Inductor component and method for manufacturing same

Abstract

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

Description

Inductor component and manufacturing method thereof

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

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

[0003] Japanese Utility Model Application Publication No. 50-20152

[0004] However, in the conventional inductor component, after assembling the first wire member and the second wire member, one end of the first wire member and one end of the second wire member must be welded to form one turn of the coil, and then multiple turns must be connected in series, which requires advanced control of the positioning of the first wire member and the second wire member when welding them.As such, the assembly of the wire members is time-consuming.

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

[0006] In order to solve the above problem, an inductor component according to one aspect of the present disclosure comprises a coil including a plurality of wire members, wherein a first end of a first wire member and a second end of a second wire member are connected in adjacent wire members, and the plurality of wire members form a spiral of the coil, and an end face of the first end is provided with a wall portion that protrudes in the center line direction of the first end, the end face of the first end faces the circumferential surface of the second end, and the side surface of the wall portion in a direction perpendicular to the center line direction of the first end faces the end face of the second end.

[0007] Here, the center line of the first end is a line passing through the center of gravity of the first end in a cross section perpendicular to the extension direction of the first end. The center line of the second end is a line passing through the center of gravity of the second end in a cross section perpendicular to the extension direction of the second end. The end face of the first end is the outer surface located at the outermost position in the center line direction of the first end. The end face of the second end is the outer surface located at the outermost position in the center line direction of the second end. The circumferential surface of the second end is the outer surface in the circumferential direction centered on the center line of the second end.

[0008] According to the above aspect, since the end face of the first end of the first wire member faces the circumferential surface of the second end of the second wire member, positioning of the first wire member in the centerline direction of the first end can be easily performed when assembling the first wire member to the second wire member. Furthermore, since the side surface of the wall portion in a direction perpendicular to the centerline direction of the first end faces the end face of the second end, positioning of the first wire member in the centerline direction of the second end can be easily performed when assembling the first wire member to the second wire member. Thus, according to the above aspect, positioning of the first wire member can be performed on two surfaces, the end face of the first end and the side surface of the wall portion, thereby facilitating the assembly of the first wire member and the second wire member. In contrast, in conventional technology, positioning is performed on only one surface, which makes assembling the wire members time-consuming.

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

[0010] According to the above embodiment, since the first end and the second end are connected by a welded portion, the occurrence of cracks and the like at the connection portion can be suppressed compared to when the first end and the second end are connected by, for example, soldering, and the long-term reliability of the connection portion can be ensured. Furthermore, since the size of the connection portion can be made smaller than when the first end and the second end are mechanically connected by, for example, crimping, the coil can be made smaller.

[0011] Preferably, in one embodiment of the inductor component, the welded portion further connects an end surface of the first end portion and a peripheral surface of the second end portion.

[0012] According to the above embodiment, the cross-sectional area of ​​the connection between the first end and the second end (connection cross-sectional area; joint cross-sectional area) is increased, thereby increasing the mechanical strength. As a result, the reliability of the connection can be improved. Furthermore, the electrical resistance of the connection can be reduced, allowing a large current to flow through the coil.

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

[0014] According to the embodiment, a portion of the end face of the second end portion is not melted by welding, which prevents the weld from expanding in a direction perpendicular to the center line of the second end portion and prevents short circuits from occurring between adjacent first wire members and adjacent second wire members.

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

[0016] According to the above embodiment, the area covered by the coating of the second wire member can be made larger compared to when the maximum length of the second exposed region is longer than the maximum length of the first exposed region, thereby ensuring insulation between adjacent second wire members.

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

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

[0019] In one embodiment of a method for manufacturing an inductor component, the method includes the steps of assembling a first wire member and a second wire member such that, in adjacent wire members, the end face of a first end of a first wire member faces the peripheral surface of the second end of a second wire member, and the side of a wall portion provided on the end face of the first end and protruding in the center line direction of the first end faces the end face of the second end; and connecting the first end of the first wire member and the second end of the second wire member.

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

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

[0022] According to the above embodiment, since the first end and the second end are connected by welding, the occurrence of cracks and the like at the connection portion can be suppressed compared to when the first end and the second end are connected by, for example, soldering, and the long-term reliability of the connection portion can be ensured. Furthermore, since the size of the connection portion can be made smaller than when the first end and the second end are connected mechanically by, for example, crimping, the coil can be made smaller.

[0023] Furthermore, because the laser is irradiated onto the wall portion of the first wire member, it is possible to prevent the laser from irradiating a portion of the second wire member other than the portion to be welded, which would cause damage such as burning to that portion. In contrast, if the end face of the first end does not have a wall portion and the end face of the first end faces the circumferential surface of the second end, and the laser is irradiated onto the portion between the end face and the circumferential surface, the laser may pass between the end face and the circumferential surface, causing the laser to irradiate a portion of the second wire member other than the portion to be welded, which would cause damage such as burning to that portion.

[0024] Furthermore, since the laser is irradiated onto the wall portion of the first wire member, the amount of heat generated in the second wire member during laser irradiation can be made smaller than the amount of heat generated in the first wire member. As a result, thermal damage that may occur in the second wire member can be reduced, and breakage of the second wire member can be suppressed. In particular, if the second wire member has a coating, deterioration and breakage of the coating due to heat can be suppressed.

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

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

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

[0028] According to the embodiment, the wall portion has a plurality of separate protrusions. Since the volume of each protrusion is smaller than the volume of the wall when the plurality of protrusions are integrated, the heat capacity of each protrusion can be smaller than the heat capacity of the wall. Therefore, the laser irradiation time for each protrusion can be shortened, and the amount of heat given to each protrusion can be reduced, so the amount of heat transferred to the second wire member can also be reduced. As a result, damage to the second wire member can be suppressed. In particular, if the second wire member has a coating, deterioration and damage of the coating due to heat can be suppressed.

[0029] Preferably, in one embodiment of the method for manufacturing an inductor component, the connecting step includes a first laser irradiation step of irradiating a laser onto one of the plurality of convex portions, a cooling step of cooling the laser-irradiated portion onto which the laser has been irradiated, and a second laser irradiation step of irradiating a laser onto another of the convex portions.

[0030] According to the embodiment, the amount of heat transferred to the second wire member can be reduced compared to when the first laser irradiation step and the second laser irradiation step are performed consecutively without the cooling step. As a result, damage to the second wire member can be further suppressed. In particular, when the second wire member has a coating, deterioration and damage of the coating due to heat can be further suppressed.

[0031] Preferably, in one embodiment of the method for manufacturing an inductor component, the connecting step includes a first laser irradiation step of irradiating a laser onto one of the plurality of convex portions, and a second laser irradiation step of irradiating a laser onto another convex portion immediately following the first laser irradiation step.

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

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

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

[0035] Furthermore, when viewed from the centerline of the second end, the area of ​​the end face of the second end facing the side surface of the wall can be made smaller than when the entire end face of the second end overlaps the wall. This further reduces the amount of heat transferred to the second wire member, further suppressing damage to the second wire member. In particular, if the second wire member has a coating, this further suppresses deterioration and damage of the coating due to heat.

[0036] Preferably, in one embodiment of the method for manufacturing an inductor element, the following formulas are satisfied in the assembling step: y≦(2 / 3)x+(19 / 3) 25≦x≦70 20≦y≦50 where, x=(thickness of wall portion in the center line direction of second end portion) / (thickness of first end portion in the center line direction of second end portion)×100 y=(length of wall portion in the center line direction of first end portion) / (length of end face of second end portion in the center line direction of first end portion)×100

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

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

[0039] Preferably, in one embodiment of the method for manufacturing an inductor component, the following formula is further satisfied: (13 / 15)x-(83 / 3)≦y

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

[0041] Preferably, in one embodiment of the method for manufacturing an inductor component, in the assembling step, an end face of the first end portion is shaped to follow a peripheral surface of the second end portion.

[0042] According to the above embodiment, even when the first wire member is moved in a direction perpendicular to the center line direction of the first end and parallel to the end face of the second end to assemble the first wire member to the second wire member, the end face of the first end is shaped to follow the circumferential surface of the second end, making it easy to position the first wire member in that direction.

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

[0044] 1 is a top perspective view showing an inductor component of a first embodiment; a bottom perspective view of the inductor component; a bottom perspective view showing the interior of the inductor component; an exploded perspective view of the inductor component; a schematic cross-sectional view of the inductor component; a schematic cross-sectional view of the inductor component; a bottom perspective view of a connection portion between a first wire member and a second wire member; an top perspective view of a connection portion between the first wire member and the second wire member; a view of the first wire member as seen from the center line direction of a first end portion of the first wire member; a schematic cross-sectional view of the connection portion between the first wire member and the second wire member; a view of the connection portion between the first wire member and the second wire member as seen from the center line direction of a second end portion of the second wire member; a schematic cross-sectional view showing an example of a method of connecting the first wire member and the second wire member; a schematic cross-sectional view showing an example of a method of connecting the first wire member and the second wire member; a diagram showing an example of the relationship between laser irradiation time and laser output; a view of the first wire member as seen from above in a first modified example of the method of connecting the first wire member and the second wire member; a bottom perspective view of the connection portion between the first wire member and the second wire member in a first modified example of the method of connecting the first wire member and the second wire member; 1 is a perspective view of a first wire member as viewed from below in a second modified example of a method for connecting a first wire member and a second wire member; FIG. 2 is a perspective view of a first wire member as viewed from above in a second modified example of a method for connecting a first wire member and a second wire member; FIG. 3 is a bottom perspective view of a connection portion of a first wire member and a second wire member in a second modified example of a method for connecting a first wire member and a second wire member; FIG. 4 is a schematic cross-sectional view showing a connection portion of a first wire member and a second wire member in an inductor component of a second embodiment; FIG. 5 is a bottom perspective view showing the interior of an inductor component of a third embodiment; FIG. 6 is a schematic cross-sectional view of an inductor component; FIG. 7 is a schematic cross-sectional view showing a connection portion of a first wire member and a second wire member; FIG. 8 is a graph showing the thermal effect when the thickness ratio x and length ratio y of the wall portion of a first wire member are changed.

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

[0046] (First embodiment) (Overall configuration of inductor component) Fig. 1 is an upper perspective view showing an inductor component according to one embodiment of the present invention. Fig. 2 is a lower perspective view of the inductor component. Fig. 3 is a lower perspective view showing the interior of the inductor component. Fig. 4 is an exploded perspective view of the inductor component.

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

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

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

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

[0051] Here, the short side direction of the case 2 as viewed from the central axis direction of the core 3 is defined as the X direction, the long side direction of the case 2 as viewed from the central axis direction of the core 3 is defined as the Y direction, and the height direction of the case 2, which is perpendicular to both the short side direction and the long side direction, is defined as the Z direction. The bottom plate portion 21 and the box portion 22 of the case 2 are disposed opposite each other in the Z direction, with the bottom plate portion 21 on the lower side and the box portion 22 on the upper side, with the upper side being defined as the forward direction in the Z direction and the lower side being the reverse direction in the Z direction. In other words, in the height direction perpendicular to the first main surface 210a, the direction from the first main surface 210a toward the core 3 is defined as the upward direction. Note that if the shape of the bottom plate portion 21 of the case 2 is square, the length of the case 2 in the X direction and the length of the case 2 in the Y direction will be the same.

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

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

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

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

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

[0057] The lower portion of the core 3 is covered by the core cover 60. That is, a portion of the core 3 on the bottom plate portion 21 side is covered by the core cover 60. It is sufficient that at least a portion of the core 3 on the bottom plate portion 21 side is covered by the core cover 60, and the entire core 3 may be covered by the core cover 60. The core cover 60 is made of a super engineering plastic such as LCP, PPA, or PPS, which improves the heat resistance, insulation, and processability of the core cover 60.

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

[0059] The resin member 90 is disposed in the recess 215 of the bottom plate portion 21, and is in contact with the bottom plate portion 21 and the inductor element L. The resin member 90 may be made of a material such as a thermosetting epoxy resin.

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

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

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

[0063] The number of turns of the first coil 41 is the same as the number of turns of the second coil 42. The winding direction of the first coil 41 around the core 3 is opposite to the winding direction of the second coil 42 around the core 3. In other words, the winding direction of the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52 is opposite to the winding direction of the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54.

[0064] The first to fourth electrode terminals 51 to 54 are connected so that a common mode current flows in the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52, and in the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54, i.e., the first to fourth electrode terminals 51 to 54 are connected so that the current flows in the same direction. When a common mode current flows in the first coil 41, a first magnetic flux is generated in the core 3 by the first coil 41. When a common mode current flows in the second coil 42, a second magnetic flux is generated in the core 3 in a direction that reinforces the first magnetic flux within the core 3. Therefore, the first coil 41 and the core 3, and the second coil 42 and the core 3, act as inductance components, and noise is removed from the common mode current.

[0065] The first coil 41 is formed by connecting a plurality of pin members by welding, such as laser welding or spot welding. Note that Fig. 3 does not show the state in which the plurality of pin members are actually welded, but shows the state in which the plurality of pin members are assembled. Furthermore, the method of connecting the plurality of pin members is not limited to welding, and other connection methods using, for example, solder or a conductive adhesive member may also be used. In the following, for simplicity of explanation, it is assumed that welding is used as the method of connecting the plurality of pin members.

[0066] The pin members are not printed wiring or conductive wires but rod-shaped members. The pin members have rigidity. Specifically, in a cross section perpendicular to the circumferential direction of the core 3, the length of the pin members is shorter than the length of one circumference of the core 3 that passes through the first end face 301, the second end face 302, the inner circumferential surface 303, and the outer circumferential surface 304 of the core 3. In addition, the pin members have high rigidity, making them difficult to bend.

[0067] The multiple pin members include a bent pin member 410 bent into a substantially U-shape, a straight pin member 412 extending in a substantially straight line, and an endmost straight pin member 411. The straight pin member 412 and the endmost straight pin member 411 are examples of a "first wire member" as defined in the claims. The bent pin member 410 is an example of a "second wire member" as defined in the claims.

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

[0069] 5 , when the bending pin member 410 is disposed along the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3, the spring index Ks of the bending pin member 410 is smaller than 3.6 for the radius of curvature R1 of the bending pin member 410 located at a corner of the outer peripheral surface 304 of the core 3 and the radius of curvature R2 of the bending pin member 410 located at a corner of the inner peripheral surface 303 of the core 3. The spring index Ks can be expressed as the radius of curvature R1, R2 of the bending pin member divided by the wire diameter r of the bending pin member. As such, the bending pin member 410 has high rigidity and is difficult to bend.

[0070] The bent pin members 410 and the straight pin members 412 are alternately connected by welding, for example, laser welding or spot welding. One end of a straight pin member 412 is connected to one end of a bent pin member 410, and the other end of the straight pin member 412 is connected to one end of another bent pin member 410. By repeating this process, multiple bent pin members 410 and straight pin members 412 are connected, and the multiple connected bent pin members 410 and straight pin members 412 are arranged in a spiral on the core 3. In other words, one set of bent pin member 410 and straight pin member 412 forms one turn.

[0071] The bent pin members 410 are arranged parallel to each other along the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3. The bent pin members 410 are arranged so that an imaginary line connecting both ends of the bent pin members 410 in the extension direction is perpendicular to the axial direction of the first coil 41. In other words, the bent pin members 410 are arranged so that a plane including the center line of the bent pin members 410 is parallel to a plane (XZ plane) perpendicular to the axial direction of the first coil 41. The straight pin members 412 are arranged parallel to each other along the first end face 301 of the core 3. The straight pin members 412 extend in the X direction at a slight incline toward the Y direction. The outermost straight pin members 411 are arranged parallel to each other along the first end face 301 of the core 3. The outermost straight pin members 411 extend in a direction parallel to the straight pin members 412.

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

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

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

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

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

[0077] 3, each of the first coil 41 and the second coil 42 (pin members 410-412, 420-422) preferably includes a conductor and a coating that covers a portion of the conductor. The conductor is, for example, a copper wire, and the coating is, for example, a polyamide-imide resin. The thickness of the coating is, for example, 0.02 to 0.04 mm.

[0078] The straight pin members 411 and 421 are made up of uncoated conductor portions 411a and 421a, the straight pin members 412 and 422 are made up of uncoated conductor portions 412a and 422a, and the bent pin members 410 and 420 are made up of conductor portions 410a and 420a and coatings 410b and 420b.

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

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

[0081] As shown in FIG. 6 , in the first coil 41, the ends of adjacent pin members are welded together at a welded portion. A welded portion refers to a portion that melts during welding and then solidifies. Specifically, the first coil 41 has a first welded portion 81 and a second welded portion 82. More specifically, in adjacent turns of the first coil 41, the straight pin member 412 and the bent pin member 410 of one turn form a first welded portion 81, where one conductor portion 412 a of the straight pin member 412 is welded to the conductor portion 410 a of the bent pin member 410, and the straight pin member 412 and the bent pin member 410 of the other turn form a second welded portion 82, where the other conductor portion 412 a of the straight pin member 412 is welded to the conductor portion 410 a of the bent pin member.

[0082] 6 illustrates a turn of the first coil 41 that is composed of the straight pin member 412 and the bent pin member 410, the same applies to a turn that is composed of the outermost straight pin member 411 and the bent pin member 410. Specifically, the outermost straight pin member 411 is welded to the conductor portion 410a of the bent pin member 410 that is connected to the conductor portion 411a, thereby forming the first welded portion 81 or the second welded portion 82.

[0083] The second coil 42 has a third weld 83 and a fourth weld 84. As with the first coil 41, in adjacent turns of the second coil 42, the straight pin member 422 and the bent pin member 420 of one turn are welded at one conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member 420, forming the third weld 83, and the straight pin member 422 and the bent pin member 420 of the other turn are welded at the other conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member 420, forming the fourth weld 84. In addition, the outermost straight pin member 421 is welded at the conductor portion 420a of the bent pin member 420 connected to its conductor portion 421a, forming the third weld 83 or the fourth weld 84. The third welded portion 83 and the fourth welded portion 84 of the second coil 42 have the same configuration as the first welded portion 81 and the second welded portion 82 of the first coil 41, and therefore a description thereof will be omitted.

[0084] The core cover 60 is disposed between the core 3 and the conductor portions and welded portions of the coils 41, 42 that are exposed from the coating. This makes it possible to more reliably insulate the conductor portions and welded portions of the coils 41, 42 from the core 3.

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

[0086] The core cover 60 is indirectly connected to the core 3. In other words, the core cover 60 is not directly connected to the core 3; specifically, the core cover 60 is connected to the core 3 via the core support member 310. By connecting the core support member 310 to a part of the core 3, the stress on the core 3 that is received from the core cover 60 can be reduced, and deterioration of the magnetic properties of the core 3 can be suppressed. In other words, a decrease in inductance value due to magnetostriction can be suppressed. Note that the core cover 60 may not be connected to the core 3 via the core support member 310, but may simply be fitted into the core 3.

[0087] The core support member 310 is provided between the first end face 301 of the core 3 and the third portion 60c of the core cover 60. This reduces the effect of magnetostriction on the core 3 and ensures a stable attachment state of the core cover 60 to the core 3.

[0088] Soft resins such as urethane resin and silicone resin can be used as the material for the core support member 310. By using such soft resin, the influence of magnetostriction can be reduced.

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

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

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

[0092] Because the resin member 90 is fixed in the recess 215 of the bottom plate 21, the resin member 90 is stably fixed to the bottom plate 21, thereby enabling the resin member 90 to stably fix the inductor element L to the bottom plate 21. Furthermore, when the liquid resin member 90 is filled into the recess 215 during the manufacturing process of the inductor component 1, the liquid resin member 90 can be retained within the recess 215, enabling the resin member 90 to reliably fix the inductor element L to the bottom plate 21. Furthermore, the resin member 90 covers the conductor portions of the coils 41 and 42 that are exposed from the coating, thereby preventing problems such as electrical shorts with the outside. Furthermore, when the inductor component 1 is subjected to external forces such as vibrations and shocks, the resin member 90 absorbs the shock and protects the coils 41 and 42.

[0093] (Detailed Configuration of Connection Portion of Wire Members) Next, a detailed configuration of the connection portion between the straight pin member 412 (first wire member) and the bent pin member 410 (second wire member) will be described. FIGS. 7 and 8 are top perspective views of the connection portion between the straight pin member 412 and the bent pin member 410. FIGS. 7 and 8 show the state immediately after the straight pin member 412 is assembled to the bent pin member 410, i.e., the state before the bent pin member 410 and the straight pin member 412 are connected by welding, for example. FIGS. 7 and 8 also show the radially inner connection portion of the connection portions between the straight pin member 412 and the bent pin member 410, which are located radially inner and outer sides of the core 3. FIG. 9 is a view of the straight pin member 412 viewed from the direction of the center line 412c of the first end 412e1 of the straight pin member 412.

[0094] As shown in FIGS. 7 to 9 , the straight pin member 412 has a rectangular cross section. In a cross section perpendicular to the extension direction (X direction), the straight pin member 412 has two corners on the forward Z direction side (the side facing the core 3) each having a curved surface C. This prevents the corners of the straight pin member 412 from hitting the core 3 and damaging the core 3 when assembling the straight pin member 412 to the bent pin member 410. The cross-sectional size of the straight pin member 412 is, for example, 1.8 mm in width in the Y direction, 2 mm in height in the Z direction, and a 0.5 mm radius of curvature of the curved surface C. The cross-sectional shape of the straight pin member 412 is not particularly limited and may be a circle, an ellipse, or a polygon other than a rectangle. Furthermore, in a cross section perpendicular to the extension direction, the straight pin member 412 may have two corners on the reverse Z direction side each having a curved surface C, or the corners may not have a curved surface C.

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

[0096] The position where the wall portion 412w is provided on the end face 412ef is not particularly limited, but as in this embodiment, it is preferable that the wall portion 412w is provided at the end on the reverse-Z direction side of the end face 412ef, and that the end face on the reverse-Z direction side of the wall portion 412w is flush with the end face on the reverse-Z direction side of the straight pin member 412 excluding the wall portion 412w. This allows the straight pin member 412 to be stably assembled to the bent pin member 410, and also allows the end face on the reverse-Z direction side of the straight pin member 412 to be flat. Therefore, for example, when a laser is irradiated onto the end face for welding, the welding can be performed satisfactorily without scattering the laser.

[0097] The bending pin member 410 has a circular cross section. The diameter of the cross section of the bending pin member 410 is, for example, 2.0 mm. However, this is not limited thereto, and the cross section of the bending pin member 410 may be elliptical, polygonal, or the like. The end surface 410ef of the second end portion 410e2 of the bending pin member 410 is flat. The end surface 410ef is perpendicular to the center line 410c of the second end portion 410e2. Similarly, the end surface of the first end portion (not shown) of the bending pin member 410 is flat. The end surface is perpendicular to the center line of the first end portion.

[0098] Fig. 10 is a schematic cross-sectional view of the connection portion between the straight pin member 412 and the bent pin member 410. Fig. 11 is a view of the connection portion between the straight pin member 412 and the bent pin member 410 as viewed from the direction of the center line 410c of the second end portion 410e2 of the bent pin member 410. Figs. 10 and 11 show the state after the bent pin member 410 and the straight pin member 412 have been connected by welding. For convenience, Fig. 11 shows the position where the first welded portion 81 is located by hatching.

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

[0100] A side surface 412wf of the wall portion 412w in a direction perpendicular to the center line 412c of the first end portion 412e1 (forward Z direction) faces an end surface 410ef of the second end portion 410e2. In this embodiment, the side surface 412wf is in surface contact with the end surface 410ef. In other words, in this embodiment, a corner of the second end portion 410e2 of the bent pin member 410 is fitted into the space surrounded by the end surface 412ef of the straight pin member 412 and the wall portion 412w. Here, the end surface 410ef of the second end portion 410e2 is the outer surface located outermost in the direction of the center line 410c of the second end portion 410e2. The entire side surface 412wf may be in surface contact with the end surface 410ef, or a portion of the side surface 412wf may be in surface contact with the end surface 410ef, or the side surface 412wf may be in surface contact with the end surface 410ef via, for example, a conductive adhesive member, etc. Among the connection portions of the multiple pin members, there may be connection portions where the side surface 412wf is not in surface contact with the end surface 410ef, i.e., the side surface 412wf and the end surface 410ef are separated by a space.

[0101] The first weld 81 extends continuously from the end face of the wall portion 412w on the reverse-Z direction side to a position beyond the end face 410ef of the second end portion 410e2. The first weld 81 is formed, for example, by irradiating the wall portion 412w with a laser from the reverse-Z direction side to melt a portion of the first end portion 412e1 and a portion of the second end portion 410e2. In this embodiment, the first weld 81 is formed by melting a portion of the wall portion 412w and a portion of the second end portion 410e2. However, this is not limited thereto, and the first weld 81 may be formed by melting the entire wall portion 412w and a portion of the second end portion 410e2. The first weld 81 connects the end face 410ef of the second end portion 410e2 and the side surface 412wf of the wall portion 412w. As a result, the first end 412e1 of the straight pin member 412 and the second end 410e2 of the bent pin member 410 are connected to each other.

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

[0103] Furthermore, if the boundary between the end face 412ef and the peripheral surface 410cf and the boundary between the side face 412wf and the end face 410ef are unclear, the wall portion 412w may be the portion that exists in the area in the above cross section where the area of ​​the first end 412e1 and the second end 410e2 that is on the forward X-direction side of the virtual line VL1 and the area that is on the reverse Z-direction side of the virtual line VL2 overlap.

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

[0105] Furthermore, when soldering is used instead of welding, the connection portion between the straight pin member 412 and the bent pin member 410 may be configured, for example, as shown in Fig. 7, with solder provided to cover the wall portion 412w. Furthermore, when a conductive adhesive member is used instead of welding, the connection portion between the straight pin member 412 and the bent pin member 410 may be configured, for example, as shown in Fig. 7, with a conductive adhesive member provided at least between the side surface 412wf of the wall portion 412w and the end surface 410ef of the bent pin member 410.

[0106] The inductor component 1 described above includes coils 41 and 42 each including bent pin members 410 and 420, straight pin members 412 and 422, and endmost straight pin members 411 and 421. In adjacent bent pin members 410 and 420 and straight pin members 412 and 422 (endmost straight pin members 411 and 421), a first end of the straight pin member 412 and 422 (endmost straight pin member 411 and 421) is connected to a second end of the bent pin member 410 and 420, and the bent pin members 410 and 420, the straight pin members 412 and 422, and the endmost straight pin members 411 and 421 form a spiral of the coil 41 and 42. A wall portion protruding in the direction of the center line of the first end is provided on an end face of the first end. The end face of the first end faces the circumferential surface of the second end. A side surface of the wall portion in a direction perpendicular to the center line direction of the first end portion faces an end face of the second end portion.

[0107] According to the inductor component 1, the end faces of the first ends of the straight pin members 412, 422 (the outermost straight pin members 411, 421) face the peripheral surfaces of the second ends of the bent pin members 410, 420, which makes it easy to position the straight pin members 412, 422 (the outermost straight pin members 411, 421) in the center line direction of the first ends when assembling the straight pin members 412, 422 (the outermost straight pin members 411, 421) to the bent pin members 410, 420. Furthermore, the side surfaces of the wall portions in the direction perpendicular to the center line direction of the first ends face the end faces of the second ends, which makes it easy to position the straight pin members 412, 422 (the outermost straight pin members 411, 421) in the center line direction of the second ends when assembling the straight pin members 412, 422 (the outermost straight pin members 411, 421) to the bent pin members 410, 420. Thus, with the inductor component 1, the straight pin members 412, 422 (the outermost straight pin members 411, 421) can be positioned on two surfaces, the end face of the first end and the side surface of the wall portion, which facilitates the assembly of the straight pin members 412, 422 (the outermost straight pin members 411, 421) and the bent pin members 410, 420. In contrast, with the prior art, positioning is performed on only one surface, which makes the assembly of the wire members time-consuming.

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

[0109] According to the above configuration, the first end 412e1 and the second end 410e2 are connected by the first welded portion 81, which makes it possible to suppress the occurrence of cracks and the like at the connection portion and ensure long-term reliability of the connection portion compared to when the first end 412e1 and the second end 410e2 are connected by, for example, soldering, etc. Furthermore, since the size of the connection portion can be made smaller than when the first end 412e1 and the second end 410e2 are mechanically connected by, for example, crimping, etc., the first coil 41 can be made smaller.

[0110] The above-described preferable configuration and effects also apply to the connection portion between the straight pin member 412 and the bent pin member 410, which is located radially outward of the core 3. The above-described preferable configuration and effects also apply to the connection portion between the straight pin member 422 and the bent pin member 420 in the second coil 42.

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

[0112] According to the above configuration, a portion of the end surface 410ef of the second end 410e2 is not melted by welding, which prevents the first welded portion 81 from expanding in a direction perpendicular to the center line 410c of the second end 410e2 and prevents short circuits from occurring between adjacent straight pin members 412 in the Y direction and between adjacent bent pin members 410 in the Y direction.

[0113] The above-described preferable configuration and effects also apply to the connection portion between the straight pin member 412 and the bent pin member 410, which is located radially outward of the core 3. The above-described preferable configuration and effects also apply to the connection portion between the straight pin member 422 and the bent pin member 420 in the second coil 42.

[0114] 7, the outer surface of the conductor portion 412a of the straight pin member 412 is preferably not covered with a coating. With this configuration, there is no need to cover the conductor portion 412a of the straight pin member 412 with a coating, which makes it easy to manufacture the straight pin member 412. This preferable configuration and effect also apply to the outer surfaces of the straight pin member 422, the outer surface of the outermost straight pin member 411, and the outer surface of the outermost straight pin member 421.

[0115] (Method of Manufacturing Inductor Component) Next, a method of manufacturing the inductor component 1 will be described.

[0116] The manufacturing method of the inductor component 1 includes the steps of assembling the straight pin members 412, 422 and the bent pin members 410, 420 so that the end face of the first end of the straight pin member 412, 422 faces the peripheral surface of the second end of the bent pin member 410, 420 and the side face of the wall portion provided on the end face of the first end and protruding in the direction of the center line of the first end faces the end face of the second end, and connecting the first end of the straight pin member 412, 422 to the second end of the bent pin member 410, 420. This configuration facilitates the assembly of the straight pin members 412, 422 and the bent pin members 410, 420.

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

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

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

[0120] Here, an example of a laser irradiation method will be described. FIG. 13 is a diagram showing an example of the relationship between laser irradiation time and laser output. As shown in FIG. 13, after irradiating the wall portion with a laser, it is preferable to reduce the laser output to a range of 60% to 80% once the wall portion begins to melt. This reduces the amount of heat transferred to the bending pin member compared to when the laser output is maintained at 100%. When the pin member is made of Cu, it easily reflects the laser (reflectivity: 90% to 95%). When the pin member melts and becomes liquid, the reflectivity drops to 60% to 70%, making it easier to absorb the laser. This allows the laser output to be reduced.

[0121] The laser may be continuously irradiated on the same location on the wall, or after irradiating the wall, the laser may be scanned outward in the extension direction of the straight pin member. A stable weld can be obtained by shifting (scanning) the laser irradiation position toward the end face of the bent pin member after melting of the wall begins. Melting a portion of the bent pin member with the laser can more reliably achieve electrical and mechanical connections. In this case, it is preferable to limit the amount of heat input to the bent pin member while ensuring the area of ​​the melted portion. Specifically, it is preferable to at least not melt the portion of the outer periphery of the end face of the bent pin member that is located in the protruding direction of the wall. In contrast, if the entire end face of the bent pin member melts, the weld may bulge, potentially causing a short circuit between adjacent pin members.

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

[0123] 12A , when soldering is used instead of welding to connect the pin members, solder may be applied to cover the wall portion 412w after assembling the straight pin member 412 to the bent pin member 410. Alternatively, when a conductive adhesive member is used instead of welding to connect the pin members, the conductive adhesive member may be attached to at least a portion of the end face 410ef of the bent pin member 410 beforehand, and then the straight pin member may be assembled to the bent pin member.

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

[0125] 6, the liquid resin member 90 is filled into the recess 215 by, for example, a potting method. At this time, the liquid resin member 90 remains in the recess 215 and spreads to wet the conductor portions of the coils 41 and 42 that are exposed from the coating and to a portion of the core cover 60. The liquid resin member 90 is also filled into the opening 216 of the bottom plate portion 21. To prevent the liquid resin member 90 from leaking from the opening 216, tape is attached to the second main surface 210b of the bottom portion 210 so as to close the opening 216.

[0126] Heat is then applied to harden the liquid resin member 90. This allows the core 3 and coils 41, 42 to be fixed to the bottom plate portion 21 by the resin member 90, and also allows the resin member 90 to cover the conductor portions of the coils 41, 42 that are exposed from the coating. The resin member 90 also fills the opening 216. A thermosetting epoxy resin is used as the material for the resin member 90, and at this time, the elastic modulus is 7 GPa. The resin member 90 is hardened by heating at 120°C for 30 minutes.

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

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

[0129] According to the above configuration, the first ends of the straight pin members 412, 422 and the second ends of the bent pin members 410, 420 are connected by welding, which reduces the occurrence of cracks and ensures long-term reliability of the connection, compared to when the first and second ends are connected by soldering, etc. Furthermore, the size of the connection can be made smaller than when the first and second ends are mechanically connected by crimping, etc., allowing the coils 41, 42 to be made smaller.

[0130] Furthermore, because the laser is irradiated onto the wall portions of the straight pin members 412, 422, it is possible to prevent the laser from being irradiated onto portions of the bending pin members 410, 420 other than the portions to be welded, which would cause damage such as burning to those portions. In contrast, if the end face of the first end does not have a wall portion and the end face of the first end faces and the peripheral surface of the second end face face each other, and the laser is irradiated onto the portion between those end faces and the peripheral surface, the laser may pass between those end faces and the peripheral surface, causing the laser to be irradiated onto portions of the bending pin members 410, 420 other than the portions to be welded, which could cause damage such as burning to those portions.

[0131] Furthermore, because the laser is irradiated onto the wall portions of the straight pin members 412, 422, the amount of heat generated in the bent pin members 410, 420 during laser irradiation can be made smaller than the amount of heat generated in the straight pin members 412, 422. As a result, thermal damage that may occur to the bent pin members 410, 420 can be reduced, and breakage of the bent pin members 410, 420 can be suppressed. In particular, when the bent pin members 410, 420 have coatings 410b, 420b, deterioration and breakage of the coatings 410b, 420b due to heat can be suppressed. Furthermore, the distance between the ends of the coatings 410b, 420b and the welded portion can be shortened, further ensuring the insulation of the bent pin members 410, 420.

[0132] When the wire diameter of the pin members is increased to allow a large current to flow through the coils 41 and 42, the thermal energy required for welding also increases, resulting in a large amount of heat during welding. For example, for extra-thick wire (wire diameter φ1 mm or greater), 500 W or several kW laser, TIG, or resistance welding is used. In this case, the heat generated during welding can easily deteriorate or damage the coatings 410 b and 420 b of the bent pin members 410 and 420 near the joint. In contrast, with the above-described configuration, the amount of heat generated can be greater on the straight pin members 412 and 422 side than on the bent pin members 410 and 420 side.

[0133] 12A , in the assembling process, it is preferable that a part of the end surface 410ef of the second end 410e2 does not overlap with the wall portion 412w when viewed from the direction of the center line 410c of the second end 410e2 of the bent pin member 410. The same applies to the connection portion between the straight pin member 422 on the second coil 42 side and the bent pin member 420.

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

[0135] Furthermore, when viewed from the center line direction of the second end of the bending pin member 410, 420, the area of ​​the portion of the end face of the second end facing the side surface of the wall can be made smaller than when the entire end face of the second end overlaps the wall. This further reduces the amount of heat transferred to the bending pin member 410, 420, further preventing damage to the bending pin member 410, 420. In particular, when the bending pin member 410, 420 has the coating 410b, 420b, deterioration and damage of the coating 410b, 420b due to heat can be further prevented.

[0136] 12A , the following formulas are preferably satisfied in the assembly process: y≦(2 / 3)x+(19 / 3) 25≦x≦70 20≦y≦50 where, x=(thickness t1 of wall portion 412w in the direction of center line 410c of second end portion 410e2) / (thickness t2 of first end portion 412e1 in the direction of center line 410c of second end portion 410e2)×100 y=(length L1 of wall portion 412w in the direction of center line 412c of first end portion 412e1) / (length L2 of end face 410ef of second end portion 410e2 in the direction of center line 412c of first end portion 412e1)×100 Note that, hereinafter, the above x is also referred to as the “thickness ratio” of the wall portion, and the above y is also referred to as the “length ratio” of the wall portion.

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

[0138] According to the above configuration, the thickness t1 and length L1 of the wall portion 412w are appropriately controlled, which further reduces the amount of heat transferred to the bent pin member 410 when the wall portion 412w is irradiated with a laser. This further reduces damage to the bent pin member 410. In particular, when the bent pin member 410 has a coating 410b, this further reduces deterioration and damage of the coating 410b due to heat. The above configuration and effects also apply to the connection portion between the straight pin member 412 and the bent pin member 410 on the radially outer side of the core 3, and the connection portion between the straight pin member 422 on the second coil 42 side and the bent pin member 420.

[0139] Preferably, the following formula is further satisfied: (13 / 15)x-(83 / 3)≦y

[0140] According to the above configuration, the thickness and length of the wall portions are appropriately controlled, allowing for stable assembly of the straight pin members 412, 422 to the bent pin members 410, 420. In contrast, if (13 / 15)x - (83 / 3) > y, the wall thickness increases and the wall length decreases. As a result, the area of ​​the portion of the outer surface of the second end of the bent pin member 410, 420 facing the first end of the straight pin member 412, 422 decreases, which may make it difficult to stably assemble the straight pin members 412, 422 to the bent pin members 410, 420.

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

[0142] In the following, we will explain the configuration of the connection portion of the pin member located radially inside the core 3 in the first coil 41, but since the connection portion of the pin member located radially outside the core 3 and the connection portion of the pin member in the second coil 42 have the same configuration, we will omit the explanation.

[0143] 14 and 15 , in the assembling process, the end face 412ef of the first end 412e1 of the straight pin member 412A is preferably shaped to follow the circumferential surface 410cf of the second end 410e2 of the bent pin member 410. Specifically, when viewed from the Z direction, the end face 412ef of the first end 412e1 is shaped like an arc so as to follow the circular shape of the circumferential surface 410cf of the second end 410e2. This allows the end face 412ef to come into surface contact with the circumferential surface 410cf when the straight pin member 412A is assembled to the bent pin member 410.

[0144] According to the above configuration, even when the straight pin member 412A is moved in a direction (Y direction) perpendicular to the center line 412c of the first end 412e1 of the straight pin member 412A and parallel to the end face 410ef of the second end 410e2 of the bent pin member 410 to assemble the straight pin member 412A to the bent pin member 410, the end face 412ef of the first end 412e1 is shaped to follow the peripheral surface 410cf of the second end 410e2, making it easy to position the straight pin member 412A in that direction.

[0145] (Second Modification of Manufacturing Method of Inductor Component) Next, a second modification of the manufacturing method of the inductor component 1 will be described. FIG. 16 is a perspective view of a straight pin member 412B in the second modification, seen from below. FIG. 17 is a perspective view of a straight pin member 412B in the second modification, seen from above. FIG. 18 is a perspective view of a bottom portion of a connection portion between the straight pin member 412B and the bent pin member 410 in the second modification. FIGS. 16 to 18 show the state immediately after the straight pin member 412B is assembled to the bent pin member 410, that is, the state before the bent pin member 410 and the straight pin member 412B are connected by, for example, welding. FIG. 18 also shows the connection portion located radially inner among the connection portions between the straight pin member 412B and the bent pin member 410 located radially inner and outer sides of the core 3.

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

[0147] An end face 412ef of the first end 412e1 of the straight pin member 412B is shaped to follow the circumferential surface 410cf of the second end 410e2 of the bent pin member 410. Specifically, when viewed from the Z direction, the end face 412ef is shaped like an arc so as to follow the circular shape of the circumferential surface 410cf.

[0148] According to the above configuration, the wall portion 412w has a plurality of separate protrusions P. The volume of each protrusion P is smaller than the volume of the wall when the plurality of protrusions P are integrated, so the heat capacity of each protrusion P can be smaller than the heat capacity of the wall portion. This shortens the laser irradiation time for each protrusion P, and reduces the amount of heat imparted to each protrusion P, thereby reducing the amount of heat transferred to the bending pin member 410. As a result, damage to the bending pin member 410 can be suppressed. In particular, when the bending pin member 410 has a coating 410b, deterioration and damage of the coating 410b due to heat can be suppressed.

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

[0150] According to the above configuration, the amount of heat transferred to the bending pin member 410 can be reduced compared to when the first laser irradiation step and the second laser irradiation step are performed consecutively without providing a cooling step. As a result, damage to the bending pin member 410 can be further suppressed. In particular, when the bending pin member 410 has a coating 410b, deterioration and damage of the coating 410b due to heat can be further suppressed.

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

[0152] The laser may also be irradiated onto the crotch portion of the wall portion 412w located between adjacent protrusions P. This can further increase the mechanical strength of the connection portion. Alternatively, the laser may be irradiated onto each of the multiple protrusions P simultaneously, or a laser with a large spot diameter may be used to irradiate multiple protrusions P at once. This allows the straight pin member 412B and the bent pin member 410 to be connected in an even shorter time.

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

[0154] 19 , the first weld 81C further connects the end surface 412ef of the first end 412e1 of the straight pin member 412 and the circumferential surface 410cf of the second end 410e2 of the bent pin member 410. Specifically, a portion of the first weld 81C exists at the contact portion between the end surface 412ef of the first end 412e1 and the circumferential surface 410cf of the second end 410e2.

[0155] According to the above configuration, the cross-sectional area (connection cross-sectional area; joint cross-sectional area) of the connection between the first end 412e1 and the second end 410e2 is increased, thereby enhancing the mechanical strength. As a result, the reliability of the connection is improved. Furthermore, the electrical resistance of the connection is reduced, allowing a large current to flow through the coils 41 and 42.

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

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

[0158] As shown in Figures 20 and 21 , the first coil 41D includes a plurality of bending pin members 410D. The bending pin members 410D are fixed to one another and spirally wound around the core 3. The bending pin members 410D are connected in series by, for example, laser welding or spot welding, and are spirally wound around the core 3. Note that solder or a conductive adhesive may be used instead of welding. Also, Figures 20 and 21 do not depict the bending pin members 410D in an actual welded state, but rather depict the bending pin members 410D in an assembled state.

[0159] The bent pin member 410D is not a printed wiring but is, for example, a copper wire. The copper wire is preferably a coated copper wire. In a cross section perpendicular to the extension direction of the core 3, the bent pin member 410D has a length equivalent to one circumferential turn that passes through the first end face 301, the second end face 302, the inner peripheral surface 303, and the outer peripheral surface 304 of the core 3, and constitutes one turn of the first coil 41D.

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

[0161] In two adjacent bent pin members 410D, 410D, a first end 414e of the fourth side 414 of one bent pin member 410D (hereinafter, sometimes referred to as the "first bent pin member 4101" and an example of the "first wire member" in the claims) on the first side 411 side is connected to a second end 411e of the first side 411 of the first side 414 of the other bent pin member 410D (hereinafter, sometimes referred to as the "second bent pin member 4102" and an example of the "second wire member" in the claims), and the multiple bent pin members 410D are spirally wound around the core 3. As a result, each of the multiple bent pin members 410D forms one turn, which reduces the number of connections required to form one turn when attaching the first coil 41D to the core 3. This facilitates the attachment of the first coil 41D to the core 3. The bent pin member 410D is formed by bending a straight wire rod at three positions.

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

[0163] Like the first coil 41D, the second coil 42D includes multiple bending pin members 420D. The multiple bending pin members 420D are fixed to each other and spirally wound around the core 3. The multiple bending pin members 420D are connected in series by welding, such as laser welding or spot welding, and are spirally wound around the core 3. The bending pin member 420D constitutes one turn of the second coil 42D. The bending pin member 420D has a first side portion 421 facing the inner circumferential surface 303 of the core 3, a second side portion 422 facing the first end face 301 of the core 3, a third side portion 423 facing the outer circumferential surface 304 of the core 3, and a fourth side portion 424 facing the second end face 302 of the core 3. With this, since each of the plurality of bent pin members 420D constitutes one turn, it is possible to reduce the number of connection points for forming one turn when attaching the second coil 42D to the core 3. This facilitates the attachment of the second coil 42D to the core 3. The bent pin members 420D are formed by bending a straight wire rod at three locations.

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

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

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

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

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

[0169] According to the above configuration, the end face 414ef of the first end 414e of the first folding pin member 4101 faces the circumferential surface 411cf of the second end 411e of the second folding pin member 4102, which makes it easy to position the first folding pin member 4101 in the direction of the center line 414c of the first end 414e when assembling the first folding pin member 4101 to the second folding pin member 4102. Furthermore, the side surface 414wf of the wall portion 414w in the direction perpendicular to the center line 414c of the first end 414e faces the end face 411ef of the second end 411e, which makes it easy to position the first folding pin member 4101 in the direction of the center line 411c of the second end 411e when assembling the first folding pin member 4101 to the second folding pin member 4102. As described above, the first bending pin member 4101 can be positioned using two surfaces: the end surface 414ef of the first end portion 414e and the side surface 414wf of the wall portion 414w, thereby facilitating the assembly work of the first bending pin member 4101 and the second bending pin member 4102.

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

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

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

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

[0174] Shape of straight pin member: Shape shown in Fig. 18 Shape of bent pin member: Shape shown in Fig. 18 (wire diameter: 2 mm) Welding position and laser output: Constant (1700 W level) Position of coating (i.e., position of the end of the coating of the bent pin member on the laser irradiation side): Position 3.8 mm away from the bottom surface of the straight pin member (i.e., the surface facing the reverse Z direction in the straight pin member in Fig. 18; irradiation surface) Softening temperature of coating: 413°C

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

[0176]

[0177]

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

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

[0180] It has also been found that the connection stability of the pin member can be further improved by further satisfying the following formula: (13 / 15)x-(83 / 3)≦y

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

[0182] REFERENCE SIGNS LIST 1 inductor component 2 case 21 bottom plate portion 210 bottom portion 210a first main surface 210b second main surface 211 side wall portion 215 recess 216 opening 22 box portion 3 core 301 first end surface (lower surface) 302 second end surface (upper surface) 303 inner circumferential surface 304 outer circumferential surface 41, 41A, 41B, 41D first coil 410, 410D bent pin member (second wire member) 410a conductor portion 410b coating 410c, 412c center line 410cf circumferential surface of bent pin member 410e2 second end portion of bent pin member 410ef end surface of bent pin member 4101 first bent pin member (first wire member) 4102 Second bent pin member (second wire member) 412, 412A, 412B Straight pin member (first wire member) 411a, 412a Conductor portion 412e1 First end of straight pin member 412e2 Second end of straight pin member 412ef End face of straight pin member 412w, 412wB, 414w Wall portion 412wf Side face of wall portion 42, 42D Second coil 420, 420D Bent pin member (second wire member) 420a Conductor portion 420b Coating 411, 421 Endmost straight pin member (first wire member) 422 Straight pin member (first wire member) 421a, 422a Conductor portion 51 to 54 First to fourth electrode terminals 60 Core covers 81 to 84 First to fourth welded portions 90 Resin member L: Inductor element L1: Length of wall portion L2: Length of end face of bent pin member L3: Length of first exposed region L4: Length of second exposed region P: Convex portion R1, R2: First and second exposed regions t1: Thickness of wall portion t2: Thickness of straight pin member VL1, VL2: Virtual line

Claims

1. a coil including a plurality of wire members; In adjacent wire members, a first end of a first wire member and a second end of a second wire member are connected to each other, and the plurality of wire members form a spiral of the coil; A wall portion protruding in a center line direction of the first end portion is provided on an end surface of the first end portion, An end surface of the first end portion faces a peripheral surface of the second end portion, An inductor component, wherein a side surface of the wall portion in a direction perpendicular to a center line direction of the first end portion faces an end face of the second end portion.

2. the coil has a welded portion at which a portion of the first end and a portion of the second end are welded to each other, The inductor component according to claim 1 , wherein the welded portion connects an end face of the second end portion and a side face of the wall portion.

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

4. The inductor component according to claim 2 , wherein a portion of an end face of the second end portion does not overlap the welded portion when viewed from a center line direction of the second end portion.

5. The first wire member includes at least a conductor portion, the second wire member includes a conductor portion and a coating covering a part of an outer surface of the conductor portion of the second wire member, an outer surface of the first wire member has a first exposed region in which the conductor portion of the first wire member is exposed from an end face of the first end portion toward a center line direction of the first end portion; an outer surface of the second wire member has a second exposed region in which the conductor portion of the second wire member is exposed from an end face of the second end portion toward a center line direction of the second end portion; 4. The inductor component according to claim 1, wherein a maximum length of the second exposed region in a center line direction of the second end portion is shorter than a maximum length of the first exposed region in a center line direction of the first end portion.

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

7. a step of assembling a first wire member and a second wire member, in which an end face of a first end of a first wire member faces a peripheral surface of a second end of a second wire member, and a side face of a wall portion provided on the end face of the first end and protruding in a center line direction of the first end faces an end face of the second end, in adjacent wire members; connecting the first end of the first wire member and the second end of the second wire member.

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

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

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

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

12. The connecting step includes: a first laser irradiation step of irradiating one of the plurality of convex portions with a laser; The method for manufacturing an inductor component according to claim 10 , further comprising: a second laser irradiation step of irradiating another convex portion with a laser beam subsequent to the first laser irradiation step.

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

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

15. The method for manufacturing an inductor component according to claim 14, further comprising satisfying the following formula: (13 / 15)x-(83 / 3)≦y

16. 10. The method for manufacturing an inductor component according to claim 7, wherein in the assembling step, an end face of the first end portion is shaped to conform to a peripheral surface of the second end portion.