Coil part

Abstract

The present invention provides a structure that, in a wire winding type coil part with a structure in which a wire is wound on a core, makes a metal terminal, which is made from a metal plate attached to a flange part of the core, less susceptible to coming off from the flange part.　Flange parts (3, 4) of a core (5) are provided with mounting surfaces (7, 8), top surfaces (9, 10), inner end faces (11, 12), outer end faces (13, 14), first side surfaces (15, 16), and second side surfaces (17, 18). Metal terminals (23, 24), which are made from metal plate, are provided with mounting surface facing parts (25, 26), outer end facing parts (27, 28), and side surface facing parts (29, 30, 31, 32) that respectively face a mounting surface, an outer end face and a first side surface and / or a second side surface. A coil part (1) further comprises second restricting parts (45, 47, 49, 51) for restricting movement in the L direction by the metal terminal with respect to the flange part, and first restricting parts (46, 48, 50, 52) for restricting movement in the T direction.

Description

Coil parts

[0001] The present invention relates to a wire-wound coil component having a structure in which a wire is wound around a core, and more particularly to a structure for attaching a metal terminal made of a metal plate to the core.

[0002] For example, Japanese Patent Laid-Open Publication No. 2006-4989 (Patent Document 1) describes a wire-wound coil component having a structure in which a wire is wound around a core. More specifically, the core has a winding core portion extending in the axial direction and a pair of flange portions provided at opposite ends of the winding core portion in the axial direction. A metal terminal made of a metal plate is attached to each flange portion. A wire is wound around the winding core portion and connected to the metal terminals.

[0003] The flange portion has a mounting surface that faces the mounting board during mounting, a top surface that faces the opposite side of the mounting surface, an inner end surface that faces the winding core portion and positions the end of the winding core portion in the axial direction, and an outer end surface that faces the opposite side of the inner end surface.

[0004] On the other hand, the metal terminal has a mounting surface facing portion, an outer end face facing portion and a top face facing portion that face the mounting surface, outer end face and top face of the flange portion, respectively, and is connected from the mounting surface facing portion to the outer end face facing portion via a bent portion, and from the outer end face facing portion to the top face facing portion via a bent portion.

[0005] In the invention described in Patent Document 1, at least one of the angles formed between the outer end face of the flange and the mounting surface and the angle formed between the outer end face and the top surface is an acute angle, so that the flange is clamped between the mounting surface facing portion and the top surface facing portion, making it difficult for the metal terminal to come off the flange.

[0006] Furthermore, Patent Document 1 describes that the mounting surface and top surface of the flange are provided with recesses with circular openings, and the metal terminal is provided with spherical protrusions on the mounting surface-facing portion and top surface-facing portion. The fitting of the protrusions into the recesses makes it easier to position the metal terminal relative to the flange, and also makes it less likely for the metal terminal to become misaligned with the flange, which also contributes to making it less likely for the metal terminal to come off the flange.

[0007] Japanese Patent Application Laid-Open No. 2006-4989

[0008] External forces acting on the core, more specifically, external forces that can cause the metal terminal to come off the flange, are typically thought to come in six directions. These directions are two positive and negative directions along the axial direction of the winding core (hereinafter also referred to as the "L direction"); two positive and negative directions along the direction perpendicular to the L direction, connecting the mounting surface and the top surface (hereinafter also referred to as the "T direction"); and two positive and negative directions along the direction in which the mounting surface and the top surface extend (hereinafter also referred to as the "W direction"). Therefore, to prevent the metal terminal from coming off the flange, it is necessary to withstand external forces in these six directions. Note that an external force in the T direction from the mounting surface to the top surface does not normally occur when the coil component is mounted on a mounting board, but it may occur instantaneously due to an impact, such as when dropped.

[0009] In the coil component described in Patent Document 1, each of the pair of metal terminals has a mounting surface facing portion, an outer end surface facing portion, and a top surface facing portion, and therefore it is considered that the coil component can adequately withstand external forces from four directions, namely, two positive and negative directions in the T direction and two positive and negative directions in the L direction, because specific surfaces of the metal terminals abut against specific surfaces of the flange portion.

[0010] On the other hand, when a temperature change occurs while the coil component is mounted on a mounting substrate, the difference in thermal expansion between the core and the mounting substrate causes the mounting substrate to thermally expand more than the core, which in turn can generate an external force in the metal terminal that rotates the metal terminal around an axis extending in the W direction. This rotational external force acts to separate the portion of the metal terminal facing the outer end face from the outer end face of the flange of the core, causing the metal terminal to come off the flange. However, the coil component described in Patent Document 1 does not have a structure that can sufficiently withstand this rotational external force.

[0011] As mentioned above, Patent Document 1 describes that the mounting surface and top surface of the flange are provided with recesses with circular openings, and the mounting surface-facing portion and top surface-facing portion of the metal terminal are provided with protrusions with spherical surfaces. However, the resistance to external forces caused by the protrusions fitting into the recesses is relatively weak, and it is thought that they are not able to adequately cope with the rotational external forces mentioned above.

[0012] Therefore, an object of the present invention is to provide a coil component having a structure that can better withstand external forces in the rotational direction compared to the technology described in Patent Document 1.

[0013] The present invention is directed to a coil component comprising a core having a winding core portion extending in an axial direction and a pair of flange portions respectively provided at opposite ends of the winding core portion in the axial direction, at least one pair of metal terminals each made of a metal plate attached to each flange portion, and at least one wire connected to each of the at least pair of metal terminals and wound around the winding core portion.

[0014] Each flange portion has a mounting surface that faces the mounting board during mounting, a top surface that faces the opposite side of the mounting surface, an inner end surface that faces the winding core portion and positions the end of the winding core portion in the axial direction, an outer end surface that faces the opposite side of the inner end surface, and a first side surface and a second side surface that connect the inner end surface and the outer end surface and face in opposite directions to each other.

[0015] In order to solve the above-mentioned technical problems, in this invention, each metal terminal has a mounting surface facing portion facing the mounting surface, an outer end face facing portion facing the outer end face, and a side face facing portion facing at least one of the first side face and the second side face, and further includes a first restricting portion for restricting movement of at least the outer end face facing portion relative to the flange portion in a direction away from the outer end face (one direction in the L direction), and a second restricting portion for restricting movement of at least the mounting surface facing portion in a direction away from the mounting surface (one direction in the T direction).

[0016] According to this invention, since the connector is provided with both a first restricting portion for restricting movement of at least the outer end face facing portion in a direction away from the outer end face (L direction) and a second restricting portion for restricting movement of at least the mounting surface facing portion in a direction away from the mounting surface (T direction), it is possible to make it difficult for the metal terminal to come off the flange not only against external forces in the L and T directions but also against an external force that rotates the metal terminal about an axis extending in the W direction. This is because an external force that rotates the metal terminal about an axis extending in the W direction can be considered to be a combination of an external force in the L direction and an external force in the T direction.

[0017] 1 is a perspective view showing the appearance of a coil component 1 according to a first embodiment of the present invention, with mounting surfaces 7 and 8 facing upward; FIG. 2 is a perspective view showing the mounted state of the coil component 1 shown in FIG. 1; FIG. 3 is a perspective view for explaining a typical external force acting on the coil component 1 in the mounted state shown in FIG. 2; FIG. 4 is a perspective view for explaining an external force acting in the rotational direction on the coil component 1 in the mounted state shown in FIG. 2; FIG. 5 is a perspective view showing the appearance of a coil component 1a according to a second embodiment of the present invention, with mounting surfaces 7 and 8 facing upward; FIG. 6 is a perspective view showing the appearance of a coil component 1b according to a third embodiment of the present invention, with mounting surfaces 7 and 8 facing upward; FIG. 7 is a perspective view showing the appearance of a coil component 1c according to a fourth embodiment of the present invention, with mounting surfaces 7 and 8 facing upward; and FIG. 8 is a perspective view showing the appearance of a coil component 1d according to a fifth embodiment of the present invention, with mounting surfaces 7 and 8 facing upward.

[0018] A coil component 1 according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 4. FIG.

[0019] The coil component 1 includes a drum-shaped core 5 having a winding core 2 extending in the axial direction (L direction) and a pair of flanges, i.e., a first flange 3 and a second flange 4, provided at opposite ends of the winding core 2 in the L direction. The core 5 is made of a magnetic material such as ferrite, a resin containing ferrite powder or metal magnetic powder, or a non-magnetic material such as alumina. In the drawing, the winding core 2 has a substantially rectangular cross-sectional shape, but may also have a polygonal shape such as a hexagon, a circle, an ellipse, or a combination of these shapes.

[0020] The first flange 3 has a mounting surface 7 that faces the mounting board 6 (see Figure 2) during mounting, a top surface 9 that faces the opposite side of the mounting surface 7, and connects the mounting surface 7 and the top surface 9.The first flange 3 has an inner end surface 11 that faces the winding core 2 and positions the end of the winding core 2 in the L direction, an outer end surface 13 that faces the opposite side of the inner end surface 11, and a first side surface 15 and a second side surface 17 that connect the inner end surface 11 and the outer end surface 13 and face in opposite directions to each other.

[0021] Similarly, the second flange portion 4 has a mounting surface 8 that faces the mounting board 6 during mounting, a top surface 10 that faces the opposite side of the mounting surface 8, an inner end surface 12 that faces the winding core portion 2 and positions the end of the winding core portion 2 in the L direction, an outer end surface 14 that faces the opposite side of the inner end surface 12, and a first side surface 16 and a second side surface 18 that connect the inner end surface 12 and the outer end surface 14 and face in opposite directions to each other.

[0022] The dimensions of the core 5 are not limited, but as an example, the dimension in the L direction is 3.2 mm, the dimension in the direction perpendicular to the L direction, in which the mounting surfaces 7 and 8 and the top surfaces 9 and 10 extend (W direction), is 2.5 mm, and the dimension in the direction connecting the mounting surfaces 7 and 8 and the top surfaces 9 and 10 (T direction) is 1.8 mm.

[0023] The coil component 1 constitutes, for example, a wire-wound inductor and includes a wire 21 wound around the winding core 2 of the core 5. The wire 21 includes, for example, a central wire made of a highly conductive metal such as copper, silver, or gold, and an insulating coating made of an electrically insulating resin such as polyamideimide, polyurethane, or polyesterimide that covers the central wire. The diameter of the central wire of the wire 21 is not important, but it is preferable to use one with a diameter of, for example, 80 μm or more and 200 μm or less. The number of turns of the wire 21 on the winding core 2 is also not important.

[0024] A pair of metal terminals 23 and 24 are attached to the flanges 3 and 4. More specifically, the first metal terminal 23 is attached to the first flange 3, and the second metal terminal 24 is attached to the second flange 4. The first and second ends of the wire 21, which are opposite to each other, are connected to the first and second metal terminals 23 and 24, respectively.

[0025] The first metal terminal 23 and the second metal terminal 24 are each made of a single metal plate and have substantially the same shape or point-symmetric shapes with each other. The metal plate constituting the metal terminals 23 and 24 may be, for example, a plate in which a base material made of phosphor bronze is plated with Ni and Sn.

[0026] The first metal terminal 23 has a mounting surface facing portion 25, an outer end face facing portion 27, a first side face facing portion 29, and a second side face facing portion 31 that respectively face the mounting surface 7, the outer end face 13, the first side face 15, and the second side face 17 of the first flange 3. The second metal terminal 24 has a mounting surface facing portion 26, an outer end face facing portion 28, a first side face facing portion 30, and a second side face facing portion 32 that respectively face the mounting surface 8, the outer end face 14, the first side face 16, and the second side face 18 of the second flange 4.

[0027] In this embodiment, in the first metal terminal 23, the outer end surface facing portion 27 is connected to the mounting surface facing portion 25 via a first bent portion 33, and the first side surface facing portion 29 and the second side surface facing portion 31 are connected to the mounting surface facing portion 25 via a second bent portion 35. Similarly, in the second metal terminal 24, the outer end surface facing portion 28 is connected to the mounting surface facing portion 26 via a first bent portion 34, and the first side surface facing portion 30 and the second side surface facing portion 32 are connected to the mounting surface facing portion 26 via a second bent portion 36.

[0028] The first and second ends of the wire 21 are connected to the mounting surface facing portion 25 of the first metal terminal 23 and the mounting surface facing portion 26 of the second metal terminal 24, respectively, by, for example, thermocompression bonding.

[0029] 2, the coil component 1 is mounted in a state in which the metal terminals 23 and 24 are connected via solder to conductive lands 37 and 38 provided on the mounting substrate 6. Fig. 2 also shows a fillet 39 formed by the solder connecting the conductive land 37 and the first metal terminal 23.

[0030] The coil component 1 is provided with a top plate 40 that connects the top surface 9 of the first flange 3 and the top surface 10 of the second flange 4 of the core 5. The top plate 40 is bonded to the core 5 with an adhesive. For example, a thermosetting epoxy resin is used as the adhesive. To improve the thermal shock resistance of the adhesive, an inorganic filler such as silica filler may be added to the adhesive. Methods for applying the adhesive include a printing method in which the adhesive is applied to the top plate 40, a method in which the top surfaces 9 and 10 of the flanges 3 and 4 of the core 5 are dipped in the adhesive, and a method in which the adhesive is dispensed onto both the top plate 40 and the core 5.

[0031] The top plate 40 may be made of a magnetic material such as ferrite, a resin containing ferrite powder or metallic magnetic powder, or a non-magnetic material such as alumina. When both the core 5 and the top plate 40 are made of magnetic materials, the core 5 and the top plate 40 form a closed magnetic circuit. A resin coating may be applied instead of the top plate 40. Note that the top plate 40 or the resin coating may not be necessary.

[0032] The above-described configuration provides the following advantageous effects.

[0033] Explaining with reference to Figures 1 to 4, when the coil component 1 is mounted, the core 5 can withstand external forces acting in two directions, positive and negative, in the L direction, through the abutment between the outer end face 13 of the first flange 3 and the outer end face opposing portion 27 of the first metal terminal 23, and the abutment between the outer end face 14 of the second flange 4 and the outer end face opposing portion 28 of the second metal terminal 24.

[0034] Furthermore, when the coil component 1 is mounted, the core 5 can withstand external forces acting in two directions, positive and negative, in the W direction, through the abutment between the first side surface 15 of the first flange 3 and the first side surface facing portion 29 of the first metal terminal 23, the abutment between the second side surface 17 of the first flange 3 and the second side surface facing portion 31 of the first metal terminal 23, the abutment between the first side surface 16 of the second flange 4 and the first side surface facing portion 30 of the second metal terminal 24, and the abutment between the second side surface 18 of the second flange 4 and the second side surface facing portion 32 of the second metal terminal 24.

[0035] Furthermore, when the coil component 1 is mounted, the external forces acting on the core 5 in the T direction from the top surfaces 9 and 10 toward the mounting surfaces 7 and 8 can be withstood by the abutment between the mounting surface 7 of the first flange 3 and the mounting surface facing portion 25 of the first metal terminal 23, and the abutment between the mounting surface 8 of the second flange 4 and the mounting surface facing portion 26 of the second metal terminal 24.

[0036] In this way, the metal terminals 23 and 24 can withstand external forces from at least the above five directions without coming off the flanges 3 and 4.

[0037] This embodiment has a structure that makes it even more difficult for the metal terminals 23 and 24 to come off the flanges 3 and 4. That is, the metal terminals 23 and 24 further have restricting portions that restrict at least the mounting surface facing portions 25 and 26 from moving in a direction away from the mounting surfaces 7 and 8 relative to the flanges 3 and 4.

[0038] As described above, among the external forces acting on the core 5, external forces in the T direction from the mounting surfaces 7 and 8 toward the top surfaces 9 and 10 do not normally occur when the coil component 1 is mounted on a mounting board, but they may occur instantaneously due to an impact when dropped, etc. The above-described restricting portion is effective against external forces acting on the core 5 that are directed from the mounting surfaces 7 and 8 toward the top surfaces 9 and 10 in the T direction.

[0039] More specifically, with respect to the first metal terminal 23, the regulating portion is provided by a first convex portion 41 provided on at least one of the first side surface 15 and the second side surface 17 of the first flange portion 3, and a notch portion 42 located on at least one of the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23 and which receives the first convex portion 41.

[0040] Furthermore, with regard to the second metal terminal 24, the regulating portion is provided by a first convex portion 43 provided on at least one of the first side surface 16 and the second side surface 18 of the second flange portion 4, and a notch portion 44 located on at least one of the first side surface facing portion 30 and the second side surface facing portion 32 of the second metal terminal 24 and which receives the first convex portion 43.

[0041] In this way, by selecting at least one of the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23 as the position where the cutout portion 42 is provided, it is possible to ensure a large area for the outer end surface facing portion 27 and the mounting surface facing portion 25 of the first metal terminal 23, which are subjected to a relatively large external force. The same can be said for the cutout portion 44 of the second metal terminal 24. Therefore, it is possible to further improve the effect of making it difficult for the metal terminals 23 and 24 to come off the flange portions 3 and 4.

[0042] In this embodiment, with respect to the first metal terminal 23, the first protrusion 41 is provided on both the first side surface 15 and the second side surface 17 of the first flange 3, and the notch 42 is located on both the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23. Also, with respect to the second metal terminal 24, the first protrusion 43 is provided on both the first side surface 16 and the second side surface 18 of the second flange 4, and the notch 44 is located on both the first side surface facing portion 30 and the second side surface facing portion 32 of the second metal terminal 24.

[0043] In this way, when the first convex portion 41 is provided on both the first side surface 15 and the second side surface 17 of the first flange portion 3 and the first convex portion 43 is provided on both the first side surface 16 and the second side surface 18 of the second flange portion 4, the metal terminals 23 and 24 are less likely to come off the flange portions 3 and 4, thereby further enhancing the effect.

[0044] The restricting portion formed by the combination of the first convex portions 41 and 43 and the cutout portions 42 and 44 as described above can restrict not only the movement of the mounting surface opposing portions 25 and 26 in the direction away from the mounting surfaces 7 and 8, but also the movement of the outer end surface opposing portions 27 and 28 in the direction away from the outer end surfaces 13 and 14.

[0045] In this embodiment, with respect to the first metal terminal 23, the first convex portion 41 provides a first raised wall 45 extending along the direction in which the top surface 9 of the first flange portion 3 and the mounting surface 7 face each other, and a second raised wall 46 extending along the direction in which the outer end surface 13 and the inner end surface 11 face each other, and the cutout portion 42 provides a first opposing wall 47 facing the first raised wall 45 and a second opposing wall 48 facing the second raised wall 46.

[0046] Furthermore, with regard to the second metal terminal 24, the first convex portion 43 provides a first raised wall 49 extending along the direction in which the top surface 10 of the second flange portion 4 and the mounting surface 8 face each other, and a second raised wall 50 extending along the direction in which the outer end surface 14 and the inner end surface 12 face each other, and the cutout portion 44 provides a first opposing wall 51 facing the first raised wall 49 and a second opposing wall 52 facing the second raised wall 50.

[0047] The abutment between the first rising walls 45 and 49 and the first opposing walls 47 and 51 restricts the movement of the metal terminals 23 and 24 relative to the flange portions 3 and 4, respectively, in a direction in which at least the outer end face opposing portions 27 and 28 move away from the outer end faces 13 and 14, but this abutment state does not necessarily have to be maintained when no external force is applied.

[0048] When viewed toward each of the first sides 15 and 16 and the second sides 17 and 18, it is preferable that the first upstanding walls 45 and 49 extend linearly parallel to the inner end faces 11 and 12, respectively, and the second upstanding walls 46 and 50 extend linearly parallel to the mounting faces 7 and 8, respectively.

[0049] In this way, since the first rising walls 45 and 49 extend linearly parallel to the inner end faces 11 and 12 and the second rising walls 46 and 50 extend linearly parallel to the mounting surfaces 7 and 8, it is possible to reliably prevent the metal terminals 23 and 24 from coming off the flange portions 3 and 4 without any bias in the direction in which the mounting surface facing portions 25 and 26 move away from the mounting surfaces 7 and 8 and in the direction in which the outer end face facing portions 27 and 28 move away from the outer end faces 13 and 14.

[0050] Furthermore, when viewed toward each of the first side surface 15 and the second side surface 17 of the first flange portion 3, the first convex portion 41 is positioned on the first side surface 15 and the second side surface 17 so as to contact the corner where the outer end surface 13 and the mounting surface 7 intersect, and the notch portion 42 is positioned a predetermined distance from the edge of the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23 on the inner end surface 11 side and the edge of the top surface 9 side. In other words, the first side surface facing portion 29 and the second side surface facing portion 31 form an L-shape that is biased toward the inner end surface 11 side and the top surface 9 side.

[0051] Similarly, when viewed toward each of the first side surface 16 and the second side surface 18 of the second flange portion 4, the first convex portion 43 is positioned on the first side surface 16 and the second side surface 18 so as to contact the corner where the outer end surface 14 and the mounting surface 8 intersect, and the notch portion 44 is positioned a predetermined distance from the edge of the first side surface facing portion 30 and the second side surface facing portion 32 of the second metal terminal 24 on the inner end surface 12 side and the top surface 10 side. In other words, the first side surface facing portion 30 and the second side surface facing portion 32 form an L-shape that is biased toward the inner end surface 12 side and the top surface 10 side.

[0052] The above-described arrangement of the first convex portions 41 and 43 and the cutout portions 42 and 44 allows for a large area for each of the first convex portions 41 and 43. Furthermore, the rising walls of the first convex portions 41 and 43 that extend along the mounting surfaces 7 and 8 are flush with the mounting surfaces 7 and 8, and the rising walls of the first convex portions 41 and 43 that extend along the outer end surfaces 13 and 14 are flush with the outer end surfaces 13 and 14, making it easy to mold the core 5 that includes the first convex portions 41 and 43.

[0053] Furthermore, it is preferable that the first flange portion 3 further includes a second convex portion 53 that faces at least a portion of the edge on the top surface 9 side of the first metal terminal 23 in the direction in which the top surface 9 and the mounting surface 7 face each other, and that the second flange portion 4 further includes a second convex portion 54 that faces at least a portion of the edge on the top surface 10 side of the second metal terminal 24 in the direction in which the top surface 10 and the mounting surface 8 face each other.

[0054] Such second protrusions 53 and 54 can more reliably prevent the metal terminals 23 and 24 from coming off the flanges 3 and 4 when subjected to the rotational external forces R1 and R2 shown in FIG. 4 . The rotational external force R1 occurs around an axis facing the W direction, and the rotational external force R2 occurs around an axis facing the L direction. Of these rotational external forces R1 and R2, the external force R1 can be generated, for example, when a temperature change occurs in a state in which the coil component 1 is mounted on the mounting substrate 6, due to a difference in thermal expansion between the core 5 and the mounting substrate 6, causing the mounting substrate 6 to thermally expand more than the core 5. These rotational external forces R1 and R2 act to move the outer end surface opposing portions 27 and 28 of the metal terminals 23 and 24 away from the core 5, causing the metal terminals 23 and 24 to come off the flanges 3 and 4.

[0055] In this embodiment, the second convex portion 53 is provided across the first side surface 15, outer end surface 13 and second side surface 17 of the first flange portion 3, and the second convex portion 54 is provided across the first side surface 16, outer end surface 14 and second side surface 18 of the second flange portion 4.

[0056] In terms of resistance to the rotational external forces R1 and R2 described above, it is particularly effective that the second convex portion 53 is arranged to face the edges of the first side surface facing portion 29 and the second side surface facing portion 31 of the first metal terminal 23 on the top surface 9 side, and that the second convex portion 54 is arranged to face the edges of the first side surface facing portion 30 and the second side surface facing portion 32 of the second metal terminal 24 on the top surface 10 side.

[0057] Although the outer end surface facing portions 27 and 28 of the metal terminals 23 and 24 may form a step on the outer end surfaces 13 and 14 sides of the flanges 3 and 4, the portions of the second protrusions 53 and 54 located on the outer end surfaces 13 and 14 contribute to eliminating or reducing such a step. Therefore, it is possible to make it less likely that the tip of a tool such as tweezers will get caught between the outer end surface facing portions 27 and 28 of the metal terminals 23 and 24 and the outer end surfaces 13 and 14 of the flanges 3 and 4.

[0058] Figures 5, 6, 7, and 8 are diagrams corresponding to Figure 1, showing a coil component 1a according to a second embodiment, a coil component 1b according to a third embodiment, a coil component 1c according to a fourth embodiment, and a coil component 1d according to a fifth embodiment of the present invention, respectively. In Figures 5 to 8, elements corresponding to the elements shown in Figure 1 or elements corresponding between Figures 5 to 8 are given the same reference numerals, and duplicated explanations will be omitted.

[0059] The coil component 1a shown in FIG. 5 differs from the coil component 1 shown in FIG. 1 in the shape and bending manner of the metal plates that form each of the metal terminals 23a and 24a.

[0060] More specifically, in the first metal terminal 23a, the outer end surface facing portion 27 is connected to the mounting surface facing portion 25 via the first bent portion 55, and the first side surface facing portion 29 and the second side surface facing portion 31 are each connected to the outer end surface facing portion 27 via the second bent portion 57.

[0061] Similarly, in the second metal terminal 24a, the outer end surface facing portion 28 is connected to the mounting surface facing portion 26 via the first bent portion 56, and the first side surface facing portion 30 and the second side surface facing portion 32 are each connected to the outer end surface facing portion 28 via the second bent portion 58.

[0062] The coil device 1b shown in FIG. 6 can be considered as a modification of the coil device 1a shown in FIG. 5 with respect to the metal terminals 23b and 24b.

[0063] More specifically, in the first metal terminal 23b, the mounting surface facing portion 25 is divided into a first mounting surface facing end portion 61 on the first side surface 15 side, a second mounting surface facing end portion 63 on the second side surface 17 side, and a mounting surface facing central portion 65 sandwiched between the first mounting surface facing end portion 61 and the second mounting surface facing end portion 63, and these first mounting surface facing end portion 61, second mounting surface facing end portion 63 and mounting surface facing central portion 65 are connected to the outer end surface facing portion 27 via the first bent portion 55.

[0064] Similarly, in the second metal terminal 24b, the mounting surface facing portion 26 is divided into a first mounting surface facing end portion 62 on the first side surface 16 side, a second mounting surface facing end portion 64 on the second side surface 18 side, and a mounting surface facing central portion 66 sandwiched between the first mounting surface facing end portion 62 and the second mounting surface facing end portion 64, and these first mounting surface facing end portion 62, second mounting surface facing end portion 64 and mounting surface facing central portion 66 are connected to the outer end surface facing portion 28 via the first bent portion 56.

[0065] In the coil component 1b shown in FIG. 6, when it is mounted on a mounting board, solder is applied to the mounting surface-facing central portions 65 and 66 of the metal terminals 23b and 24b.

[0066] On the other hand, in the first metal terminal 23b, a first end of the wire 21 is connected to either the first mounting surface facing end 61 or the second mounting surface facing end 63, for example, the first mounting surface facing end 61, and in the second metal terminal 24b, a second end of the wire 21 is connected to either the first mounting surface facing end 62 or the second mounting surface facing end 64, for example, the second mounting surface facing end 64.

[0067] 6 , as described above, mounting surface-facing central portions 65 and 66, to which solder is applied during mounting, are separated from first mounting surface-facing ends 61 and 26 or second mounting surface-facing ends 63 and 64, to which wire 21 may be connected. This makes it possible to make first mounting surface-facing ends 61 and 62 or second mounting surface-facing ends 63 and 64 less susceptible to loads such as heat and stress applied to mounting surface-facing central portions 65 and 66, and to make mounting surface-facing central portions 65 and 66 less susceptible to loads such as heat and stress applied to first mounting surface-facing ends 61 and 62 or second mounting surface-facing ends 63 and 64. This improves the reliability of connection between the mounting board and metal terminals 23b and 24b, and between metal terminals 23b and 24b and wire 21.

[0068] The coil device 1c shown in FIG. 7 can be considered as a modification of the coil device 1b shown in FIG. 6 with respect to the metal terminals 23c and 24c.

[0069] 6 , in the first metal terminal 23c, the mounting surface facing portion 25 is divided into a first mounting surface facing end portion 61 on the first side surface 15 side, a second mounting surface facing end portion 63 on the second side surface 17 side, and a mounting surface facing central portion 65 sandwiched between the first mounting surface facing end portion 61 and the second mounting surface facing end portion 63. The mounting surface facing central portion 65 is connected to the outer end surface facing portion 27 via a first bent portion 55, while the first mounting surface facing end portion 61 and the second mounting surface facing end portion 63 are connected to the first side surface facing portion 29 and the second side surface facing portion 31 via a third bent portion 67, respectively.

[0070] Similarly, in the second metal terminal 24c, the mounting surface facing portion 26 is divided into a first mounting surface facing end portion 62 on the first side surface 16 side, a second mounting surface facing end portion 64 on the second side surface 18 side, and a mounting surface facing central portion 66 sandwiched between the first mounting surface facing end portion 62 and the second mounting surface facing end portion 64. The mounting surface facing central portion 66 is connected to the outer end surface facing portion 28 via a first bent portion 56, while the first mounting surface facing end portion 62 and the second mounting surface facing end portion 64 are connected to the first side surface facing portion 30 and the second side surface facing portion 32 via a third bent portion 68, respectively.

[0071] In the coil component 1c shown in Figure 7, as in the case of the coil component 1b shown in Figure 6, when it is mounted on a mounting board, solder is applied to the mounting surface-facing central portions 65 and 66 of the metal terminals 23c and 24c.

[0072] Furthermore, in the first metal terminal 23c, a first end of the wire 21 is connected to either the first mounting surface facing end 61 or the second mounting surface facing end 63, for example, the first mounting surface facing end 61, and in the second metal terminal 24c, a second end of the wire 21 is connected to either the first mounting surface facing end 62 or the second mounting surface facing end 64, for example, the second mounting surface facing end 64.

[0073] 6 , the coil component 1c shown in FIG. 7 has mounting surface-facing central portions 65 and 66 to which solder is applied during mounting, and mounting surface-facing end portions 61-64 to which wire 21 may be connected, which are separated from each other. However, in the coil component 1c shown in FIG. 7 , the mounting surface-facing end portions 61-64 are connected to the outer end surface-facing portions 27 and 28 via the side surface-facing portions 29-32. Therefore, compared to the coil component 1b shown in FIG. 6 , the mounting surface-facing end portions 61-64 are less susceptible to the effects of loads such as heat and stress on the mounting surface-facing central portions 65 and 66, and the mounting surface-facing central portions 65 and 66 are less susceptible to the effects of loads such as heat and stress on the mounting surface-facing end portions 61-64. Therefore, the connection reliability between the mounting board and the metal terminals 23c and 24c, and the connection reliability between the metal terminals 23c and 24c and the wire 21 can be improved compared to the coil component 1b shown in FIG. 6 .

[0074] The coil component 1d shown in FIG. 8 differs from the coil component 1a shown in FIG. 5 in the positions of the first protrusions 41d and 43d.

[0075] 5, the first protrusion 41 is positioned on the first side surface 15 and the second side surface 17 of the first flange 3 so as to contact the corner where the outer end surface 13 intersects with the mounting surface 7, and the first protrusion 43 is positioned on the first side surface 16 and the second side surface 18 of the second flange 4 so as to contact the corner where the outer end surface 14 intersects with the mounting surface 8. In contrast, in the coil component 1d shown in FIG. 8, the first protrusion 41d is positioned on the first side surface 15 and the second side surface 17 of the first flange 3, away from the corner where the outer end surface 13 intersects with the mounting surface 7, and the first protrusion 43d is positioned on the first side surface 16 and the second side surface 18 of the second flange 4, away from the corner where the outer end surface 14 intersects with the mounting surface 8.

[0076] In accordance with the above-described changes to the first protrusions 41d and 43d, the positions of the notches 42d and 44d provided in the metal terminals 23d and 24d are also changed.

[0077] The functions of the first protrusions 41 d and 43 d are substantially the same as those of the first protrusions 41 and 43 .

[0078] Although the present invention has been described above with reference to the illustrated embodiment, various other embodiments are possible within the scope of the present invention.

[0079] For example, the coil component to which this invention is directed may be one that constitutes a single coil as in the illustrated embodiment, or one that constitutes a common mode choke coil, a transformer, a balun, etc. Therefore, the number of wires may be changed depending on the function of the coil component, and the number of metal terminals provided on each flange may also be changed accordingly. Typically, two metal terminals may be arranged side by side in the W direction on one flange.

[0080] As described above, when two metal terminals are arranged side by side in the W direction on one flange, each metal terminal has a mounting surface-facing portion facing an area less than half the width of the mounting surface, an outer end surface-facing portion facing an area less than half the width of the outer end surface, and a side surface-facing portion facing one of the first side surface and the second side surface. The mounting surface-facing portion has a mounting connection portion that can be connected to a conductor on the mounting board during mounting, and a wire connection portion to which a wire can be connected. However, the mounting surface-facing central portion that serves as the mounting connection portion is less than half the width of the illustrated portion, and therefore has one mounting surface-facing end portion as the wire connection portion.

[0081] In addition, in the present invention, fixing with an adhesive is not essential when attaching the metal terminals 23 and 24 to the flanges 3 and 4. However, fixing with an adhesive can encounter the following problems.

[0082] (1) The stronger the adhesive fixation, the less useful the metal terminal becomes. The advantage of a metal terminal is that, due to the springiness of the metal plate, even if a small external force is applied, the metal terminal itself deflects, releasing the stress and preventing damage. However, the more firmly the metal terminal is fixed with adhesive, the less the springiness of the metal plate can be utilized. In other words, the terminal becomes vulnerable to the development of solder cracks during long-term reliability tests and to deflection tests.

[0083] (2) Adhesives are generally sensitive to heat and lose their adhesive properties after being exposed to temperatures of around 300°C for just a few minutes. However, when manufacturing coil components using conventional metal terminals, it is necessary to attach the metal terminals to the core and then connect the wire to the metal terminals using heat, which inevitably results in the adhesive being exposed to heat.

[0084] However, according to the present invention, adhesive is not required for attachment of the metal terminals 23 and 24 to the flanges 3 and 4, and sufficient heat can be applied when connecting the wires to the metal terminals. This allows for the use of relatively thick wires in the coil component. However, the present invention does not exclude the use of adhesives. Furthermore, when constructing a coil component according to the present invention, partial substitution or combination of the configurations among the different embodiments described in this specification is possible.

[0085] The embodiments of the present invention include the following:

[0086] <1> A core having a winding core portion extending in an axial direction and a pair of flange portions provided at opposite ends of the winding core portion in the axial direction; at least one pair of metal terminals each made of a metal plate attached to each of the flange portions; and at least one wire connected to each of the at least one pair of metal terminals and wound around the winding core portion, wherein each of the flange portions has a mounting surface that faces a mounting board when mounted, a top surface that faces the opposite side of the mounting surface, an inner end surface that connects the mounting surface and the top surface and faces the winding core portion and positions an end of the winding core portion in the axial direction, an outer end surface that faces the opposite side of the inner end surface, and a first side surface and a second side surface that connect the inner end surface and the outer end surface and face in opposite directions to each other, each of the metal terminals has a mounting surface facing portion facing the mounting surface, an outer end face facing portion facing the outer end face, and a side face facing portion facing at least one of the first side face and the second side face, and the metal terminal further comprises a first restricting portion for restricting at least the mounting surface facing portion from moving in a direction away from the mounting surface relative to the flange portion, and a second restricting portion for restricting at least the outer end face facing portion from moving in a direction away from the outer end face.

[0087] <2> The coil component according to <1>, wherein the flange portion has a first rising wall extending along an extension direction of the inner end surface, the metal terminal has a first opposing wall opposing the first rising wall, and the first restricting portion is provided by abutment between the first rising wall and the first opposing wall.

[0088] <3> The coil component according to <2>, wherein the flange portion has a second rising wall extending along an extension direction of the mounting surface, the metal terminal has a second opposing wall opposing the second rising wall, and the second restricting portion is provided by abutment between the first rising wall and the first opposing wall.

[0089] <4> The coil component according to <3>, wherein a first convex portion is provided on at least one of the first side surface and the second side surface; a cutout portion that receives the first convex portion is provided in the side surface opposing portion; the first convex portion has an outer circumferential wall that provides the first rising wall and the second rising wall; and the cutout portion has an inner circumferential wall that provides the first opposing wall and the second opposing wall.

[0090] <5> The coil component according to any one of <1> to <4>, wherein the outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the mounting surface facing portion via a second bent portion.

[0091] <6> The coil component according to any one of <1> to <4>, wherein the outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the outer end surface facing portion via a second bent portion.

[0092] <7> The coil component according to <6>, wherein the metal terminal further includes a mounting surface facing end portion that faces the mounting surface while being adjacent to the mounting surface facing portion at an end portion of at least one of the first side surface side and the second side surface side of the mounting surface.

[0093] <8> The coil component according to <7>, wherein the mounting surface facing end portion is continuous with the outer end surface facing portion via a third bent portion.

[0094] <9> The coil component according to <7>, wherein the mounting surface facing end is continuous with the side surface facing portion via a third bent portion.

[0095] <10> The coil component described in <4>, wherein, when viewed toward each of the first side surface and the second side surface, the first convex portion is positioned on at least one of the first side surface and the second side surface so as to contact a corner where the outer end surface and the mounting surface intersect, and the cutout portion is positioned at a predetermined distance from an edge of the side surface opposing portion on the inner end surface side and an edge of the top surface side.

[0096] <11> The coil component according to <4>, wherein the flange portion further includes a second protrusion portion that faces at least a part of the edge of the metal terminal on the top surface side.

[0097] <12> The coil component according to <11>, wherein the second protrusion faces an edge of the side surface facing portion on the top surface side.

[0098] <13> The coil component according to any one of <1> to <12>, wherein each of the metal terminals has, as the side surface facing portion, a first side surface facing portion facing the first side surface and a second side surface facing portion facing the second side surface, which are connected via the outer end surface facing portion.

[0099] DESCRIPTION OF SYMBOLS 1, 1a, 1b, 1c, 1d Coil component 2 Winding core 3 First flange 4 Second flange 5 Core 6 Mounting board 7, 8 Mounting surface 9, 10 Top surface 11, 12 Inner end surface 13, 14 Outer end surface 15, 16 First side surface 17, 18 Second side surface 21 Wire 23, 23a, 23b, 23c, 23d First metal terminal 24, 24a, 24b, 24c, 24d Second metal terminal 25, 26 Mounting surface facing portion 27, 28 Outer end surface facing portion 29, 30 First side surface facing portion 31, 32 Second side surface facing portion 33, 34, 55, 56 First bent portion 35, 36, 57, 58 Second bent portion 37, 38 Conductive land 39 Fillet 41, 43, 41d, 43d First convex portion 42, 44, 42d, 44d Notch portion 45, 49 First rising wall 46, 50 Second rising wall 47, 51 First opposing wall 48, 52 Second opposing wall 53, 54 Second convex portion 61, 62 First mounting surface opposing end portion 63, 64 Second mounting surface opposing end portion 65, 66 Mounting surface opposing center portion 67, 68 Third bent portion

Claims

1. a core having a winding core portion extending in an axial direction and a pair of flange portions provided at opposite ends of the winding core portion in the axial direction; At least one pair of metal terminals, each made of a metal plate, attached to each of the flanges; At least one wire connected to each of the at least one pair of metal terminals and wound around the winding core; Equipped with each of the flange portions has a mounting surface that faces the mounting board during mounting, a top surface that faces the opposite side to the mounting surface, and connects the mounting surface and the top surface, and has an inner end surface that faces the winding core portion and positions an end of the winding core portion in the axial direction, an outer end surface that faces the opposite side to the inner end surface, and a first side surface and a second side surface that connect the inner end surface and the outer end surface and face in opposite directions to each other, each of the metal terminals has a mounting surface facing portion facing the mounting surface, an outer end surface facing portion facing the outer end surface, and a side surface facing portion facing at least one of the first side surface and the second side surface; The metal terminal further includes a first restricting portion for restricting at least the outer end surface facing portion from moving in a direction away from the outer end surface relative to the flange portion, and a second restricting portion for restricting at least the mounting surface facing portion from moving in a direction away from the mounting surface. Coil parts.

2. The flange portion has a first rising wall extending along a direction in which the inner end surface extends, the metal terminal has a first opposing wall opposed to the first rising wall, The first restricting portion is provided by abutment between the first rising wall and the first opposing wall. The coil component according to claim 1 .

3. the flange portion has a second rising wall extending along an extension direction of the mounting surface, the metal terminal has a second opposing wall opposed to the second rising wall, The second restriction portion is provided by abutment between the second rising wall and the second opposing wall. The coil component according to claim 2 .

4. a first protrusion is provided on at least one of the first side surface and the second side surface; The side surface facing portion is provided with a notch portion for receiving the first protrusion, the first protrusion has an outer peripheral wall that provides the first raised wall and the second raised wall, The cutout portion includes an inner circumferential wall that defines the first opposing wall and the second opposing wall. The coil component according to claim 3 .

5. The coil component according to claim 1 , wherein the outer end face facing portion is connected to the mounting surface facing portion via a first bent portion, and the side face facing portion is connected to the mounting surface facing portion via a second bent portion.

6. The coil component according to claim 1 , wherein the outer end surface facing portion is connected to the mounting surface facing portion via a first bent portion, and the side surface facing portion is connected to the outer end surface facing portion via a second bent portion.

7. 7. The coil component according to claim 6, wherein the metal terminal further includes a mounting surface facing end portion that faces the mounting surface while being adjacent to the mounting surface facing portion at at least one end portion of the first side surface side and the second side surface side of the mounting surface.

8. The coil component according to claim 7 , wherein the mounting surface facing end portion is continuous with the outer end surface facing portion via a third bent portion.

9. The coil component according to claim 7 , wherein the mounting surface facing end is continuous with the side surface facing portion via a third bent portion.

10. when viewed toward each of the first side surface and the second side surface, the first protrusion is positioned so as to be in contact with a corner at which the outer end surface and the mounting surface intersect on at least one of the first side surface and the second side surface, The cutout portion is positioned at a predetermined distance from an edge of the side facing portion on the inner end surface side and an edge of the top surface side. The coil component according to claim 4 .

11. The coil component according to claim 4 , wherein the flange portion further includes a second protrusion facing at least a portion of an edge of the metal terminal on the top surface side.

12. The coil component according to claim 11 , wherein the second protrusion faces an edge of the side surface facing portion on the top surface side.

13. 2. The coil component according to claim 1, wherein each of the metal terminals has, as the side facing portion, a first side facing portion facing the first side and a second side facing portion facing the second side, which are connected via the outer end face facing portion.