount of heat generated in the bent pin members 410 and 420 during laser irradiation can be made smaller than the amount of heat in the straight pin members 412 and 422. As a result, the thermal damage that can occur in the bent pin members 410 and 420 can be reduced, and damage to the bent pin members 410 and 420 can be suppressed. In particular, when the bent pin members 410 and 420 have coatings 410b and 420b, it is possible to suppress the coatings 410b and 420b from deteriorating and being damaged by heat. In addition, the distance between the ends of the coatings 410b and 420b and the welded portion can be shortened, and the insulation of the bent pin members 410 and 420 can be further ensured.

[0132] When the wire diameter of the pin member is increased to allow a large current to flow through the coils 41 and 42, the heat energy required for welding also increases, and the amount of heat during welding becomes large. For example, for extremely thick wires (wire diameter of φ1 mm or more), lasers, TIG, or resistance welding in the 500 W or several kW class is used. In this case, due to the heat during welding, the coatings 410b and 420b of the bent pin members 410 and 420 in the vicinity of the connection portion are likely to deteriorate and be damaged. On the other hand, according to the above configuration, the amount of heat transfer generated can be made larger on the side of the straight pin members 412 and 422 than in the bent pin members 410 and 420.

[0133] Preferably, as shown in FIG. 12A, in the assembling step, a part of the end face 410ef of the second end portion 410e2 does not overlap with the wall portion 412w when viewed in the direction of the center line 410c of the second end portion 410e2 of the bent pin member 410. The same applies to the connection portion between the straight pin member 422 on the second coil 42 side and the bent pin member 420.

[0134] According to the above configuration, after irradiating the walls of the straight pin members 412 and 422 with a laser, the laser can be scanned to irradiate the end faces of the second ends of the bent pin members 410 and 420. As a result, the melting amount of the first ends of the straight pin members 412 and 422 and the melting amount of the second ends of the bent pin members 410 and 420 due to laser irradiation can be increased, and the metals of the straight pin members 412 and 422 and the metals of the bent pin members 410 and 420 can be more mixed. As a result, the mechanical strength of the connection portion can be further increased.

[0135] Also, when viewed in the center line direction of the second end portions of the bent pin members 410 and 420, the area of the portion of the end face of the second end portion facing the side surface of the wall portion can be made smaller than when the entire end face of the second end portion overlaps with the wall portion. As a result, the amount of heat transmitted to the bent pin members 410 and 420 can be further reduced, and breakage of the bent pin members 410 and 420 can be further suppressed. In particular, when the bent pin members 410 and 420 have coatings 410b and 420b, deterioration and breakage of the coatings 410b and 420b due to heat can be further suppressed.

[0136] Preferably, as shown in FIG. 12A, in the assembling step, the following formula is satisfied. y ≦ (2 / 3)x + (19 / 3) 25 ≦ x ≦ 70 20 ≦ y ≦ 50 However, x = (thickness t1 of the wall portion 412w in the direction of the center line 410c of the second end portion 410e2) / (thickness t2 of the first end portion 412e1 in the direction of the center line 410c of the second end portion 410e2) × 100 y = (Length L1 of the wall portion 412w in the direction of the center line 412c of the first end portion 412e1) / (Length L2 of the end face 410ef of the second end portion 410e2 in the direction of the center line 412c of the first end portion 412e1) × 100 In the following, the above x is also referred to as the "thickness ratio" of the wall portion, and the above y is also referred to as the "length ratio" of the wall portion.

[0137] Here, the thickness of the wall portion 412w in the direction of the center line 410c of the second end portion 410e2 refers to the maximum thickness of the wall portion 412w in the direction of the center line 410c of the second end portion 410e2 in a cross section including the center line 412c of the first end portion 412e1 and the center line 410c of the second end portion 410e2 (that is, the cross section shown in Fig. 12A). The thickness of the first end portion 412e1 in the direction of the center line 410c of the second end portion 410e2 refers to the maximum thickness of the first end portion 412e1 in the direction of the center line 410c of the second end portion 410e2 in the above cross section. The length of the wall portion 412w in the direction of the center line 412c of the first end portion 412e1 refers to the maximum length of the wall portion 412w in the direction of the center line 412c of the first end portion 412e1 in the above cross section. The length of the end face 412ef of the second end portion 410e2 in the direction of the center line 412c of the first end portion 412e1 refers to the length of the end face 412ef in the above cross section.

[0138] According to the above configuration, since the thickness t1 and the length L1 of the wall portion 412w are appropriately controlled, when the wall portion 412w is irradiated with a laser, the amount of heat transferred to the bending pin member 410 can be further reduced. Thereby, the breakage of the bending pin member 410 can be further suppressed. In particular, when the bending pin member 410 has the coating 410b, the deterioration and breakage of the coating 410b due to heat can be further suppressed. The above configuration and effects are the same for the connection portion between the linear pin member 412 and the bending pin member 410 on the outer side in the radial direction of the core 3, and the connection portion between the linear pin member 422 and the bending pin member 420 on the second coil 42 side.

[0139] Preferably, it is further made to satisfy the following formula. (13 / 15)x - (83 / 3) ≤ y

[0140] According to the above configuration, since the thickness and length of the wall portion are appropriately controlled, the linear pin members 412 and 422 can be stably assembled to the bent pin members 410 and 420. On the other hand, when (13 / 15)x - (83 / 3) > y, the thickness of the wall portion increases and the length of the wall portion decreases. As a result, since the area of the portion of the outer surface of the second end portion of the bent pin members 410 and 420 that faces the first end portions of the linear pin members 412 and 422 decreases, it may be difficult to stably assemble the linear pin members 412 and 422 to the bent pin members 410 and 420.

[0141] (First Modification of the Method for Manufacturing Inductor Components) Next, a first modification of the method for manufacturing the inductor component 1 will be described. FIG. 14 is a view of the linear pin member 412A in the first modification as seen from above. FIG. 15 is a bottom perspective view of the connection portion between the linear pin member 412A and the bent pin member 410 in the first modification. FIGS. 14 and 15 show the state immediately after the linear pin member 412A is assembled to the bent pin member 410, that is, the state before the bent pin member 410 and the linear pin member 412A are connected by, for example, welding. Further, FIG. 15 shows the connection portion located on the radially inner side of the connection portions between the linear pin member 412A and the bent pin member 410, which are located on the radially inner side and the radially outer side of the core 3.

[0142] Hereinafter, the configuration of the connection portion of the pin members located on the radially inner side of the core 3 in the first coil 41 will be described. However, since the connection portions of the pin members located on the radially outer side of the core 3 and the connection portions of the pin members in the second coil 42 have the same configuration, the description thereof will be omitted.

[0143] Preferably, as shown in FIGS. 14 and 15, in the assembling step, the end face 412ef of the first end portion 412e1 of the straight pin member 412A is shaped along the circumferential surface 410cf of the second end portion 410e2 of the bent pin member 410. Specifically, when viewed from the Z direction, the end face 412ef of the first end portion 412e1 is arc-shaped along the circular shape of the circumferential surface 410cf of the second end portion 410e2. Thereby, when the straight pin member 412A is assembled to the bent pin member 410, the end face 412ef is in surface contact with the circumferential surface 410cf.

[0144] According to the above configuration, even when the straight pin member 412A is moved in the direction (Y direction) orthogonal to the direction of the center line 412c of the first end portion 412e1 of the straight pin member 412A and parallel to the end face 410ef of the second end portion 410e2 of the bent pin member 410 to assemble the straight pin member 412A to the bent pin member 410, since the end face 412ef of the first end portion 412e1 is shaped along the circumferential surface 410cf of the second end portion 410e2, the positioning of the straight pin member 412A in that direction can be facilitated.

[0145] (Second Modification of the Method for Manufacturing Inductor Parts) Next, a second modification of the method for manufacturing the inductor part 1 will be described. FIG. 16 is a perspective view of the straight pin member 412B in the second modification as viewed from below. FIG. 17 is a perspective view of the straight pin member 412B in the second modification as viewed from above. FIG. 18 is a bottom perspective view of the connecting portion between the straight pin member 412B and the bent pin member 410 in the second modification. FIGS. 16 to 18 show the state immediately after the straight pin member 412B is assembled to the bent pin member 410, that is, the state before connecting the bent pin member 410 and the straight pin member 412B by, for example, welding. Further, FIG. 18 shows the connecting portion located on the inner side in the radial direction among the connecting portions between the straight pin member 412B and the bent pin member 410 located on the inner side and the outer side in the radial direction of the core 3.

[0146] Preferably, as shown in FIGS. 16 to 18, when viewed from the direction of the center line 410c (Z direction) of the second end portion 410e2 of the bent pin member 410, the tip of the wall portion 412w in the direction of the center line 412c of the first end portion 412e1 of the straight pin member 412B has a plurality of separated convex portions P, and each of the plurality of convex portions P is irradiated with a laser. Specifically, when viewed from the Z direction, the tip of the wall portion 412w in the direction of the center line 412c has two separated convex portions P. The two convex portions P are arranged side by side in the Y direction. In short, when viewed from the Z direction, the tip of the wall portion 412w in the direction of the center line 412c is bifurcated. Note that the number of the convex portions P is not particularly limited, and may be three or more.

[0147] The end face 412ef of the first end portion 412e1 of the straight pin member 412B is shaped along the peripheral surface 410cf of the second end portion 410e2 of the bent pin member 410. Specifically, when viewed from the Z direction, the end face 412ef is formed in an arc shape as a shape along the circular shape of the peripheral surface 410cf.

[0148] According to the above configuration, the wall portion 412w has a plurality of separated convex portions P. Since the volume of each convex portion P is smaller than the volume of the wall portion when the plurality of convex portions P are integrated, the heat capacity of each convex portion P can be made smaller than the heat capacity of the wall portion. Therefore, the laser irradiation time for each convex portion P can be shortened, the amount of heat applied to each convex portion P can be made smaller, and the amount of heat transmitted to the bent pin member 410 can also be made smaller. As a result, breakage of the bent pin member 410 can be suppressed. In particular, when the bent pin member 410 has the coating 410b, deterioration and breakage of the coating 410b due to heat can be suppressed.

[0149] Preferably, the connecting step includes a first laser irradiation step of irradiating a laser to one of the plurality of convex portions P, a cooling step of cooling the laser irradiation portion irradiated with the laser, and a second laser irradiation step of irradiating a laser to another one of the convex portions P. Specifically speaking, after irradiating a laser to one of the two convex portions P shown in FIG. 18, the laser irradiation portion is cooled to solidify the melted pin member. The cooling method is, for example, air cooling, but is not limited thereto, and natural cooling may also be used. Thereafter, a laser is irradiated to the other convex portion P.

[0150] According to the above configuration, the amount of heat transferred to the bent pin member 410 can be made smaller than in the case where the first laser irradiation step and the second laser irradiation step are continuously performed without providing the cooling step. As a result, breakage of the bent pin member 410 can be further suppressed. In particular, when the bent pin member 410 has the coating 410b, deterioration and breakage of the coating 410b due to heat can be further suppressed.

[0151] Preferably, the connecting step includes a first laser irradiation step of irradiating a laser to one of the plurality of convex portions P and a second laser irradiation step of irradiating a laser to another one of the convex portions P continuously following the first laser irradiation step. Specifically speaking, after irradiating a laser to one of the two convex portions P shown in FIG. 18, a laser is continuously irradiated to the other convex portion P without performing the cooling step. According to this configuration, the straight pin member 412B and the bent pin member 410 can be connected in a short time.

[0152] In addition, a laser may be further irradiated to the crotch portion of the wall portion 412w located between the adjacent convex portions P. Thereby, the mechanical strength of the connection portion can be further increased. Also, a laser may be irradiated to each of the plurality of convex portions P simultaneously, or a laser having a large spot diameter may be used to irradiate the plurality of convex portions P with a laser at once. Thereby, the straight pin member 412B and the bent pin member 410 can be connected in an even shorter time.

[0153] (Second Embodiment) FIG. 19 is a schematic cross-sectional view showing a connection portion between the linear pin member 412 and the bent pin member 410 in the inductor component of the second embodiment. FIG. 19 corresponds to FIG. 10. In the second embodiment, the shape of the first welded portion is different from that in the first embodiment. This difference will be described below. Other configurations are the same as those in the first embodiment, and the same reference numerals as those in the first embodiment are given and the description thereof is omitted.

[0154] As shown in FIG. 19, the first welded portion 81C further connects the end face 412ef of the first end portion 412e1 of the linear pin member 412 and the circumferential surface 410cf of the second end portion 410e2 of the bent pin member 410. Specifically, a part of the first welded portion 81C exists at the contact portion between the end face 412ef of the first end portion 412e1 and the circumferential surface 410cf of the second end portion 410e2.

[0155] According to the above configuration, the cross-sectional area (connection cross-sectional area; joint cross-sectional area) of the connection portion between the first end portion 412e1 and the second end portion 410e2 increases, and the mechanical strength can be enhanced. As a result, the reliability of the connection portion can be improved. Further, since the electrical resistance of the connection portion is reduced, a large current can flow through the coils 41 and 42.

[0156] As a manufacturing method of the inductor component of the second embodiment, for example, in the connecting step, the wall portion 412w is irradiated with a laser to further weld the end face 412ef of the first end portion 412e1 of the linear pin member 412 and the circumferential surface 410cf of the second end portion 410e2 of the bent pin member 410. According to this configuration, the connection strength between the linear pin member 412 and the bent pin member 410 can be enhanced.

[0157] (Third Embodiment) FIG. 20 is a bottom perspective view showing the inside of the inductor component of the third embodiment. FIG. 21 is a schematic cross-sectional view of the inductor component. In the third embodiment, the configuration of the coil is different from that in the first embodiment. This difference will be described below. Other configurations are the same as those in the first embodiment, and the same reference numerals as those in the first embodiment are given and the description thereof is omitted.

[0158] As shown in FIGS. 20 and 21, the first coil 41D includes a plurality of bent pin members 410D. The plurality of bent pin members 410D are fixed to each other and wound around the core 3 in a spiral shape. The plurality of bent pin members 410D are connected in series, for example, by laser welding or spot welding, and wound around the core 3 in a spiral shape. Note that, instead of welding, solder or a conductive adhesive member may be used. Also, FIGS. 20 and 21 do not show a state where the plurality of bent pin members 410D are actually welded, for example, but show a state where the plurality of bent pin members 410D are assembled.

[0159] The bent pin member 410D is not a printed wiring, but is, for example, a copper wire. The copper wire is preferably a coated copper wire. The bent pin member 410D has a length corresponding to one turn in the circumferential direction passing through the first end face 301, the second end face 302, the inner circumferential face 303, and the outer circumferential face 304 of the core 3 in a cross section orthogonal to the extending direction of the core 3, and constitutes one turn of the first coil 41D.

[0160] The bent pin member 410D has a first side portion 411 facing the inner circumferential face 303 of the core 3, a second side portion 412 facing the first end face 301 of the core 3, a third side portion 413 facing the outer circumferential face 304 of the core 3, and a fourth side portion 414 facing the second end face 302 of the core 3. The first side portion 411 is arranged in parallel along the inner circumferential face 303 of the core 3, the second side portion 412 is arranged in parallel along the first end face 301 of the core 3, the third side portion 413 is arranged in parallel along the outer circumferential face 304 of the core 3, and the fourth side portion 414 is arranged in parallel along the second end face 302 of the core 3.

[0161] In two adjacent bent pin members 410D, 410D, in one bent pin member 410D (hereinafter sometimes referred to as "first bent pin member 4101", which corresponds to an example of the "first wire member" described in the claims), a first end portion 414e on the first side portion 411 side of the fourth side portion 414 and a second end portion 411e on the fourth side portion 414 side of the first side portion 411 in the other bent pin member 410D (hereinafter sometimes referred to as "second bent pin member 4102", which corresponds to an example of the "second wire member" described in the claims) are connected, and the plurality of bent pin members 410D are wound around the core 3 in a spiral shape. According to this, since each of the plurality of bent pin members 410D constitutes one turn, the connection points for forming one turn when attaching the first coil 41D to the core 3 can be reduced. Therefore, the work of attaching the first coil 41D to the core 3 can be facilitated. The bent pin member 410D is formed by bending three locations of a straight wire rod.

[0162] A first electrode terminal (not shown) is connected to the bent pin member 410D at the outermost end in the reverse Y direction. A second electrode terminal (not shown) is connected to the bent pin member 410D at the outermost end in the forward Y direction.

[0163] Similar to the first coil 41D, the second coil 42D includes a plurality of bent pin members 420D. The plurality of bent pin members 420D are fixed to each other and wound spirally around the core 3. The plurality of bent pin members 420D are connected in series by welding such as laser welding or spot welding and wound spirally around the core 3. The bent pin member 420D constitutes one turn of the second coil 42D. The bent pin member 420D has a first side portion 421 facing the inner peripheral surface 303 of the core 3, a second side portion 422 facing the first end surface 301 of the core 3, a third side portion 423 facing the outer peripheral surface 304 of the core 3, and a fourth side portion 424 facing the second end surface 302 of the core 3. According to this, since each of the plurality of bent pin members 420D constitutes one turn, the connection points for forming one turn when attaching the second coil 42D to the core 3 can be reduced. Therefore, the work of attaching the second coil 42D to the core 3 can be facilitated. The bent pin member 420D is formed by bending three places of a linear wire rod.

[0164] A third electrode terminal (not shown) is connected to the bent pin member 420D at the extreme end in the reverse Y direction. A fourth electrode terminal (not shown) is connected to the bent pin member 420D at the extreme end in the forward Y direction.

[0165] The first coil 41D includes a conductor portion 410a and a coating 410b covering the conductor portion 410a, and the second coil 42D includes a conductor portion 420a and a coating 420b covering the conductor portion 420a. Note that the conductor portions 410a and 420a may not be covered by the coatings 410b and 420b, respectively. In FIG. 20, for the sake of convenience, dots are added to the coatings 410b and 420b. Specifically speaking, preferably, the bent pin members 410D and 420D are composed of the conductor portions 410a and 420a and the coatings 410b and 420b. That is, preferably, at one end 411e and the other end 414e of the bent pin member 410D of the first coil 41D, the conductor portion 410a is exposed from the coating 410b. Similarly, preferably, at one end 421e and the other end 424e of the bent pin member 420D of the second coil 42D, the conductor portion 420a is exposed from the coating 420b.

[0166] In the bent pin member 410D of the first coil 41D, the second side portion 412 has a bent portion 418 bent so as to protrude toward the core 3 side. The bent portion 418 is located at the center of the second side portion 412. A first corner portion 415 is provided between the first side portion 411 and the second side portion 412, a second corner portion 416 is provided between the second side portion 412 and the third side portion 413, and a third corner portion 417 is provided between the third side portion 413 and the fourth side portion 414. In FIG. 21, the ranges of the first corner portion 415, the second corner portion 416, the third corner portion 417, and the bent portion 418 are indicated by a two-dot chain line, and these ranges are, respectively, the ranges having the side surfaces of the curved surface in the bent pin member 410D when viewed from the Y direction.

[0167] Note that the bent pin member 420D of the second coil 42D has the same configuration. The second side portion 422 has a bent portion 428 bent so as to protrude toward the core 3 side. A first corner portion 425 is provided between the first side portion 421 and the second side portion 422, a second corner portion 426 is provided between the second side portion 422 and the third side portion 423, and a third corner portion 427 is provided between the third side portion 423 and the fourth side portion 424.

[0168] FIG. 22 is a schematic cross-sectional view showing a connection portion between the first bent pin member 4101 and the second bent pin member 4102. As shown in FIG. 22, a wall portion 414w protruding in the direction of the center line 414c of the first end portion 414e is provided on the end surface 414ef of the first end portion 414e of the first bent pin member 4101. The end surface 414ef of the first end portion 414e faces the peripheral surface 411cf of the second end portion 411e of the second bent pin member 4102. The side surface 414wf of the wall portion 414w in the direction orthogonal to the direction of the center line 414c of the first end portion 414e (forward Z direction) faces the end surface 411ef of the second end portion 411e.

[0169] According to the above configuration, since the end face 414ef of the first end portion 414e of the first bent pin member 4101 faces the peripheral surface 411cf of the second end portion 411e of the second bent pin member 4102, when assembling the first bent pin member 4101 to the second bent pin member 4102, the positioning of the first bent pin member 4101 in the direction of the center line 414c of the first end portion 414e can be facilitated. Further, since the side surface 414wf of the wall portion 414w in the direction orthogonal to the direction of the center line 414c of the first end portion 414e faces the end face 411ef of the second end portion 411e, when assembling the first bent pin member 4101 to the second bent pin member 4102, the positioning of the first bent pin member 4101 in the direction of the center line 411c of the second end portion 411e can be facilitated. Thus, according to the above, since the positioning of the first bent pin member 4101 can be performed on two surfaces, i.e., the end face 414ef of the first end portion 414e and the side surface 414wf of the wall portion 414w, the assembly work of the first bent pin member 4101 and the second bent pin member 4102 can be facilitated.

[0170] Preferably, as shown in FIG. 22, the first bent pin member 4101 includes at least a conductor portion 410a. Specifically, the first bent pin member 4101 includes a conductor portion 410a and a coating 410b that covers a part of the outer surface of the conductor portion 410a. The second bent pin member 4102 includes a conductor portion 410a and a coating 410b that covers a part of the outer surface of the conductor portion 410a. The outer surface of the first bent pin member 4101 has a first exposed region R1 where the conductor portion 410a is exposed from the end face 414ef of the first end portion 414e toward the direction of the center line 414c of the first end portion 414e. The outer surface of the second bent pin member 4102 has a second exposed region R2 where the conductor portion 410a is exposed from the end face 411ef of the second end portion 411e toward the direction of the center line 411c of the second end portion 411e. The maximum length L4 of the second exposed region R2 in the direction of the center line 411c of the second end portion 411e is shorter than the maximum length L3 of the first exposed region R1 in the direction of the center line 414c of the first end portion 414e.

[0171] According to the above configuration, compared to when the maximum length L4 of the second exposed region R2 is longer than the maximum length L3 of the first exposed region R1, the area covered by the coating 410b of the second bending pin member 4102 can be made larger, thereby ensuring insulation between adjacent second bending pin members 4102. Furthermore, because the maximum length L4 of the second exposed region R2 is relatively short, the height in the Z direction of the resin member 90 shown in FIG. 6 can also be reduced, thereby reducing the amount of resin member 90 applied.

[0172] The present disclosure is not limited to the above-described embodiments, and design modifications are possible within the scope of the present disclosure. For example, various combinations of the features of the first to third embodiments may be used. The shape of the case and the shape of the core are not limited to the present embodiment, and design modifications are possible. Furthermore, the number of coils is not limited to the present embodiment, and design modifications are possible. Furthermore, the case box portion may not be provided, and the core cover may not be provided.

[0173] (Example) The relationship between the thickness ratio x and length ratio y of the wall portion and the temperature rise of the coating when the wall portion is irradiated with a laser was investigated. Specifically, the temperature rise of the coating was simulated when the thickness ratio x and length ratio y of the wall portion were changed. The temperature of the coating was taken as the temperature at the end of the coating on the bending pin member on the laser irradiation side (i.e., the end of the coating on the reverse Z direction side of the bending pin member 410 shown in FIG. 18). In other words, the distance from the laser irradiation surface to the simulation position was kept constant (in this example, the distance was 3.8 mm), and the temperature at that simulation position was simulated. The simulation was performed using Femtet, manufactured by Murata Software Co., Ltd. The simulation conditions were set as follows:

[0174] Shape of the straight pin member: Shape shown in Figure 18 Shape of bent pin member: Shape shown in Figure 18 (wire diameter: 2 mm) Welding position and laser power: constant (1700W level). Position of the coating (i.e., the position of the end of the coating of the bent pin member on the laser irradiation side): a position 3.8 mm away from the bottom surface of the straight pin member (i.e., the surface facing the reverse Z direction in the straight pin member in FIG. 18; the irradiation surface) Coating softening temperature: 413℃

[0175] The laser irradiation time was changed so that the amount of melting of the pin member would be constant (in other words, so that the penetration depth of the straight pin member would be constant). Table 1 shows the laser irradiation time when the wall thickness ratio x and length ratio y were changed. Table 2 shows the simulation results for the temperature at the position of the coating. The condition where the temperature at the position of the coating was lower than the softening resistance temperature of the coating (413°C) was considered to be pass. In Table 2, the failing conditions are underlined.

[0176] [Table 1]

[0177] [Table 2]

[0178] Figure 23 is a graph of the results of Table 2. In Figure 23, ◯ indicates a pass condition, × indicates a fail condition, and △ indicates an unfavorable condition from the perspective of connection stability of the pin member. Line G1 is y = (2 / 3)x + (19 / 3). Line G2 is y = (13 / 15)x - (83 / 3).

[0179] As shown in FIG. 23, under the condition that satisfies the following formula, when a laser is irradiated onto the wall portion, the temperature at the position of the coating becomes lower than the softening resistance temperature of the coating, and it is found that the temperature rise of the bending pin member can be suppressed. y≦(2 / 3)x+(19 / 3) 25≦x≦70 20≦y≦50

[0180] Furthermore, it was found that the connection stability of the pin member can be further improved by further satisfying the following formula. (13 / 15)x-(83 / 3)≦y

[0181] This disclosure includes the following aspects. <1> Comprising a coil including a plurality of wire members, In adjacent wire members, a first end portion of a first wire member and a second end portion of a second wire member are connected, and the plurality of wire members form a helix of the coil, On an end face of the first end portion, a wall portion protruding in a central axis direction of the first end portion is provided, The end face of the first end portion faces a peripheral surface of the second end portion, An inductor component, wherein a side surface of the wall portion in a direction orthogonal to the central axis direction of the first end portion faces an end face of the second end portion. <2> The coil has a welded portion where a part of the first end portion and a part of the second end portion are welded, The inductor component according to <1>, wherein the welded portion connects the end face of the second end portion and the side surface of the wall portion. <3> The inductor component according to <2>, wherein the welded portion further connects the end face of the first end portion and the peripheral surface of the second end portion. <4> The inductor component according to <2> or <3>, wherein a part of the end face of the second end portion does not overlap the welded portion when viewed from the central axis direction of the second end portion. <5> The first wire member includes at least a conductor portion, The second wire member includes a conductor portion and a coating covering a part of an outer surface of the conductor portion of the second wire member, The outer surface of the first wire member has a first exposed region where the conductor portion of the first wire member is exposed from the end face of the first end portion in the central axis direction of the first end portion, The outer surface of the second wire member has a second exposed region where the conductor portion of the second wire member is exposed in a direction of the center line of the second end portion from an end surface of the second end portion. The maximum length of the second exposed region in the center line direction of the second end portion is shorter than the maximum length of the first exposed region in the center line direction of the first end portion, the inductor component according to any one of <1> to <4>. <6> The outer surface of the conductor portion of the first wire member is not covered with a coating, the inductor component according to <5>. <7> In adjacent wire members, a step of assembling a first wire member and a second wire member, in which an end surface of a first end portion of the first wire member is opposed to a peripheral surface of a second end portion of the second wire member, and a side surface of a wall portion provided on the end surface of the first end portion and protruding in a direction of the center line of the first end portion is opposed to an end surface of the second end portion. A method of manufacturing an inductor component, comprising: a step of connecting the first end portion of the first wire member and the second end portion of the second wire member. <8> In the connecting step, the method of manufacturing an inductor component according to <7>, in which a laser is irradiated onto the wall portion to weld the end surface of the second end portion and the side surface of the wall portion. <9> In the connecting step, the method of manufacturing an inductor component according to <8>, in which a laser is irradiated onto the wall portion to further weld the end surface of the first end portion and the peripheral surface of the second end portion. <10> In the connecting step, as viewed from a direction of the center line of the second end portion, a tip of the wall portion in the direction of the center line of the first end portion has a plurality of separated convex portions, and a laser is irradiated onto each of the plurality of convex portions, the method of manufacturing an inductor component according to <8> or <9>. <11> The connecting step A first laser irradiation step of irradiating a laser onto one of the plurality of convex portions A cooling step of cooling a laser irradiation portion irradiated with the laser A method for manufacturing an inductor component according to <10>, including a second laser irradiation step of irradiating another convex portion with a laser. <12> The step of connecting includes: a first laser irradiation step of irradiating one of the plurality of convex portions with a laser; A method for manufacturing an inductor component according to <10>, including a second laser irradiation step of continuously irradiating another convex portion with a laser following the first laser irradiation step. <13> In the assembling step, a method for manufacturing an inductor component according to any one of <8> to <12>, wherein a part of the end face of the second end portion does not overlap with the wall portion when viewed from the center line direction of the second end portion. <14> In the assembling step, a method for manufacturing an inductor component according to any one of <8> to <13>, wherein the following formula is satisfied. y ≦ (2 / 3)x + (19 / 3) 25 ≦ x ≦ 70 20 ≦ y ≦ 50 However, x = (thickness of the wall portion in the center line direction of the second end portion) / (thickness of the first end portion in the center line direction of the second end portion) × 100 y = (length of the wall portion in the center line direction of the first end portion) / (length of the end face of the second end portion in the center line direction of the first end portion) × 100 <15> Furthermore, a method for manufacturing an inductor component according to <14>, wherein the following formula is satisfied. (13 / 15)x - (83 / 3) ≦ y <16> In the assembling step, a method for manufacturing an inductor component according to any one of <7> to <15>, wherein the end face of the first end portion has a shape along the circumferential surface of the second end portion.

Explanation of Reference Numerals

[0182] 1 Inductor component 2 Case 21 Bottom plate portion 210 Bottom 210a First main surface 210b Second main surface 211 Side wall portion 215 Recessed portion 216 Opening 22 Box portion 3 Core 301 First end face (bottom face) 302 Second end face (top face) 303 Inner peripheral surface 304 Outer peripheral surface 41, 41A, 41B, 41D First coil 410, 410D Bent pin member (second wire member) 410a Conductor portion 410b Coating 410c, 412c Center line 410cf Peripheral surface of bent pin member 410e2 Second end portion of bent pin member 410ef End face of bent pin member 4101 First bent pin member (first wire member) 4102 Second bent pin member (second wire member) 412, 412A, 412B Straight pin member (first wire member) 411a, 412a Conductor portion 412e1 First end portion of straight pin member 412e2 Second end portion of straight pin member 412ef End face of straight pin member 412w, 412wB, 414w Wall portion 412wf Side face of wall portion 42, 42D Second coil 420, 420D Bent pin member (second wire member) 420a Conductor portion 420b Coating 411, 421 Outermost straight pin member (first wire member) 422 Straight pin member (first wire member) 421a, 422a Conductor portion 51 - 54 First - fourth electrode terminals 60 Core cover 81 - 84 First - fourth welding portions 90 resin member L inductor element Length of the L1 wall portion Length of the end face of the L2 bent pin member Length of the L3 first exposed region Length of the L4 second exposed region P convex portion [[ID=Q15]]R1, R2 first and second exposed regions t1 thickness of the wall portion t2 thickness of the straight pin member[[ID=2Q0]] VL1, VL2 virtual lines It should be noted that there seems to be an error in the original text where the tag in line 15 is incorrect. I have corrected it to "Q15" in the translation for the sake of following the numbering pattern. If this is not what you intended, please check the original text.

Claims

1. Comprising a coil including a plurality of wire members, In adjacent wire members, a first end portion of a first wire member and a second end portion of a second wire member are connected, and the plurality of wire members form a helix of the coil, On an end face of the first end portion, a wall portion protruding in a central line direction of the first end portion is provided, The end face of the first end portion faces the peripheral surface of the second end portion, An inductor component in which a side surface of the wall portion in a direction orthogonal to the central line direction of the first end portion faces the end face of the second end portion.

2. The coil has a welded portion where a part of the first end portion and a part of the second end portion are welded, The inductor component according to claim 1, wherein the welded portion connects the end face of the second end portion and the side surface of the wall portion.

3. The inductor component according to claim 2, wherein the welded portion further connects the end face of the first end portion and the peripheral surface of the second end portion.

4. The inductor component according to claim 2 or 3, wherein a part of the end face of the second end portion does not overlap the welded portion when viewed in the central line direction of the second end portion.

5. The first wire member includes at least a conductor portion, The second wire member includes a conductor portion and a coating covering a part of an outer surface of the conductor portion of the second wire member, The outer surface of the first wire member has a first exposed region where the conductor portion of the first wire member is exposed from the end face of the first end portion in the central line direction of the first end portion, The outer surface of the second wire member has a second exposed region where the conductor portion of the second wire member is exposed from the end face of the second end portion in the central line direction of the second end portion, The inductor component according to any one of claims 1 to 3, wherein a maximum length of the second exposed region in the central line direction of the second end portion is shorter than a maximum length of the first exposed region in the central line direction of the first end portion.

6. The inductor component according to claim 5, wherein an outer surface of the conductor portion of the first wire member is not covered with a coating.

7. A step of assembling a first wire member and a second wire member, in adjacent wire members, facing an end face of a first end portion of the first wire member to a peripheral surface of a second end portion of the second wire member, and facing a side surface of a wall portion provided on the end face of the first end portion and protruding in a central line direction of the first end portion to the end face of the second end portion. A method for manufacturing an inductor component, comprising a step of connecting the first end portion of the first wire member and the second end portion of the second wire member.

8. The method for manufacturing an inductor component according to claim 7, wherein in the connecting step, a laser is irradiated onto the wall portion to weld the end face of the second end portion and the side face of the wall portion.

9. The method for manufacturing an inductor component according to claim 8, wherein in the connecting step, a laser is irradiated onto the wall portion to further weld the end face of the first end portion and the circumferential surface of the second end portion.

10. The method for manufacturing an inductor component according to claim 8 or 9, wherein in the connecting step, as viewed from the center line direction of the second end portion, the tip of the wall portion in the center line direction of the first end portion has a plurality of separated convex portions, and a laser is irradiated onto each of the plurality of convex portions.

11. The connecting step includes a first laser irradiation step of irradiating a laser onto one of the plurality of convex portions, a cooling step of cooling the laser irradiation portion irradiated with the laser, and a second laser irradiation step of irradiating a laser onto another one of the plurality of convex portions. The method for manufacturing an inductor component according to claim 10.

12. The connecting step includes a first laser irradiation step of irradiating a laser onto one of the plurality of convex portions, and a second laser irradiation step of irradiating a laser onto another one of the plurality of convex portions continuously following the first laser irradiation step. The method for manufacturing an inductor component according to claim 10.

13. The method for manufacturing an inductor component according to claim 8 or 9, wherein in the assembling step, a part of the end face of the second end portion does not overlap with the wall portion as viewed from the center line direction of the second end portion.

14. The method for manufacturing an inductor component according to claim 8 or 9, wherein in the assembling step, the following formula is satisfied. y ≤ (2 / 3)x + (19 / 3) 25 ≤ x ≤ 70 20 ≤ y ≤ 50 However, x = (thickness of the wall portion in the center line direction of the second end portion) / (thickness of the first end portion in the center line direction of the second end portion) × 100 y = (length of the wall portion in the center line direction of the first end portion) / (length of the end face of the second end portion in the center line direction of the first end portion) × 100

15. The method for manufacturing an inductor component according to claim 14, wherein the following formula is further satisfied. (13 / 15)x - (83 / 3) ≤ y

16. The manufacturing method of an inductor component according to any one of claims 7 to 9, wherein, in the assembling step, an end face of the first end portion has a shape along a circumferential surface of the second end portion.

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