Coil parts

Abstract

Provided is a coil component that can reduce separation of an electrode terminal and a mounting part. A coil component according to the present invention comprises an annular core, a coil that is wound around the core, an electrode terminal that is connected to the coil, and a mounting part on which the electrode terminal is mounted. The mounting part has an inside end surface that faces the core side, an outside end surface that faces the opposite side from the inside end surface, a bottom surface that links the inside end surface and the outside end surface, and a top surface that faces the opposite side from the bottom surface. The mounting part also has a slit hole that passes through the inside end surface and the outside end surface. The electrode terminal has a first flat part, a second flat part, and a linking part that links the first flat part and the second flat part. The first flat part and the second flat part are opposite each other. The first flat part is inserted into the slit hole, the linking part is opposite the outside end surface, the second flat part is opposite the bottom surface, and the first flat part is connected to an end part of the coil.

Description

[Technical Field]

[0001] The present disclosure relates to a coil component. [Background technology]

[0002] A conventional coil component is described in WO2017 / 169737 (Patent Document 1). This coil component includes an annular core, a coil wound around the core, an electrode terminal connected to the coil, and a case that covers the core and the coil. The electrode terminal is attached to the bottom surface of a bottom plate of the case. In other words, the bottom plate includes a mounting base to which the electrode terminal is attached. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] WO2017 / 169737 Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional coil components described above, the electrode terminals are fixed to the bottom surface of the bottom plate of the case, for example, by an adhesive material. Therefore, if vibrations or impacts are applied to the coil component when it is mounted on a mounting board, there is a risk that the electrode terminals will separate from the bottom plate (mounting base). In particular, as the core becomes larger to accommodate larger currents and the weight of the coil component increases, the vibrations and impacts become even greater, making the electrode terminals more likely to separate from the bottom plate (mounting base).

[0005] Therefore, an object of the present disclosure is to provide a coil component that can reduce peeling between the electrode terminal and the mounting base portion. [Means for solving the problem]

[0006] In order to solve the above problems, a coil component according to one aspect of the present disclosure comprises: an annular core; a coil wound around the core; an electrode terminal connected to the coil; a mounting base portion to which the electrode terminal is attached; Equipped with the mounting base portion has an inner end surface facing the core side, an outer end surface facing the opposite side to the inner end surface, a bottom surface connecting the inner end surface and the outer end surface, and a top surface facing the opposite side to the bottom surface, and the mounting base portion has a slit hole penetrating the inner end surface and the outer end surface, the electrode terminal has a first flat plate portion, a second flat plate portion, and a connecting portion connecting the first flat plate portion and the second flat plate portion, the first flat plate portion and the second flat plate portion facing each other, The first flat plate portion is inserted into the slit hole, the connecting portion faces the outer end surface, the second flat plate portion faces the bottom surface, and the first flat plate portion is connected to the end of the coil.

[0007] Here, the bottom surface refers to the surface that faces the mounting board when the coil component is mounted on the mounting board.

[0008] According to the above aspect, the first flat plate portion of the electrode terminal is inserted into the slit hole of the mounting base, so that the electrode terminal is inserted into the mounting base and attached. This allows the electrode terminal to be reliably fixed to the mounting base, and even if vibrations or shocks are applied to the coil component when the coil component is mounted on a mounting board, peeling between the electrode terminal and the mounting base can be reduced. In particular, even if the core becomes larger due to an increase in current, the weight of the coil component increases, and vibrations and shocks become greater, peeling between the electrode terminal and the mounting base can be reduced.

[0009] Preferably, in one embodiment of the coil component, the core is an oval ring-shaped body when viewed from the central axis direction, the mount portion includes a first mount portion and a second mount portion, When viewed from the central axis direction, the first and second mounting base portions are located on either side of the core in the longitudinal direction of the core.

[0010] According to the embodiment, the first and second mounts are located on either side of the core in the longitudinal direction of the core when viewed from the central axis, so the first electrode terminal attached to the first mount and the second electrode terminal attached to the second mount can be positioned in the longitudinal direction of the core with respect to the core. This allows the coils connected to the first and second electrode terminals to be wound around the oval longitudinal portion of the core along the longitudinal direction of the core, ensuring a sufficient number of coil turns.

[0011] Preferably, in one embodiment of the coil component, the first mount portion and the second mount portion each have a plurality of the slit holes.

[0012] According to the embodiment, the first mounting base portion and the second mounting base portion each have a plurality of slit holes, so that an electrode terminal can be inserted into each slit hole.

[0013] Preferably, in one embodiment of the coil component, an outer surface of the connecting portion opposite to the outer end surface forms a fillet-forming region that becomes a portion where solder wets up.

[0014] According to the above embodiment, when the coil component is mounted on a mounting substrate, the solder wets and rises in the fillet-forming region of the connecting portion, thereby improving the mounting strength of the coil component to the mounting substrate. Furthermore, if vibration or impact is applied to the coil component when the coil component is mounted on the mounting substrate, stress is applied to the connecting portion. However, since the solder wets and rises in the fillet-forming region of the connecting portion, the stress can be reduced by the solder. Furthermore, since the connecting portion faces the outer end surface, the solder can be confirmed from the outside.

[0015] Preferably, in one embodiment of the coil component, an end face of a tip end portion of the second flat plate portion opposite to the connecting portion forms a fillet forming region that becomes a portion where solder wets up.

[0016] According to the embodiment, when the coil component is mounted on the mounting board, the solder wets and rises up the fillet-forming region of the second flat plate portion, thereby improving the mounting strength of the coil component to the mounting board.

[0017] Preferably, in one embodiment of the coil component, a tip end portion of the first flat plate portion opposite to the connecting portion protrudes from the inner end surface and is connected to the end portion of the coil.

[0018] According to the embodiment, the tip of the first flat plate portion protrudes from the inner end surface, making it easy to connect the end of the coil. Furthermore, since the tip of the first flat plate portion is connected to the end of the coil, for example, when the end of the coil is connected to the tip of the first flat plate portion by welding, the welding heat is transmitted sequentially through the first flat plate portion and the connecting portion. This makes it difficult for the welding heat to be transmitted to the second flat plate portion, reducing discoloration and modification of the Ni, Sn, or other plating layer of the second flat plate portion and ensuring mounting reliability.

[0019] Preferably, in one embodiment of the coil component, a connection portion between the first flat plate portion and the end portion of the coil is covered with an adhesive member made of resin.

[0020] According to the embodiment, the connection between the first flat plate portion and the end of the coil is covered with an adhesive material made of resin, which reliably secures the connection and ensures insulation. In addition, the first flat plate portion is fixed to the adhesive material, which prevents the electrode terminal from slipping out of the slit hole in the mounting base.

[0021] Preferably, in one embodiment of the coil component, an opening dimension of the slit hole in the short side direction on the outer end face side is larger than an opening dimension of the slit hole in the short side direction on the inner end face side.

[0022] According to the embodiment, the opening dimension of the slit hole on the outer end face side is larger than the opening dimension of the slit hole on the inner end face side, making it easier to insert the first flat plate portion of the electrode terminal into the slit hole from the outer end face toward the inner end face.

[0023] Preferably, in one embodiment of the coil component, the first flat plate portion is press-fitted into at least an opening of the slit hole on the inner end face side.

[0024] According to the embodiment, the first flat plate portion is press-fitted into the slit hole, so that the electrode terminal can be firmly fixed to the mounting base portion.

[0025] Preferably, in one embodiment of the coil component, a dimension of the slit in the short side direction decreases continuously from the outer end surface toward the inner end surface.

[0026] According to the above embodiment, the dimension of the slit hole in the short direction becomes continuously smaller from the outer end face toward the inner end face, so that the accuracy of positioning the electrode terminal relative to the mounting base is improved when fixing the electrode terminal to the mounting base.

[0027] Preferably, in one embodiment of the coil component, the inner surface of the slit has a stepped surface that reduces the dimension of the slit in the short side direction in stages from the outer end surface toward the inner end surface.

[0028] According to the embodiment, the inner surface of the slit has a stepped surface, which makes it easier to smoothly insert the first flat plate portion of the electrode terminal into the slit from the outer end surface toward the inner end surface.

[0029] Preferably, in one embodiment of the coil component, the step surface is an inclined surface in which the dimension of the slit in the short side direction continuously decreases from the outer end surface toward the inner end surface.

[0030] According to the embodiment, the step surface is an inclined surface, which makes it easier to insert the first flat plate portion of the electrode terminal into the slit hole smoothly from the outer end surface toward the inner end surface. [Effects of the Invention]

[0031] According to the coil component according to one aspect of the present disclosure, peeling between the electrode terminal and the mounting base can be reduced. [Brief explanation of the drawings]

[0032] [Figure 1] FIG. 2 is a top perspective view showing the coil component of the first embodiment. [Figure 2] FIG. [Figure 3] FIG. 2 is a bottom perspective view showing the inside of the coil component. [Figure 4] FIG. [Figure 5] FIG. 2 is a schematic cross-sectional view of a coil component. [Figure 6] FIG. 6 is a cross-sectional view taken along the line VI-VI in FIG. [Figure 7] 10 is a top perspective view of a connection portion between an endmost straight pin member and a bent pin member in the first coil. FIG. [Figure 8] FIG. 2 is a top perspective view of a first electrode terminal. [Figure 9] FIG. 3 is a cross-sectional view of a first electrode terminal. [Figure 10] FIG. [Figure 11] FIG. [Figure 12] FIG. 4 is a cross-sectional view of a portion of the base case including a slit hole in the first mounting base portion. [Figure 13] FIG. 2 is a bottom view of the coil component excluding the bottom plate portion and the coil adhesive member. [Figure 14] 14 is a cross-sectional view taken along the line XIV-XIV in FIG. 13. [Figure 15] 10 is a cross-sectional view of a portion of a base case including a slit hole in a first mounting base portion, showing a coil component according to a second embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0033] Hereinafter, a coil component and a method for manufacturing the same according to an aspect of the present disclosure will be described in detail with reference to the illustrated embodiments. Note that the drawings include some schematic views and may not reflect actual dimensions or proportions.

[0034] First Embodiment (Overall structure of coil parts) FIG. 1 is a top perspective view showing a coil component according to one embodiment of the present invention. FIG. 2 is a bottom perspective view of the coil component. FIG. 3 is a bottom perspective view showing the interior of the coil component. FIG. 4 is an exploded perspective view of the coil component. As shown in FIGS. 1 to 4, the coil component 1 includes an annular core 3, a base case 22 that covers at least a portion of the core 3, a first coil 41 and a second coil 42 wound around the core 3 and the base case 22, first to fourth electrode terminals 51 to 54 attached to the base case 22, and a bottom plate portion 21 attached to the base case 22. The coil component 1 is, for example, a common mode choke coil.

[0035] Base case 22 and bottom plate 21 are made of a material that is strong and heat-resistant, and preferably flame-retardant. Base case 22 is made of a resin such as PPS (polyphenylene sulfide), LCP (liquid crystal polymer), or PPA (polyphthalamide), or ceramics.

[0036] The base case 22 has a core cover part 60 that covers at least a part of the core 3, a first mounting base part 71 to which the first and third electrode terminals 51, 53 are attached, and a second mounting base part 72 to which the second and fourth electrode terminals 52, 54 are attached. The core cover part 60, the first mounting base part 71, and the second mounting base part 72 are an integrated, one-piece molded product.

[0037] The core cover part 60 is an annular container body. Specifically, the core cover part 60 has an inner peripheral part 60a, an outer peripheral part 60b, and a bottom part 60c. The core cover part 60 has an annular recessed part 61 that covers the lower part of the core 3. The annular recessed part 61 is a space surrounded by the inner peripheral part 60a, the outer peripheral part 60b, and the bottom part 60c. The core cover part 60 (annular recessed part 61) is an oval (track-shaped) annular body. The shape of the core cover part 60 may be rectangular, elliptical, or circular.

[0038] The first mounting base portion 71 and the second mounting base portion 72 are formed in the shape of a rectangular parallelepiped flange, and are located on either side of the core cover portion 60. Specifically, the first mounting base portion 71 and the second mounting base portion 72 are located radially outward from the core cover portion 60. In this embodiment, the first mounting base portion 71 and the second mounting base portion 72 are located axially outward from the annular recess 61.

[0039] The first mounting base portion 71 has slit holes 70 into which the first and third electrode terminals 51 and 53 are inserted, respectively. The second mounting base portion 72 has slit holes 70 into which the second and fourth electrode terminals 52 and 54 are inserted, respectively.

[0040] The bottom plate portion 21 has a bottom portion 210, two side wall portions 211, and a partition wall portion 212. The bottom portion 210 includes a first main surface 210a and a second main surface 210b that face each other. The two side wall portions 211 are provided on the first main surface 210a of the bottom portion 210 along each of a pair of facing sides of the bottom portion 210. The partition wall portion 212 is provided between the two side wall portions 211 on the first main surface 210a of the bottom portion 210. The bottom plate portion 21 has a recessed portion 215, and the recessed portion 215 is configured by being surrounded by the bottom portion 210, the side wall portion 211, and the partition wall portion 212.

[0041] The bottom plate portion 21 is attached to the bottom 60c side of the core cover portion 60. The bottom plate portion 21 is attached to the base case 22 so that the central axis of the core 3 is perpendicular 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 bottom plate portion 21 is rectangular when viewed from the central axis direction of the core 3. In this embodiment, the shape of the bottom plate portion 21 is rectangular when viewed from the central axis direction of the core 3.

[0042] Here, the direction in which the first mounting base 71 and the second mounting base 72 face each other as viewed from the central axis direction of the core 3 is defined as the Y direction, the direction perpendicular to the Y direction as viewed from the central axis direction of the core 3 is defined as the X direction, and the height direction of the coil component 1, which is perpendicular to both the X and Y directions, is defined as the Z direction. The bottom plate 21 and the base case 22 are disposed facing each other in the Z direction, with the bottom plate 21 on the lower side and the base case 22 on the upper side, with the upper side being defined as the forward direction of the Z direction and the lower side being the reverse direction of the Z direction. In other words, in the height direction perpendicular to the first main surface 210a, the direction from the first main surface 210a toward the core 3 is defined as the upward direction. In this embodiment, the Y direction is the major axis direction of the core cover 60, and the X direction is the minor axis direction of the core cover 60.

[0043] The first to fourth electrode terminals 51 to 54 are attached to the base case 22. The first electrode terminal 51 and the second electrode terminal 52 are located at two corners of the base case 22 that face 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 base case 22 that face 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.

[0044] The first and third electrode terminals 51, 53 are attached by being inserted into slit holes 70 in the first mounting base 71. The second and fourth electrode terminals 52, 54 are attached by being inserted into slit holes 70 in the second mounting base 72. Specifically, the first to fourth electrode terminals 51-54 are each a metal plate bent into a U-shape. One end of each of the first to fourth electrode terminals 51-54 is inserted into the slit hole 70 and connected to the coils 41, 42. One end of each of the first to fourth electrode terminals 51-54 has slit portions 51a-54a. The other end of each of the first to fourth electrode terminals 51-54 is located outside the mounting bases 71, 72 and is connected to a mounting board (not shown).

[0045] A dummy terminal 55 is attached to the second main surface 210b of the bottom plate portion 21. For example, the dummy terminal 55 is adhered to the second main surface 210b with an adhesive or the like. The dummy terminal 55 is not electrically connected to the first coil 41 or the second coil 42. By providing the dummy terminal 55, when the coil component 1 is mounted on a mounting board (not shown), the dummy terminal 55 can be connected to the mounting board via solder in addition to the first to fourth electrode terminals 51 to 54. This can improve the mounting strength of the coil component 1.

[0046] The core 3 is a toroidal core, and is an oval (track-shaped) annular body when viewed from the central axis direction. When viewed from the central axis direction, the core 3 includes a pair of long portions 31 extending along the major axis and facing each other in the minor axis direction, and a pair of short portions 32 extending along the minor axis and facing each other in the major axis direction. The shape of the core 3 may be rectangular, elliptical, or circular when viewed from the central axis direction.

[0047] 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 that face each other in the central axis direction, as well as 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 is located on the bottom plate portion 21 side. The second end face 302 is the upper end face of the core 3. The short side portion 32 has a convex portion on the second end face 302. In other words, the region of the second end face 302 that is located at the short side portion 32 is located higher in the Z direction than the region of the second end face 302 that is located at the long side portion 31.

[0048] The shape of a cross section perpendicular to the circumferential direction as viewed from the central axis direction of core 3 is rectangular. First end face 301 and second end face 302 are disposed perpendicular to the central axis direction of core 3. Inner peripheral surface 303 and outer peripheral surface 304 are disposed parallel to the central axis direction of core 3. In this specification, "perpendicular" does not necessarily mean a completely perpendicular state, but also includes a substantially perpendicular state. Furthermore, "parallel" does not necessarily mean a completely parallel state, but also includes a substantially parallel state.

[0049] The core 3 is housed in the core cover part 60 of the base case 22 so that the long axis direction of the core 3 coincides with the Y direction. A portion of the core 3 on the first end face 301 side is covered by the core cover part 60. In other words, the lower portion of the core 3 is fitted into the annular recess 61 of the core cover part 60, so that the core 3 can be attached to the core cover part 60. It is sufficient that at least a portion of the core 3 on the first end face 301 side is covered by the core cover part 60, and the entire core 3 may also be covered by the core cover part 60.

[0050] The core 3 is connected to the core cover part 60 via a core adhesive member 91. The core adhesive member 91 is disposed in the annular recess 61 and bonds the first end face 301 of the core 3 and the bottom part 60c of the core cover part 60 together.

[0051] The first coil 41 and the second coil 42 are connected to the bottom plate portion 21 via a coil adhesive member 90. The coil adhesive member 90 is disposed in the recess 215 of the bottom plate portion 21, and is in contact with the first coil 41, the second coil 42, and the base case 22.

[0052] The first coil 41 is wound around the core 3 and the core cover part 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.

[0053] The second coil 42 is wound around the core 3 and the core cover part 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.

[0054] The first coil 41 and the second coil 42 are spirally wound around the core 3 and the core cover part 60 along the circumferential direction of the core 3 as viewed from the central axis direction of the core 3. Specifically, the first coil 41 is wound around one longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal direction of the core 3, and the second coil 42 is wound around the other longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal direction of the core 3. The winding axis of the first coil 41 and the winding axis of the second coil 42 run parallel to each other. The first coil 41 and the second coil 42 are symmetrical with respect to the longitudinal axis of the core 3.

[0055] The number of turns of the first coil 41 is the same as the number of turns of the second coil 42. The winding direction of the first coil 41 around the core 3 is opposite to the winding direction of the second coil 42 around the core 3. In other words, the winding direction of the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52 is opposite to the winding direction of the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54.

[0056] The first to fourth electrode terminals 51 to 54 are connected so that a common mode current flows in the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52, and in the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54; that is, the first to fourth electrode terminals 51 to 54 are connected so that the current flows in the same direction. When a common mode current flows in the first coil 41, a first magnetic flux is generated in the core 3 by the first coil 41. When a common mode current flows in the second coil 42, a second magnetic flux is generated in the core 3 in a direction that reinforces the first magnetic flux within the core 3. Therefore, 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.

[0057] 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 does not show the state in which the plurality of pin members are actually welded, but shows the state in which the plurality of pin members are assembled. Furthermore, the method for connecting the plurality of pin members is not limited to welding, and other connection methods using, for example, solder or a conductive adhesive member may also be used. In the following, for the sake of simplicity, it is assumed that welding is used as the method for connecting the plurality of pin members.

[0058] The multiple pin members are rod-shaped members rather than printed wiring or conductive wires. The pin members have rigidity. Specifically, in a cross section perpendicular to the circumferential direction of the core 3, the pin members are shorter than the length of one circumference of the core 3 passing through the first end face 301, the second end face 302, the inner circumferential surface 303, and the outer circumferential surface 304 of the core 3. Furthermore, the pin members have high rigidity, making them difficult to bend. The multiple pin members include multiple bent pin members 410 bent into a substantially U-shape and multiple straight pin members 411, 412 extending in a substantially straight line. The straight pin members 411, 412 and the bent pin member 410 are alternately connected to form the spiral of the first coil 41. The multiple straight pin members 411, 412 include an endmost straight pin member 411 located at the end of at least one side of the first coil 41 in the axial direction. Of the plurality of straight pin members, the straight pin members other than the endmost straight pin member 411 are referred to as normal straight pin members 412 (hereinafter simply referred to as straight pin members 412).

[0059] The first coil 41 includes, in order from one end to the other, an endmost straight pin member 411 on one end side (one), a plurality of sets of bent pin members 410 and straight pin members 412, and an endmost straight pin member 411 on the other end side (the other). In this embodiment, the endmost straight pin member 411 and the straight pin member 412 have the same shape. However, this is not limiting, and the endmost straight pin member 411 and the straight pin member 412 may have different shapes. For example, the length of the endmost straight pin member 411 in the extension direction may be shorter than the length of the straight pin member 412 in the extension direction.

[0060] 5, when the bending pin member 410 is disposed along the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3, the bending pin member 410 has a spring index Ks smaller than 3.6 for a radius of curvature R1 of the bending pin member 410 located at a corner of the outer peripheral surface 304 of the core 3 and a radius of curvature R2 of the bending pin member 410 located at a corner of the inner peripheral surface 303 of the core 3. The spring index Ks can be expressed as the radius of curvature R1, R2 of the bending pin member divided by the wire diameter r of the bending pin member. As such, the bending pin member 410 has high rigidity and is difficult to bend.

[0061] The bent pin members 410 and the straight pin members 412 are alternately connected by welding, for example, laser welding or spot welding. One end of a straight pin member 412 is connected to one end of a 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 process, multiple bent pin members 410 and straight pin members 412 are connected, and the multiple connected bent pin members 410 and straight pin members 412 are arranged spirally on the core 3. In other words, one set of bent pin member 410 and straight pin member 412 forms one turn.

[0062] The bent pin members 410 are arranged parallel to each other along the second end face 302, the inner peripheral face 303, and the outer peripheral face 304 of the core 3. The bent pin members 410 extend in the X direction with an imaginary line connecting both ends of the bent pin members 410 slightly tilted in the Y direction when viewed from the central axis direction of the core 3. In other words, the bent pin members 410 are arranged such that a plane including the center line of the bent pin members 410 is slightly tilted in the Y direction with respect to a plane (XZ plane) perpendicular to the axial direction of the first coil 41. The straight pin members 412 are arranged parallel to each other along the first end face 301 of the core 3. The straight pin members 412 extend in the X direction. The outermost straight pin members 411 are arranged parallel to each other along the first end face 301 of the core 3. The outermost straight pin members 411 extend in a direction parallel to the straight pin members 412.

[0063] The first electrode terminal 51 is connected to one of the endmost straight pin members 411, which is connected to one end of the bent pin member 410 of the adjacent turn to the endmost straight pin member 411. A portion of the first electrode terminal 51 faces the endmost straight pin member 411, and the circumferential surface of the endmost straight pin member 411 is connected to the first electrode terminal 51. Specifically, a portion of the first electrode terminal 51 passes through a slit hole 70 of the first mounting base portion 71 and is connected to the circumferential surface of the endmost straight pin member 411.

[0064] The second electrode terminal 52 is connected to the other endmost straight pin member 411, which is connected to one end of the bent pin member 410 of the turn adjacent to the other endmost straight pin member 411. A portion of the second electrode terminal 52 faces the other endmost straight pin member 411, and the circumferential surface of the other endmost straight pin member 411 is connected to the second electrode terminal 52. Specifically, a portion of the second electrode terminal 52 passes through the slit hole 70 of the second mounting base portion 72 and is connected to the circumferential surface of the other endmost straight pin member 411.

[0065] The second coil 42, like the first coil 41, is composed of a plurality of pin members. That is, the second coil 42 includes, in order from one end to the other, an endmost straight pin member 421 on one end side (one), a plurality of sets of bent pin members 420 and straight pin members 422, and an endmost straight pin member 421 on the other end side (the other). The bent pin members 420 and 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.

[0066] The third electrode terminal 53 is connected to one of the endmost straight pin members 421, which is connected to one end of the bent pin member 420 of the adjacent turn to the endmost straight pin member 421. A portion of the third electrode terminal 53 faces the endmost straight pin member 421, and the circumferential surface of the endmost straight pin member 421 is connected to the third electrode terminal 53. Specifically, a portion of the third electrode terminal 53 passes through the slit hole 70 of the first mount portion 71 and is connected to the circumferential surface of the endmost straight pin member 421.

[0067] The fourth electrode terminal 54 is connected to the other endmost straight pin member 421, which is connected to one end of the bent pin member 420 of the turn adjacent to the other endmost straight pin member 421. A portion of the fourth electrode terminal 54 faces the other endmost straight pin member 421, and the circumferential surface of the other endmost straight pin member 421 is connected to the fourth electrode terminal 54. Specifically, a portion of the fourth electrode terminal 54 passes through the slit hole 70 of the second mount portion 72 and is connected to the circumferential surface of the other endmost straight pin member 421.

[0068] 3, each of the first coil 41 and the second coil 42 (pin members 410-412, 420-422) preferably includes a conductor and a coating that covers a portion of the conductor. The conductor 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.

[0069] The straight pin members 411 and 421 are made up of uncoated conductor portions 411a and 421a, the straight pin members 412 and 422 are made up of uncoated conductor portions 412a and 422a, and the bent pin members 410 and 420 are made up of conductor portions 410a and 420a and coatings 410b and 420b.

[0070] At one end and the other end of the bent pin members 410, 420, the conductor portions 410a, 420a are exposed from the coatings 410b, 420b. That is, the endmost straight pin members 411, 421, the straight pin members 412, 422, and the bent pin members 410, 420 are welded to one another, for example, at the exposed conductor portions 411a, 421a, 412a, 422a, 410a, 420a. These conductor portions not covered by the coating, i.e., the conductor portions exposed (without the coating), can be electrically connected to the outside.

[0071] FIG. 6 is a cross-sectional view taken along the line VI-VI of FIG. 1. In FIG. 6, the dummy terminal 55 is omitted. As shown in FIG. 6, in the first coil 41, the ends of adjacent pin members are welded together at a welded portion. A welded portion refers to a portion that melts during welding and then solidifies. 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 is welded to the conductor portion 410a of the bent pin member 410, 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 is welded to the conductor portion 410a of the bent pin member.

[0072] 6 illustrates a turn of the first coil 41 that is composed of the straight pin member 412 and the bent pin member 410, the same applies to a turn that is 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 411a of the bent pin member 410 at the conductor portion 410a, which is connected to the conductor portion 411a, to form the first welded portion 81 or the second welded portion 82.

[0073] The second coil 42 has a third welded portion 83 and a fourth welded portion 84. As with the first coil 41, in adjacent turns of the second coil 42, 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 welded 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 420 to form the fourth welded portion 84. In addition, the outermost straight pin member 421 is welded at the conductor portion 420a of the bent pin member 420 connected to the conductor portion 421a to form the third welded portion 83 or the fourth welded portion 84. The third welded portion 83 and the fourth welded portion 84 of the second coil 42 have the same configuration as the first welded portion 81 and the second welded portion 82 of the first coil 41, and therefore a description thereof will be omitted.

[0074] The core cover portion 60 is located between the conductor portions and welded portions of the coils 41, 42 that are exposed from the coating and the core 3. This makes it possible to more reliably insulate the conductor portions and welded portions of the coils 41, 42 from the core 3.

[0075] The core cover part 60 is provided over the first end face 301 of the core 3, a portion of the inner circumferential surface 303 of the core 3, and a portion of the outer circumferential surface 304 of the core 3. The core cover part 60 has an inner circumferential part 60a facing the inner circumferential surface 303 of the core 3, an outer circumferential part 60b facing the outer circumferential surface 304 of the core 3, and a bottom part 60c facing the first end face 301 of the core 3. The bottom part 60c has a first surface 60c1 opposite the first end face 301.

[0076] The core 3 is connected to the core cover part 60 via a core adhesive member 91. By connecting the core adhesive member 91 to a part of the core 3, the stress on the core 3 received from the core cover part 60 is reduced, and deterioration of the magnetic properties of the core 3 can be suppressed. In other words, a decrease in inductance value caused by magnetostriction can be suppressed. Note that the core cover part 60 may not be connected to the core 3 via the core adhesive member 91, but may simply be fitted into the core 3.

[0077] The core adhesive member 91 is provided between the first end face 301 of the core 3 and the bottom part 60c of the core cover part 60. This reduces the influence of magnetostriction on the core 3 and ensures stable attachment of the core cover part 60 to the core 3.

[0078] Soft resins such as urethane resin and silicone resin can be used as the material for the core adhesive member 91. By using such soft resin, the influence of magnetostriction can be reduced.

[0079] 6, the core bonding member 91 is provided over the entire area between the first end face 301 of the core 3 and the bottom portion 60c of the core cover part 60, but it may be provided only in a portion. Also, in FIG. 6, the core bonding member 91 is provided between the first end face 301 of the core 3 and the bottom portion 60c of the core cover part 60, but it may be provided between the inner circumferential surface 303 of the core 3 and the inner circumferential portion 60a of the core cover part 60, or between the outer circumferential surface 304 of the core 3 and the outer circumferential portion 60b of the core cover part 60, or may be provided in multiple locations among these.

[0080] 6, the conductor portions of the coils 41, 42 that are exposed from the coating are disposed in the recess 215 so as to be located on the first main surface 210a side. The coil bonding member 90 is fixed in the recess 215 to bond the coils 41, 42 to the bottom plate portion 21 and cover at least a portion of the conductor portions that are exposed from the coating of the coils 41, 42. Preferably, the coil bonding member 90 covers the entire conductor portions.

[0081] The coil adhesive member 90 is made of, for example, a thermosetting resin, and is fixed to the coils 41, 42, the core cover portion 60, and the bottom plate portion 21 upon hardening. The coil adhesive member 90 contacts the inner surface of the recess 215, a portion of the inner circumferential portion 60a of the core cover portion 60, a portion of the outer circumferential portion 60b of the core cover portion 60, and a portion of the bottom portion 60c of the core cover portion 60, and covers the conductor portions 411a, 412a, 410a exposed from the coating 410b of the first coil 41 and the conductor portions 421a, 422a, 420a exposed from the coating 420b of the second coil 42. Furthermore, the coil adhesive member 90 also covers the welded portions 81 to 84 of the coils 41, 42.

[0082] Because the coil bonding member 90 is fixed in the recess 215 of the bottom plate portion 21, the coil bonding member 90 is stably fixed to the bottom plate portion 21, and as a result, the coil bonding member 90 can stably fix the coils 41, 42 to the bottom plate portion 21. Furthermore, because the coil bonding member 90 covers the conductor portions of the coils 41, 42 that are exposed from the coating, problems such as electrical short circuits with the outside can be prevented. Furthermore, when the coil component 1 is subjected to external forces such as vibrations and shocks, the coil bonding member 90 can absorb the shock and protect the coils 41, 42.

[0083] Silicon resin can be used as the material for the coil adhesive member 90. By using silicon resin, it is possible to improve reflow heat resistance and mechanical strength.

[0084] (Detailed configuration of the pin member connection) Next, the detailed configuration of the connection portion between the outermost straight pin member 411 and the bent pin member 410 will be described. Fig. 7 is a top perspective view of the connection portion between the outermost straight pin member 411 and the bent pin member 410 in the first coil 41. Fig. 7 shows the state immediately after the outermost straight pin member 411 is assembled to the bent pin member 410, that is, the state before the bent pin member 410 and the outermost straight pin member 411 are connected by, for example, welding. The same applies to the connection portion between the straight pin member 412 and the bent pin member 410, and therefore a description thereof will be omitted. The same applies to the connection portion between the straight pin members 421 and 422 and the bent pin member 420 in the second coil 42, and therefore a description thereof will be omitted.

[0085] 7, the cross section of the outermost straight pin member 411 is rectangular. The cross section of the outermost straight pin member 411 is not particularly limited, and may be circular, elliptical, or any other polygonal shape other than rectangular.

[0086] The end face 411ef of the second end 411e2 of the outermost straight pin member 411 is provided with a wall portion 411w that protrudes in the direction of the center line 411c of the second end 411e2. Similarly, the end face 411ef of the first end 411e1 of the outermost straight pin member 411 is provided with a wall portion 411w that protrudes in the direction of the center line 411c of the first end 411e1. Here, the center line 411c of the second end 411e2 is a line that passes through the center of gravity of the second end 411e2 in a cross section perpendicular to the extension direction (X direction) of the second end 411e2. The end face 411ef of the second end 411e2 is the outer surface located outermost in the direction of the center line 411c of the second end 411e2. The same applies to the end face 411ef of the first end 411e1. The end face 411ef is perpendicular to the direction of the center line 411c of the second end 411e2. The shape of the wall portion 411w is not particularly limited, but in this embodiment, it is a rectangular parallelepiped. The wall portion 411w can be formed, for example, by pressing a part of the end surface of the second end portion 411e2 toward the center line 411c. Alternatively, the wall portion 411w can be formed, for example, by cutting a part of the end surface of the second end portion 411e2.

[0087] The position where the wall portion 411w is provided on the end face 411ef is not particularly limited, but as in this embodiment, it is preferable that the wall portion 411w is provided at the end of the end face 411ef on the reverse-Z direction side, and that the end face of the wall portion 411w on the reverse-Z direction side and the end face of the last straight pin member 411 excluding the wall portion 411w on the reverse-Z direction side are flush with each other. This allows the last straight pin member 411 to be stably assembled to the bent pin member 410, and also makes it possible to flatten the end face on the reverse-Z direction side of the last straight pin member 411. Therefore, for example, when a laser is irradiated onto the end face for welding, the welding can be performed satisfactorily without scattering the laser.

[0088] The bending pin member 410 has a circular cross section. However, the cross section of the bending pin member 410 may be elliptical, polygonal, or the like. An end face 410ef of a first end 410e1 of the bending pin member 410 is flat. The end face 410ef is perpendicular to the center line 410c of the first end 410e1. Similarly, an end face of a second end (not shown) of the bending pin member 410 is flat. The end face is perpendicular to the center line of the second end.

[0089] The end face 411ef of the second end 411e2 of the outermost straight pin member 411 faces the peripheral surface 410cf of the first end 410e1 of the bent pin member 410. In this embodiment, a portion of the end face 411ef is in contact with the peripheral surface 410cf. Here, the center line 410c of the first end 410e1 is a line passing through the center of gravity of the first end 410e1 in a cross section perpendicular to the extension direction of the first end 410e1. The peripheral surface 410cf of the first end 410e1 is the outer surface in the circumferential direction centered on the center line of the first end 410e1. Note that the end face 411ef may be in contact with the peripheral surface 410cf via, for example, a conductive adhesive member. Note that, among the connection portions of the multiple pin members, there may be connection portions where the end face 411ef is not in contact with the peripheral surface 410cf, i.e., the end face 411ef and the peripheral surface 410cf are separated by a space.

[0090] A side surface 411wf of the wall portion 411w in a direction perpendicular to the center line 411c of the second end portion 411e2 (forward Z direction) faces an end surface 410ef of the first end portion 410e1. In this embodiment, the side surface 411wf is in surface contact with the end surface 410ef. In short, in this embodiment, a corner portion of the first end portion 410e1 of the bent pin member 410 is fitted into a space surrounded by the end surface 411ef of the outermost straight pin member 411 and the wall portion 411w. Here, the end surface 410ef of the first end portion 410e1 is an outer surface located outermost in the direction of the center line 410c of the first end portion 410e1. The entire surface of the side surface 411wf may be in surface contact with the end surface 410ef, or a portion of the side surface 411wf may be in surface contact with the end surface 410ef, or the side surface 411wf may be in surface contact with the end surface 410ef via, for example, a conductive adhesive member etc. Among the connection portions of the multiple pin members, there may be a connection portion where the side surface 411wf is not in surface contact with the end surface 410ef, i.e., the side surface 411wf and the end surface 410ef are separated by a space.

[0091] (Detailed configuration of electrode terminals) Fig. 8 is a top perspective view of the first electrode terminal 51. Fig. 9 is a cross-sectional view of the first electrode terminal 51. Note that, although the first electrode terminal 51 will be described below, the configurations of the second electrode terminal 52, the third electrode terminal 53, and the fourth electrode terminal 54 are similar to the configuration of the first electrode terminal 51, and therefore detailed description thereof will be omitted.

[0092] 8 and 9, the first electrode terminal 51 has a first flat plate portion 511, a second flat plate portion 512, and a connecting portion 513 that connects the first flat plate portion 511 and the second flat plate portion 512. The first flat plate portion 511 and the second flat plate portion 512 face each other. The first electrode terminal 51 is formed by bending a metal plate into a U-shape.

[0093] The first flat plate portion 511 is formed in a flat plate shape parallel to the XY plane. The first flat plate portion 511 has a connection portion 511a connected to a first end portion 513a of the coupling portion 513, and a tip portion 511b on the opposite side of the connection portion 511a. The tip portion 511b has a slit portion 51a. In other words, the tip portion 511b has a bifurcated shape.

[0094] The second flat plate portion 512 is formed in a flat plate shape parallel to the XY plane. The second flat plate portion 512 has a connection portion 512a connected to the second end portion 513b of the coupling portion 513, and a tip portion 512b on the opposite side to the connection portion 512a.

[0095] The first flat plate portion 511 is located further in the Z direction than the second flat plate portion 512, and the first flat plate portion 511 and the second flat plate portion 512 face each other in the Z direction. The connection portion 511a of the first flat plate portion 511 and the connection portion 512a of the second flat plate portion 512 face each other in the Z direction.

[0096] The connecting portion 513 is formed in a flat plate shape parallel to the XZ plane except for the first end portion 513a and the second end portion 513b. The first end portion 513a and the second end portion 513b are formed in a curved shape.

[0097] The thickness of the first electrode terminal 51 is, for example, 0.3 mm. The first flat plate portion 511, the second flat plate portion 512, and the connecting portion 513 all have the same thickness. The first electrode terminal 51 is made of, for example, a copper plate and a plating layer covering the copper plate. The plating layer is made of, for example, Ni or Sn.

[0098] (Details of the base case) FIG. 10 is a top perspective view of the base case. FIG. 11 is a bottom perspective view of the base case. As shown in FIGS. 10 and 11 , the base case 22 includes a core cover portion 60 that covers at least a portion of the core 3, a first mounting base portion 71 to which the first and third electrode terminals 51 and 53 are attached, and a second mounting base portion 72 to which the second and fourth electrode terminals 52 and 54 are attached. The core cover portion 60, the first mounting base portion 71, and the second mounting base portion 72 are integrated into a single molded product. According to the above configuration, since the core cover portion 60 and the mounting base portions 71 and 72 are integrated, the core 3 housed in the core cover portion 60 is supported by the mounting base portions 71 and 72, thereby stabilizing the position of the core 3. Furthermore, since the number of components constituting the coil device 1 can be reduced, the manufacturing process for the coil device 1 can be simplified.

[0099] The core cover part 60 has an inner peripheral part 60a, an outer peripheral part 60b, and a bottom part 60c. The annular recess 61 is a space surrounded by the inner peripheral part 60a, the outer peripheral part 60b, and the bottom part 60c. The core cover part 60 is an oval ring-shaped body with its major axis direction in the Y direction and its minor axis direction in the X direction. The bottom part 60c has a first surface 60c1 on the side opposite to the opening side of the annular recess 61. The first surface 60c1 is the surface that faces the mounting board when the coil component 1 is mounted on the mounting board.

[0100] The first surface 60c1 has a first region 60c11 around which the first coil 41 is wound and a second region 60c12 around which the second coil 42 is wound. The first region 60c11 and the second region 60c12 each correspond to a longitudinal portion of the core cover part 60 extending along the major axis.

[0101] The first mounting base 71 and the second mounting base 72 are formed in the shape of a rectangular parallelepiped flange and are located on both sides of the core cover 60. Specifically, the first mounting base 71 and the second mounting base 72 are located outside the core cover 60 in the longitudinal direction (Y direction). In other words, when viewed from the central axis direction of the core 3, the first mounting base 71 and the second mounting base 72 are located on both sides of the core 3 in the longitudinal direction of the core 3. This allows the first electrode terminal attached to the first mounting base 71 and the second electrode terminal attached to the second mounting base 72 to be positioned in the longitudinal direction of the core. This allows the first coil 41 connected to the first electrode terminal 51 and the second electrode terminal 52 to be wound around the oval longitudinal portion 31 of the core 3 along the longitudinal direction of the core 3, ensuring the number of turns of the first coil 41.

[0102] The first mounting base 71 has an inner end surface 711 facing the core cover 60, an outer end surface 712 facing the opposite side to the inner end surface 711, a bottom surface 713 connecting the inner end surface 711 and the outer end surface 712, a top surface 714 facing the opposite side to the bottom surface 713, and two first and second side surfaces 715 and 716 connecting the inner end surface 711 and the outer end surface 712 and connecting the bottom surface 713 and the top surface 714. The bottom surface 713 is a surface that faces the mounting board when the coil component 1 is mounted on the mounting board. The core cover 60 is attached to the inner end surface 711 of the first mounting base 71.

[0103] The second mounting base 72 has an inner end surface 721 facing the core cover 60, an outer end surface 722 facing the opposite side from the inner end surface 721, a bottom surface 723 facing the mounting board during mounting, a top surface 724 facing the opposite side from the bottom surface 723, and two first and second side surfaces 725 and 726 connecting the inner and outer end surfaces 721 and 722 and connecting the bottom and top surfaces 723 and 724. The bottom surface 723 is the surface that faces the mounting board when the coil component 1 is mounted on the mounting board. The core cover 60 is attached to the inner end surface 721 of the second mounting base 72.

[0104] The first mounting base portion 71 has a plurality of slit holes 70. The first and third electrode terminals 51, 53 are inserted into each slit hole 70. The slit holes 70 are provided to penetrate the inner end face 711 and the outer end face 712 in the Y direction. When viewed from a direction perpendicular to the outer end face 712, the slit holes 70 extend in a direction in which the first side face 715 and the second side face 716 face each other (the X direction). One slit hole 70, into which the first electrode terminal 51 is inserted, is provided on the bottom face 713 side and the first side face 715 side. The other slit hole 70, into which the third electrode terminal 53 is inserted, is provided on the bottom face 713 side and the second side face 716 side.

[0105] The second mounting base portion 72 has a plurality of slit holes 70. The second and fourth electrode terminals 52, 54 are inserted into the respective slit holes 70. The slit holes 70 are provided to penetrate the inner end face 721 and the outer end face 722 in the Y direction. When viewed from a direction perpendicular to the outer end face 722, the slit holes 70 extend in a direction in which the first side face 725 and the second side face 726 face each other (the X direction). One slit hole 70, into which the second electrode terminal 52 is inserted, is provided on the bottom face 723 side and the first side face 725 side. The other slit hole 70, into which the fourth electrode terminal 54 is inserted, is provided on the bottom face 723 side and the second side face 726 side.

[0106] 12 is a cross-sectional view of a portion including the slit hole 70 of the first mounting base portion 71 in the base case 22. Note that, although the slit hole 70 of the first mounting base portion 71 will be described below, the configuration of the slit hole 70 of the second mounting base portion 72 is similar to the configuration of the slit hole 70 of the first mounting base portion 71, and therefore a detailed description thereof will be omitted.

[0107] 11 and 12, the slit 70 is a long, narrow hole extending in the X direction when viewed from a direction perpendicular to the inner end surface 711 or the outer end surface 712. That is, the longitudinal direction of the slit 70 is the X direction, which is the extension direction of the slit 70, and the lateral direction of the slit 70 is the Z direction, which is the direction perpendicular to the extension direction of the slit 70. The first flat plate portion 511 of the first electrode terminal 51 is inserted into the slit 70.

[0108] An opening dimension W1 in the short side direction on the outer end face 712 side of the slit hole 70 is larger than an opening dimension W2 in the short side direction on the inner end face 711 side of the slit hole 70. This makes it easier to insert the first flat plate portion 511 of the first electrode terminal 51 into the slit hole 70 from the outer end face 712 toward the inner end face 711.

[0109] Preferably, the first flat plate portion 511 of the first electrode terminal 51 is press-fitted into at least the opening on the inner end surface 711 side of the slit hole 70. This allows the first flat plate portion 511 to be press-fitted into the slit hole 70, and the first electrode terminal 51 can be firmly fixed to the first mounting base portion 71. In addition, the coil adhesive 90 does not leak out of the base case 22 from the slit hole 70. Preferably, before the first flat plate portion 511 is inserted into the slit hole 70, that is, when the first flat plate portion 511 is removed from the slit hole 70, the opening dimension W2 on the inner end surface 711 side of the slit hole 70 is smaller than the thickness of the first flat plate portion 511 of the first electrode terminal 51. This allows the first flat plate portion 511 to be press-fitted into the slit hole 70, and the first electrode terminal 51 can be firmly fixed to the first mounting base portion 71.

[0110] The inner surface of the slit hole 70 has a stepped surface 701c that gradually reduces the dimension of the slit hole 70 in the short side direction from the outer end surface 712 toward the inner end surface 711. This makes it easier to smoothly insert the first flat plate portion 511 of the first electrode terminal 51 into the slit hole 70 from the outer end surface 712 toward the inner end surface 711.

[0111] Specifically, in a cross section (YZ cross section) including the short-side direction (Z direction) of the slit 70 and the penetration direction (Y direction) of the slit 70, the inner surface of the slit 70 includes a first inner surface 701 on the upper side in the Z direction and a second inner surface 702 on the lower side in the Z direction. The second inner surface 702 is a flat surface parallel to the Y direction. The first inner surface 701 includes a first surface 701a on the outer end surface 712 side, a second surface 701b on the inner end surface 711 side, and a step surface 701c connecting the first surface 701a and the second surface 701b. The first surface 701a and the second surface 701b are each flat surfaces parallel to the Y direction. The second surface 701b is closer to the second inner surface 702 than the first surface 701a. The step surface 701c is an inclined surface in which the dimension in the short direction of the slit hole 70 continuously decreases from the outer end surface 712 toward the inner end surface 711. In other words, the step surface 701c is inclined at an angle smaller than 90° with respect to the penetration direction (Y direction) of the slit hole 70. Thus, because the step surface 701c is an inclined surface, the first flat plate portion 511 of the first electrode terminal 51 can be more easily inserted into the slit hole 70 from the outer end surface 712 toward the inner end surface 711.

[0112] (Connection relationship between the most straight pin member, the bent pin member and the electrode terminal) Fig. 13 is a bottom view of the coil component, in which the bottom plate portion and the coil adhesive member are not shown for the sake of convenience.

[0113] 13, in the first coil 41, the endmost straight pin member 411 on the first electrode terminal 51 side faces the first surface 60c1 (first region 60c11) of the bottom 60c. A first end 411e1 of the endmost straight pin member 411 is connected to the tip portion 511b of the first flat plate portion 511 of the first electrode terminal 51. A second end 411e2 of the endmost straight pin member 411 is connected to the first end 410e1 of the bent pin member 410.

[0114] In the first coil 41, the outermost straight pin member 411 on the second electrode terminal 52 side faces the first surface 60c1 (first region 60c11) of the bottom 60c. A first end 411e1 of the outermost straight pin member 411 is not connected to the bent pin member 410 or the second electrode terminal 52. A second end 411e2 of the outermost straight pin member 411 is connected to the bent pin member 410 and the second electrode terminal 52.

[0115] In the second coil 42, the outermost straight pin member 421 on the third electrode terminal 53 side faces the first surface 60c1 (second region 60c12) of the bottom 60c. A first end 421e1 of the outermost straight pin member 421 is connected to the third electrode terminal 53. A second end 421e2 of the outermost straight pin member 421 is connected to the bent pin member 420.

[0116] In the second coil 42, the outermost straight pin member 421 on the fourth electrode terminal 54 side faces the first surface 60c1 (second region 60c12) of the bottom 60c. A first end 421e1 of the outermost straight pin member 421 is not connected to the bent pin member 420 or the fourth electrode terminal 54. A second end 421e2 of the outermost straight pin member 421 is connected to the bent pin member 420 and the fourth electrode terminal 54.

[0117] (Connection between mounting base and electrode terminal) Figure 14 is a cross-sectional view taken along the line XIV-XIV in Figure 13. Note that Figure 14 illustrates a bottom plate portion and a coil adhesive member that are not shown in Figure 13. Below, the connection relationship between the first electrode terminal 51 and the first mount base portion 71 will be described, but the connection relationship between the second electrode terminal 52 and the second mount base portion 72, the connection relationship between the third electrode terminal 53 and the first mount base portion 71, and the connection relationship between the fourth electrode terminal 54 and the second mount base portion 72 are similar to the connection relationship between the first electrode terminal 51 and the first mount base portion 71, and therefore detailed description thereof will be omitted.

[0118] 14 , the first electrode terminal 51 is attached to the first mounting base portion 71 and connected to an end of the first coil 41. Specifically, the first flat plate portion 511 is inserted into the slit hole 70, the connecting portion 513 faces the outer end surface 712, the second flat plate portion 512 faces the bottom surface 713, and the first flat plate portion 511 is connected to an end of the outermost straight pin member 411 of the first coil 41.

[0119] According to the above configuration, the first flat plate portion 511 of the first electrode terminal 51 is inserted into the slit hole 70 of the first mounting base portion 71, and the first electrode terminal 51 is thus inserted into and attached to the first mounting base portion 71. This allows the first electrode terminal 51 to be reliably fixed to the first mounting base portion 71, and even if vibrations or impacts are applied to the coil component 1 when the coil component 1 is mounted on the mounting substrate 100, peeling between the first electrode terminal 51 and the first mounting base portion 71 can be reduced. In particular, even if the core 3 is enlarged to accommodate larger currents, the weight of the coil component 1 increases, and vibrations and impacts become greater, peeling between the first electrode terminal 51 and the first mounting base portion 71 can be reduced.

[0120] Furthermore, since the second flat plate portion 512 of the first electrode terminal 51 faces the bottom surface 713 of the first mounting base portion 71, when the coil component 1 is mounted on the mounting substrate 100, the second flat plate portion 512 can be connected to the mounting substrate 100 via the solder 110. Specifically, the first electrode terminal 51 is connected to the pad portion 101 of the mounting substrate 100 via the solder 110.

[0121] 14 , outer surface 513c of connecting portion 513 opposite outer end surface 712 constitutes a fillet-forming region that becomes a wet-up portion of solder 110. Accordingly, when coil component 1 is mounted on mounting board 100, solder 110 wets up the fillet-forming region of connecting portion 513, thereby improving the mounting strength of coil component 1 to mounting board 100. Furthermore, when mounting coil component 1 on mounting board 100, if vibration or impact is applied to coil component 1, stress is applied to connecting portion 513. However, since solder 110 wets up the fillet-forming region of connecting portion 513, the stress can be reduced by solder 110. Furthermore, since connecting portion 513 faces outer end surface 712, solder 110 can be seen from the outside.

[0122] 14, end surface 512b1 of tip portion 512b of second flat plate portion 512 constitutes a fillet-forming region that becomes a wet-up portion of solder 110. Accordingly, when coil component 1 is mounted on mounting substrate 100, solder 110 wets up the fillet-forming region of second flat plate portion 512, thereby improving the mounting strength of coil component 1 to mounting substrate 100.

[0123] 14, the tip portion 511b of the first flat plate portion 511 protrudes from the inner end surface 711 and is connected to the end of the first coil 41. Specifically, the tip portion 511b protrudes from the inner end surface 711 toward the second mounting base portion 72. The endmost straight pin member 411 of the first coil 41 is placed on the upper surface of the tip portion 511b of the first flat plate portion 511. The upper surface of the tip portion 511b of the first flat plate portion 511 is the surface opposite to the surface of the tip portion 511b on the second flat plate portion 512 side.

[0124] According to this, tip portion 511b of first flat plate portion 511 protrudes from inner end surface 711, and therefore, the end portion of first coil 41 can be easily connected. Furthermore, tip portion 511b of first flat plate portion 511 is connected to the end portion of first coil 41. Therefore, for example, when the end portion of first coil 41 is connected to tip portion 511b of first flat plate portion 511 by welding, the heat of welding is transmitted sequentially through first flat plate portion 511 and coupling portion 513. Therefore, the heat of welding is less likely to be transmitted to second flat plate portion 512, and discoloration and modification of the plating layer of Ni, Sn, or the like of second flat plate portion 512 can be reduced, thereby ensuring mounting reliability.

[0125] 14, the connection portion between the first flat plate portion 511 and the end of the first coil 41 is covered with a coil adhesive member 90 made of resin. The coil adhesive member 90 is present in the recess 215 of the bottom plate portion 21, in a space surrounded by the bottom plate portion 21, the core cover portion 60, the first mounting base portion 71, and the second mounting base portion 72. This ensures that the connection portion between the first flat plate portion 511 and the end of the first coil 41 is fixed and insulated reliably by the coil adhesive member 90. Furthermore, because the first flat plate portion 511 is fixed to the coil adhesive member 90, the first electrode terminal 51 can be prevented from slipping out of the slit hole 70 of the first mounting base portion 71.

[0126] (Manufacturing method of coil components) Next, a method for manufacturing the coil device 1 will be described.

[0127] 4, the annular core 3 is housed in the core cover portion 60 of the base case 22 so that the first end face 301 located in the central axis direction of the core 3 is covered. The core 3 is adhered to the core cover portion 60 by a core adhesive member 91.

[0128] Then, referring to Figure 13, multiple straight pin members 411, 412, 421, 422 and multiple bent pin members 410, 420 are arranged around the core 3 and the core cover part 60 so that the ends of each straight pin member 411, 412, 421, 422 and the ends of each bent pin member 410, 420 are positioned on the first surface 60c1 side of the core cover part 60.

[0129] Specifically, the straight pin members 411, 412 and the bent pin member 410 of the first coil 41 are wound around the core 3 with the core cover part 60 fitted therein, and the straight pin members 421, 422 and the bent pin member 420 of the second coil 42 are wound around the core 3 so that the winding axes of the first coil 41 and the second coil 42 run parallel to each other. At this time, the respective ends of the straight pin members 411, 412 and the bent pin member 410 of the first coil 41 and the respective ends of the straight pin members 421, 422 and the bent pin member 420 of the second coil 42 are arranged on the first surface 60c1 side of the core cover part 60.

[0130] Then, the ends of the straight pin members 411, 412, 421, 422 and the ends of the bent pin members 410, 420 are connected to form coils 41, 42 in which the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420 are alternately connected.

[0131] Specifically, the first coil 41 is formed by connecting the end of each straight pin member 411, 412 to the end of each bent pin member 410. The second coil 42 is formed by connecting the end of each straight pin member 421, 422 to the end of each bent pin member 420.

[0132] Furthermore, the first electrode terminal 51 and the third electrode terminal 53 are inserted into the two slits 70 of the first mounting base portion 71 of the base case 22, respectively, from the outer end surface 712 toward the inner end surface 711. The second electrode terminal 52 and the fourth electrode terminal 54 are inserted into the two slits 70 of the second mounting base portion 72 of the base case 22, respectively, from the outer end surface 722 toward the inner end surface 721.

[0133] Then, first to fourth electrode terminals 51 to 54 are connected to the outermost straight pin members 411, 421, and the electrode terminals 51 to 54 are connected to the coils 41, 42. Specifically, the first electrode terminal 51 and the second electrode terminal 52 are connected to the first coil 41. The third electrode terminal 53 and the fourth electrode terminal 54 are connected to the second coil 42.

[0134] Thereafter, the bottom plate portion 21 is attached to the base case 22 to manufacture the coil device 1. Specifically, the bottom plate portion 21 is attached to the first surface 60c1 side of the core cover portion 60. The bottom plate portion 21 is adhered to the coils 41, 42 and the base case 22 with the coil adhesive member 90.

[0135] Second Embodiment Fig. 15 is a cross-sectional view showing a coil component of the second embodiment. The second embodiment differs from the first embodiment (Fig. 12) in the shape of the slit holes. This difference in configuration will be explained below. The other configurations are the same as those of the first embodiment, and the same reference numerals as those of the first embodiment are used, and the explanation thereof will be omitted.

[0136] 15 is a cross-sectional view of a portion including slit hole 70A of first mount base portion 71 in base case 22. Note that, although slit hole 70A of first mount base portion 71 will be described below, the configuration of the slit hole of second mount base portion 72 may be similar to the configuration of slit hole 70A of first mount base portion 71, and detailed description thereof will be omitted.

[0137] 15, similar to the configuration of the slit 70 in the first embodiment, the slit 70A is a long and narrow hole extending in the X direction when viewed from a direction perpendicular to the inner end face 711 or the outer end face 712. That is, the longitudinal direction of the slit 70A is the X direction in which the slit 70A extends, and the lateral direction of the slit 70A is the Z direction orthogonal to the extension direction of the slit 70A.

[0138] Similar to the configuration of the slit 70 in the first embodiment, the opening dimension W1 in the short direction on the outer end surface 712 side of the slit 70A is larger than the opening dimension W2 in the short direction on the inner end surface 711 side of the slit 70A. Preferably, before the first flat plate portion 511 is inserted into the slit 70, that is, in the state where the first flat plate portion 511 is removed from the slit 70, the opening dimension W2 on the inner end surface 711 side of the slit 70A is smaller than the thickness of the first flat plate portion 511 of the first electrode terminal 51.

[0139] The dimension of the slit hole 70A in the short side direction continuously decreases from the outer end face 712 toward the inner end face 711. This increases the accuracy of positioning the first electrode terminal 51 with respect to the first mounting base portion 71 when fixing the first electrode terminal 51 to the first mounting base portion 71. Note that while the first flat plate portion 511 is inserted into the slit hole 70, the dimension of the slit hole 70A in the short side direction continuously decreases from the outer end face 712 toward the inner end face 711. However, before the first flat plate portion 511 is inserted into the slit hole 70, that is, when the first flat plate portion 511 is removed from the slit hole 70, the dimension of the slit hole 70A in the short side direction may also continuously decrease from the outer end face 712 toward the inner end face 711.

[0140] Specifically, in a cross section (YZ cross section) including the short-side direction (Z direction) of the slit 70 and the penetration direction (Y direction) of the slit 70, the inner surface of the slit 70 includes a first inner surface 701 on the upper side in the Z direction and a second inner surface 702 on the lower side in the Z direction. The first inner surface 701 and the second inner surface 702 are each flat. The first inner surface 701 and the second inner surface 702 are each inclined at an angle smaller than 90° with respect to the penetration direction (Y direction) of the slit 70. The first inner surface 701 and the second inner surface 702 are inclined with respect to the Y direction so as to approach each other from the outer end surface 712 toward the inner end surface 711.

[0141] <Other embodiments> The present disclosure is not limited to the above-described embodiments, and design modifications are possible without departing from the spirit of the present disclosure. For example, the respective features of the first and second embodiments may be combined in various ways.

[0142] The coil component comprises at least a core, a coil, an electrode terminal, and a mounting base portion, the mounting base portion having a slit hole, the electrode terminal having a first flat plate portion, a second flat plate portion, and a connecting portion, the first flat plate portion being inserted into the slit hole, the connecting portion facing the outer end surface, the second flat plate portion facing the bottom surface, and the first flat plate portion being connected to the end of the coil.

[0143] Although the core cover and the mounting base are integrated, they may be separate, or may be spaced apart from each other. Alternatively, the core cover may be omitted. Alternatively, the mounting base may be integrated with the bottom plate.

[0144] The shape of the inner surface of the slit may be any shape as long as the widthwise opening dimension of the outer end face of the slit is larger than the widthwise opening dimension of the inner end face of the slit. Alternatively, the widthwise opening dimension of the outer end face of the slit may be smaller than or the same as the widthwise opening dimension of the inner end face of the slit.

[0145] One turn of the coil is composed of one straight pin member and one bent pin member, but may also be composed of one bent pin member. In this case, the bent pin member has a length approximately equal to the length of one circumference of the core that passes through the first end face, second end face, inner peripheral surface, and outer peripheral surface of the core. Alternatively, one turn of the coil may be composed of multiple straight pin members.

[0146] The shape of the case and the shape of the core are not limited to those of the first embodiment and can be modified in design. The number of coils is not limited to those of the first embodiment and can be modified in design. The number of electrode terminals is not limited to those of the first embodiment and can be modified in design.

[0147] The present disclosure includes the following aspects. <1> an annular core; a coil wound around the core; an electrode terminal connected to the coil; a mounting base portion to which the electrode terminal is attached; Equipped with the mounting base portion has an inner end surface facing the core side, an outer end surface facing the opposite side to the inner end surface, a bottom surface connecting the inner end surface and the outer end surface, and a top surface facing the opposite side to the bottom surface, and the mounting base portion has a slit hole penetrating the inner end surface and the outer end surface, the electrode terminal has a first flat plate portion, a second flat plate portion, and a connecting portion connecting the first flat plate portion and the second flat plate portion, the first flat plate portion and the second flat plate portion facing each other, A coil component, wherein the first flat plate portion is inserted into the slit hole, the connecting portion faces the outer end surface, the second flat plate portion faces the bottom surface, and the first flat plate portion is connected to an end of the coil. <2> the core is an oval ring-shaped body when viewed from the central axis direction, the mount portion includes a first mount portion and a second mount portion, When viewed from the central axis direction, the first mounting base portion and the second mounting base portion are located on both sides of the core in the longitudinal direction of the core. <1> The coil component according to claim 1. <3> The first mounting base portion and the second mounting base portion each have a plurality of the slit holes. <2> The coil component according to claim 1. <4> an outer surface of the connecting portion opposite to the outer end surface constitutes a fillet forming region that becomes a portion where solder wets up; <1> from <3> 1. The coil component according to claim 1 . <5> An end surface of a tip end portion of the second flat plate portion opposite to the connecting portion constitutes a fillet formation region that becomes a portion where the solder wets up. <1> from <4> 1. The coil component according to claim 1 . <6> a tip end portion of the first flat plate portion opposite the connecting portion protrudes from the inner end surface and is connected to the end portion of the coil; <1> from <5> 1. The coil component according to claim 1 . <7> a connection portion between the first flat plate portion and the end portion of the coil is covered with an adhesive member made of resin; <1> from <6> 1. The coil component according to claim 1 . <8> an opening dimension of the slit hole in the short-side direction on the outer end surface side is larger than an opening dimension of the slit hole in the short-side direction on the inner end surface side; <1> from <7> 1. The coil component according to claim 1 . <9> The first flat plate portion is press-fitted into at least the opening of the slit hole on the inner end surface side. <8> The coil component according to claim 1. <10> a dimension of the slit in a lateral direction continuously decreasing from the outer end surface toward the inner end surface; <8> or <9> The coil component according to claim 1. <11> The inner surface of the slit hole has a stepped surface that gradually reduces the dimension of the slit hole in the short side direction from the outer end surface toward the inner end surface. <8> or <9> The coil component according to claim 1. <12> The step surface is an inclined surface in which the dimension in the short side direction of the slit hole continuously decreases from the outer end surface toward the inner end surface. <11> The coil component according to claim 1. [Explanation of symbols]

[0148] 1 Coil parts 21 Bottom plate part 22 Pedestal case 3 cores 301 1st end face 302 Second end face 41 First coil 410 Bent pin member 411 Endmost straight pin member 411e1 1st end 411e2 2nd end 412 Straight pin member 42 Second coil 420 Bent pin member 421 Endmost straight pin member 421e1 1st end 421e2 2nd end 422 Straight Pin Member 51~54 1st~4th electrode terminal 51a~54a Slit section 511 1st flat plate part 511b Tip 512 2nd flat plate part 512b Tip 512b1 End face 513 Connecting part 513c Exterior 60 Core cover part 60c bottom 60c1 1st page 70,70A slit hole 701, 702 First and second inner surfaces 701a,701b 1st and 2nd sides 701c step surface 71, 72 First and second mounting bases 90 Coil adhesive material 91 Core adhesive material 100 Mounting board 110 Solder W1 Outer end face opening dimension W2 Inner end face opening dimension

Claims

1. an annular core; a coil wound around the core; an electrode terminal connected to the coil; a mounting base portion to which the electrode terminal is attached; Equipped with the mounting base portion has an inner end surface facing the core side, an outer end surface facing the opposite side to the inner end surface, a bottom surface connecting the inner end surface and the outer end surface, and a top surface facing the opposite side to the bottom surface, and the mounting base portion has a slit hole penetrating the inner end surface and the outer end surface, the electrode terminal has a first flat plate portion, a second flat plate portion, and a connecting portion connecting the first flat plate portion and the second flat plate portion, the first flat plate portion and the second flat plate portion facing each other, A coil component, wherein the first flat plate portion is inserted into the slit hole, the connecting portion faces the outer end surface, the second flat plate portion faces the bottom surface, and the first flat plate portion is connected to an end of the coil.

2. the core is an oval ring-shaped body when viewed from the central axis direction, the mount portion includes a first mount portion and a second mount portion, The coil component according to claim 1 , wherein the first and second mount portions are located on opposite sides of the core in the longitudinal direction of the core when viewed from the central axis direction.

3. The coil component according to claim 2 , wherein the first mount portion and the second mount portion each have a plurality of the slit holes.

4. The coil component according to claim 1 , wherein an outer surface of the connecting portion opposite to the outer end surface forms a fillet-forming region where solder wets up.

5. The coil component according to claim 1 , wherein an end face of the tip end portion of the second flat plate portion opposite the connecting portion forms a fillet-forming region that becomes a portion where solder wets up.

6. The coil component according to claim 1 , wherein a tip end portion of the first flat plate portion opposite the connecting portion protrudes from the inner end surface and is connected to the end portion of the coil.

7. The coil component according to claim 1 , wherein a connecting portion between the first flat plate portion and the end portion of the coil is covered with an adhesive member made of resin.

8. 4. The coil component according to claim 1, wherein an opening dimension of the slit hole in the short-side direction on the outer end face side is larger than an opening dimension of the slit hole in the short-side direction on the inner end face side.

9. The coil component according to claim 8 , wherein the first flat plate portion is press-fitted into at least an opening of the slit hole on the inner end surface side.

10. The coil component according to claim 8 , wherein a dimension of the slit in a lateral direction continuously decreases from the outer end surface toward the inner end surface.

11. 9. The coil component according to claim 8, wherein an inner surface of the slit has a stepped surface that reduces the dimension of the slit in the short side direction in stages from the outer end surface toward the inner end surface.

12. The coil component according to claim 11 , wherein the step surface is an inclined surface in which the dimension of the slit in the short side direction continuously decreases from the outer end surface toward the inner end surface.

Images