Coil component

Abstract

Provided is a coil component that, through a step for connecting a wire to a metal terminal and a step for mounting the wire on a mounting substrate, can make it unlikely for external forces to concentrate on a specific portion.　Flange parts (3, 4) of a core (5) have mounting surfaces (7, 8), top surfaces (9, 10), inner end surfaces (11, 12), outer end surfaces (13, 14), first lateral surfaces (15, 16), and second lateral surfaces (17, 18). Metal terminals (23, 24) have mounting surface opposing parts (25, 26), outer end surface opposing parts (27, 28), and lateral surface opposing parts (29, 30, 31, 32) that oppose the mounting surfaces, the outer end surfaces, and the first lateral surfaces and / or the second lateral surfaces. The mounting surface opposing parts have mounting connection portions (63, 64) and wire connection portions (61 to 64), and the mounting connection portions and the wire connection portions are separated from each other. The mounting connection portions are continuous from either the outer end surface opposing parts or the lateral surface opposing parts, and the wire connection portions are continuous from the other of the outer end surface opposing parts or the lateral surface opposing parts.

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 of a metal terminal made of a metal plate attached to the core.

[0002] For example, Japanese Patent Application Laid-Open No. 2017-199841 (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. Metal terminals made of metal plates are attached to each flange portion and fixed with adhesive. 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] The metal terminal has a mounting surface facing portion and an outer end surface facing portion that face the mounting surface and outer end surface of the flange, respectively. The mounting surface facing portion has a mounting connection portion that is connected to a conductor on the mounting board during mounting, and a wire connection portion to which a wire is connected, and the mounting connection portion and the wire connection portion are separated from each other.

[0005] Patent Document 1 describes that laser welding is applied to connect the wire to the wire connection portion. As described above, if the mounting connection portion and the wire connection portion are separated from each other, it is expected that heat generated when welding the wire will be less likely to be transmitted to the mounting connection portion.

[0006] Japanese Patent Application Laid-Open No. 2017-199841

[0007] In the coil component described in Patent Document 1, the mounting connection portion and the wire connection portion that constitute the mounting surface facing portion of the metal terminal are both connected to the outer end surface facing portion via a bent portion.

[0008] When attempting to connect a wire to the wire connection portion by thermocompression, the external force acting on the wire connection portion during thermocompression acts on the outer end surface facing portion connected to the wire connection portion. Furthermore, when mounting the coil component on a mounting board, the external force acting on the mounting connection portion also acts on the outer end surface facing portion connected to the mounting connection portion. Such a concentration of external force acting on the outer end surface facing portion can cause the terminal electrode to come off the flange.

[0009] Therefore, an object of the present invention is to provide a coil component having a structure that makes it difficult for external forces to concentrate on specific points of the coil component during the process of connecting the wire to the metal terminal and the process of mounting the coil component on a mounting board.

[0010] The present invention is directed to a coil component comprising: a core having a winding core portion extending in an axial direction and a first flange portion and a second flange portion respectively provided at opposite axial ends of the winding core portion; a metal terminal made of a metal plate attached to the first flange portion; and at least one wire connected to the metal terminal and wound around the winding core portion.

[0011] The first 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.

[0012] In order to solve the above-mentioned technical problems, the present invention is characterized by having the following configuration.

[0013] The metal terminal 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.

[0014] 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 that can be connected to a wire.

[0015] The mounting connection and the wire connection are separated from each other.

[0016] The mounting connection portion is connected to either the outer end face facing portion or the side face facing portion via a bent portion, and the wire connection portion is connected to the other of the outer end face facing portion or the side face facing portion via a bent portion.

[0017] According to this invention, not only are the mounting connection portion and the wire connection portion separated from each other, but the mounting connection portion is connected to either the outer end face facing portion or the side face facing portion, while the wire connection portion is connected to the other of the outer end face facing portion or the side face facing portion, so that the load on the mounting connection portion is applied to either the outer end face facing portion or the side face facing portion, and the load on the wire connection portion is applied to the other of the outer end face facing portion or the side face facing portion, thereby advantageously distributing these loads. As a result, the wire connection portion is less susceptible to the effects of loads such as heat and stress applied to the mounting connection portion, and the mounting connection portion is less susceptible to the effects of loads such as heat and stress applied to the wire connection portion.

[0018] Furthermore, the metal terminal has not only a mounting surface facing portion facing the mounting surface and an outer end face facing portion facing the outer end face, but also a side face facing portion facing at least one of the first side face and the second side face, so that face-to-face opposition is realized in at least three locations between the metal terminal and the first flange portion.

[0019] These features make it possible to advantageously distribute loads such as heat and stress acting on the metal terminal, thereby making it difficult for the metal terminal to come off the first flange portion.

[0020] 5 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. 6 is a perspective view showing the mounted state of the coil component 1 shown in FIG. 1. FIG. 7 is a perspective view for explaining typical external forces acting on the coil component 1 in the mounted state shown in FIG. 2. FIG. 8 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. 9 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. 10 is a cross-sectional view taken along line VI-VI in FIG.

[0021] A coil component 1 according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 3. FIG.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] In the first metal terminal 23, 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.

[0031] Similarly, in the second metal terminal 24, 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 the 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 the third bent portion 68, respectively.

[0032] As shown in Fig. 2, the coil component 1 is mounted with the metal terminals 23 and 24 connected via solder to conductive lands 37 and 38 provided on the mounting substrate 6. At this time, solder is applied to mounting surface-facing central portions 65 and 66 of the metal terminals 23 and 24. In the mounted state shown in Fig. 2, the mounting surface-facing central portions 65 and 66 serve as "mounting connection portions" that can be connected to the conductive lands 37 and 38 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.

[0033] Furthermore, in the first metal terminal 23, a first end of the wire 21 is connected to one of the first mounting surface facing end 61 and the second mounting surface facing end 63, for example, the first mounting surface facing end 61. In the second metal terminal 24, a second end of the wire 21 is connected to one of the first mounting surface facing end 62 and the second mounting surface facing end 64, for example, the second mounting surface facing end 64. Therefore, the first mounting surface facing end 61 and the second mounting surface facing end 63 and the first mounting surface facing end 62 and the second mounting surface facing end 64 form "wire connection portions" to which the wire 21 can be connected. Note that wires are not necessarily connected to all of the first mounting surface facing end 61 and the second mounting surface facing end 63 and the first mounting surface facing end 62 and the second mounting surface facing end 64 that form "wire connection portions." Therefore, a "wire connection portion" should be understood to be a portion to which a wire can be connected.

[0034] For example, thermocompression bonding is used to connect the wire 21 to the metal terminals 23 and 24. As shown in the figure, after the first end of the wire 21 is connected to the first mounting surface-facing end 61 of the first metal terminal 23 and the second end of the wire 21 is connected to the second mounting surface-facing end 64 of the second metal terminal 24, the excess portion of the tip of the wire 21 is cut off and removed. For example, the edges of the first mounting surface-facing end 61 and the second mounting surface-facing end 64 on the outer end surfaces 13 and 14 sides can be advantageously used for this cutting.

[0035] 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.

[0036] 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.

[0037] The above-described configuration provides the following advantageous effects.

[0038] Explaining with reference to Figures 1 to 3, 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] This embodiment has a structure that makes it even more difficult for the metal terminals 23 and 24 to come off the flange portions 3 and 4. That is, the metal terminals 23 and 24 further have restricting portions that restrict movement of at least the mounting surface facing portions 25 and 26 in directions away from the mounting surfaces 7 and 8 and at least the outer end surface facing portions 27 and 28 in directions away from the outer end surfaces 13 and 14, relative to the flange portions 3 and 4.

[0043] Of 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-mentioned 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] Such second protrusions 53 and 54 can more reliably prevent the metal terminals 23 and 24 from coming off the flanges 3 and 4 in response to external forces in the rotational direction generated around the axis oriented in the W direction and external forces in the rotational direction generated around the axis oriented in the L direction. Note that the external forces in the rotational direction generated around the axis oriented in the W direction 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.

[0059] 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.

[0060] In terms of resistance to the external force in the rotational direction 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.

[0061] 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.

[0062] According to the coil component 1 described above, the mounting surface-facing central portions 65 and 66, which serve as "mounting connection portions," and the mounting surface-facing end portions 61 to 64, which serve as "wire connection portions," are separated from each other. Moreover, the mounting surface-facing end portions 61 to 64 are connected to the outer end surface-facing portions 27 and 28 via the side surface-facing portions 29 to 32.

[0063] Therefore, the mounting surface-facing ends 61 to 64 are less susceptible to the effects of loads such as heat and stress acting 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 acting on the mounting surface-facing ends 61 to 64. This makes it possible to improve the connection reliability between the mounting board 6 and the metal terminals 23 and 24, and between the metal terminals 23 and 24 and the wire 21.

[0064] The stress acting on the mounting surface-facing ends 61-64 may be, for example, stress acting on a particular one of the mounting surface-facing ends 61-64 when the wire 21 is thermocompression bonded. If the mounting surface-facing ends 61-64, which serve as the "wire connection portions," were directly connected to the outer end surface-facing portions 27 and 28 via bent portions, the stress described above could cause the mounting surface-facing ends 61-64 to move in a tilting manner in the T direction, with the ridge where the outer end surfaces 13 and 14 of the flanges 3 and 4 intersect with the mounting surfaces 7 and 8 as a fulcrum. The movement of the mounting surface-facing ends 61-64 is particularly large on the side of the inner end surfaces 11 and 12, which are relatively far from the fulcrum.

[0065] Here, because the wires 21 extend from the inner end faces 11 and 12, poor connection of the wires 21 may occur, or the wires 21 may be cut at the edge portions of the mounting surface-facing ends 61 to 64. In particular, when the drawing direction of the wires 21 and the extending direction of the edge portions of the mounting surface-facing ends 61 to 64 are perpendicular to each other, the wires 21 are more likely to be cut.

[0066] In contrast, when the mounting surface facing ends 61 to 64, which form the "wire connection portions," extend from the side surface facing portions 29 to 32, the ridge where the sides 15 to 18 intersect with the mounting surfaces 7 and 8 serves as a fulcrum, and the distance from this fulcrum to the inner end faces 11 and 12 of the mounting surface facing ends 61 to 64 is relatively short, so that the amount of deflection of the mounting surface facing ends 61 to 64 during thermocompression bonding can be reduced, making it less likely that poor connection of the wire 21 will occur.

[0067] Furthermore, if the mounting surface facing ends 61 to 64 that serve as "wire connection portions" extend from the side surface facing portions 29 to 32, the metal terminals 23 and 24 can be made less likely to come off the flange portions 3 and 4.

[0068] Figures 4 and 5 are views corresponding to Figure 1, showing a coil component 1a according to a second embodiment of the present invention and a coil component 1b according to a third embodiment of the present invention, respectively. Figure 6 is a cross-sectional view taken along line VI-VI in Figure 5. In Figures 4 to 6, elements corresponding to those shown in Figure 1 are given the same reference numerals, and duplicated explanations will be omitted.

[0069] The coil component 1a shown in Fig. 4 differs from the coil component 1 shown in Fig. 1 in the shape of the mounting surface-facing ends 61-64 of each of the metal terminals 23a and 24a. More specifically, of the mounting surface-facing ends 61-64 that become the "wire connection portions," the mounting surface-facing ends 61 and 64 that actually become the "wire connection portions" form a gradient that decreases from the outer end faces 13 and 14 toward the inner end faces 11 and 12 with respect to the height from the mounting surfaces 7 and 8 of the flanges 3 and 4.

[0070] With this configuration, when connecting the wire 21 to a specific one of the mounting surface facing ends 61 to 64, the wire 21 can be smoothly guided and pulled out, and after connecting the wire 21, the risk of the wire 21 being undesirably cut at the edges on the inner end faces 11 and 12 side of the mounting surface facing ends 61 to 64 can be reduced.

[0071] All of the mounting surface-facing ends 61 to 64, which are the "wire connection portions," may have a gradient that becomes lower from the outer end faces 13 and 14 toward the inner end faces 11 and 12. This configuration allows the wire 21 to remain thick after crimping, making it less likely for the wire 21 to break.

[0072] 5 and 6 is characterized in that, in metal terminals 23b and 24b, mounting surface-facing central portions 65 and 66 serving as "mounting connection portions" are higher than mounting surface-facing end portions 61 to 64 serving as "wire connection portions" in terms of the height from mounting surfaces 7 and 8 of flange portions 3 and 4. Figure 6 clearly shows the positional relationship between mounting surface-facing central portion 66 and mounting surface-facing end portions 62 and 64 with respect to mounting surface 8 of second flange portion 4.

[0073] Although the ends of the wires 21 connected to specific ones of the mounting surface-facing ends 61 to 64 are crushed by thermocompression, the height difference described above can absorb the thickness of the connected ends of the wires 21. A gap 69 (see FIG. 6 ) between the mounting surface-facing central portions 65 and 66 and the mounting surfaces 7 and 8 of the flanges 3 and 4, which is caused by this height difference, is preferably set to, for example, 200 μm or less, and the gaps between the mounting surface-facing ends 61 to 64 and the mounting surfaces 7 and 8 of the flanges 3 and 4 are made narrower than gap 69.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] In addition, in the present invention, it is not essential to use an adhesive to fix the metal terminals 23 and 24 to the flanges 3 and 4. However, the present invention does not exclude the use of an adhesive.

[0078] Furthermore, mounting surface facing central portion 65 is located between first mounting surface facing end portion 61 and second mounting surface facing end portion 63, and mounting surface facing central portion 66 is located between first mounting surface facing end portion 62 and second mounting surface facing end portion 64, but wires 21 may be connected to mounting surface facing central portions 65 and 66, and first mounting surface facing end portions 61 and 62 or second mounting surface facing end portions 63 and 64 may be connected to conductive lands on the mounting board.

[0079] In the illustrated embodiment, the first metal terminal 23 and the second metal terminal 24 have the same configuration, but either the first metal terminal 23 or the second metal terminal 24, for example, only the first metal terminal 23, may have the characteristic configuration of the present invention. In this case, the second metal terminal 24 may be made of a metal plate that does not have the characteristic configuration of the present invention, or may be made of a conductive film obtained by firing a conductive paste, for example.

[0080] Furthermore, when configuring the coil component according to the present invention, partial substitution or combination of configurations is possible between the different embodiments described in this specification.

[0081] The embodiments of the present invention include the following:

[0082] <1> A core having a winding core portion extending in an axial direction and a first flange portion and a second flange portion provided at opposite ends of the winding core portion in the axial direction, a metal terminal made of a metal plate attached to the first flange portion, and at least one wire connected to the metal terminal and wound around the winding core portion, wherein the first flange portion 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, the 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, the mounting surface facing portion has a mounting connection portion that can be connected to a conductor on a mounting board during mounting, and a wire connection portion to which the wire can be connected, the mounting connection portion and the wire connection portion are separated from each other, the mounting connection portion is continuous from either the outer end face facing portion or the side face facing portion via a bent portion, and the wire connection portion is continuous from the other of the outer end face facing portion or the side face facing portion via a bent portion.

[0083] <2> The coil component according to <1>, wherein the mounting connection portion is continuous with the outer end surface opposing portion via a bent portion, and the wire connection portion is continuous with the side surface opposing portion via a bent portion.

[0084] <3> The coil component according to <1> or <2>, wherein the side surface facing portion is continuous with the outer end surface facing portion via a bent portion.

[0085] <4> The coil component according to any one of <1> to <3>, wherein the metal terminal has, as the side surface facing portion, a first side surface facing portion facing the first side surface and a second side surface facing the second side surface, the mounting surface facing portion has, as the wire connection portion, a first wire connection portion and a second wire connection portion, when the direction in which the first side surface and the second side surface face each other is defined as a width direction, the first wire connection portion and the second wire connection portion are arranged at each end of the mounting surface in the width direction, with the mounting connection portion sandwiched between them, and the wire is connected to at least one of the first wire connection portion and the second wire connection portion.

[0086] <5> The coil component according to any one of <1> to <4>, wherein the mounting connection portion is higher than the wire connection portion with respect to the height of the first flange portion from the mounting surface.

[0087] <6> The coil component according to any one of <1> to <5>, wherein the wire connection portion has a height from the mounting surface of the first flange portion that is gradually reduced from the outer end surface side toward the inner end surface side.

[0088] <7> The coil component according to any one of <1> to <6>, further comprising a restricting portion for restricting movement of at least the mounting surface facing portion in a direction away from the mounting surface and at least the outer end surface facing portion in a direction away from the outer end surface, relative to the first flange portion, wherein the restricting portion is defined by a first protrusion provided on at least one of the first side surface and the second side surface of each of the pair of flange portions, and a cutout portion located on at least one of the first side surface facing portion and the second side surface facing portion of the metal terminal, and receiving each of the first protrusions.

[0089] <8> The coil component according to <7>, wherein each of the pair of flange portions further includes a second protrusion that faces at least a part of an edge of the metal terminal on the top surface side in a direction in which the top surface and the mounting surface face each other.

[0090] <9> The coil component according to <8>, wherein the second protrusion faces an edge of the side surface facing portion of the metal terminal on the top surface side.

[0091] <10> The coil component according to any one of <1> to <9>, further comprising a second metal terminal made of a metal plate attached to the second flange, wherein the second metal terminal has a configuration similar to that of the metal terminal.

[0092] REFERENCE SIGNS LIST 1, 1a, 1b 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 First metal terminal 24, 24a, 24b 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 37, 38 Conductive land 39 Fillet 41, 43 First convex portion 42, 44 Notch portion 45, 49 First rising wall 46, 50 Second rising wall 47, 51 First facing wall 48, 52 Second opposing wall 53, 54 Second protrusion 55, 56 First bent portion 57, 58 Second bent portion 61, 62 First mounting surface opposing end (wire connection portion) 63, 64 Second mounting surface opposing end (wire connection portion) 65, 66 Mounting surface opposing center portion (mounting connection portion) 67, 68 Third bent portion 69 Gap

Claims

1. a core having a winding core portion extending in an axial direction and a first flange portion and a second flange portion provided at opposite ends of the winding core portion in the axial direction; a metal terminal made of a metal plate attached to the first flange; At least one wire connected to the metal terminal and wound around the winding core; Equipped with the first flange portion has a mounting surface that faces a 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, the metal terminal 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 mounting surface facing portion has a mounting connection portion that can be connected to a conductor on a mounting board during mounting, and a wire connection portion to which the wire can be connected; the mounting connection portion and the wire connection portion are separated from each other; the mounting connection portion is connected to one of the outer end face facing portion and the side face facing portion via a bent portion, and the wire connection portion is connected to the other of the outer end face facing portion and the side face facing portion via a bent portion. Coil parts.

2. The coil component according to claim 1 , wherein the mounting connection portion is connected to the outer end face facing portion via a bent portion, and the wire connection portion is connected to the side face facing portion via a bent portion.

3. The coil component according to claim 1 , wherein the side surface facing portion is continuous with the outer end surface facing portion via a bent portion.

4. the metal terminal 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; the mounting surface facing portion has a first wire connecting portion and a second wire connecting portion as the wire connecting portion, when a direction in which the first side surface and the second side surface face each other is defined as a width direction, the first wire connection portion and the second wire connection portion are disposed at respective ends of the mounting surface in the width direction, with the mounting connection portion therebetween, The coil component according to claim 1 , wherein the wire is connected to at least one of the first wire connection portion and the second wire connection portion.

5. The coil component according to claim 1 , wherein the mounting connection portion is higher than the wire connection portion in terms of height from the mounting surface of the first flange portion.

6. The coil component according to claim 1 , wherein the wire connection portion has a height from the mounting surface of the first flange portion that is gradually decreased from the outer end surface side toward the inner end surface side.

7. a restricting portion for restricting movement of the metal terminal relative to the first flange portion in a direction in which at least the mounting surface facing portion moves away from the mounting surface and in a direction in which at least the outer end surface facing portion moves away from the outer end surface, 5. The coil component according to claim 4, wherein the regulating portion is provided by a first convex portion provided on at least one of the first side surface and the second side surface of each of the pair of flange portions, and a cutout portion located on at least one of the first side surface facing portion and the second side surface facing portion of the metal terminal and receiving each of the first convex portions.

8. 8. The coil component according to claim 7, wherein each of the pair of flange portions further includes a second protrusion that faces at least a portion of an edge of the metal terminal on the top surface side in a direction in which the top surface and the mounting surface face each other.

9. The coil component according to claim 8 , wherein the second protrusion faces an edge of the side surface facing portion of the metal terminal on the top surface side.

10. The coil component according to claim 1 , further comprising a second metal terminal made of a metal plate attached to the second flange portion, the second metal terminal having a similar configuration to the metal terminal.