Coil component and method for manufacturing same

Abstract

Provided is a coil component in which power consumption is significantly reduced by reducing thermal load. The coil component comprises an annular core, a core cover portion covering at least a part of the core, and a coil wound around the core and the core cover portion. The core has a first end face and a second end face opposing each other in a central axis direction. The core cover portion includes a first part opposing the first end face. The first part includes a protruding portion on a first face thereof opposite the first end face. The coil includes a plurality of linear pin members and a plurality of bent pin members. The linear pin members and the bent pin members are alternately connected to form the spiral of the coil. The plurality of linear pin members include a furthest-end linear pin member positioned at least at one furthest end in the axial direction of the coil. The furthest-end linear pin member opposes the first face of the first part. A first end portion of the furthest-end linear pin member is in contact with the protruding portion. A second end portion of the furthest-end linear pin member is spaced apart from the first face and is connected to the bent pin member.

Description

Coil component and manufacturing method thereof

[0001] The present disclosure relates to a coil component and a method for manufacturing the same.

[0002] A conventional coil component is described in Japanese Patent Laid-Open Publication No. 2021-150314 (Patent Document 1). This coil component includes an annular core, a resin cap that covers a portion of the core, and a coil wound around the core and the cap. The coil includes a plurality of straight pin members and a plurality of bent pin members, and the straight pin members and the bent pin members are alternately connected to form a spiral coil. The plurality of straight pin members includes an endmost straight pin member located at the axial end of the coil.

[0003] Japanese Patent Application Laid-Open No. 2021-150314

[0004] However, in the conventional coil component, the most distal straight pin member is connected to the bent pin member in a cantilevered state, which may cause the posture of the most distal straight pin member to become unstable, resulting in an unstable connection between the most distal straight pin member and the bent pin member, which may reduce the reliability of the connection between the most distal straight pin member and the bent pin member.

[0005] For example, when assembling the coil, the second end of the outermost straight pin member is connected to the bent pin member by welding or the like without restraining the first end of the outermost straight pin member, which means that the outermost straight pin member is connected to the bent pin member in an unstable position, which may reduce the reliability of the connection between the outermost straight pin member and the bent pin member.

[0006] Therefore, an object of the present disclosure is to provide a coil component that can improve the connection reliability between the outermost straight pin member and the bent pin member, and a method for manufacturing the same.

[0007] In order to solve the above problem, a coil component according to one aspect of the present disclosure comprises: an annular core; a core cover portion covering at least a portion of the core; and a coil wound around the core and the core cover portion; the core has a first end face and a second end face that face each other in a central axis direction; the core cover portion has a first portion that faces the first end face, and the first portion has a protrusion portion on a first face opposite the first end face; the coil includes a plurality of straight pin members and a plurality of bent pin members, and the straight pin members and the bent pin members are alternately connected to form a spiral of the coil, and the plurality of straight pin members include an endmost straight pin member that is located at an end on at least one side of the coil in the axial direction, and the endmost straight pin member faces the first face of the first portion, a first end of the endmost straight pin member contacts the protrusion portion, and a second end of the endmost straight pin member is spaced from the first face and connected to the bent pin member.

[0008] According to the above aspect, the most distal straight pin member faces the first surface of the first portion, the first end of the most distal straight pin member contacts the protrusion, and the second end of the most distal straight pin member is connected to the bent pin member away from the first surface. This allows the first end of the most distal straight pin member to be supported by the protrusion, and the second end of the most distal straight pin member to be supported by the bent pin member. In other words, the most distal straight pin member is connected to the bent pin member in a doubly supported beam state. This stabilizes the posture of the most distal straight pin member, and stabilizes the connection between the most distal straight pin member and the bent pin member. This improves the connection reliability between the most distal straight pin member and the bent pin member.

[0009] For example, when assembling the coil, the second end of the most distal straight pin member can be connected to the bent pin member by welding or the like while the first end of the most distal straight pin member is supported by the protrusion, so that the most distal straight pin member can be connected to the bent pin member in a stable position, thereby improving the connection reliability between the most distal straight pin member and the bent pin member.

[0010] Furthermore, since the second end of the most distal straight pin member is spaced apart from the first surface, the heat generated when connecting the most distal straight pin member and the bent pin member by welding or the like is less likely to be transmitted to the core cover portion, thereby reducing deterioration of the core cover portion due to heat.

[0011] Preferably, in one embodiment of the coil component, the coil component further includes an electrode terminal connected to the coil, and the endmost straight pin member is connected to the electrode terminal.

[0012] According to the embodiment, the outermost straight pin member is connected to the electrode terminal. This stabilizes the posture of the outermost straight pin member, thereby stabilizing the connection between the outermost straight pin member and the electrode terminal. This improves the connection reliability between the outermost straight pin member and the electrode terminal.

[0013] Preferably, in one embodiment of the coil component, the first end of the outermost straight pin member is connected to the electrode terminal.

[0014] According to the embodiment, the first end of the most distal straight pin member is connected to the electrode terminal while being supported by the protrusion. This allows the electrode terminal to be connected to the first end in a stable position, thereby making the connection between the most distal straight pin member and the electrode terminal more stable. Furthermore, when connecting the electrode terminal to the first end of the most distal straight pin member by welding or the like, the protrusion can withstand the pressing force applied to the first end, thereby reducing the load on the first end.

[0015] Preferably, in one embodiment of the coil component, the protrusion overlaps the electrode terminal when viewed in a direction perpendicular to the first surface.

[0016] According to the above embodiment, the electrode terminal is connected to the first end of the most distal straight pin member in a more stable position, which makes the connection between the most distal straight pin member and the electrode terminal more stable. Furthermore, when connecting the electrode terminal to the first end of the most distal straight pin member by welding or the like, the load caused by the pressing force on the first end can be further reduced.

[0017] Preferably, in one embodiment of the coil component, the second end of the outermost straight pin member is connected to the electrode terminal.

[0018] According to the above embodiment, the second end of the most distal straight pin member is spaced apart from the first surface. This makes it difficult for heat generated when connecting the most distal straight pin member and the electrode terminal by welding or the like to propagate to the core cover portion, thereby reducing deterioration of the core cover portion due to heat.

[0019] Preferably, in one embodiment of the coil component, the protrusion is spaced apart from the electrode terminal when viewed in a direction perpendicular to the first surface.

[0020] According to the above embodiment, the amount of heat generated when connecting the outermost straight pin member and the electrode terminal by welding or the like is less likely to be transmitted by the protrusion and less likely to be transmitted by the core cover.

[0021] Preferably, in one embodiment of the coil component, the outermost straight pin member and the electrode terminal are connected by welding.

[0022] According to the embodiment, the outermost straight pin member and the electrode terminal are connected by welding, which improves the connection strength compared to connections made by soldering.

[0023] Preferably, in one embodiment of the coil component, the coil component further includes a mounting base portion to which the electrode terminal is attached, and the core cover portion and the mounting base portion are integrally molded into one piece.

[0024] According to the embodiment, since the core cover and the mounting base are integrated, the core housed in the core cover is supported by the mounting base, and the position of the core is stabilized. In addition, the number of parts constituting the coil component can be reduced, thereby simplifying the manufacturing process of the coil component.

[0025] Preferably, in one embodiment of the method for manufacturing a coil component, the method comprises the steps of: accommodating an annular core in a core cover portion so that a first end face located in the central axial direction of the core is covered; arranging a plurality of straight pin members and a plurality of bent pin members around the core and the core cover portion so that an end of each straight pin member and an end of each bent pin member are located on a first surface side of the core cover portion opposite the first end face; and connecting the end of each straight pin member to the end of each bent pin member to form a coil in which the straight pin members and the bent pin members are alternately connected, wherein the step of arranging the straight pin members and the bent pin members includes: facing an endmost straight pin member located at an end on at least one side of the axial direction of the coil among the plurality of straight pin members to the first surface; and bringing a first end of the endmost straight pin member into contact with a protrusion provided on the first surface, The process of forming the coil includes supporting the first end of the outermost straight pin member on the protrusion portion, and separating the second end of the outermost straight pin member from the first surface and connecting it to the bent pin member.

[0026] According to the above embodiment, the second end of the most distal straight pin member can be connected to the bent pin member while the first end of the most distal straight pin member is supported by the protrusion, and the most distal straight pin member can be connected to the bent pin member in a stable position, thereby improving the connection reliability between the most distal straight pin member and the bent pin member.

[0027] Furthermore, since the second end of the most distal straight pin member is spaced apart from the first surface, the heat generated when connecting the most distal straight pin member and the bent pin member by welding or the like is less likely to be transmitted to the core cover portion, thereby reducing deterioration of the core cover portion due to heat.

[0028] Preferably, in one embodiment of the method for manufacturing a coil component, the method further comprises the step of connecting an electrode terminal to the outermost straight pin member and connecting the electrode terminal to the coil.

[0029] According to the embodiment, the outermost straight pin member is connected to the electrode terminal. This stabilizes the posture of the outermost straight pin member, thereby stabilizing the connection between the outermost straight pin member and the electrode terminal. This improves the connection reliability between the outermost straight pin member and the electrode terminal.

[0030] Preferably, in one embodiment of the method for manufacturing a coil component, the step of forming the coil includes connecting the ends of each straight pin member and each bent pin member while fitting the straight pin members and each bent pin member into grooves of a jig.

[0031] According to the above embodiment, the straight pin members and the bent pin members can be connected while being positioned, thereby improving the reliability of the connection between the straight pin members and the bent pin members.

[0032] Preferably, in one embodiment of the method for manufacturing a coil component, the step of forming the coil includes connecting the ends of each of the straight pin members and the ends of each of the bent pin members while exposing the ends of each of the straight pin members and the ends of each of the bent pin members from the hole portion of the jig.

[0033] According to the embodiment, all of the straight pin members and all of the bent pin members can be connected in one step while the jig remains attached.

[0034] Preferably, in one embodiment of the manufacturing method of a coil component, the step of forming the coil includes connecting an end of each of the straight pin members and each of the bent pin members with an end of each of the straight pin members while fitting the straight pin members and each of the bent pin members into grooves of a jig, and the step of connecting the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while inserting a positioning protrusion of the jig into a slit of the electrode terminal.

[0035] According to the above embodiment, the straight pin members and the bent pin members can be connected while being positioned, thereby improving the connection reliability between the straight pin members and the bent pin members. Also, the electrode terminals can be connected to the outermost straight pin members while being positioned, thereby improving the connection reliability between the outermost straight pin members and the electrode terminals.

[0036] Preferably, in one embodiment of the method for manufacturing a coil component, the step of forming the coil includes connecting an end of each of the straight pin members and an end of each of the bent pin members while exposing the end of each of the straight pin members and the end of each of the bent pin members from a hole portion of the jig, and the step of forming the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while exposing the endmost straight pin member and the electrode terminal from the hole portion of the jig.

[0037] According to the embodiment, the connection between the straight pin member and the bent pin member and the connection between the outermost straight pin member and the electrode terminal can be performed in one step while the jig remains attached.

[0038] According to the coil component and the manufacturing method thereof according to one aspect of the present disclosure, the connection reliability between the outermost straight pin member and the bent pin member can be improved.

[0039] 10 is a top perspective view showing a coil component of a first embodiment; FIG. 11 is a bottom perspective view of the coil component; FIG. 12 is a bottom perspective view showing the interior of the coil component; FIG. 13 is an exploded perspective view of the coil component; FIG. 14 is a schematic cross-sectional view of the coil component; FIG. 15 is a cross-sectional view taken along line VI-VI of FIG. 1; FIG. 16 is an top perspective view of a connection portion between an endmost straight pin member and a bent pin member in a first coil; FIG. 17 is a top perspective view of a base case; FIG. 18 is a bottom perspective view of the coil component excluding a bottom plate portion; FIG. 19 is a cross-sectional view taken along line XI-XI of FIG. 10; FIG. 19 is a perspective view of a jig used in a manufacturing method for a coil component; and FIG. 20 is a bottom view showing a state in which the jig is used in a manufacturing method for a coil component. FIG. 21 is a perspective view in which the core and base case are omitted from FIG.

[0040] Hereinafter, a coil component and a method for manufacturing the same according to an aspect of the present disclosure will be described in detail with reference to the illustrated embodiments. Note that the drawings include some schematic views and may not reflect actual dimensions or proportions.

[0041] (First embodiment) (Overall configuration of coil component) Fig. 1 is an upper perspective view showing a coil component according to one embodiment of the present invention. Fig. 2 is a lower perspective view of the coil component. Fig. 3 is a lower perspective view showing the interior of the coil component. Fig. 4 is an exploded perspective view of the coil component. As shown in Figs. 1 to 4, the coil component 1 has an annular core 3, a base case 22 that covers at least a portion of the core 3, a first coil 41 and a second coil 42 wound around the core 3 and the base case 22, first to fourth electrode terminals 51 to 54 attached to the base case 22, and a bottom plate portion 21 attached to the base case 22. The coil component 1 is, for example, a common mode choke coil.

[0042] The base case 22 and the bottom plate 21 are made of a material that is strong and heat-resistant, preferably a flame-retardant material. The base case 22 is made of a resin such as PPS (polyphenylene sulfide), LCP (liquid crystal polymer), or PPA (polyphthalamide), or ceramics.

[0043] The base case 22 has a core cover part 60 that covers at least a part of the core 3, a first mounting base part 71 to which the first and third electrode terminals 51, 53 are attached, and a second mounting base part 72 to which the second and fourth electrode terminals 52, 54 are attached. The core cover part 60, the first mounting base part 71, and the second mounting base part 72 are an integrated, one-piece molded product.

[0044] The core cover part 60 is an annular container body. Specifically, the core cover part 60 has an inner peripheral part 60a, an outer peripheral part 60b, and a bottom part 60c. The core cover part 60 has an annular recessed part 61 that covers the lower part of the core 3. The annular recessed part 61 is a space surrounded by the inner peripheral part 60a, the outer peripheral part 60b, and the bottom part 60c. The core cover part 60 (annular recessed part 61) is an oval (track-shaped) annular body. The shape of the core cover part 60 may be rectangular, elliptical, or circular.

[0045] The first mounting base portion 71 and the second mounting base portion 72 are formed in the shape of a rectangular parallelepiped flange, and are located on either side of the core cover portion 60. Specifically, the first mounting base portion 71 and the second mounting base portion 72 are located radially outward from the core cover portion 60. In this embodiment, the first mounting base portion 71 and the second mounting base portion 72 are located axially outward from the annular recess 61.

[0046] The first mounting base portion 71 has slit holes 70 into which the first and third electrode terminals 51 and 53 are inserted, respectively. The second mounting base portion 72 has slit holes 70 into which the second and fourth electrode terminals 52 and 54 are inserted, respectively.

[0047] The bottom plate portion 21 has a bottom portion 210, two side wall portions 211, and a partition wall portion 212. The bottom portion 210 includes a first main surface 210a and a second main surface 210b that face each other. The two side wall portions 211 are provided on the first main surface 210a of the bottom portion 210 along each of a pair of facing sides of the bottom portion 210. The partition wall portion 212 is provided between the two side wall portions 211 on the first main surface 210a of the bottom portion 210. The bottom plate portion 21 has a recess 215, and the recess 215 is configured to be surrounded by the bottom portion 210, the side wall portion 211, and the partition wall portion 212.

[0048] The bottom plate portion 21 is attached to the bottom portion 60c side of the core cover portion 60. The bottom plate portion 21 is attached to the base case 22 so that the central axis of the core 3 is perpendicular to the first main surface 210a of the bottom portion 210. The central axis of the core 3 refers to the central axis of the inner diameter hole of the core 3. The shape of the bottom plate portion 21 is rectangular when viewed from the central axis direction of the core 3. In this embodiment, the shape of the bottom plate portion 21 is rectangular when viewed from the central axis direction of the core 3.

[0049] Here, the direction in which the first mounting base 71 and the second mounting base 72 face each other as viewed from the central axis direction of the core 3 is defined as the Y direction, the direction perpendicular to the Y direction as viewed from the central axis direction of the core 3 is defined as the X direction, and the height direction of the coil component 1, which is perpendicular to both the X and Y directions, is defined as the Z direction. The bottom plate 21 and the base case 22 are disposed facing each other in the Z direction, with the bottom plate 21 on the lower side and the base case 22 on the upper side, with the upper side being defined as the forward direction of the Z direction and the lower side being the reverse direction of the Z direction. In other words, in the height direction perpendicular to the first main surface 210a, the direction from the first main surface 210a toward the core 3 is defined as the upward direction. In this embodiment, the Y direction is the major axis direction of the core cover 60, and the X direction is the minor axis direction of the core cover 60.

[0050] The first to fourth electrode terminals 51 to 54 are attached to the base case 22. The first electrode terminal 51 and the second electrode terminal 52 are located at two corners of the base case 22 that face each other in the Y direction, and the third electrode terminal 53 and the fourth electrode terminal 54 are located at two corners of the base case 22 that face each other in the Y direction. The first electrode terminal 51 and the third electrode terminal 53 face each other in the X direction, and the second electrode terminal 52 and the fourth electrode terminal 54 face each other in the X direction.

[0051] The first and third electrode terminals 51, 53 are attached by being inserted into slit holes 70 in the first mounting base 71. The second and fourth electrode terminals 52, 54 are attached by being inserted into slit holes 70 in the second mounting base 72. Specifically, the first to fourth electrode terminals 51-54 are each a metal plate bent into a U-shape. One end of each of the first to fourth electrode terminals 51-54 is inserted into the slit hole 70 and connected to the coils 41, 42. One end of each of the first to fourth electrode terminals 51-54 has a slit portion 51a-54a. The other end of each of the first to fourth electrode terminals 51-54 is located outside the mounting bases 71, 72 and is connected to a mounting board (not shown).

[0052] A dummy terminal 55 is attached to the second main surface 210b of the bottom plate portion 21. For example, the dummy terminal 55 is adhered to the second main surface 210b with an adhesive or the like. The dummy terminal 55 is not electrically connected to the first coil 41 or the second coil 42. By providing the dummy terminal 55, when the coil component 1 is mounted on a mounting board (not shown), the dummy terminal 55 can be connected to the mounting board via solder in addition to the first to fourth electrode terminals 51 to 54. This can improve the mounting strength of the coil component 1.

[0053] The core 3 is a toroidal core, and is an oval (track-shaped) annular body when viewed from the central axis direction. When viewed from the central axis direction, the core 3 includes a pair of long portions 31 extending along the major axis and facing each other in the minor axis direction, and a pair of short portions 32 extending along the minor axis and facing each other in the major axis direction. The shape of the core 3 may be rectangular, elliptical, or circular when viewed from the central axis direction.

[0054] 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 is located on the bottom plate portion 21 side. The second end face 302 is the upper end face of the core 3. The short side portion 32 has a convex portion on the second end face 302. In other words, the region of the second end face 302 that is located at the short side portion 32 is located higher in the Z direction than the region of the second end face 302 that is located at the long side portion 31.

[0055] 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.

[0056] The core 3 is housed in the core cover part 60 of the base case 22 so that the long axis direction of the core 3 coincides with the Y direction. A portion of the core 3 on the first end face 301 side is covered by the core cover part 60. In other words, the lower portion of the core 3 is fitted into the annular recess 61 of the core cover part 60, so that the core 3 can be attached to the core cover part 60. It is sufficient that at least a portion of the core 3 on the first end face 301 side is covered by the core cover part 60, and the entire core 3 may also be covered by the core cover part 60.

[0057] The core 3 is connected to the core cover part 60 via a core adhesive member 91. The core adhesive member 91 is disposed in the annular recess 61 and bonds the first end face 301 of the core 3 and the bottom part 60c of the core cover part 60 together.

[0058] The first coil 41 and the second coil 42 are connected to the bottom plate portion 21 via a coil adhesive member 90. The coil adhesive member 90 is disposed in the recess 215 of the bottom plate portion 21 and contacts the first coil 41, the second coil 42, and the base case 22.

[0059] The first coil 41 is wound around the core 3 and the core cover part 60 between the first electrode terminal 51 and the second electrode terminal 52. One end of the first coil 41 is connected to the first electrode terminal 51. The other end of the first coil 41 is connected to the second electrode terminal 52.

[0060] The second coil 42 is wound around the core 3 and the core cover part 60 between the third electrode terminal 53 and the fourth electrode terminal 54. One end of the second coil 42 is connected to the third electrode terminal 53. The other end of the second coil 42 is connected to the fourth electrode terminal 54.

[0061] The first coil 41 and the second coil 42 are spirally wound around the core 3 and the core cover part 60 along the circumferential direction of the core 3 as viewed from the central axis direction of the core 3. Specifically, the first coil 41 is wound around one longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal axis direction of the core 3, and the second coil 42 is wound around the other longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] The multiple pin members are rod-shaped members rather than printed wiring or conductive wires. The pin members have rigidity. Specifically, in a cross section perpendicular to the circumferential direction of the core 3, the pin members are shorter than the length of one circumference of the core 3 passing through the first end face 301, the second end face 302, the inner circumferential surface 303, and the outer circumferential surface 304 of the core 3. Furthermore, the pin members have high rigidity, making them difficult to bend. The multiple pin members include multiple bent pin members 410 bent into a substantially U-shape and multiple straight pin members 411, 412 extending in a substantially straight line. The straight pin members 411, 412 and the bent pin member 410 are alternately connected to form the spiral of the first coil 41. The multiple straight pin members 411, 412 include an endmost straight pin member 411 located at the end of at least one side of the first coil 41 in the axial direction. Of the plurality of straight pin members, the straight pin members other than the outermost straight pin member 411 are referred to as normal straight pin members 412 (hereinafter simply referred to as straight pin members 412).

[0066] 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). 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.

[0067] 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.

[0068] 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.

[0069] 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 imaginary line connecting both ends of the bent pin members 410 in the extension direction extends in the X direction with a slight inclination in the Y direction when viewed from the central axis direction of the core 3. In other words, the bent pin members 410 are arranged such that a plane including the center line of the bent pin members 410 is slightly inclined in the Y direction with respect to a plane (XZ plane) perpendicular to the axial direction of the first coil 41. The straight pin members 412 are arranged parallel to each other along the first end face 301 of the core 3. The straight pin members 412 extend in the X direction. The outermost straight pin members 411 are arranged parallel to each other along the first end face 301 of the core 3. The outermost straight pin members 411 extend in a direction parallel to the straight pin members 412.

[0070] The first electrode terminal 51 is connected to one of the endmost straight pin members 411, which is connected to one end of the bent pin member 410 of the adjacent turn to the endmost straight pin member 411. A portion of the first electrode terminal 51 faces the endmost straight pin member 411, and the circumferential surface of the endmost straight pin member 411 is connected to the first electrode terminal 51. Specifically, a portion of the first electrode terminal 51 passes through the slit hole 70 of the first mounting base 71 and is connected to the circumferential surface of the endmost straight pin member 411.

[0071] The second electrode terminal 52 is connected to the other endmost straight pin member 411, which is connected to one end of the bent pin member 410 of the turn adjacent to the other endmost straight pin member 411. A portion of the second electrode terminal 52 faces the other endmost straight pin member 411, and the circumferential surface of the other endmost straight pin member 411 is connected to the second electrode terminal 52. Specifically, a portion of the second electrode terminal 52 passes through the slit hole 70 of the second mounting base 72 and is connected to the circumferential surface of the other endmost straight pin member 411.

[0072] 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.

[0073] The third electrode terminal 53 is connected to one of the endmost straight pin members 421, which is connected to one end of the bent pin member 420 of the adjacent turn to the endmost straight pin member 421. A portion of the third electrode terminal 53 faces the endmost straight pin member 421, and the circumferential surface of the endmost straight pin member 421 is connected to the third electrode terminal 53. Specifically, a portion of the third electrode terminal 53 passes through the slit hole 70 of the first mounting base 71 and is connected to the circumferential surface of the endmost straight pin member 421.

[0074] The fourth electrode terminal 54 is connected to the other endmost straight pin member 421, which is connected to one end of the bent pin member 420 of the turn adjacent to the other endmost straight pin member 421. A portion of the fourth electrode terminal 54 faces the other endmost straight pin member 421, and the circumferential surface of the other endmost straight pin member 421 is connected to the fourth electrode terminal 54. Specifically, a portion of the fourth electrode terminal 54 passes through the slit hole 70 of the second mounting base portion 72 and is connected to the circumferential surface of the other endmost straight pin member 421.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] FIG. 6 is a cross-sectional view taken along the line VI-VI of FIG. 1 . The dummy terminal 55 is omitted from the illustration. 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. 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 410.

[0079] 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.

[0080] 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.

[0081] The core cover portion 60 is located 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.

[0082] The core cover part 60 is provided over the first end face 301 of the core 3, a portion of the inner circumferential surface 303 of the core 3, and a portion of the outer circumferential surface 304 of the core 3. The core cover part 60 has an inner circumferential part 60a facing the inner circumferential surface 303 of the core 3, an outer circumferential part 60b facing the outer circumferential surface 304 of the core 3, and a bottom part 60c facing the first end face 301 of the core 3. The bottom part 60c corresponds to an example of a "first portion" recited in the claims. The bottom part 60c has a first surface 60c1 opposite the first end face 301.

[0083] The core 3 is connected to the core cover part 60 via the core adhesive member 91. By connecting the core adhesive member 91 to a part of the core 3, the stress on the core 3 received from the core cover part 60 is reduced, and deterioration of the magnetic properties of the core 3 can be suppressed. In other words, a decrease in inductance value caused by magnetostriction can be suppressed. Note that the core cover part 60 may not be connected to the core 3 via the core adhesive member 91, and may simply be fitted into the core 3.

[0084] The core adhesive member 91 is provided between the first end face 301 of the core 3 and the bottom portion 60c of the core cover portion 60. This reduces the effect of magnetostriction on the core 3 and ensures stable attachment of the core cover portion 60 to the core 3.

[0085] Soft resins such as urethane resin and silicone resin can be used as the material for the core adhesive member 91. By using such soft resin, the influence of magnetostriction can be reduced.

[0086] 6, the core adhesive member 91 is provided over the entire area between the first end face 301 of the core 3 and the bottom portion 60c of the core cover portion 60, but it may be provided only in a portion. Also, in FIG. 6, the core adhesive member 91 is provided between the first end face 301 of the core 3 and the bottom portion 60c of the core cover portion 60, but it may be provided between the inner circumferential surface 303 of the core 3 and the inner circumferential portion 60a of the core cover portion 60, or between the outer circumferential surface 304 of the core 3 and the outer circumferential portion 60b of the core cover portion 60, or may be provided in multiple locations among these.

[0087] 6 , the conductor portions of the coils 41, 42 that are exposed from the coating are disposed in the recess 215 so as to be located on the first main surface 210a side. The coil bonding member 90 is fixed in the recess 215 to bond the coils 41, 42 to the bottom plate portion 21 and cover at least a portion of the conductor portions that are exposed from the coating of the coils 41, 42. Preferably, the coil bonding member 90 covers the entire conductor portions.

[0088] The coil adhesive member 90 is made of, for example, a thermosetting resin, and is fixed to the coils 41, 42, the core cover portion 60, and the bottom plate portion 21 upon hardening. The coil adhesive member 90 contacts the inner surface of the recess 215, a portion of the inner circumferential portion 60a of the core cover portion 60, a portion of the outer circumferential portion 60b of the core cover portion 60, and a portion of the bottom portion 60c of the core cover portion 60, and covers the conductor portions 411a, 412a, 410a exposed from the coating 410b of the first coil 41 and the conductor portions 421a, 422a, 420a exposed from the coating 420b of the second coil 42. Furthermore, the coil adhesive member 90 also covers the welded portions 81 to 84 of the coils 41, 42.

[0089] Because the coil bonding member 90 is fixed in the recess 215 of the bottom plate portion 21, the coil bonding member 90 is stably fixed to the bottom plate portion 21, and as a result, the coil bonding member 90 can stably fix the coils 41, 42 to the bottom plate portion 21. In addition, because the coil bonding member 90 covers the conductor portions of the coils 41, 42 that are exposed from the coating, problems such as electrical short circuits with the outside can be prevented. Furthermore, when the coil component 1 is subjected to external forces such as vibrations and shocks, the coil bonding member 90 absorbs the shock and can protect the coils 41, 42.

[0090] Silicon resin can be used as the material for the coil adhesive member 90. By using silicon resin, it is possible to improve reflow heat resistance and mechanical strength.

[0091] (Detailed Structure of Pin Member Connection Portion) Next, a detailed structure of the connection portion between the outermost straight pin member 411 and the bent pin member 410 will be described. Fig. 7 is a top perspective view of the connection portion between the outermost straight pin member 411 and the bent pin member 410 in the first coil 41. Fig. 7 shows the state immediately after the outermost straight pin member 411 is assembled to the bent pin member 410, that is, the state before the bent pin member 410 and the outermost straight pin member 411 are connected by, for example, welding. The same applies to the connection portion between the straight pin member 412 and the bent pin member 410, and therefore a description thereof will be omitted. The same applies to the connection portion between the straight pin members 421, 422 and the bent pin member 420 in the second coil 42, and therefore a description thereof will be omitted.

[0092] 7, the cross section of the outermost straight pin member 411 is rectangular. The cross section of the outermost straight pin member 411 is not particularly limited, and may be circular, elliptical, or any other polygonal shape other than rectangular.

[0093] The end face 411ef of the second end 411e2 of the outermost straight pin member 411 is provided with a wall portion 411w that protrudes in the direction of the center line 411c of the second end 411e2. Similarly, the end face 411ef of the first end 411e1 of the outermost straight pin member 411 is provided with a wall portion 411w that protrudes in the direction of the center line 411c of the first end 411e1. Here, the center line 411c of the second end 411e2 is a line that passes through the center of gravity of the second end 411e2 in a cross section perpendicular to the extension direction (X direction) of the second end 411e2. The end face 411ef of the second end 411e2 is the outer surface located at the outermost position in the direction of the center line 411c of the second end 411e2. The same applies to the end face 411ef of the first end 411e1. The end face 411ef is perpendicular to the direction of the center line 411c of the second end 411e2. The shape of the wall portion 411w is not particularly limited, but in this embodiment, it is a rectangular parallelepiped. The wall portion 411w can be formed, for example, by pressing a part of the end surface of the second end portion 411e2 toward the center line 411c. Alternatively, the wall portion 411w can be formed, for example, by cutting a part of the end surface of the second end portion 411e2.

[0094] The position where the wall portion 411w is provided on the end face 411ef is not particularly limited, but as in this embodiment, it is preferable that the wall portion 411w is provided at the end portion on the reverse-Z direction side of the end face 411ef, and that the end face on the reverse-Z direction side of the wall portion 411w is flush with the end face on the reverse-Z direction side of the portion of the last straight pin member 411 excluding the wall portion 411w. This allows the last straight pin member 411 to be stably assembled to the bent pin member 410, and also allows the end face on the reverse-Z direction side of the last straight pin member 411 to be flat. Therefore, for example, when a laser is irradiated onto the end face for welding, the welding can be performed well without scattering the laser.

[0095] The bending pin member 410 has a circular cross section. However, the cross-sectional shape of the bending pin member 410 may be elliptical, polygonal, or the like. An end surface 410ef of a first end portion 410e1 of the bending pin member 410 is flat. The end surface 410ef is perpendicular to the center line 410c of the first end portion 410e1. Similarly, an end surface of a second end portion (not shown) of the bending pin member 410 is flat. The end surface is perpendicular to the center line of the second end portion.

[0096] The end face 411ef of the second end 411e2 of the outermost straight pin member 411 faces the peripheral surface 410cf of the first end 410e1 of the bent pin member 410. In this embodiment, a portion of the end face 411ef is in contact with the peripheral surface 410cf. Here, the center line 410c of the first end 410e1 is a line passing through the center of gravity of the first end 410e1 in a cross section perpendicular to the extension direction of the first end 410e1. The peripheral surface 410cf of the first end 410e1 is the outer surface in the circumferential direction centered on the center line of the first end 410e1. Note that the end face 411ef may be in contact with the peripheral surface 410cf via, for example, a conductive adhesive member. Among the connection portions of the multiple pin members, there may be a connection portion where the end face 411ef is not in contact with the circumferential surface 410cf, that is, the end face 411ef and the circumferential surface 410cf are separated by a space.

[0097] A side surface 411wf of the wall portion 411w in a direction perpendicular to the center line 411c of the second end portion 411e2 (forward Z direction) faces the end surface 410ef of the first end portion 410e1. In this embodiment, the side surface 411wf is in surface contact with the end surface 410ef. In other words, in this embodiment, the corner portion of the first end portion 410e1 of the bent pin member 410 is fitted into the space surrounded by the end surface 411ef of the outermost straight pin member 411 and the wall portion 411w. Here, the end surface 410ef of the first end portion 410e1 is the outer surface located outermost in the direction of the center line 410c of the first end portion 410e1. The entire side surface 411wf may be in surface contact with the end surface 410ef, or a portion of the side surface 411wf may be in surface contact with the end surface 410ef, or the side surface 411wf may be in surface contact with the end surface 410ef via, for example, a conductive adhesive member, etc. Among the connection portions of the multiple pin members, there may be connection portions where the side surface 411wf is not in surface contact with the end surface 410ef, i.e., the side surface 411wf and the end surface 410ef are separated by a space.

[0098] (Detailed Configuration of the Base Case) FIG. 8 is an upper perspective view of the base case. FIG. 9 is a lower perspective view of the base case. As shown in FIGS. 8 and 9 , the base case 22 includes a core cover portion 60 that covers at least a portion of the core 3, a first mounting base portion 71 to which the first and third electrode terminals 51, 53 are attached, and a second mounting base portion 72 to which the second and fourth electrode terminals 52, 54 are attached. The core cover portion 60, the first mounting base portion 71, and the second mounting base portion 72 are integrated into a single molded product. According to the above configuration, since the core cover portion 60 and the mounting base portions 71, 72 are integrated, the core 3 housed in the core cover portion 60 is supported by the mounting base portions 71, 72, thereby stabilizing the position of the core 3. Furthermore, since the number of components constituting the coil component 1 can be reduced, the manufacturing process for the coil component 1 can be simplified.

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

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

[0101] The first surface 60c1 has first to fourth protrusions 621 to 624. The first protrusion 621 and the second protrusion 622 are provided in the first region 60c11. The first protrusion 621 is provided on the first mounting base 71 side and on the outer periphery 60b side. In other words, the first protrusion 621 is provided on the first electrode terminal 51 side. The second protrusion 622 is provided on the second mounting base 72 side and on the inner periphery 60a side. In other words, the second protrusion 622 is provided on the second electrode terminal 52 side.

[0102] The third protrusion 623 and the fourth protrusion 624 are provided in the second region 60c12. The third protrusion 623 is provided on the first mounting base 71 side and on the outer periphery 60b side. In other words, the third protrusion 623 is provided on the third electrode terminal 53 side. The fourth protrusion 624 is provided on the second mounting base 72 side and on the inner periphery 60a side. In other words, the fourth protrusion 624 is provided on the fourth electrode terminal 54 side.

[0103] The first mounting base 71 and the second mounting base 72 are formed in the shape of a rectangular parallelepiped flange, and are located on either side of the core cover part 60. Specifically, the first mounting base 71 and the second mounting base 72 are located outside the core cover part 60 in the longitudinal direction (Y direction).

[0104] The first mounting base 71 has an inner end surface 711 facing the core cover 60, an outer end surface 712 facing the opposite side to the inner end surface 711, a bottom surface 713 connecting the inner end surface 711 and the outer end surface 712, a top surface 714 facing the opposite side to the bottom surface 713, and two first and second side surfaces 715 and 716 connecting the inner end surface 711 and the outer end surface 712 and connecting the bottom surface 713 and the top surface 714. The bottom surface 713 is the surface that faces the mounting board when the coil component 1 is mounted on the mounting board. The core cover 60 is attached to the inner end surface 711 of the first mounting base 71.

[0105] The second mounting base 72 has an inner end surface 721 facing the core cover 60, an outer end surface 722 facing the opposite side from the inner end surface 721, a bottom surface 723 facing the mounting board during mounting, a top surface 724 facing the opposite side from the bottom surface 723, and two first and second side surfaces 725 and 726 connecting the inner and outer end surfaces 721 and 722 and connecting the bottom and top surfaces 723 and 724. The bottom surface 723 is the surface that faces the mounting board when the coil component 1 is mounted on the mounting board. The core cover 60 is attached to the inner end surface 721 of the second mounting base 72.

[0106] The first mounting base portion 71 has two slit holes 70 into which the first and third electrode terminals 51, 53 are inserted, respectively. The slit holes 70 are provided so as to penetrate between the inner end face 711 and the outer end face 712. When viewed from a direction perpendicular to the outer end face 712, the slit holes 70 extend in a direction in which the first side face 715 and the second side face 716 face each other (the X direction). One slit hole 70, into which the first electrode terminal 51 is inserted, is provided on the bottom face 713 side and the first side face 715 side. The other slit hole 70, into which the third electrode terminal 53 is inserted, is provided on the bottom face 713 side and the second side face 716 side.

[0107] The second mounting base portion 72 has two slit holes 70 into which the second and fourth electrode terminals 52, 54 are inserted, respectively. The slit holes 70 are provided to penetrate the inner end face 721 and the outer end face 722. When viewed from a direction perpendicular to the outer end face 722, the slit holes 70 extend in a direction in which the first side face 725 and the second side face 726 face each other (the X direction). One slit hole 70, into which the second electrode terminal 52 is inserted, is provided on the bottom face 723 side and the first side face 725 side. The other slit hole 70, into which the fourth electrode terminal 54 is inserted, is provided on the bottom face 723 side and the second side face 726 side.

[0108] (Positional Relationship Between the Protrusion, the Endmost Straight Pin Member, and the Electrode Terminals) Fig. 10 is a bottom view of the coil component excluding the bottom plate portion. Fig. 11 is a cross-sectional view taken along line XI-XI in Fig. 10. For convenience, the first to fourth electrode terminals 51 to 54 are indicated by dashed double-dashed lines in Fig. 10.

[0109] 10 and 11 , in the first coil 41, the outermost straight pin member 411 on the first electrode terminal 51 side faces the first surface 60c1 (first region 60c11) of the bottom portion 60c. The first end 411e1 of the outermost straight pin member 411 contacts the first protrusion 621. The second end 411e2 of the outermost straight pin member 411 is spaced from the first surface 60c1 (first region 60c11) and connected to the first end 410e1 of the bent pin member 410. The first end 411e1 and the second end 411e2 each correspond to one-third of the length of the outermost straight pin member 411 in the extension direction.

[0110] According to the above configuration, the outermost straight pin member 411 faces the first surface 60c1 of the bottom portion 60c, the first end 411e1 of the outermost straight pin member 411 contacts the first protrusion 621, and the second end 411e2 of the outermost straight pin member 411 is connected to the bent pin member 410 away from the first surface 60c1. As a result, the first end 411e1 of the outermost straight pin member 411 is supported by the first protrusion 621, and the second end 411e2 of the outermost straight pin member 411 is supported by the first end 410e1 of the bent pin member 410. In other words, the outermost straight pin member 411 is connected to the bent pin member 410 in a doubly supported state. This stabilizes the posture of the outermost straight pin member 411, and stabilizes the connection between the outermost straight pin member 411 and the bent pin member 410. For example, the outermost straight pin member 411 can be kept parallel to the first surface 60c1 of the bottom portion 60c, stabilizing the posture of the outermost straight pin member 411. Therefore, the connection reliability between the outermost straight pin member 411 and the bent pin member 410 is improved.

[0111] For example, when assembling the first coil 41, the second end 411e2 of the outermost straight pin member 411 can be connected to the bent pin member 410 by welding or the like while the first end 411e1 of the outermost straight pin member 411 is supported by the first protrusion 621, thereby enabling the outermost straight pin member 411 to be connected to the bent pin member 410 in a stable position. This improves the connection reliability between the outermost straight pin member 411 and the bent pin member 410.

[0112] In addition, since the second end 411e2 of the endmost straight pin member 411 is separated from the first surface 60c1, the heat generated when connecting the endmost straight pin member 411 and the bent pin member 410 by welding or the like is less likely to be transmitted to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

[0113] 10 and 11 , the outermost straight pin member 411 is connected to the first electrode terminal 51. This stabilizes the posture of the outermost straight pin member 411, stabilizing the connection between the outermost straight pin member 411 and the first electrode terminal 51. This improves the connection reliability between the outermost straight pin member 411 and the first electrode terminal 51.

[0114] Specifically, the first end 411e1 of the outermost straight pin member 411 is connected to the first electrode terminal 51. This allows the first electrode terminal 51 to be connected to the first end 411e1 in a stable position, thereby further stabilizing the connection between the outermost straight pin member 411 and the first electrode terminal 51. Furthermore, when connecting the first electrode terminal 51 to the first end 411e1 of the outermost straight pin member 411 by welding or the like, the first protrusion 621 can bear the pressing force applied to the first end 411e1, thereby reducing the load on the first end 411e1. The amount of heat generated when connecting the outermost straight pin member 411 and the first electrode terminal 51 by welding or the like is typically smaller than the amount of heat generated when connecting the outermost straight pin member 411 and the bent pin member 410 by welding or the like, and is therefore less likely to propagate to the core cover portion 60.

[0115] Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the first protrusion 621 overlaps the first electrode terminal 51. This allows the first electrode terminal 51 to be connected to the first end 411e1 in a more stable position, thereby more stabilizing the connection between the outermost straight pin member 411 and the first electrode terminal 51. Furthermore, when connecting the first electrode terminal 51 to the first end 411e1 of the outermost straight pin member 411 by welding or the like, the load caused by the pressing force on the first end 411e1 can be further reduced.

[0116] Preferably, the outermost straight pin member 411 and the first electrode terminal 51 are connected by welding, which can improve the connection strength compared to connection by soldering.

[0117] As shown in Figure 10, in the first coil 41, the endmost straight pin member 411 on the second electrode terminal 52 side faces the first surface 60c1 (first region 60c11) of the bottom 60c, the first end 411e1 of the endmost straight pin member 411 contacts the second protrusion 622, and the second end 411e2 of the endmost straight pin member 411 is connected to the bent pin member 410 away from the first surface 60c1 (first region 60c11).

[0118] As a result, the first end 411e1 of the outermost straight pin member 411 is supported by the second protrusion 622, and the second end 411e2 of the outermost straight pin member 411 is supported by the first end 410e1 of the bent pin member 410. In other words, the outermost straight pin member 411 is connected to the bent pin member 410 in a doubly supported state. This stabilizes the posture of the outermost straight pin member 411, and stabilizes the connection between the outermost straight pin member 411 and the bent pin member 410. This improves the connection reliability between the outermost straight pin member 411 and the bent pin member 410.

[0119] In addition, since the second end 411e2 of the endmost straight pin member 411 is separated from the first surface 60c1, the heat generated when connecting the endmost straight pin member 411 and the bent pin member 410 by welding or the like is less likely to be transmitted to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

[0120] 10 , the second end 411e2 of the outermost straight pin member 411 on the second electrode terminal 52 side is connected to the second electrode terminal 52. In this way, the second end 411e2 of the outermost straight pin member 411 is spaced apart from the first surface 60c1, and therefore, heat generated when connecting the outermost straight pin member 411 and the second electrode terminal 52 by welding or the like is less likely to propagate to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

[0121] Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the second protrusion 622 is spaced apart from the second electrode terminal 52. This makes it difficult for heat generated when connecting the outermost straight pin member 411 and the second electrode terminal 52 by welding or the like to propagate through the second protrusion 622 and the core cover part 60.

[0122] Preferably, the outermost straight pin member 421 and the second electrode terminal 52 are connected by welding, which can improve the connection strength compared to connection by soldering.

[0123] As shown in Figure 10, in the second coil 42, the endmost straight pin member 421 on the third electrode terminal 53 side faces the first surface 60c1 (second region 60c12) of the bottom 60c, the first end 421e1 of the endmost straight pin member 421 contacts the third protrusion 623, and the second end 421e2 of the endmost straight pin member 421 is connected to the bent pin member 420 away from the first surface 60c1 (second region 60c12).

[0124] As a result, the first end 421e1 of the outermost straight pin member 421 is supported by the second protrusion 622, and the second end 421e2 of the outermost straight pin member 421 is supported by the first end of the bent pin member 420. In other words, the outermost straight pin member 421 is connected to the bent pin member 420 in a doubly supported state. This stabilizes the posture of the outermost straight pin member 421, and stabilizes the connection between the outermost straight pin member 421 and the bent pin member 420. This improves the connection reliability between the outermost straight pin member 421 and the bent pin member 420.

[0125] Furthermore, since the second end 421e2 of the endmost straight pin member 421 is spaced apart from the first surface 60c1, the heat generated when connecting the endmost straight pin member 421 and the bent pin member 420 by welding or the like is less likely to be transmitted to the core cover portion 60, thereby reducing deterioration of the core cover portion 60 due to heat.

[0126] As shown in FIG. 10 , the first end 421e1 of the outermost straight pin member 421 on the third electrode terminal 53 side is connected to the third electrode terminal 53. This allows the third electrode terminal 53 to be connected to the first end 421e1 in a stable position, thereby further stabilizing the connection between the outermost straight pin member 421 and the third electrode terminal 53. Furthermore, when connecting the third electrode terminal 53 to the first end 421e1 of the outermost straight pin member 421 by welding or the like, the third protrusion 623 can bear the pressing force applied to the first end 421e1, thereby reducing the load on the first end 421e1. Note that the amount of heat generated when connecting the outermost straight pin member 421 and the third electrode terminal 53 by welding or the like is typically smaller than the amount of heat generated when connecting the outermost straight pin member 421 and the bent pin member 420 by welding or the like, and is therefore less likely to propagate to the core cover portion 60.

[0127] Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the third protrusion 623 overlaps the third electrode terminal 53. This allows the third electrode terminal 53 to be connected to the first end 421e1 in a more stable position, thereby more stabilizing the connection between the outermost straight pin member 421 and the third electrode terminal 53. Furthermore, when connecting the third electrode terminal 53 to the first end 421e1 of the outermost straight pin member 421 by welding or the like, the load caused by the pressing force on the first end 421e1 can be further reduced.

[0128] Preferably, the outermost straight pin member 421 and the third electrode terminal 53 are connected by welding, which can improve the connection strength compared to connection by soldering.

[0129] As shown in Figure 10, in the second coil 42, the endmost straight pin member 421 on the fourth electrode terminal 54 side faces the first surface 60c1 (second region 60c12) of the bottom 60c, the first end 421e1 of the endmost straight pin member 421 contacts the fourth protrusion 624, and the second end 421e2 of the endmost straight pin member 421 is connected to the bent pin member 420 away from the first surface 60c1 (second region 60c12).

[0130] As a result, the first end 421e1 of the outermost straight pin member 421 is supported by the fourth protrusion 624, and the second end 421e2 of the outermost straight pin member 421 is supported by the first end of the bent pin member 420. In other words, the outermost straight pin member 421 is connected to the bent pin member 420 in a doubly supported state. This stabilizes the posture of the outermost straight pin member 421, and stabilizes the connection between the outermost straight pin member 421 and the bent pin member 420. This improves the connection reliability between the outermost straight pin member 421 and the bent pin member 420.

[0131] Furthermore, since the second end 421e2 of the endmost straight pin member 421 is spaced apart from the first surface 60c1, the heat generated when connecting the endmost straight pin member 421 and the bent pin member 420 by welding or the like is less likely to be transmitted to the core cover portion 60, thereby reducing deterioration of the core cover portion 60 due to heat.

[0132] 10 , the second end 421e2 of the outermost straight pin member 421 on the fourth electrode terminal 54 side is connected to the fourth electrode terminal 54. In this way, the second end 421e2 of the outermost straight pin member 421 is spaced apart from the first surface 60c1, and therefore, heat generated when connecting the outermost straight pin member 421 and the fourth electrode terminal 54 by welding or the like is less likely to propagate to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

[0133] Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the fourth protrusion 624 is spaced apart from the fourth electrode terminal 54. This makes it difficult for heat generated when connecting the outermost straight pin member 421 and the fourth electrode terminal 54 by welding or the like to be transmitted by the fourth protrusion 624, and therefore by the core cover part 60.

[0134] Preferably, the outermost straight pin member 421 and the fourth electrode terminal 54 are connected by welding, which can improve the connection strength compared to connection by soldering.

[0135] (Method for Manufacturing Coil Component) Next, a method for manufacturing the coil component 1 will be described.

[0136] 4, the annular core 3 is housed in the core cover portion 60 of the base case 22 so as to cover the first end face 301 located in the central axis direction of the core 3. This is called a core housing step.

[0137] 10 , the multiple straight pin members 411, 412, 421, 422 and the multiple bent pin members 410, 420 are arranged around the core 3 and the core cover part 60 so that the end of each straight pin member 411, 412, 421, 422 and the end of each bent pin member 410, 420 are positioned on the first surface 60c1 side of the core cover part 60. This is called the pin member arrangement process.

[0138] Specifically, the straight pin members 411, 412 and the bent pin member 410 of the first coil 41 are wound around the core 3 with the core cover part 60 fitted therein, and the straight pin members 421, 422 and the bent pin member 420 of the second coil 42 are wound around the core 3 so that the winding axes of the first coil 41 and the second coil 42 run parallel to each other. At this time, the respective ends of the straight pin members 411, 412 and the bent pin member 410 of the first coil 41 and the respective ends of the straight pin members 421, 422 and the bent pin member 420 of the second coil 42 are arranged on the first surface 60c1 side of the core cover part 60.

[0139] The pin member arrangement process includes: placing the endmost straight pin members 411, 421, which are located at the end of at least one side of the coils 41, 42 in the axial direction of the coils 41, 42, among the plurality of straight pin members 411, 412, 421, 422, facing the first surface 60c1; and contacting the first ends 411e1, 421e1 of the endmost straight pin members 411, 421 with the first to fourth protrusions 621 to 624 provided on the first surface 60c1.

[0140] Specifically, the first end 411e1 of the outermost straight pin member 411 on the first electrode terminal 51 side is brought into contact with the first protrusion 621. The first end 411e1 of the outermost straight pin member 411 on the second electrode terminal 52 side is brought into contact with the second protrusion 622. The first end 421e1 of the outermost straight pin member 421 on the third electrode terminal 53 side is brought into contact with the third protrusion 623. The first end 421e1 of the outermost straight pin member 421 on the fourth electrode terminal 54 side is brought into contact with the fourth protrusion 624.

[0141] Then, the ends of the straight pin members 411, 412, 421, and 422 are connected to the ends of the bent pin members 410 and 420 to form coils 41 and 42 in which the straight pin members 411, 412, 421, and 422 are alternately connected to the bent pin members 410 and 420. This is called the coil forming process.

[0142] Specifically, the first coil 41 is formed by connecting the end of each straight pin member 411, 412 to the end of each bent pin member 410. The second coil 42 is formed by connecting the end of each straight pin member 421, 422 to the end of each bent pin member 420.

[0143] The coil forming process includes supporting the first ends 411e1, 421e1 of the most distal straight pin members 411, 421 on the first to fourth protrusions 621 to 624, and then separating the second ends 411e2, 421e2 of the most distal straight pin members 411, 421 from the first surface 60c1 and connecting them to the bent pin members 410, 420.

[0144] Specifically, with the first end 411e1 of the outermost straight pin member 411 on the first electrode terminal 51 side supported by the first protrusion 621, the second end 411e2 of the outermost straight pin member 411 is spaced from the first surface 60c1 and connected to the bent pin member 410. With the first end 411e1 of the outermost straight pin member 411 on the second electrode terminal 52 side supported by the second protrusion 622, the second end 411e2 of the outermost straight pin member 411 is spaced from the first surface 60c1 and connected to the bent pin member 410. With the first end 421e1 of the outermost straight pin member 421 on the third electrode terminal 53 side supported by the third protrusion 623, the second end 421e2 of the outermost straight pin member 421 is spaced from the first surface 60c1 and connected to the bent pin member 420. With the first end 421e1 of the endmost straight pin member 421 on the fourth electrode terminal 54 side supported by the fourth protrusion 624, the second end 421e2 of the endmost straight pin member 421 is separated from the first surface 60c1 and connected to the bent pin member 420.

[0145] Then, the first to fourth electrode terminals 51 to 54 are connected to the outermost straight pin members 411 and 421, and the electrode terminals 51 to 54 are connected to the coils 41 and 42. This is called the electrode terminal connecting step.

[0146] Specifically, the first electrode terminal 51 is connected to a first end 411e1 of the outermost straight pin member 411 on the first electrode terminal 51 side, and the second electrode terminal 52 is connected to a second end 411e2 of the outermost straight pin member 411 on the second electrode terminal 52 side, thereby connecting the first electrode terminal 51 and the second electrode terminal 52 to the first coil 41. The third electrode terminal 53 is connected to a first end 421e1 of the outermost straight pin member 421 on the third electrode terminal 53 side, and the fourth electrode terminal 54 is connected to a second end 421e2 of the outermost straight pin member 421 on the fourth electrode terminal 54 side, thereby connecting the third electrode terminal 53 and the fourth electrode terminal 54 to the second coil 42.

[0147] Thereafter, the bottom plate portion 21 is attached to the base case 22 to manufacture the coil component 1. Specifically, the bottom plate portion 21 is attached to the first surface 60c1 side of the core cover portion 60. The bottom plate portion 21 is adhered to the coils 41, 42 and the base case 22 via the coil adhesive member 90.

[0148] According to the above-described method for manufacturing the coil device 1, with the first ends 411e1, 421e1 of the outermost straight pin members 411, 421 supported by the first to fourth protrusions 621 to 624, the second ends 411e2, 421e2 of the outermost straight pin members 411, 421 can be connected to the bent pin members 410, 420, and the outermost straight pin members 411, 421 can be connected to the bent pin members 410, 420 in a stable position. Therefore, the connection reliability between the outermost straight pin members 411, 421 and the bent pin members 410, 420 is improved.

[0149] Furthermore, since the second ends 411e2, 421e2 of the endmost straight pin members 411, 421 are spaced apart from the first surface 60c1, the heat generated when connecting the endmost straight pin members 411, 421 and the bent pin members 410, 420 by welding or the like is less likely to be transmitted to the core cover portion 60, thereby reducing deterioration of the core cover portion 60 due to heat.

[0150] Furthermore, the outermost straight pin members 411, 421 are connected to the first to fourth electrode terminals 51 to 54. This stabilizes the posture of the outermost straight pin members 411, 421, stabilizing the connection between the outermost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54. This improves the connection reliability between the outermost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54.

[0151] Preferably, a jig is used in the coil forming step and the electrode terminal connecting step. Fig. 12 is a perspective view of the jig. As shown in Fig. 12, the jig 100 has a first support portion 111, a second support portion 112, a first connecting portion 121, a second connecting portion 122, and a third connecting portion 123. The first support portion 111 and the second support portion 112 each extend in the X direction and are arranged parallel to each other in the Y direction. The first connecting portion 121, the second connecting portion 122, and the third connecting portion 123 connect the first support portion 111 and the second support portion 112, respectively. The first connecting portion 121, the second connecting portion 122, and the third connecting portion 123 each extend in the Y direction and are arranged parallel to each other in the X direction.

[0152] The first connecting portion 121 has a plurality of grooves 121a on its first main surface in the Z direction. The plurality of grooves 121a each extend in the X direction and are arranged parallel to one another in the Y direction. The first connecting portion 121 has a first positioning protrusion 131 and a second positioning protrusion 132 on its first main surface in the Z direction that protrude in the Z direction. The first positioning protrusion 131 is provided on the first support portion 111 side, and the second positioning protrusion 132 is provided on the second support portion 112 side.

[0153] The second connecting portion 122 has a plurality of first grooves 122a on a first side surface on one side in the X direction. The plurality of first grooves 122a each extend in the Z direction and are arranged parallel to one another in the Y direction. The second connecting portion 122 has a plurality of second grooves 122b on a second side surface on the other side in the X direction. The plurality of second grooves 122b each extend in the Z direction and are arranged parallel to one another in the Y direction.

[0154] The third connecting portion 123 has a plurality of grooves 123a on its first main surface in the Z direction. The grooves 123a each extend in the X direction and are arranged parallel to one another in the Y direction. The third connecting portion 123 has a third positioning protrusion 133 and a fourth positioning protrusion 134 on its first main surface in the Z direction that protrude in the Z direction. The third positioning protrusion 133 is provided on the first support portion 111 side, and the fourth positioning protrusion 134 is provided on the second support portion 112 side.

[0155] The jig 100 has first to fourth holes 141 to 144 that penetrate in the Z direction. The first hole 141 is located on the side of the first connecting portion 121 opposite to the second connecting portion 122 side (the reverse X direction side). The second hole 142 is located between the first connecting portion 121 and the second connecting portion 122. The third hole 143 is located between the second connecting portion 122 and the third connecting portion 123. The fourth hole 124 is located on the side of the third connecting portion 121 opposite to the second connecting portion 122 side (the forward X direction side).

[0156] Fig. 13 is a bottom view showing a state in which a jig is used in a method for manufacturing a coil component, and Fig. 14 is a perspective view of Fig. 13 with the core and base case omitted.

[0157] As shown in Figures 13 and 14, the coil forming process includes connecting the ends of each straight pin member 411, 412, 421, 422 and each bent pin member 410, 420 with the ends of each bent pin member 410, 420 while fitting each straight pin member 411, 412, 421, 422 into grooves 121a, 122a, 122b, 123a of jig 100.

[0158] Specifically, the straight pin members 411, 412 of the first coil 41 are fitted into the groove 121a of the first connecting portion 121. The bent pin member 410 of the first coil 41 is fitted into the first groove 122a of the second connecting portion 122. The straight pin members 421, 422 of the second coil 42 are fitted into the groove 123a of the third connecting portion 123. The bent pin member 420 of the second coil 42 is fitted into the second groove 122b of the second connecting portion 122.

[0159] Therefore, the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420 can be connected while being positioned, thereby improving the connection reliability of the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420.

[0160] As shown in Figures 13 and 14, the coil forming process includes connecting the ends of each straight pin member 411, 412, 421, 422 and the ends of each bent pin member 410, 420 while exposing the ends of each straight pin member 411, 412, 421, 422 and the ends of each bent pin member 410, 420 from the first to fourth hole portions 141 to 144 of the jig 100.

[0161] 13, the connection points between the end of each straight pin member 411, 412, 421, 422 and the end of each bent pin member 410, 420 are exposed from the first to fourth hole portions 141 to 144. Then, for example, a welding tool is inserted through the first to fourth hole portions 141 to 144 to weld the connection points.

[0162] Therefore, all of the straight pin members 411, 412, 421, 422 and all of the bent pin members 410, 420 can be connected in one step while the jig 100 remains attached.

[0163] As shown in Figures 13 and 14, the electrode terminal connecting process includes connecting the first to fourth electrode terminals 51 to 54 to the endmost straight pin members 411, 421 in a state where the first to fourth positioning protrusions 131 to 134 of the jig 100 are inserted into the slit portions 51 a to 54 a of the first to fourth electrode terminals 51 to 54.

[0164] Specifically, the first electrode terminal 51 is connected to the outermost straight pin member 411 with the first positioning protrusion 131 of the jig 100 inserted into the slit 51a of the first electrode terminal 51. The second electrode terminal 52 is connected to the outermost straight pin member 411 with the second positioning protrusion 132 of the jig 100 inserted into the slit 52a of the second electrode terminal 52. The third electrode terminal 53 is connected to the outermost straight pin member 421 with the third positioning protrusion 133 of the jig 100 inserted into the slit 53a of the third electrode terminal 53. The fourth electrode terminal 54 is connected to the outermost straight pin member 421 with the fourth positioning protrusion 134 of the jig 100 inserted into the slit 54a of the fourth electrode terminal 54.

[0165] Therefore, the first to fourth electrode terminals 51 to 54 can be connected to the outermost straight pin members 411, 421 while being positioned, thereby improving the connection reliability between the outermost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54.

[0166] As shown in Figures 13 and 14, the electrode terminal connecting process includes connecting the first to fourth electrode terminals 51 to 54 to the endmost straight pin members 411, 421 while exposing the endmost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54 from the first to fourth hole portions 141 to 144 of the jig 100.

[0167] Specifically, as shown by the black circles in Fig. 13 , the connection point between the outermost straight pin member 411 and the first electrode terminal 51 is exposed from the first and second hole portions 141 and 142, and the connection point between the outermost straight pin member 411 and the second electrode terminal 52 is exposed from the first and second hole portions 141 and 142. Also, as shown by the black circles in Fig. 13 , the connection point between the outermost straight pin member 421 and the third electrode terminal 53 is exposed from the third and fourth hole portions 143 and 144, and the connection point between the outermost straight pin member 421 and the fourth electrode terminal 54 is exposed from the third and fourth hole portions 143 and 144. Then, for example, a welding tool is inserted through the first to fourth hole portions 141 to 144 to weld the above-mentioned connection points.

[0168] Therefore, while the jig 100 remains attached, the connection between the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420 and the connection between the outermost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54 can be performed in one step.

[0169] Other Embodiments The present disclosure is not limited to the above-described embodiments, and design changes are possible without departing from the gist of the present disclosure.

[0170] The coil component comprises at least a core, a core cover portion, and a coil, the most-end straight pin member facing a first surface of the first part of the core cover portion, the first end of the most-end straight pin member contacting a protrusion portion on the first surface of the first part of the core cover portion, and the second end of the most-end straight pin member being spaced from the first surface and connected to the bent pin member.

[0171] Although the core cover and the mounting base are integrated, they may be separate or may be spaced apart. Also, the mounting base may be omitted and the electrode terminals may be attached to the bottom plate.

[0172] The shape of the case and the shape of the core are not limited to those in the first embodiment and can be modified in design. The number of coils is not limited to those in the first embodiment and can be modified in design. The number of electrode terminals is not limited to those in the first embodiment and can be modified in design.

[0173] The present disclosure includes the following aspects: <1> A coil component comprising: an annular core; a core cover portion covering at least a portion of the core; and a coil wound around the core cover portion, wherein the core has a first end face and a second end face facing each other in a central axis direction, the core cover portion has a first portion facing the first end face, and the first portion has a protrusion portion on a first face opposite the first end face, the coil includes a plurality of straight pin members and a plurality of bent pin members, the straight pin members and the bent pin members are alternately connected to form the spiral of the coil, and the plurality of straight pin members include an endmost straight pin member located at an end on at least one side of the coil in the axial direction, the endmost straight pin member faces the first face of the first portion, a first end of the endmost straight pin member contacts the protrusion portion, and a second end of the endmost straight pin member is connected to the bent pin member at a distance from the first face. <2> The coil component according to <1>, further comprising an electrode terminal connected to the coil, wherein the outermost straight pin member is connected to the electrode terminal. <3> The coil component according to <2>, wherein the first end of the outermost straight pin member is connected to the electrode terminal. <4> The coil component according to <3>, wherein the protrusion overlaps the electrode terminal when viewed in a direction perpendicular to the first surface. <5> The coil component according to <2>, wherein the second end of the outermost straight pin member is connected to the electrode terminal. <6> The coil component according to <5>, wherein the protrusion is spaced apart from the electrode terminal when viewed in a direction perpendicular to the first surface. <7> The coil component according to any one of <2> to <6>, wherein the outermost straight pin member and the electrode terminal are connected by welding. <8> The coil component according to any one of <2> to <7>, further comprising a mounting base for mounting the electrode terminal, wherein the core cover portion and the mounting base are an integrated, one-piece molded product.<9> A method for manufacturing a coil coil assembly, comprising: a step of accommodating an annular core in a core cover portion so that a first end face located in the central axis direction of the core is covered; a step of arranging a plurality of straight pin members and a plurality of bent pin members around the core and the core cover portion so that an end of each straight pin member and an end of each bent pin member are located on a first surface side of the core cover portion opposite the first end face; and a step of connecting the end of each straight pin member to an end of each bent pin member to form a coil in which the straight pin members and the bent pin members are alternately connected, wherein the step of arranging the straight pin members and the bent pin members includes: facing an endmost straight pin member located at an end on at least one side of the coil in the axial direction of the coil among the plurality of straight pin members to the first surface; and bringing a first end of the endmost straight pin member into contact with a protrusion provided on the first surface. The method for manufacturing a coil component, in which the step of forming the coil includes connecting the second end of the outermost straight pin member to the bent pin member while the first end of the outermost straight pin member is supported on the protrusion. <10> The method for manufacturing a coil component according to <9>, further comprising the step of connecting an electrode terminal to the outermost straight pin member and connecting the electrode terminal to the coil. <11> The method for manufacturing a coil component according to <9> or <10>, in which the step of forming the coil includes connecting an end of each of the outermost straight pin members to an end of each of the bent pin members while the outermost straight pin members and the bent pin members are fitted in grooves of a jig. <12> The method for manufacturing a coil component according to <11>, in which the step of forming the coil includes connecting an end of each of the outermost straight pin members to an end of each of the bent pin members while the end of each of the outermost straight pin members and the bent pin members are exposed from holes in the jig. <13> The method for manufacturing a coil component according to <10>, wherein the step of forming the coil includes connecting an end of each of the straight pin members and each of the bent pin members with an end of each of the straight pin members while fitting the straight pin members and each of the bent pin members into grooves of a jig; and the step of connecting the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while inserting a positioning protrusion of the jig into a slit of the electrode terminal.<14> The method for manufacturing a coil component according to <13>, wherein the step of forming the coil includes connecting an end of each of the straight pin members and an end of each of the bent pin members while exposing the end of each of the straight pin members and the end of each of the bent pin members from a hole in the jig, and the step of forming the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while exposing the endmost straight pin member and the electrode terminal from the hole in the jig.

[0174] 1 Coil component 21 Bottom plate portion 22 Base case 3 Core 301 First end surface 302 Second end surface 41 First coil 410 Bent pin member 411 Endmost straight pin member 411e1 First end 411e2 Second end 412 Straight pin member 42 Second coil 420 Bent pin member 421 Endmost straight pin member 421e1 First end 421e2 Second end 422 Straight pin member 51 to 54 First to fourth electrode terminals 51a to 54a Slit portion 60 Core cover portion 60c Bottom portion (first portion) 60c1 First surface 621 to 624 First to fourth protrusions 70 Slit holes 71, 72 First and second mounting base portions 90 Coil adhesive member 91 Core adhesive member 100 Jig 111, 112 First and second support portions 121 to 123 First to third connecting portions 121a Groove portion 122a, 122b First and second groove portions 123a Groove portion 131 to 134 First to fourth positioning protrusions 141 to 144 First to fourth hole portions

Claims

1. An annular core; A core cover portion that covers at least a portion of the core; A coil wound around the core and the core cover; Equipped with the core has a first end surface and a second end surface opposed to each other in a central axis direction, the core cover portion has a first portion facing the first end surface, the first portion having a protrusion on a first surface opposite the first end surface, the coil includes a plurality of straight pin members and a plurality of bent pin members, the straight pin members and the bent pin members being alternately connected to form a spiral of the coil, and the plurality of straight pin members include an endmost straight pin member located at an end on at least one side of the axial direction of the coil, a coil component, wherein the endmost straight pin member faces the first surface of the first portion, a first end of the endmost straight pin member contacts the protrusion portion, and a second end of the endmost straight pin member is spaced from the first surface and connected to the bent pin member.

2. further comprising an electrode terminal connected to the coil; The coil component according to claim 1 , wherein the endmost straight pin member is connected to the electrode terminal.

3. The coil component according to claim 2 , wherein the first end of the outermost straight pin member is connected to the electrode terminal.

4. The coil component according to claim 3 , wherein the protrusion overlaps the electrode terminal when viewed in a direction perpendicular to the first surface.

5. The coil component according to claim 2 , wherein the second end of the outermost straight pin member is connected to the electrode terminal.

6. The coil component according to claim 5 , wherein the protrusion is spaced apart from the electrode terminal when viewed in a direction perpendicular to the first surface.

7. 7. The coil component according to claim 2, wherein the endmost straight pin member and the electrode terminal are connected by welding.

8. A mounting portion for mounting the electrode terminal is further provided. The coil component according to claim 2 , wherein the core cover portion and the mounting base portion are formed as a single, integrally molded product.

9. a step of housing the annular core in a core cover portion so that a first end face of the core located in a central axis direction is covered; a step of arranging a plurality of straight pin members and a plurality of bent pin members around the core and the core cover portion such that an end of each straight pin member and an end of each bent pin member are located on a first surface side of the core cover portion opposite the first end surface; connecting an end of each of the straight pin members to an end of each of the bent pin members to form a coil in which the straight pin members and the bent pin members are alternately connected; Equipped with The step of arranging the straight pin members and the bent pin members includes: placing an endmost straight pin member located at an end on at least one side of the axial direction of the coil among the plurality of straight pin members against the first surface; and contacting a first end of the endmost straight pin member with a protrusion provided on the first surface; The method for manufacturing a coil component, in the process of forming the coil, includes supporting the first end of the endmost straight pin member on the protrusion portion and connecting the second end of the endmost straight pin member to the bent pin member while separating the second end of the endmost straight pin member from the first surface.

10. The method for manufacturing a coil component according to claim 9 , further comprising the step of connecting an electrode terminal to the end straight pin member and connecting the electrode terminal to the coil.

11. 11. The method for manufacturing a coil component according to claim 9 or 10, wherein the step of forming the coil includes connecting ends of the straight pin members and ends of the bent pin members while fitting the straight pin members and the bent pin members into grooves of a jig.

12. 12. The method for manufacturing a coil component according to claim 11, wherein the step of forming the coil includes connecting the ends of each of the straight pin members and the ends of each of the bent pin members while exposing the ends of each of the straight pin members and the ends of each of the bent pin members from holes in the jig.

13. the step of forming the coil includes connecting an end of each of the straight pin members and an end of each of the bent pin members in a state in which the straight pin members and the bent pin members are fitted into grooves of a jig; 11. The method for manufacturing a coil component according to claim 10, wherein the step of connecting the electrode terminal includes connecting the electrode terminal to the endmost straight pin member in a state in which a positioning protrusion of the jig is inserted into a slit portion of the electrode terminal.

14. the step of forming the coil includes connecting the ends of the straight pin members and the ends of the bent pin members while exposing the ends of the straight pin members and the ends of the bent pin members from holes in the jig; 14. The method for manufacturing a coil component according to claim 13, wherein the step of forming the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while exposing the endmost straight pin member and the electrode terminal from the hole of the jig.