Coil component and method for manufacturing coil component

Abstract

A coil component according to one embodiment of the present invention comprises: a coil part having an annular conductor part that has a center axis along a first direction and has two electrical ends; and a body part that covers the annular conductor part by means of a first intersection surface and a second intersection surface arranged in the first direction, and that includes a binder and a magnetic powder held by the binder. The coil part has a first end surface exposed from a surface of the body part and connected to one of the two electrical ends of the annular conductor part, and a second end surface exposed from a surface of the body part and connected to the other of the two electrical ends of the annular conductor part. The first end surface is covered by a first external electrode having a portion provided on the second intersection surface. The second end surface is covered by a second external electrode that is electrically separated from the first external electrode on the outside of the body part and that has a portion provided on the second intersection surface. An outer surface of the body part that is positioned between the first intersection surface and the second intersection surface has a tapered outer surface that moves away from the central axis as the outer surface approaches the first intersection surface.

Description

Coil component and method for manufacturing the same

[0001] The present invention relates to a coil component and a method for manufacturing a coil component.

[0002] Patent Literature 1 discloses a coil component that can improve the aspect ratio of each turn of a coil pattern while maintaining the rigidity of a support substrate. The coil component includes a support substrate, a coil section including a first conductive layer arranged to contact one surface of the support substrate and a second conductive layer arranged on the first conductive layer to be spaced apart from the one surface of the support substrate, and a main body in which the support substrate and the coil section are embedded, and one side of the first conductive layer is arranged closer to the center in the width direction of the second conductive layer than one side of the second conductive layer.

[0003] Patent Document 2 discloses a method for manufacturing a common mode filter. This method may include a step of forming a second coil pattern having a larger cross-sectional area than the first coil pattern by electrolytic plating a first coil pattern made of a conductive material, thereby realizing a common mode filter that meets the demand for miniaturization and has improved characteristics such as inductance and DC resistance.

[0004] JP 2021-034715 A JP 2013-197588 A

[0005] When mounting a coil component on a substrate, electrodes on the substrate are joined to the first and second external electrodes of the coil component via solder fillets provided on the electrodes. During reflow, solder melts from the fillets and wets the outer surfaces, increasing the contact area between the solder and the coil component, thereby improving the conductivity and adhesion between the coil component and the electrodes. To ensure proper wetting, it is preferable for the electrodes to extend outside the coil component, and for the solder to properly wet and spread over this extended portion. However, the presence of this extended portion has been an obstacle to achieving high-density mounting. Furthermore, when manufacturing small coil components, reducing processing load while improving productivity is important for efficiently manufacturing highly reliable coil components.

[0006] An object of the present invention is to provide a coil component that can achieve high-density mounting and improve connection reliability, and a method for manufacturing a coil component that can improve productivity.

[0007] A coil component according to one aspect of the present invention comprises: a coil portion having an annular conductor portion with a central axis along a first direction and two electrical ends; and a main body portion covering the annular conductor portion at first and second intersecting planes aligned in the first direction, and including a binder and magnetic powder held in the binder. The coil portion has a first end face exposed from the surface of the main body portion and connected to one of the two electrical ends of the annular conductor portion, and a second end face exposed from the surface of the main body portion and connected to the other of the two electrical ends of the annular conductor portion. The first end face is covered by a first external electrode having a portion provided on the second intersecting plane, and the second end face is covered by a second external electrode outside the main body portion, the second end face being electrically separated from the first external electrode and having a portion provided on the second intersecting plane. An outer surface of the main body portion located between the first intersecting plane and the second intersecting plane has a tapered outer surface that moves away from the central axis as it approaches the first intersecting plane.

[0008] By providing the tapered outer surface on the outer surface of the main body, the area of ​​the second intersecting plane side of the main body, which is the mounting surface side of the coil component, is smaller than the area of ​​the opposite side (the first intersecting plane side of the main body), thereby realizing a reduction in the mounting area of ​​the coil component without reducing the area of ​​the electrodes of the coil component.

[0009] In the coil component, the first external electrode and the second external electrode may each extend so as to cover at least a portion of the tapered outer surface. If the external electrodes are provided on the tapered outer surface, the solder will preferentially wet up the tapered outer surface, thereby more stably improving the adhesion of the coil component to the solder.

[0010] In the coil component, the tapered outer surface may have a farthest portion of the main body farthest from the central axis. By positioning the farthest portion of the main body on the tapered outer surface in this manner, the mounting area of ​​the coil component after mounting is smaller than when the farthest portion is located at the boundary with the first intersecting plane. Furthermore, since the portion removed from the main body is the portion relatively far from the central axis, the effect on the magnetic properties is small.

[0011] In the coil component, the surface roughness of the farthest portion may be greater than the surface roughness of other portions of the tapered outer surface, and both the first external electrode and the second external electrode may extend so as to cover at least a portion of the farthest portion, thereby improving adhesion of the first external electrode and the second external electrode covering at least a portion of the farthest portion.

[0012] In the coil component, at least one of the first end face and the second end face may have a portion exposed from the tapered outer surface, where the external electrodes are located on the tapered outer surface, thereby improving the electrical conductivity of the external electrodes and improving adhesion to the solder.

[0013] In the coil component, at least a portion of the first end face may be exposed from the second intersecting plane, and at least a portion of the second end face may be exposed from a portion of the second intersecting plane different from the portion of the second intersecting plane where at least a portion of the first end face is exposed, thereby establishing electrical conduction between the annular conductor and the first and second external electrodes at the second intersecting plane.

[0014] In the coil component, the tapered outer surface may have a portion that includes a surface that includes a relatively large number of processing marks in the first direction. Because such a surface includes processing marks, its surface roughness is higher than that of a molded surface that is entirely pressurized using a mold. Therefore, the adhesion of a member positioned to cover the surface that includes a relatively large number of processing marks in the first direction is improved.

[0015] In the coil component, the magnetic powder may be made of a metallic material, and the cut surface of the magnetic powder may not be located on the surface containing a relatively large number of processing marks in the first direction, thereby making it difficult for corrosion to occur even if the magnetic powder has a portion made of a metallic material.

[0016] A coil component according to another aspect of the present invention comprises a coil portion having a ring-shaped conductor portion with a central axis along a first direction and two electrical ends, and a main body portion covering the ring-shaped conductor portion with first and second intersecting planes aligned in the first direction, and including a magnetic powder having a portion made of a metal-based material and a binder, wherein the outer surface located between the first and second intersecting planes of the main body portion has a surface that contains relatively many processing marks of the first direction component, and the cut surface of the magnetic powder is not located on the surface that contains relatively many processing marks in the first direction.

[0017] This makes it difficult for corrosion to occur even when the magnetic powder has a portion made of a metallic material.

[0018] In the coil component, the binder may contain a cured product of a curable resin, and the magnetic powder may be subjected to a surface insulation treatment.

[0019] Another aspect of the present invention provides a method for manufacturing a coil component comprising: a coil portion having a ring-shaped conductor portion with a central axis along a first direction and two electrical ends; and a main body portion covering the ring-shaped conductor portion with first and second intersecting planes aligned in the first direction, and including a binder and magnetic powder held in the binder. The method includes forming a first intermediate member including a first member including a semi-hardened product of the binder and the magnetic powder, and a coil portion having a portion embedded in the first member; performing at least one of a slit forming process and a groove forming process on the first intermediate member to form a second intermediate member; and forming a third intermediate member by performing a hardening process to harden the semi-hardened product contained in the second intermediate member into a binder.

[0020] In this specification, the term "slit forming process" refers to a process for forming a slit that penetrates the intermediate member in a first direction, and the term "groove forming process" refers to a process for forming a groove that does not penetrate the intermediate member in the first direction. According to this configuration, by performing processing on the first intermediate member that contains a semi-hardened material that is relatively soft compared to the binder, the processing load is reduced, and improvement in productivity of coil components, such as an extension of tool life, is realized.

[0021] In the above-described method for manufacturing a coil component, the second intermediate member may be formed by performing at least a groove forming process on the first intermediate member, and the third intermediate member may be subjected to a fracture process in which the third intermediate member is fractured from a surface formed by the groove forming process, whereby the fracture process is performed starting from a part of the groove formed in the third intermediate member, thereby dividing the third intermediate member.

[0022] In the above-described method for manufacturing a coil component, the second intermediate member may be formed by performing slit forming and groove forming processes on the first intermediate member. When the first intermediate member has a large number of coil portions, dividing the member to be broken to a certain extent before performing the breaking process simplifies subsequent processes and improves productivity of the coil component. With regard to this dividing process, dividing the first intermediate member containing a semi-hardened material by performing not only groove forming but also slit forming processes is expected to extend the life of tools used in the slit forming processes, rather than dividing the third intermediate member containing a binder obtained by hardening a semi-hardened material by performing slit forming processes on the first intermediate member containing a semi-hardened material.

[0023] In the above-described method for manufacturing a coil component, the third intermediate member may be subjected to slit formation processing before being subjected to fracture processing. When the first intermediate member has a large number of coil portions, the third intermediate member may be divided after hardening before being subjected to subsequent processes, which may improve the shape accuracy after processing. Improved shape accuracy after processing reduces the rate of defective products, thereby improving the productivity of coil components.

[0024] In the above-described method for manufacturing a coil component, the first member and one or more coil portions may be placed in a cavity of a mold provided with at least one of a tool for forming a slit and a tool for forming a groove, and the process for forming the first intermediate member and at least one of the slit and groove processes may be performed in a single process to form the second intermediate member. This allows the second intermediate member to be formed without a process for handling the first intermediate member, thereby reducing the total number of processes and improving the productivity of coil components.

[0025] In the above-described method for manufacturing coil components, the second intermediate member may be formed by performing slit forming processing on the first intermediate member, and the third intermediate member may be formed by performing slit forming processing on the third intermediate member. This simplifies subsequent processes and improves productivity of coil components, since the second intermediate member is formed by dividing the first intermediate member to a certain extent, even if the first intermediate member has a large number of coils. Furthermore, because this division is performed before hardening, the life of the dividing tool is extended, thereby improving productivity of coil components.

[0026] In the above-described method for manufacturing coil components, the third intermediate member may be divided after the third intermediate member is subjected to an exterior coating process. This simplifies the manufacturing process and improves productivity of the coil components, since the third intermediate member is covered with the exterior coating except for the surfaces formed by the process for dividing the third intermediate member.

[0027] In the above-described method for manufacturing a coil component, the groove forming process may be performed from both the surface side of the first intermediate member corresponding to the first intersecting plane and the surface side of the first intermediate member corresponding to the second intersecting plane. In this manner, the groove forming process is performed from both the side of the first intersecting plane and the side of the second intersecting plane, which facilitates the process of dividing the third intermediate member, particularly the fracture process, and improves the productivity of the coil component.

[0028] In the method for manufacturing the coil component, the third intermediate member may be divided, and then an exterior coating process may be performed to apply an exterior coating to the members obtained by the division of the third intermediate member, whereby the exterior coating is applied to a wide range of the exposed surfaces of the members obtained by dividing the third intermediate member.

[0029] According to the present invention, a coil component that can achieve high-density mounting and improve connection reliability is provided, and a method for manufacturing a coil component that can improve productivity by extending tool life and simplifying processes is also provided.

[0030] 11B is a perspective view conceptually illustrating the shape of a coil component according to an embodiment of the present invention. FIG. 11C is a diagram illustrating the structure of a coil conductor included in a coil component according to an embodiment of the present invention. FIG. 11D is an XY plan view illustrating the structure of a first spiral conductor included in a coil component according to an embodiment of the present invention. FIG. 11E is an XY plan view illustrating the structure of a second spiral conductor included in a coil component according to an embodiment of the present invention. FIG. 11F is a cross-sectional view illustrating the structure of a coil portion ...B is a schematic view illustrating a state in which a coil component is mounted on a substrate. FIG. 11C is a schematic view illustrating a state in which a coil component is mounted on a substrate. FIG. 11D is a cross-sectional view illustrating a coil component according to a second embodiment. FIG. 11F is a cross-sectional view illustrating a coil component according to a third embodiment. FIG. 11F is a cross-sectional view illustrating a coil component according to a fourth embodiment. FIG. 11B is a diagram illustrating a first manufacturing method of a coil component (a diagram illustrating a state in which coil conductor portions are formed on a sheet base material). FIG. 11B is a diagram illustrating a first manufacturing method of a coil component (a diagram illustrating a state in which a coil array sheet is formed by removing a portion of the sheet base material). FIG. 11C is a diagram illustrating a first manufacturing method of a coil component (a cross-sectional view taken along line CC' in FIG. 11B). 14 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing a state in which a constituent material of a first member is placed in a mold); FIG. 15 is a diagram illustrating a state in which pressure has started to be applied to the constituent material of the first member in the mold); FIG. 16 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing a state in which the first member is formed in a mold); FIG. 17 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing a state in which a first member and a coil array sheet are placed in a mold); FIG. 18 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing a state in which a first intermediate member is formed in a mold); FIG. 19 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing the first intermediate member removed from the mold); FIG. 19 is a diagram illustrating a first method for manufacturing a coil component (a diagram showing a state in which a second intermediate member is formed by performing slit formation processing on the first intermediate member); and FIG. 19 is a cross-sectional view taken along line D-D' in FIG. 14 . 15A and 15B are cross-sectional views taken along line EE' in FIG. 14 illustrating a first method for manufacturing a coil component.17A and 17B are diagrams illustrating a first method for manufacturing a coil component (a diagram showing a state in which an exterior coating process has been applied to a third intermediate member); FIG. 17B are diagrams illustrating a first method for manufacturing a coil component (a diagram showing a state in which the third intermediate member has been subjected to exterior coating process); FIG. 17C are diagrams illustrating a first method for manufacturing a coil component (a diagram showing a state in which the third intermediate member has been divided to form coil component members); FIG. 17C are diagrams illustrating a first method for manufacturing a coil component (a cross-sectional view taken along line D-D' in FIG. 17); FIG. 17D are diagrams illustrating a first method for manufacturing a coil component (a cross-sectional view taken along line E-E' in FIG. 17); FIG. 17C are diagrams illustrating a first method for manufacturing a coil component (a diagram showing a coil component in which first terminal portions and second terminal portions are formed on coil component members); FIG. 17D are diagrams illustrating a second method for manufacturing a coil component (a diagram showing a state in which a first member and a coil array sheet are arranged in a mold); and FIG. 17E are diagrams illustrating a second method for manufacturing a coil component (a diagram showing a state in which a second intermediate member has been formed in a mold). 21 )。 FIG. 23 ) is a diagram illustrating a second method for manufacturing a coil component (a diagram showing the second intermediate member removed from the mold). FIG. 24 ) is a diagram illustrating a second method for manufacturing a coil component (a cross-sectional view taken along line D-D' in FIG. 21 ). FIG. 25 ) is a diagram illustrating a second method for manufacturing a coil component (a cross-sectional view taken along line E-E' in FIG. 21 ). FIG. 26 ) is a diagram illustrating a second method for manufacturing a coil component (a diagram showing a state in which slit formation processing has been performed on a second intermediate member having grooves). FIG. 27 ) is a diagram illustrating a second method for manufacturing a coil component (a cross-sectional view taken along line E-E' in FIG. 23 ). FIG. 28 ) is a diagram illustrating a second method for manufacturing a coil component (a diagram showing a state in which an exterior coating processing has been performed on a third intermediate member). FIG. 29 ) is a diagram illustrating a second method for manufacturing a coil component (a diagram showing a state in which an exterior coating processing has been performed on a third intermediate member). 1 is a diagram illustrating a second manufacturing method of a coil component (a diagram showing a state in which a coil component member is formed by performing fracture processing on a third intermediate member); FIG. 2 is a diagram illustrating a second manufacturing method of a coil component (a diagram showing a coil component in which a first terminal portion and a second terminal portion are formed on a coil component member); and FIG. 3 is a diagram illustrating a modified example 2 of the second manufacturing method of a coil component (a diagram showing a state in which a cutting tool for processing a first intermediate member to form a groove is arranged).A diagram illustrating a second modification of the second manufacturing method of the coil component (a diagram showing a state where a groove forming process is performed on the first intermediate member to form the second intermediate member). A diagram illustrating a second modification of the second manufacturing method of the coil component (a diagram showing a state where the cutting tool is separated from the second intermediate member). A schematic perspective view illustrating the states of the surfaces formed by the groove forming process and the surfaces formed by the breaking process. A schematic cross-sectional view illustrating the state of the surface formed by the breaking process. A schematic cross-sectional view illustrating the state of cutting. A diagram illustrating the third manufacturing method of the coil component (a diagram showing a state where the first member and the coil array sheet are arranged in the mold). A diagram illustrating the third manufacturing method of the coil component (a diagram showing a state where the second intermediate member is formed in the mold). A diagram illustrating the third manufacturing method of the coil component (a diagram showing the second intermediate member taken out from the mold). A diagram illustrating the third manufacturing method of the coil component (a diagram showing a state where a breaking process is performed on the third intermediate member to form the coil component member). A diagram illustrating the third manufacturing method of the coil component (a diagram showing a state where a coil component having the first terminal portion and the second terminal portion formed on the coil component member is obtained). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing a state where the first member and the coil array sheet are arranged in the mold). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing a state where the second intermediate member is formed in the mold). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing the second intermediate member taken out from the mold). A diagram illustrating the fourth manufacturing method of the coil component (a cross-sectional view taken along line D-D' in FIG. 31). A diagram illustrating the fourth manufacturing method of the coil component (a cross-sectional view taken along line E-E' in FIG. 31). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing a state where a slit forming process is performed on the second intermediate member having grooves). A diagram illustrating the fourth manufacturing method of the coil component (a cross-sectional view taken along line D-D' in FIG. 33). A diagram illustrating the fourth manufacturing method of the coil component (a cross-sectional view taken along line E-E' in FIG. 33). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing a state where an exterior coating process is performed on the third intermediate member). A diagram illustrating the fourth manufacturing method of the coil component (a diagram showing a state where an exterior coating process is performed on the third intermediate member).A diagram illustrating a fourth manufacturing method of a coil component (a diagram showing a state where a coil component member is formed by performing a breaking process on a third intermediate member). A diagram illustrating a fourth manufacturing method of a coil component (a diagram showing a coil component in which a first terminal portion and a second terminal portion are formed on a coil component member). A diagram illustrating a fifth manufacturing method of a coil component (a diagram showing a state where a second intermediate member is formed by performing a slit forming process by pressing on a first intermediate member). A diagram illustrating a fifth manufacturing method of a coil component (a cross-sectional view taken along line D-D' of FIG. 37). A diagram illustrating a fifth manufacturing method of a coil component (a cross-sectional view taken along line E-E' of FIG. 37). A diagram illustrating a fifth manufacturing method of a coil component (a diagram showing a state where an outer coating process is performed on a third intermediate member). A diagram illustrating a fifth manufacturing method of a coil component (a diagram showing a state where an outer coating process is performed on a third intermediate member). A diagram illustrating a fifth manufacturing method of a coil component (a diagram showing a state where a coil component member is formed by dividing a third intermediate member). A diagram illustrating a fifth manufacturing method of a coil component (a cross-sectional view taken along line D-D' of FIG. 40). A diagram illustrating a fifth manufacturing method of a coil component (a cross-sectional view taken along line E-E' of FIG. 40). A diagram illustrating a fifth manufacturing method of a coil component (a coil component in which a first terminal portion and a second terminal portion are formed on a coil component member). A diagram illustrating a fifth manufacturing method of a coil component (a diagram showing a state where an outer coating process is performed on a surface formed when dividing a third intermediate member).

[0031] Hereinafter, embodiments of the present invention will be described in detail while referring to the drawings.

[0032] (First Embodiment) FIG. 1 is a perspective view conceptually illustrating the shape of a coil component according to one embodiment of the present invention. FIG. 2 is a view illustrating the structure of a coil conductor included in a coil component according to one embodiment of the present invention. For convenience of explanation, in FIG. 2, the coil conductor is depicted with a solid line, the main body is depicted with a dashed line, and other components are not shown. FIG. 3 is an XY plan view illustrating the structure of a first spiral conductor included in a coil component according to one embodiment of the present invention. FIG. 4 is an XY plan view illustrating the structure of a second spiral conductor included in a coil component according to one embodiment of the present invention. FIGS. 5 and 6 are cross-sectional views illustrating the structure of a coil portion included in a coil component according to one embodiment of the present invention. Note that FIG. 2 is a view seen from the Z1 side in the Z1-Z2 direction. FIG. 3 is a plan view seen from the Z1 side in the Z1-Z2 direction, in which the coil conductor is depicted with a solid line and other parts are depicted with dashed lines. FIG. 4 is a plan view seen from the Z2 side in the Z1-Z2 direction, in which the coil conductor is depicted with a solid line and other parts are depicted with dashed lines. In Fig. 5, the main body, terminals, and exterior coating are indicated by dashed lines, and the cross section taken along line A-A' in Fig. 3 is shown as an XZ cross section. In Fig. 6, the main body and exterior coating are indicated by dashed lines, and the cross section taken along line B-B' in Fig. 3 is shown as a YZ cross section.

[0033] (Overall configuration) As shown in Figures 1 and 2, a coil component 100A according to one embodiment of the present invention includes a coil portion 10 having a coil conductor portion 20, which is an example of an annular conductor portion, a main body portion 30, a first terminal portion 41, a second terminal portion 42, and exterior coatings 50 and 60.

[0034] (Coil) As shown in Figures 2 and 3, the coil portion 10 has a coil conductor portion 20 including a first coil conductor portion 201 having a spiral-shaped first spiral conductor portion 11 that is arranged around a central axis O along a first direction (Z1-Z2 direction) from an inner peripheral end portion 12, which is the inner peripheral end of a pair of ends of the first spiral conductor portion 11, toward an outer peripheral end portion 13, which is the outer peripheral end of the pair of ends of the first spiral conductor portion 11, and that moves away from the central axis O. In Figure 2, the first spiral conductor portion 11 has conductors arranged in a spiral shape that moves away from the central axis O in a clockwise direction from the inner peripheral end portion 12 toward the outer peripheral end portion 13, as viewed from the Z1 side in the Z1-Z2 direction. In this specification, the "spiral direction" of the spiral portion (first spiral conductor portion 11, second spiral conductor portion 21) means the direction from the inner peripheral end portion to the outer peripheral end portion. Furthermore, "viewed in the first direction" means that it may be viewed from the Z1 side in the Z1-Z2 direction, or from the Z2 side in the Z1-Z2 direction.

[0035] The conductor (conductive material) constituting the coil conductor portion 20 is not limited as long as it has appropriate conductivity. Specific examples of the conductor constituting the coil conductor portion 20 include metals such as copper, copper alloys, aluminum, and aluminum alloys. The coil conductor portion 20 can be manufactured using a film formation technique such as plating. The coil portion 10 has an insulating coil insulation portion (not shown in FIGS. 1 to 4 ) on the surface of the coil conductor portion 20. This coil insulation portion ensures insulation between adjacent conductors (between the surfaces of the conductors facing each other) in the coil conductor portion 20. The coil insulation portion is made of, for example, a resin material. The ends (first lead-out exposed surface 140, second lead-out exposed surface 240) of the two ends (first lead-out portion 14, second lead-out portion 24) of the coil conductor portion 20 are not provided with coil insulation, and the coil portion 10 can be electrically connected to other components at these ends.

[0036] 2 and 4, the coil conductor portion 20 includes a second coil conductor portion 202 having a second spiral conductor portion 21 arranged alongside the first spiral conductor portion 11 in the first direction. The second spiral conductor portion 21 has a spiral shape around a central axis O along the first direction (Z1-Z2 direction), from one end (inner peripheral end portion 22) which is an end on the inner peripheral side of the second spiral conductor portion 21 to the other end (outer peripheral end portion 23) which is an end on the outer peripheral side of the second spiral conductor portion 21, and moving away from the central axis O. In the second spiral conductor portion 21, the conductor is arranged in a spiral shape moving away from the central axis O in the opposite direction to the first spiral conductor portion 11 (counterclockwise in FIG. 2) when viewed from the Z1 side in the Z1-Z2 direction.

[0037] The average value of the separation distance in the first direction (Z1-Z2 direction) between the first spiral conductor portion 11 and the second spiral conductor portion 21 is not particularly limited. The smaller this separation distance, the easier it is to reduce the height (dimension in the Z1-Z2 direction) of the coil component 100A. However, if the separation distance is too small, the insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21 is likely to deteriorate. From the viewpoint of achieving both a low profile (low height) of the coil component 100A and high insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21, it may be preferable that the separation distance be 0.4 μm or more and 20 μm or less. In order to reduce variation in the separation distance and more reliably support the coil in the same plane during manufacturing, the separation distance is more preferably 1.0 μm or more, and even more preferably 5.0 μm or more.

[0038] The inner peripheral end 12, which is one end of the first spiral conductor portion 11, and the inner peripheral end 22, which is one end of the second spiral conductor portion 21, are electrically connected by a via conductor portion VP. Starting from the connection portion to the via conductor portion VP, the first spiral conductor portion 11 and the second spiral conductor portion 21 spiral in opposite directions. The via conductor portion VP may be composed of the same conductor as the coil conductor portion 20. In a specific example, the via conductor portion VP is made of the same material as the first spiral conductor portion 11 and the second spiral conductor portion 21, and is manufactured simultaneously with the first spiral conductor portion 11 and the second spiral conductor portion 21. In this case, the via conductor portion VP is integrated with one inner peripheral end portion 12 of the first spiral conductor portion 11 and one inner peripheral end portion 22 of the second spiral conductor portion 21.

[0039] A first lead 14 is connected to the outer circumferential end 13, which is the other end of the first spiral conductor 11, as a part of the first coil conductor 201, and a second lead 24 is connected to the outer circumferential end 23, which is the other end of the second spiral conductor 21, as a part of the second coil conductor 202. Therefore, the outer circumferential end 13 of the first spiral conductor 11 is essentially the interface with the first lead 14, and the outer circumferential end 23 of the second spiral conductor 21 is essentially the interface with the second lead 24. In a specific example, the first lead 14 and the second lead 24 are made of the same material as the first spiral conductor 11 and the second spiral conductor 21, and are manufactured simultaneously with the first spiral conductor 11 and the second spiral conductor 21. That is, the first coil conductor portion 201 is manufactured as a single unit, and the second coil conductor portion 202 is also manufactured as a single unit. In this case, the first lead portion 14 is seamlessly integrated with the outer peripheral end portion 13 of the first spiral conductor portion 11, and the second lead portion 24 is seamlessly integrated with the outer peripheral end portion 23 of the second spiral conductor portion 21.

[0040] That is, in this embodiment, the coil conductor 20, which is an example of an annular conductor, includes a first coil conductor 201 having a first spiral conductor 11 and a first lead-out portion 14, a second coil conductor 202 having a second spiral conductor 21 and a second lead-out portion 24, and a via conductor VP, all of which are formed from a common conductive material. Furthermore, the two outer peripheral ends 13, 23 of the coil conductor 20 constitute the two electrical ends of the annular conductor. As shown in Figures 3 and 4 , each turn of the first spiral conductor 11 and each turn of the second spiral conductor 21 are aligned in a first direction (Z1-Z2 direction).

[0041] (Main body portion) The main body portion 30 includes a binder and magnetic powder held in the binder, and has outer surfaces 30a, 30b, 30c, and 30d having a plurality of surfaces extending in a first direction, and a pair of intersecting surfaces aligned in the first direction, namely, a first intersecting surface 30e and a second intersecting surface 30f. The main body portion 30 covers at least a portion of the coil portion 10 with the first intersecting surface 30e and the second intersecting surface 30f.

[0042] In this embodiment, the main body 30 is formed by outer surfaces 30a, 30b, 30c, and 30d located between the first intersecting surface 30e and the second intersecting surface 30f, and at least a portion of the outer surfaces 30a and 30b has tapered outer surfaces 301 and 302. The tapered outer surfaces 301 and 302 are surfaces that become more distant from the central axis O as they approach the first intersecting surface 30e.

[0043] The outer surfaces 30a, 30b, 30c, and 30d, the first intersecting plane 30e, and the second intersecting plane 30f that form the main body 30 are referred to as the surface of the main body 30. The main body 30 also includes the portions of the coil 10 other than the outermost end face (X2 side in the X1-X2 direction) of the first lead 14 and the outermost end face (X1 side in the X1-X2 direction) of the second lead 24, which are located at the ends of the coil 10. The first lead 14 has a first lead exposed surface 140 that is exposed from the surface of the main body 30. The first lead exposed surface 140 is a first end face of the coil 10 that is exposed from the surface of the main body 30 and is electrically connected to the outer peripheral end 13, which is one electrical end of the coil conductor 20, which is an annular conductor. In addition, the second draw-out portion 24 has a second draw-out exposed surface 240 exposed from the surface of the main body portion 30, and the second draw-out exposed surface 240 is a second end face in the coil portion 10 that is exposed from the surface of the main body portion 30 and is electrically connected to the outer peripheral end portion 23, which is the other electrical end portion of the coil conductor portion 20, which is an annular conductor portion.

[0044] The structure of the magnetic powder is not limited. This structure may include a crystalline phase or an amorphous phase. Here, a crystalline material is defined as a material consisting of a crystalline phase, an amorphous material as a material consisting of an amorphous phase, and a composite material as a material consisting of a crystalline phase and an amorphous material. If the diffraction spectrum obtained by a general X-ray diffraction method includes a sharp diffraction peak that can identify the type of crystalline phase, the material contains a crystalline phase. Also, if the diffraction spectrum obtained by a general X-ray diffraction method includes a broad peak indicating an amorphous phase, the material contains an amorphous phase. If the DSC curve obtained by differential thermal analysis includes a peak indicating crystallization, i.e., heat generation associated with a phase change from an amorphous phase to a crystalline phase, the material also contains an amorphous phase.

[0045] The material system of the magnetic powder is not limited. Specific examples of crystalline materials include Fe—Si—Cr alloys, Fe—Ni alloys, Fe—Co alloys, Fe—V alloys, Fe—Al alloys, Fe—Si alloys, Fe—Si—Al alloys, pure iron, and ferrite. Carbonyl iron powder is preferred as pure iron powder. Specific examples of amorphous materials include Fe—Si—B alloys, Fe—P—C alloys, and Co—Fe—Si—B alloys. Specific examples of composite materials include Fe—Zr alloys, Fe—Zr—B alloys, Fe—Si—B—Nb—Cu alloys, and Fe—Si—B—P—Cu alloys. When the magnetic powder is a metal powder containing Fe, the synergistic effect of improving magnetic properties is particularly large.

[0046] The chemical composition of the magnetic powder is not limited. For example, an Fe—Si—Cr alloy may be composed of 1.0 to 10.0 mass% Si, 1.0 to 10.0 mass% Cr, and the balance consisting of Fe and impurities. Also, for example, an Fe—Ni alloy may be composed of 1.0 to 99.0 mass% Ni, and the balance consisting of Fe and impurities. Furthermore, for example, an Fe—P—C alloy may be composed of 1.0 to 13.0 atomic% P, 1.0 to 13.0 atomic% C, and the balance consisting of Fe and impurities. This Fe—P—C alloy may contain one or more optional elements selected from the group consisting of Ni, Sn, Cr, B, and Si. In this case, for example, the amount of Ni may be 0 to 10.0 atomic %, the amount of Sn may be 0 to 3.0 atomic %, the amount of Cr may be 0 to 6.0 atomic %, the amount of B may be 0 to 9.0 atomic %, and the amount of Si may be 0 to 7.0 atomic %. The amount of Fe is preferably 65 atomic % or more. Furthermore, for example, the Fe-Si-B-Nb-Cu alloy may be composed of 1.0 to 16.0 atomic % Si, 1.0 to 15.0 atomic % B, 0.50 to 5.0 atomic % Nb, 0.50 to 5.0 atomic % Cu, and the balance consisting of Fe and impurities. In this case, the amount of Fe is preferably 65 atomic % or more.

[0047] The shape of the magnetic powder is not limited. The magnetic powder may be spherical, elliptical, scaly, or irregularly shaped. The manufacturing method for obtaining these shapes is also not limited.

[0048] The particle size distribution of the magnetic powder is not limited. The particle size distribution of the magnetic powder can be obtained, for example, by analyzing an image (secondary electron image) obtained by capturing an image of a cut surface of the main body 30 using a scanning electron microscope. For example, the average equivalent circle diameter of the magnetic powder may be 0.50 to 50.0 μm. The distribution of equivalent circle diameters may include multiple peaks.

[0049] The magnetic powder may be subjected to a surface insulating treatment. When the magnetic powder is subjected to a surface insulating treatment, the insulation resistance of the main body 30 is improved. The type of surface insulating treatment to be applied to the magnetic powder is not limited. Examples include phosphate treatment, phosphate salt treatment, and oxidation treatment. The magnetic powder may have an insulating coating on the surface of the magnetic particles. This insulating coating may contain at least one element selected from the group consisting of Si, P, and B, and O (oxygen).

[0050] The magnetic powder may be a mixture of a plurality of powder materials. The magnetic powder is preferably a ferromagnetic material, and more preferably a soft magnetic material.

[0051] The binder contained in the main body 30 binds together particles such as magnetic powder contained in the main body 30. This binder is preferably an insulating material in order to impart insulation resistance to the main body 30.

[0052] The material constituting the binder may be an organic material, an inorganic material, or a mixture of an organic material and an inorganic material. The organic material may be a resin material. Examples of the resin material include acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, melamine resin, and polyester resin. Examples of the inorganic material include glass-based materials such as water glass.

[0053] The material constituting the binder may be a cured product of a curable material that can be cured by heating or the like. In this case, it may be preferable that the curable material be cured to a semi-cured state (so-called B-stage state) that is less cured than the binder and has plasticity. From this perspective, it is preferable that the curable material contains an organic material, and more preferably is composed of multiple materials with different curing initiation temperatures. Therefore, in this specification, the curable material composed of an organic material includes not only the monomer of the resin material, but also the concept of a curing agent such as an amine compound or acid anhydride in epoxy resin, and a crosslinking agent such as a polyisocyanate compound or a compound containing a polyvalent metal ion.

[0054] There are no limitations on the dimensions of the main body 30. For example, the maximum dimension of the main body 30 may be 3.2 mm or less.

[0055] (External Electrodes) As shown in FIG. 2 , the outermost end face (first exposed lead surface 140) of the first lead portion 14 (on the X2 side in the X1-X2 direction) and the outermost end face (second exposed lead surface 240) of the second lead portion 24 (on the X1 side in the X1-X2 direction) located at the end of the coil portion 10 are exposed from the main body portion 30 on side surfaces of the main body portion 30 aligned in the X1-X2 direction. A first terminal portion 41 (see FIG. 1 ) is provided in electrical contact with the first exposed lead surface 140, and a second terminal portion 42 (see FIG. 1 ) is provided in electrical contact with the second exposed lead surface 240. The first terminal portion 41 is an example of a first external electrode, and the second terminal portion 42 is an example of a second external electrode. Note that the first terminal portion 41 and the second terminal portion 42 are electrically separated from each other on the outside of the main body portion 30.

[0056] The first terminal portion 41 has a bottom surface portion 41b (see FIG. 1) provided so as to cover a portion of the second intersecting surface 30f of the main body portion 30. The second terminal portion 42 has a bottom surface portion 42b (see FIG. 1) provided so as to cover another portion of the second intersecting surface 30f of the main body portion 30. These bottom surface portions 41b and 42b are portions that face the substrate 800 when the coil device 100A is mounted on the substrate 800 (see FIGS. 7A and 7B).

[0057] The materials and configurations of the first terminal 41 and the second terminal 42 are not limited as long as they have appropriate conductivity. One non-limiting example of the first terminal 41 and the second terminal 42 is a layer having a Cu-plated / Ni-plated / Sn-plated structure from the side proximal to the surface of the main body 30. The first terminal 41 and the second terminal 42 may be composed of a coated electrode in which a conductive material such as silver is dispersed in a resin or the like. Alternatively, the first terminal 41 and the second terminal 42 may be a combination of plating and a coated electrode.

[0058] (External Coating) An insulating external coating 60 is provided as an insulating layer on the first intersecting plane 30e of the main body 30 and on the outer surfaces 30c and 30d aligned in the Y1-Y2 direction. An insulating external coating 50 is provided on the second intersecting plane 30f of the main body 30, in a portion where the bottom surface 41b of the first terminal 41 and the bottom surface 42b of the second terminal 42 are not provided (between the bottom surface 41b and the bottom surface 42b). The external coatings 50 and 60 may include a layer made of resin with an average thickness of 0.10 μm to 15.0 μm. This facilitates maintaining the magnetic properties of the coil component 100A, improving the insulation of the surface of the coil component 100A to increase the reliability of the coil component 100A, and improving the appearance of the coil component 100A. The coil component 100A may not necessarily include the external coatings 50 and 60. The exterior coats 50, 60 can be formed at any desired position on the surface of the main body 30 depending on the purpose.

[0059] (First Insulating Portion) As shown in the cross-sectional views of Figures 5 and 6, the coil insulating portion includes a first insulating portion 90 that contacts one of the ends of the first spiral conductor portion 11 on the first direction side, specifically, at least a part of the end on the side facing the second spiral conductor portion 21 (the Z2 side in the Z1-Z2 direction). The first insulating portion 90 shown in the cross-sectional view of Figure 5 contacts one of the ends of the second spiral conductor portion 21 on the first direction side, specifically, at least a part of the end on the side facing the first spiral conductor portion 11 (the Z1 side in the Z1-Z2 direction) on the side (the Z2 side in the Z1-Z2 direction) opposite to the side contacting the first spiral conductor portion 11 (the Z1 side in the Z1-Z2 direction). That is, the first insulating portion 90 is interposed between the first spiral conductor portion 11 and the second spiral conductor portion 21 that are aligned in the first direction and contacts both of them. In this way, the first insulating portion 90 contacts the first spiral conductor portion 11, thereby reliably insulating the first spiral conductor portion 11. Furthermore, the first insulating portion 90 contacts both the first spiral conductor portion 11 and the second spiral conductor portion 21, thereby reliably preventing a short circuit between the first spiral conductor portion 11 and the second spiral conductor portion 21.

[0060] The material constituting the first insulating portion 90 is not limited as long as it has appropriate insulating properties. The first insulating portion 90 has a volume resistivity of 1.0×10 14 In some cases, it is preferable that the volume resistivity is 1.0×10 Ωcm or more. 15 More preferably, it is 1.0×10 Ωcm or more. 16 The upper limit of the volume resistivity is not particularly limited. 20The dielectric constant may be Ωcm or less. Furthermore, it is preferable that the first insulating portion 90 has excellent dielectric properties. Specifically, it may be preferable that the dielectric constant at 60 Hz obtained by ASTM D150 is 4.0 or less. This dielectric constant is more preferably 3.5 or less, and even more preferably 3.0 or less. The lower limit of this dielectric constant is not particularly limited. The dielectric constant may be 1.0 or more. The method for measuring the volume resistivity and dielectric constant of the first insulating portion 90 is not limited. For example, a measurement sample is separately prepared by preparing a material corresponding to the first insulating portion 90 to the dimensions required for measurement, and this measurement sample is used to identify the constituent materials through analytical techniques such as component analysis and FT-IR, and the characteristics of the material, such as volume resistivity, are evaluated.

[0061] The material constituting the first insulating portion 90 may be an organic material, an inorganic material, or a composite material of an organic material and an inorganic material. When the first insulating portion 90 is made of a composite material, the inorganic material may be in a particulate form and dispersed in a matrix of an organic material. Specific examples of organic materials include polyimide resin, polyethylene resin, polypropylene resin, polyamide resin, polyester resin, polyamideimide resin, polysulfone resin, polycarbonate resin, liquid crystal polymer resin, polyvinylidene fluoride resin, and polytetrafluoroethylene resin. Specific examples of inorganic materials, particularly inorganic materials in composite materials, include inorganic materials such as oxides, carbides, nitrides, and inorganic salts. Examples of oxides include silica, alumina, and zirconia. Examples of carbides and nitrides include silicon carbide, boron nitride, and silicon nitride, respectively. Examples of inorganic salts include minerals such as wollastonite, kaolin, and mica. Of these, oxide-based materials such as oxides, silicates, and phosphates are preferred in terms of cost and insulating properties. For example, the inorganic material preferably contains at least one selected from the group consisting of silicon (Si), phosphorus (P), boron (B), and calcium (Ca).

[0062] (Second insulating portion) The coil insulating portion has a second insulating portion 80, and as shown in Figures 5 and 6, the second insulating portion 80 is provided on at least a portion of the surface of the first spiral conductor portion 11 and the surface of the second spiral conductor portion 21.

[0063] In this embodiment, the material constituting the second insulating portion 80 is not limited as long as it has appropriate insulating properties. For example, the second insulating portion 80 is thermoplastic and includes a thermoplastic resin containing a paraxylylene-based polymer. Other examples of thermoplastic resins include polyethylene, polypropylene, polyamide, polyester, polyamideimide, polyimide, polysulfone, polycarbonate, liquid crystal polymer, polyvinylidene fluoride, and polytetrafluoroethylene. The second insulating portion 80 as a whole preferably has thermoplastic properties, and may contain, in addition to the above-mentioned thermoplastic resin, for example, inorganic insulating particles. Furthermore, the second insulating portion 80 may be made of the same material as the first insulating portion 90.

[0064] The second insulating portion 80 preferably has excellent insulating properties, specifically, a volume resistivity of 1.0×10 obtained by ASTM D257. 14 In some cases, it is preferable that the volume resistivity is 1.0×10 Ωcm or more. 15 More preferably, it is 1.0×10 Ωcm or more. 16 The upper limit of the volume resistivity is not particularly limited. 20 The dielectric constant may be Ωcm or less. Furthermore, it is preferable that the second insulating portion 80 has excellent dielectric properties. Specifically, it may be preferable that the dielectric constant at 60 Hz obtained by ASTM D150 is 4.0 or less. This dielectric constant is more preferably 3.5 or less, and even more preferably 3.0 or less. The lower limit of this dielectric constant is not particularly limited. The dielectric constant may be 1.0 or more. To measure the volume resistivity and dielectric constant, a separately prepared material corresponding to the second insulating portion 80 is adjusted to the dimensions required for measurement and used. The material corresponding to the second insulating portion 80 can be identified, as in the case of the first insulating portion 90, through analytical techniques such as component analysis and FT-IR.

[0065] (Mounted State) Figures 7A and 7B are schematic diagrams illustrating the mounted state of a coil component on a substrate. Figure 7A shows the mounted state of the coil component 100A according to this embodiment, and Figure 7B shows the mounted state of a coil component 200 according to a comparative example. The coil component 200 has a different outer shape compared to the coil component 100A. Specifically, the coil component 200 has a substantially hexahedral outer shape and does not have the tapered outer side surfaces 301, 302 that the outer side surfaces 30a, 30b of the coil component 100A have. Therefore, when comparing the length in the X1-X2 direction (length between terminal portions) between the X2 end portion in the X1-X2 direction of the portion of the first terminal portion 41 located on the second intersecting plane 30f and the intersection with the X1 end portion in the X1-X2 direction of the portion of the second terminal portion 42 located on the second intersecting plane 30f, the length between terminal portions L2 in coil portion 200 is longer than the length between terminal portions L1 in coil portion 100A.

[0066] When mounting the coil components 100A and 200, the electrodes 810 provided on the substrate 800 are joined to the first terminal portion 41 and the second terminal portion 42 via the solder 850 provided on the electrodes 810.

[0067] Here, the fillet 851 formed during reflow increases the contact area between the solder 850 and the coil components 100A and 200 as the molten solder 850 wets and rises along the outer surfaces 30a and 30b of the main body 30, thereby improving the conductivity and adhesion between the coil components 100A and 200 and the electrode 810.

[0068] To ensure this proper wetting, it is preferable that the electrodes 810 extend to the outside of the coil components 100A and 200, and that the solder 850 properly wets and spreads over this extending portion.

[0069] When the width of coil component 100A according to the present embodiment shown in Fig. 7A and the width of coil component 200 according to the comparative example shown in Fig. 7B are equal, the installation widths W1 and W2 of electrode 810 are determined in either case taking into account the spread of fillet 851 of solder 850. In the case of coil component 200 according to the comparative example shown in Fig. 7B, most of the spread of fillet 851 is located outside outer surfaces 30a and 30b of main body 30 of coil component 200, and therefore the installation width W2 of electrode 810 needs to be determined taking into account the spread of this fillet 851.

[0070] 7A , the coil component 100A according to this embodiment has tapered outer surfaces 301 and 302 on the outer surfaces 30a and 30b of the main body 30, so that the area of ​​the second intersecting surface 30f of the main body 30, which is the mounting surface side of the coil component 100A, is smaller than the area of ​​the first intersecting surface 30e on the opposite side. As a result, as described above, the length L1 between the terminals of the coil component 100A is narrower than the length L2 between the terminals of the coil component 200. Therefore, in the coil component 100A, the installation width W1 of the electrode 810 can be made narrower than the installation width W2 of the electrode 810 required for mounting the coil component 200, without narrowing the width of the electrode 810 (the length in the X1-X2 direction). If an attempt is made to increase the wetting height of the tapered outer surfaces 301, 302 of the solder 850, the fillet 851 inevitably widens (the length in the X1-X2 direction increases), and therefore the width (length in the X1-X2 direction) of the electrode 810 needs to be increased, but a wide installation width W1 of the electrode 810 is an obstacle from the perspective of achieving high-density mounting. As in the coil component 100A according to this embodiment, the installation width W1 of the electrode 810 can be narrowed without narrowing the width (length in the X1-X2 direction) of the electrode 810, thereby achieving an improvement in mounting density without impairing the joint quality of the coil component 100A.

[0071] Here, the tapered outer side surfaces 301 and 302 may have a farthest portion 35 that is farthest from the central axis O in the main body portion 30. In this way, by positioning the farthest portion 35 of the main body portion 30 on the tapered outer side surfaces 301 and 302, it is possible to reduce the mounting area of ​​the coil component 100A after mounting compared to when the tapered outer side surfaces 301 and 302 have the same inclination angle with respect to the central axis O and the farthest portion 35 is located at the boundary with the first intersecting plane 30e, that is, when the farthest portion 35 is located at the end portion of the main body portion 30 on the Z1 side in the Z1-Z2 direction.

[0072] In addition, in coil device 100A, it is preferable that the surface roughness of farthest portion 35 be greater than the surface roughness of other portions of tapered outer side surfaces 301 and 302. As a result, if first terminal portion 41 and second terminal portion 42 are each extended so as to cover at least a portion of farthest portion 35, the adhesion of first terminal portion 41 and second terminal portion 42, which cover at least a portion of farthest portion 35, to main body portion 30 is improved.

[0073] The first terminal 41 may have a side surface 41a provided to cover at least a portion of the outer surface 30a, including the tapered outer surface 301, of the main body 30. The second terminal 42 may have a side surface 42a provided to cover at least a portion of the outer surface 30b, including the tapered outer surface 302, of the main body 30. In this case, at least one of the first end face (first drawn-out exposed surface 140) of the first drawn-out portion 14 and the second end face (second drawn-out exposed surface 240) of the second drawn-out portion 24 may have a portion exposed from the tapered outer surfaces 301 and 302. This positions the first terminal 41 or the second terminal 42 on the tapered outer surface 301 or 302, thereby improving the conductivity of the first terminal 41 or the second terminal 42 and improving adhesion to the solder 850. In the coil component 100A according to this embodiment, as shown in FIGS. 5 and 6, a portion (on the Z2 side in the Z1-Z2 direction) of the second drawn-out exposed surface 240, which is the second end surface, is exposed from the tapered outer surface 302.

[0074] In coil component 100A, side surface portion 41a of first terminal portion 41 covers tapered outer surface 301 and further extends toward first intersecting plane 30e of outer surface 30a, so that first terminal portion 41 located on outer surface 30a is multifaceted. This improves adhesion of first terminal portion 41 of coil component 100A to main body portion 30 compared to coil component 200. Similarly, side surface portion 42a of second terminal portion 42 located on outer surface 30b is also multifaceted, so that improves adhesion of second terminal portion 42 to main body portion 30.

[0075] In coil device 100A, tapered outer surfaces 301 and 302 may include a relatively large number of machining marks in the first direction (Z1-Z2 direction). An example of a process that results in such machining marks is a push-cutting process in which a blade moves in the first direction. The surface roughness of tapered outer surfaces 301 and 302 having such machining marks is higher than the surface roughness of a molded surface formed by a molding process that uses a mold or other die to increase the overall pressure on a workpiece within the die and transfer the shape of the mold surface to the workpiece. Therefore, the adhesion of members (specifically, first terminal portion 41 and second terminal portion 42) positioned to cover tapered outer surfaces 301 and 302 to main body portion 30 is enhanced.

[0076] When the tapered outer surfaces 301 and 302 are processed by press-cutting and contain the above-described processing marks, the magnetic powder located on the tapered outer surfaces 301 and 302 does not have a cut surface. In other words, the magnetic powder located on the tapered outer surfaces 301 and 302 is made of raw powder that has not been subjected to cutting. When the magnetic powder is made of raw powder, corrosion is less likely to occur even if the magnetic powder contains a metallic material. Therefore, the main body 30 has excellent stability of magnetic properties over time.

[0077] Second Embodiment FIG. 8 is a cross-sectional view illustrating a coil component according to a second embodiment. In a coil component 100B according to the second embodiment, the entire outer surface 30a of the main body 30 is a tapered outer surface 301, and the entire outer surface 30b of the main body 30 is a tapered outer surface 302. As a result, when viewed from the first direction, the coil component 100B has a wider overlapping area with the electrode 810 than the coil component 100A according to the first embodiment. Therefore, when the coil component 100B is mounted, the amount of fillet 851 (see FIG. 7A ) of the solder 850 (see FIG. 7A ) that is hidden in the shadow of the coil component 100B when viewed from the first direction can be increased, thereby achieving higher joint stability than the coil component 100A without increasing the installation width W1 (see FIG. 7A ) of the electrode 810.

[0078] Third Embodiment Fig. 9 is a cross-sectional view illustrating a coil component according to a third embodiment. In a coil component 100C according to the third embodiment, the outer surface 30a of the main body 30 includes a tapered outer surface 301 and a tapered outer surface 303, and the outer surface 30b of the main body 30 includes a tapered outer surface 302 and a tapered outer surface 304. Unlike the tapered outer surface 301, the tapered outer surface 303 is an inclined surface that approaches the central axis O (see Fig. 2) as it approaches the first intersecting plane 30e. Similarly, unlike the tapered outer surface 302, the tapered outer surface 304 is an inclined surface that approaches the central axis O (see Fig. 2) as it approaches the first intersecting plane 30e. A non-inclined surface may or may not be provided between the tapered outer surface 301 and the tapered outer surface 303 on the outer surface 30a.

[0079] 10 is a cross-sectional view illustrating a coil component according to a fourth embodiment. In a coil component 100D according to the fourth embodiment, at least a portion of a first lead-out exposed surface 140, which is an end face of a first lead-out portion 14, is exposed from the second intersecting surface 30f, and at least a portion of a second lead-out exposed surface 240, which is an end face of a second lead-out portion 24, is exposed from a portion of the second intersecting surface 30f different from the exposed portion of the first lead-out exposed surface 140. That is, in the coil component 100D, each of the first lead-out portion 14 and the second lead-out portion 24 extends in the Z1-Z2 direction Z2 and reaches the second intersecting surface 30f.

[0080] 10 , the first drawn exposed surface 140 and the second drawn exposed surface 240 may be exposed only on the second intersecting surface 30f of the main body portion 30, without being exposed on the outer side surfaces 30a and 30b of the main body portion 30. Alternatively, the first drawn exposed surface 140 may be exposed from both the second intersecting surface 30f and the outer side surface 30a, or the second drawn exposed surface 240 may be exposed from both the second intersecting surface 30f and the outer side surface 30b. That is, in the coil device 100D, at least a portion of the first drawn exposed surface 140 is exposed from the second intersecting surface 30f, and at least a portion of the second drawn exposed surface 240 is exposed from the second intersecting surface 30f.

[0081] In such a coil device 100D, electrical conduction is established between the coil conductor portion 20 and the first terminal portion 41 and the second terminal portion 42 at least on the second intersecting surface 30f of the main body portion 30. In this case, the first terminal portion 41 and the second terminal portion 42 may be provided only on a portion of the second intersecting surface 30f of the main body portion 30.

[0082] (Manufacturing Method of Coil Component) Next, a manufacturing method of the coil component according to this embodiment will be described. In the manufacturing method of the coil component according to this embodiment, a member including the coil portion 10 and the semi-hardened material 401h (described in detail below) is subjected to slit formation processing and / or groove formation processing, and then a hardening step is performed to harden the semi-hardened material 401h. This makes it possible to manufacture not only the coil components 100A to 100D according to this embodiment described above, but also the coil component 200 with high productivity.

[0083] (First Manufacturing Method) FIGS. 11A to 19 are diagrams illustrating a first manufacturing method of a coil component. First, as shown in FIG. 11A , multiple spiral portions (first spiral conductor portion 11, second spiral conductor portion 21) are formed. Specifically, the first spiral conductor portion 11 is formed on one surface (specifically, the surface on the Z1 side in the Z1-Z2 direction) of an insulating sheet base material 91, and the second spiral conductor portion 21 is formed on the other surface (specifically, the surface on the Z2 side in the Z1-Z2 direction) of the sheet base material 91. The formation process of the first spiral conductor portion 11 and the second spiral conductor portion 21 is not particularly limited. For example, they can be formed by a plating process. In this embodiment, via conductor portions VP and the first and second lead portions 14 and 24 are also formed simultaneously in this process.

[0084] Here, the sheet substrate 91 is not particularly limited as long as it has the mechanical properties necessary to function as a support when forming the first spiral conductor 11 and the second spiral conductor 21, and the suitability (removal properties) for the process described below. Examples of materials constituting the sheet substrate 91 include organic materials, inorganic materials, and composite materials thereof. Specific examples of organic materials include thermoplastic resins such as polyimide resin and polyethylene resin, thermosetting resins such as epoxy resin and phenolic resin, and cellulose. Specific examples of inorganic materials include oxide-based materials such as glass and alumina, metal-based materials such as aluminum and magnesium, and inorganic salt-based materials such as calcium carbonate. Specific examples of composite materials include a structure in which an inorganic material is dispersed in a matrix of an organic material. Among these materials, polyimide resin and epoxy resin are preferred. In particular, polyimide resin is most preferred when combined with a plating process.

[0085] Next, at least a portion of the sheet base material 91 is removed. Specifically, when viewed in the first direction (Z1-Z2 direction), the sheet base material 91 is removed so as to include the region of the sheet base material 91 that is surrounded by the inner edge of the first spiral conductor portion 11. Portions of the sheet base material 91 on both ends in the first direction, on which the components of the coil conductor portion 20 (such as the first spiral conductor portion 11 and the second spiral conductor portion 21) are formed, remain without being removed and become the first insulating portion 90 (see FIG. 11C ).

[0086] The specific removal process for the sheet substrate 91 is set appropriately depending on the constituent material of the sheet substrate 91. Removal processes are broadly classified into dry processes such as plasma etching and wet processes such as wet etching. A portion of the sheet substrate 91 may be removed by the removal process, with the remaining portion remaining unremoved. For example, the sheet substrate 91 may be made of a composite material of an organic material and an inorganic material, and only the organic material may be removed by the removal process.

[0087] Next, an insulating coating is applied to the exposed surfaces of the coil conductor portion 20, including the first spiral conductor portion 11 and the second spiral conductor portion 21. The process for forming the insulating coating is appropriately determined depending on the constituent material of the second insulating portion 80. For example, if the second insulating portion 80 is made of a paraxylylene-based polymer, it is formed by a dry process (CVD). If the second insulating portion 80 contains a curable resin material such as epoxy resin, it can be formed by applying a powder or liquid containing the constituent material of the second insulating portion 80 to the exposed surface and then solidifying the deposit by heating or the like. Other methods include dip coating, sputtering, PVD, and autodeposition. As a result, a coil array sheet 500 is formed in which multiple coil portions 10 are supported by the first insulating portion 90, which is made up of the remaining portion of the sheet substrate 91, as shown in the XY plan view of FIG. 11B and the XZ cross-sectional view of FIG. 11C (cross-section taken along line CC' in FIG. 11B).

[0088] Next, as shown in FIGS. 12A to 12C , a first member 410 is formed, which includes a semi-hardened product 401h of the curable material 401 and magnetic powder 402. Specifically, as shown in FIG. 12A , a member material 405 including the curable material 401 and magnetic powder 402 is placed in the cavity C1 of the mold M1, and as shown in FIG. 12B , the member material 405 in the cavity C1 is heated while being pressed with the upper mold M11. This pressing and heating causes the curable material 401 to harden to a certain extent, forming a semi-hardened product 401h that is in a state before reaching the binder 403 and has plasticity. In this way, as shown in FIG. 12C , a first member 410 including the semi-hardened product 401h and magnetic powder 402 is formed in the cavity C1 of the mold M1. Because the first member 410 includes the semi-hardened product 401h that has plasticity, it is in a so-called B-stage state, which is plastic as a whole. The curable material 401 contained in the member material 405 may already be a semi-hardened material 401h before being placed in the cavity C1 of the mold M1. In this case, only pressure is applied to the member material 405 inside the mold M1, which causes plastic deformation of the semi-hardened material 401h to form a first member 410 having a shape corresponding to the cavity C1.

[0089] 13A and 13B, the first member 410 and the coil portion 10 are accommodated in the cavity C2 of the mold M2. Specifically, a plurality of coil portions 10 are included in the coil array sheet 500. The coil array sheet 500 including the coil portions 10 is sandwiched between the pair of first members 410 in the cavity C2 and pressed by the upper mold M21 in this state. The pressing by the upper mold M21 integrates the pair of first members 410 in the cavity C2, and a first intermediate member 420 (see FIG. 13C) is formed in which the coil portions 10 are embedded in the integrated first members 410.

[0090] 14 to 15B, a slit is formed in the first intermediate member 420 (see FIG. 13C) including the semi-hardened material 401h to obtain a second intermediate member 430. Fig. 14 shows an XY plan view of the second intermediate member 430, Fig. 15A shows a cross section taken along line DD' in Fig. 14, and Fig. 15B shows a cross section taken along line EE' in Fig. 14.

[0091] In the slit forming process performed in this manufacturing method, slits 421 are formed along the X1-X2 direction between multiple coil portions 10 aligned in the Y1-Y2 direction, penetrating the first intermediate member 420 in the Z1-Z2 direction. This results in the formation of multiple second intermediate members 430, each of which is formed by dividing the first intermediate member 420 into multiple pieces. The specific processing means for the slit forming process is arbitrary, and specific examples include cutting with a blade or cutting with a dicing saw. Figures 14 to 15B show the case where cutting with a dicing saw is performed.

[0092] After the second intermediate member 430 is formed, a curing process is performed to harden the semi-hardened material 401h contained in the second intermediate member 430 into a binder 403 (see FIG. 16A). This forms a third intermediate member 440 (see FIG. 16A). The specific conditions for the curing process are set appropriately depending on the composition and hardened state of the semi-hardened material 401h, and a specific example is holding the semi-hardened material 401h at about 175°C for 5 hours.

[0093] Next, as shown in Figures 16A and 16B, an exterior coating process is applied to the third intermediate member 440. Figure 16A shows a cross section of the third intermediate member 440 when viewed from the same position as line D-D' in Figure 14, and Figure 16B shows a cross section of the third intermediate member 440 when viewed from the same position as line E-E' in Figure 14. By the exterior coating process, necessary parts of the surface of the third intermediate member 440, including the inner surfaces of the slits 421 formed by the slit forming process, are covered with an exterior coating material 600.

[0094] Next, as shown in Fig. 17 to Fig. 18B, the third intermediate member 440 (see Fig. 16A) is divided into individual pieces. Fig. 17 shows an XY plan view of the third intermediate member 440 shown in Fig. 16A after it has been divided into individual pieces, Fig. 18A shows a cross section taken along line DD' in Fig. 17, and Fig. 18B shows a cross section taken along line EE' in Fig. 17.

[0095] In this manufacturing method, a dividing process is performed to divide the plurality of coil portions 10 arranged in the X1-X2 direction in the third intermediate member 440 in a direction perpendicular to the processing direction of the slit forming process (specifically, the Y1-Y2 direction). This dividing process forms slits 422 that run along the Y1-Y2 direction and penetrate the third intermediate member 440 in the Z1-Z2 direction between the plurality of coil portions 10 arranged in the X1-X2 direction. The specific processing means for the dividing process are arbitrary, and specific examples include cutting with a blade or cutting with a dicing saw. FIG. 18A shows the case where cutting with a dicing saw is performed. By dividing the third intermediate member 440, the third intermediate member 440 is divided into individual coil portions 10, and coil component members 451 are formed. In the coil component member 451, when the third intermediate member 440 is divided by cutting with a dicing saw, the first draw-out portion 14 and the second draw-out portion 24 of the coil section 10 are formed, and the first draw-out exposed surface 140 and the second draw-out exposed surface 240 are exposed from the inner surface (first processed surface 450a) of the slit 422 formed by the dividing process.

[0096] After forming the coil component member 451, as shown in FIG. 19 , the first terminal portion 41 and the second terminal portion 42 are formed on the surface of the coil component member 451, including the first processed surface 450a, on which the exterior coating material 600 is not provided. Because the first exposed lead surface 140 and the second exposed lead surface 240 are exposed from the first processed surface 450a of the coil component member 451, forming the first terminal portion 41 and the second terminal portion 42 on the first processed surface 450a establishes electrical continuity between the coil portion 10 and the first terminal portion 41 and the second terminal portion 42. This completes the coil component 100E. The shape of the coil component 100E is identical to that of the coil component 200. Therefore, the first manufacturing method according to this embodiment enables high productivity even for the coil component 200 according to the prior art.

[0097] 20A to 26B are diagrams illustrating a second manufacturing method of a coil component. In the second manufacturing method, the process up to the formation of the coil array sheet 500 and the first member 410 is the same as in the first manufacturing method. Next, as shown in FIG. 20A , the first member 410 and the coil section 10 are housed in the cavity C3 of the mold M3. In this manufacturing method, a plurality of coil sections 10 are included in the coil array sheet 500. The coil array sheet 500 including the coil sections 10 is sandwiched between a pair of first members 410 in the cavity C3 and pressed in this state by the upper mold M31.

[0098] In the second manufacturing method, a mountain-shaped protrusion P1 is provided on the upper mold M31. By pressing this protrusion P1 toward the first member 410 with the upper mold M31, the pair of first members 410 are integrated within the cavity C3, sandwiching the coil portion 10. At this time, a groove forming process is performed in which the protrusion P1 processes a portion of the first member 410 to form the groove G1, thereby forming the second intermediate member 430. That is, as shown in FIG. 20B , in the second manufacturing method, in contrast to the first manufacturing method, the process of forming the first intermediate member 420 and the groove forming process of forming the groove G1 are performed in a single process to form the second intermediate member 430. Therefore, the member removed from the mold M3 becomes the second intermediate member 430 (see FIGS. 21 to 22B ).

[0099] The shape, size, and arrangement of the protrusions P1 (see FIGS. 20A and 20B), which are the processing means for groove formation in this example, are set as appropriate. As will be described later, when fracture processing is performed from the surface of the groove G1 formed by the protrusions P1, the shape of the protrusions P1 is set so that the surface of the groove G1 has a shape that makes it easy to form a starting point for fracture processing.

[0100] 21 to 22B show a second intermediate member 430 having a groove G1. Fig. 21 shows an XY plan view of the second intermediate member 430, Fig. 22A shows a cross section taken along line DD' in Fig. 21, and Fig. 22B shows a cross section taken along line EE' in Fig. 21.

[0101] The second intermediate member 430 has a substantially V-shaped groove G1 to which the shape of the protrusion P1 (see FIGS. 20A and 20B) has been transferred. The protrusion P1 is disposed at a position corresponding to a gap between the multiple coil portions 10, and is provided extending in one direction (specifically, the Y1-Y2 direction). As a result, the groove G1 is also provided extending in one direction (specifically, the Y1-Y2 direction) between the multiple coil portions 10 in accordance with the extension of the protrusion P1. Specifically, the groove G1 is provided on the Z1 side of the second intermediate member 430 in the Z1-Z2 direction, and is provided in a substantially V-shape that is pointed toward the Z2 side.

[0102] Next, as shown in Figures 23 to 24B, slit formation processing is performed on the second intermediate member 430. Figure 23 shows an XY plan view of the second intermediate member 430, Figure 24A shows a cross section taken along line DD' in Figure 23, and Figure 24B shows a cross section taken along line EE' in Figure 23.

[0103] This slit formation process forms slits 423 that penetrate the second intermediate member 430 along the X1-X2 direction and in the Z1-Z2 direction between the multiple coil portions 10 aligned in the Y1-Y2 direction, dividing the second intermediate member 430 into multiple pieces. Any processing method can be used for the slit formation process, and specific examples include cutting with a blade or cutting with a dicing saw. Figures 23 and 24B show a case where cutting with a dicing saw is used as the slit formation process. The surface formed by the slit formation process (the inner surface of the slit 423) is aligned in the first direction (the Z1-Z2 direction). This processing increases the volume of the main body 30 and improves its magnetic properties, compared to when the inner surface of the slit 423 includes a tapered surface.

[0104] After the slits 423 are formed in the second intermediate member 430, a curing process is performed to harden the semi-hardened material 401h contained in the second intermediate member 430 into the binder 403 (see FIG. 25A). This forms the third intermediate member 440 (see FIG. 25A). The specific conditions for the curing process are set appropriately depending on the composition and hardened state of the semi-hardened material 401h, and a specific example is holding it at about 175°C for 5 hours.

[0105] Next, as shown in Figures 25A and 25B, an exterior coating process is applied to the third intermediate member 440. Figure 25A shows a cross section of the third intermediate member 440 when viewed from the same position as line D-D' in Figure 23, and Figure 25B shows a cross section of the third intermediate member 440 when viewed from the same position as line E-E' in Figure 23. By the exterior coating process, necessary parts of the surface of the third intermediate member 440, including the inner surfaces of the slits 423 formed by the slit forming process, are covered with an exterior coating material 600.

[0106] Next, a third intermediate member 440 having a plurality of coil portions 10 aligned in the X1-X2 direction is subjected to a breaking process, in which the third intermediate member 440 is broken along the surface of the groove G1 formed by the groove forming process (see FIGS. 26A and 26B ). As a result, the third intermediate member 440 is divided, and a second processed surface 450b is formed in the third intermediate member 440, the second processed surface 450b including the extension direction of the groove G1 (the Y1-Y2 direction) and the first direction (the Z1-Z2 direction) as in-plane directions.

[0107] In this manufacturing method, the breaking process is performed by an existing snap break method. By the breaking process, the third intermediate member 440 having a plurality of coil portions 10 arranged in the X1-X2 direction is separated into individual coil portions 10, forming coil component members 452. In the coil component member 452, when the third intermediate member 440 is broken, the first lead portion 14 and the second lead portion 24 of the coil portion 10 are formed, and the first lead exposed surface 140 and the second lead exposed surface 240 are exposed from the second processed surface 450b.

[0108] 26B , after the coil component member 452 is formed, the first terminal 41 and the second terminal 42 are formed on the surface of the coil component member 452, including the second processed surface 450b, on which the exterior coating material 600 is not provided. Because the first drawn-out exposed surface 140 and the second drawn-out exposed surface 240 are exposed from the second processed surface 450b of the coil component member 452, forming the first terminal 41 and the second terminal 42 on the second processed surface 450b establishes electrical continuity between the coil portion 10 and the first terminal 41 and the second terminal 42. This completes the coil component 100F.

[0109] In addition, in the coil component 100F (see FIG. 26B ) obtained by the second manufacturing method, dummy electrodes 71 are formed at opposing positions of the first lead portion 14 and at opposing positions of the second lead portion 24, with the first insulating portion 90 sandwiched therebetween. The dummy electrodes 71 are not electrically connected to the first terminal portion 41 and the second terminal portion 42, and are not electrically connected to the first spiral conductor portion 11 and the second spiral conductor portion 21. When forming the coil array sheet 500, it is possible to manufacture a coil component 100F that does not substantially include the dummy electrodes 71 by shortening the length in the X1-X2 direction of the portion that extends outside the first lead portion 14 and the portion that extends outside the second lead portion 24 that overlap in the first direction (Z1-Z2 direction). Alternatively, a coil component 100F in which the dummy electrodes 71 are not substantially formed can be manufactured by performing a slit forming process instead of the breaking process for obtaining the coil component members 452.

[0110] (Variation 1 of the Second Manufacturing Method) In the second manufacturing method described above, the curing process for curing the semi-hardened material 401h to obtain the binder 403 may be performed between the groove forming process for forming the groove G1 shown in FIGS. 21 to 22B and the slit forming process for forming the slit 423 shown in FIG. 23 . In this case, the slit forming process for forming the slit 423 shown in FIG. 23 is performed on the third intermediate member 440 containing the binder 403 obtained by hardening the semi-hardened material 401h. Therefore, in the groove forming process for forming the groove G1, the semi-hardened material 401h is likely to undergo plastic deformation during processing. As a result, the magnetic powder 402 moves relatively easily inside the first intermediate member 420. Therefore, a cut surface of the magnetic powder 402 is unlikely to be formed. On the other hand, in the slit forming process for forming the slit 423, the third intermediate member 440 is cut in a state in which the magnetic powder 402 is supported by the binder 403 obtained by hardening the semi-hardened material 401h. Therefore, the magnetic powder 402 is relatively difficult to move inside the third intermediate member 440. Therefore, cut surfaces of the magnetic powder 402 are easily formed.

[0111] (Variant 2 of the second manufacturing method) In the above-described second manufacturing method, the first intermediate member 420 and the second intermediate member 430 are formed in a single process including processing to form the first intermediate member 420 and groove forming processing to form the groove G1 using the mold M3 and the upper mold M31 having the protrusion P1 shown in Figures 21 to 22B, but these processes may also be performed in separate processes.

[0112] Specifically, after forming the first intermediate member 420 using a mold that does not have the protrusions P1, as shown in Figures 26C to 26E, the grooves G1 may be formed in the first intermediate member 420 removed from the mold by press-cutting using a cutting tool B1 having a protruding blade P11. In this case, the semi-hardened material 401h is likely to undergo plastic deformation during processing. Therefore, the magnetic powder 402 moves relatively easily inside the first intermediate member 420, and a cut surface of the magnetic powder 402 is unlikely to be formed. Therefore, corrosion is unlikely to occur even if the magnetic powder 402 includes a portion made of a metallic material.

[0113] 27A is a schematic perspective view illustrating a surface formed by groove forming processing and a surface formed by fracture processing. Fig. 27A shows the state of the outer surface 30b (see Fig. 2) of the main body 30 (see Fig. 2) formed by fracture processing starting from the portion formed by groove forming processing (groove G1).

[0114] The side surface of the groove G1 formed by the groove forming process has a third processed surface 450c that includes a relatively large number of processing marks M of a component in the first direction (Z1-Z2 direction) due to the push-cutting by the protrusion P1 (see FIGS. 20A and 20B) compared to the case of the molding process. Comparing the third processed surface 450c by push-cutting with the surface formed by the molding process, in the case of the groove forming process by push-cutting, the force that deforms the first member 410 (the mixture of the semi-hardened material 401h and the magnetic powder 402) in the first intermediate member 420 is applied unilaterally and dynamically from a blade (tool), whereas in the molding process, the force is applied isotropically and statically from a mold (tool). For this reason, in the groove forming process, the amount of deformation of the first member 410 near the tool is non-uniform, reflecting the distribution of the magnetic powder 402 inside that part (region farther from the tool), but in the molding process, the pressure across the entire first member 410 is highly uniform, so the amount of deformation of the first member 410 near the mold is relatively uniform and is not affected by the distribution of the magnetic powder 402 inside the first member 410. Therefore, the third machined surface 450c formed by the groove forming process has more machining marks M than the surface formed by the molding process.

[0115] As described above, the third processed surface 450c has a relatively large number of processing marks M, and therefore its surface roughness is higher than that of a molded surface formed by molding using a mold such as a die, etc. Therefore, the adhesion of a member positioned to cover the third processed surface 450c is improved.

[0116] In the breaking process, the processing force is applied to the workpiece in a shorter time than in the groove forming process using a push cut. Therefore, the surface roughness of the second processed surface 450b formed by breaking starting from the groove G1 in the binder 403 tends to be higher than that of the third processed surface 450c. Therefore, when the first exposed drawer surface 140 and the second exposed drawer surface 240 are exposed from the second processed surface 450b, the adhesion of the first terminal portion 41 and the second terminal portion 42 formed on the second processed surface 450b is improved, thereby improving the conductivity between the first exposed drawer surface 140 and the first terminal portion 41 and between the second exposed drawer surface 240 and the second terminal portion 42.

[0117] FIG. 27B is a schematic cross-sectional view illustrating the fracture state, with the coil portion 10 omitted for ease of understanding. FIG. 27C is a schematic cross-sectional view illustrating the cutting state, with the coil portion 10 omitted for ease of understanding. As shown in FIG. 27B , when the third intermediate member 440 is fractured starting from the groove G1, the binder 403 is destroyed, causing the third intermediate member 440 to split. As a result, a portion of the magnetic powder 402 is exposed from the second processed surface 450b, or the magnetic powder 402 is missing, leaving traces (depressions: recesses) where the magnetic powder 402 was present on the second processed surface 450b. Therefore, the magnetic powder 402 located near the second processed surface 450b is made of unprocessed powder with no cut surface. Therefore, even if the magnetic powder 402 includes a portion made of a metallic material, corrosion is less likely to occur near the second processed surface 450b. 27C , when the third intermediate member 440 is divided by cutting, not only the binder 403 contained in the third intermediate member 440 but also the magnetic powder 402 is cut. As a result, the processing marks of the magnetic powder 402 are exposed from the fourth processed surface 450d formed by the cutting process.

[0118] 28A to 29B are diagrams illustrating a third manufacturing method of a coil component. The third manufacturing method is a manufacturing method in which, in the second manufacturing method described above, instead of providing a protrusion P1 on the upper mold M31 shown in FIGS. 20A and 20B , a protrusion P2 is provided on the bottom surface of the cavity C4 of the mold M4 as shown in FIG. 28A .

[0119] 28A, a mold M4 is prepared in which a protrusion P2 is provided on the bottom surface of a cavity C4, and a first member 410 and a coil portion 10 are housed in this cavity C4. In this manufacturing method, a plurality of coil portions 10 are included in a coil array sheet 500. The coil array sheet 500 including the coil portions 10 is sandwiched between a pair of first members 410 in the cavity C4, and in this state is pressed by an upper mold M41. The upper mold M41 is not provided with a protrusion P1.

[0120] 28B and 28C, in the third manufacturing method, groove formation processing is performed using a protrusion P2 provided in a cavity C4 of a mold M4, thereby forming a second intermediate member 430 having a groove G2 on the Z2 side in the Z1-Z2 direction. The groove G2 is provided in a generally V-shape that is pointed toward the Z1 side in the Z1-Z2 direction.

[0121] The shape, size, and arrangement of the protrusions P2, which are processing means for groove formation in this example, are set as appropriate. As will be described later, when fracture processing is performed from the surface of the groove G2 formed by the protrusions P2, the shape of the protrusions P2 is set so that the surface of the groove G2 has a shape that makes it easy to form a starting point for fracture processing.

[0122] Then, the second intermediate member 430 is subjected to a slit forming process and a hardening process similar to the slit forming process for forming the slit 423 in the second manufacturing method, to obtain a third intermediate member 440. This third intermediate member 440 is subjected to a fracture process, in which the third intermediate member 440 is fractured from the surface on which the groove G2 is formed by the groove forming process. As a result, as shown in FIG. 29A , the third intermediate member 440 is divided, and a second processed surface 450b is formed in the third intermediate member 440, the second processed surface 450b including the extension direction of the groove G2 (Y1-Y2 direction) and the first direction (Z1-Z2 direction) as in-plane directions.

[0123] The breaking process is performed by an existing snap break method. By the breaking process, the third intermediate member 440 having a plurality of coil portions 10 arranged in the X1-X2 direction is separated into individual coil portions 10, thereby forming a coil component member 453. In the coil component member 453, when the third intermediate member 440 is broken, the first lead portion 14 and the second lead portion 24 of the coil portion 10 are formed, and the first lead exposed surface 140 and the second lead exposed surface 240 are exposed from the second processed surface 450b.

[0124] After forming the coil component member 453, as shown in FIG. 29B , the first terminal 41 and the second terminal 42 are formed on the surface of the coil component member 453, including the second processed surface 450b, that is not provided with the exterior coating material 600. Because the first exposed lead surface 140 and the second exposed lead surface 240 are exposed from the second processed surface 450b of the coil component member 453, forming the first terminal 41 and the second terminal 42 on the second processed surface 450b establishes electrical continuity between the coil portion 10 and the first terminal 41 and the second terminal 42. This completes the coil component 100G. The coil component 100G corresponds to the coil component 100A (see FIG. 5 ).

[0125] The coil component 100G obtained by the third manufacturing method is provided with the dummy electrodes 71, as is the coil component 100F obtained by the second manufacturing method, but it does not have to be provided with the dummy electrodes 71. As in the second manufacturing method, it is possible to prevent the dummy electrodes 71 from being formed by changing the shape of the coil array sheet 500A or by changing the processing means for obtaining the coil component member 453.

[0126] The third manufacturing method may also have the same variations as the second manufacturing method. That is, as shown in Figures 24A to 25B, the curing process for curing the semi-hardened material 401h to obtain the binder 403 may be performed between the groove forming process for forming the groove G2 and the slit forming process for forming the slit 423 in the direction (X1-X2 direction) perpendicular to the extension direction of the groove G2 (Y1-Y2 direction). Alternatively, the process for forming the first intermediate member 420 and the groove forming process for forming the second intermediate member 430 may be performed in separate steps.

[0127] As another modification, instead of the groove forming process for forming the groove G2, a slit forming process extending in the Y1-Y2 direction may be performed by pressing. In this case, a configuration is formed in which the entire outer surface 30a is made of the tapered outer surface 301 and the entire outer surface 30b is made of the tapered outer surface 302, i.e., the coil component 100B according to the second embodiment (see FIG. 8) is formed. In this modification, the slit forming process may be performed in the same process as the molding process, or a molding process may be performed first to obtain a first intermediate member 420, and then a slit forming process may be performed on this first intermediate member 420 to obtain a second intermediate member 430.

[0128] 30A to 36B are diagrams illustrating a fourth manufacturing method of a coil component. In the fourth manufacturing method, as shown in FIG. 30A , a protrusion P31 is provided on an upper mold M51, and a protrusion P32 is also provided on the bottom surface of a cavity C5 of a mold M5.

[0129] In the fourth manufacturing method, the process up to the formation of the coil array sheet 500 and the first member 410 is the same as in the first manufacturing method. Next, as shown in Figures 30A and 30B, the first member 410 and the coil section 10 are housed in the cavity C5 of the mold M5. In this manufacturing method, a plurality of coil sections 10 are included in the coil array sheet 500. The coil array sheet 500 including the coil sections 10 is sandwiched between a pair of first members 410 in the cavity C5 and pressed in this state by the upper mold M51.

[0130] In the fourth manufacturing method, a mountain-shaped protrusion P31 is provided on the upper mold M51, and a mountain-shaped protrusion P32 is provided on the cavity C5 of the mold M5. The coil array sheet 500 is sandwiched between a pair of first members 410, placed in the cavity C5, and pressed by the upper mold M51, thereby integrating the pair of first members 410 within the cavity C5, and forming a first intermediate member 420 in which the integrated first members 410 include a coil portion 10. At this time, groove forming processing is performed to form grooves G31 (see FIG. 31) and G32 (see FIG. 32A) in the first member 410 using the protrusions P31 and P32, thereby forming a second intermediate member 430 (see FIG. 31). In other words, in this manufacturing method, the processing for forming the first intermediate member 420 and the processing for forming the grooves are performed in a single process, thereby forming the second intermediate member 430.

[0131] In this example, the shape, size, and arrangement of the protrusions P31 and P32, which are the processing means for groove formation, are set as appropriate. As will be described later, when fracture processing is performed from the surface of the groove G31 or the surface of the groove G32 formed by the protrusions P31 and P32, the shape of the protrusions P31 or P32 is set so that the surface of the groove G31 or the surface of the groove G32 has a shape that makes it easy to form a starting point for fracture processing. In addition, the width and height of the groove on the side that does not become the starting point for fracture processing are also set so that the second processed surface 450b is easily formed appropriately.

[0132] Figures 31 to 32B show a second intermediate member 430 having grooves G31 and G32. Figure 31 shows an XY plan view of the second intermediate member 430, Figure 32A shows a cross section taken along line DD' in Figure 31, and Figure 32B shows a cross section taken along line EE' in Figure 31.

[0133] The second intermediate member 430 has a substantially V-shaped groove G31 to which the shape of the protrusion P31 (see FIGS. 30A and 30B) has been transferred, and also has a substantially V-shaped groove G32 to which the shape of the protrusion P32 (see FIGS. 30A and 30B) has been transferred. Because the protrusions P31 and P32 are disposed opposite each other in the Z1-Z2 direction, the grooves G31 and G32 formed in the second intermediate member 430 are also provided at opposing positions.

[0134] The protrusions P31 and P32 are each disposed at a position corresponding to a gap between the multiple coil portions 10 and extend in one direction (specifically, the Y1-Y2 direction). As a result, the grooves G31 and G32 are also provided extending in one direction (specifically, the Y1-Y2 direction) between the multiple coil portions 10 in accordance with the extension of the protrusions P31 and P32. The groove G31 is provided on the Z1 side of the second intermediate member 430 in the Z1-Z2 direction and has a generally V-shape that tapers toward the Z2 side. The groove G32 is provided on the Z2 side of the second intermediate member 430 in the Z1-Z2 direction and has a generally V-shape that tapers toward the Z1 side.

[0135] Next, as shown in Figures 33 to 34B, a slit forming process is performed to form slits 423 in the second intermediate member 430. Figure 33 shows an XY plan view of the second intermediate member 430, Figure 34A shows a cross section taken along line DD' in Figure 33, and Figure 34B shows a cross section taken along line EE' in Figure 33.

[0136] This slit formation process forms slits 423 that penetrate the second intermediate member 430 along the X1-X2 direction and in the Z1-Z2 direction between the multiple coil portions 10 aligned in the Y1-Y2 direction, dividing the second intermediate member 430 into multiple pieces. Any processing method can be used for the slit formation process, and specific examples include cutting with a blade or cutting with a dicing saw. Figures 33 and 34B show a case where cutting with a dicing saw is used as the slit formation process. The surface formed by the slit formation process (the inner surface of the slit 423) is aligned in the first direction (the Z1-Z2 direction). This processing increases the volume of the main body 30 and improves its magnetic properties, compared to when the inner surface of the slit 423 includes a tapered surface.

[0137] After the slits 423 are formed in the second intermediate member 430, a curing process is performed to harden the semi-hardened material 401h contained in the second intermediate member 430 into the binder 403 (see FIG. 35A ). This forms the third intermediate member 440 (see FIG. 35A ). The specific conditions for the curing process are set appropriately depending on the composition and hardened state of the semi-hardened material 401h, and a specific example is holding it at about 175°C for 5 hours.

[0138] Next, as shown in Figures 35A and 35B, an exterior coating process is applied to the third intermediate member 440. Figure 35A shows a cross section of the third intermediate member 440 when viewed from the same position as line D-D' in Figure 33, and Figure 35B shows a cross section of the third intermediate member 440 when viewed from the same position as line E-E' in Figure 33. By the exterior coating process, necessary parts of the surface of the third intermediate member 440, including the inner surfaces of the slits 423 formed by the slit forming process, are covered with exterior coating material 600.

[0139] Next, the third workpiece 440 is subjected to a breaking process (see FIG. 36A ) to break the workpiece from the surface where the grooves G31 and G32 are formed by the groove forming process. As a result, the third workpiece 440 is divided, and a second processed surface 450b is formed in the third workpiece 440, the second processed surface 450b including the extension direction (Y1-Y2 direction) of the groove G31 or the groove G32 and the first direction (Z1-Z2 direction) as in-plane directions.

[0140] The breaking process is performed by an existing snap break method. By the breaking process, the third intermediate member 440 having a plurality of coil portions 10 arranged in the X1-X2 direction is separated into individual coil portions 10, thereby forming coil component members 454. In the coil component member 454, when the third intermediate member 440 is broken, the first lead portion 14 and the second lead portion 24 of the coil portion 10 are formed, and the first lead exposed surface 140 and the second lead exposed surface 240 are exposed from the second processed surface 450b.

[0141] After forming the coil component member 454, as shown in FIG. 36B , the first terminal 41 and the second terminal 42 are formed on the surface of the coil component member 454, including the second processed surface 450b, that is not provided with the exterior coating material 600. Because the first exposed lead surface 140 and the second exposed lead surface 240 are exposed from the second processed surface 450b of the coil component member 454, forming the first terminal 41 and the second terminal 42 on the second processed surface 450b establishes electrical continuity between the coil portion 10 and the first terminal 41 and the second terminal 42. This completes the coil component 100H. The coil component 100H corresponds to the coil component 100C (see FIG. 9 ).

[0142] The coil component 100H obtained by the fourth manufacturing method is provided with the dummy electrodes 71, as is the coil component 100F obtained by the second manufacturing method, but it is not necessary to provide the dummy electrodes 71. As in the second manufacturing method, it is possible to prevent the dummy electrodes 71 from being formed by changing the shape of the coil array sheet 500A or by changing the processing means for obtaining the coil component member 454.

[0143] In coil device 100H, the side surfaces of grooves G31 and G32 formed by groove forming processing are formed by pressing and cutting with protrusions P31 and P32 shown in Figures 30A and 30B, and therefore have a processed surface that includes a relatively large number of processing marks M of the component in the first direction (Z1-Z2 direction), similar to third processed surface 450c shown in Figure 27A. As described above, third processed surface 450c that includes a large number of processing marks M is higher than a molded processed surface formed using a mold or other die. Therefore, the adhesion of the members positioned to cover the side surfaces of grooves G31 and G32 formed by groove forming processing is improved.

[0144] Furthermore, in the fourth manufacturing method, the grooves G31 and G32 provided on both sides (Z1 side and Z2 side) of the third intermediate member 440 in the Z1-Z1 direction are arranged so that their pointed sides face each other, so that the direction of fracture starting from these grooves G31 and G32 is stable, and fracture processing can be performed easily and reliably.

[0145] The fourth manufacturing method may also have the same variations as the second manufacturing method. That is, the curing process for curing the semi-hardened material 401h to obtain the binder 403 may be performed between the groove forming process for forming the grooves G31 and G32 and the slit forming process for forming the slits 423 extending in a direction (X1-X2 direction) perpendicular to the extension direction (Y1-Y2 direction) of the grooves G31 and G32. Alternatively, the process for forming the first intermediate member 420 and the groove forming process may be performed in separate steps.

[0146] 37 to 42B are diagrams illustrating a fifth manufacturing method of a coil component. In the fifth manufacturing method, the process up to the formation of the coil array sheet 500 and the first intermediate member 420 is the same as in the first manufacturing method.

[0147] Next, as shown in Fig. 37 to Fig. 38B, a slit forming process is performed to form slits 424 in first intermediate member 420 including semi-hardened material 401h. Fig. 37 shows an XY plan view of first intermediate member 420, Fig. 38A shows a cross section taken along line DD' in Fig. 41, and Fig. 38B shows a cross section taken along line EE' in Fig. 37.

[0148] This slit forming process divides the first intermediate member 420 into multiple pieces to form the second intermediate member 430. Any processing method can be used for the slit forming process, including, for example, push-cutting with a blade or cutting with a dicing saw. In this manufacturing method, the slits are formed by push-cutting, so the inner surface of the slit 424 is formed as a third processed surface 450c, which is tapered. Specifically, as shown in FIGS. 37 and 38A, the slit 424 is formed so that its width narrows from the Z1 side to the Z2 side in the Z1-Z2 direction. This slit forming process forms the first lead portion 14 and the second lead portion 24 of the coil portion 10, and the first lead exposed surface 140 and the second lead exposed surface 240 are exposed from the third processed surface 450c.

[0149] After the second intermediate member 430 is formed, a curing process is performed to harden the semi-hardened material 401h contained in the second intermediate member 430 into the binder 403 (see FIG. 39A ). This forms the third intermediate member 440 (see FIG. 39A ). The specific conditions for the curing process are set appropriately depending on the composition and hardened state of the semi-hardened material 401h, and a specific example is holding the semi-hardened material 401h at about 175°C for 5 hours.

[0150] Next, as shown in Figures 39A and 39B, an exterior coating process is applied to the third intermediate member 440. Figure 39A shows a cross section of the third intermediate member 440 as viewed from the same position as line D-D' in Figure 37, and Figure 39B shows a cross section of the third intermediate member 440 as viewed from the same position as line E-E' in Figure 37. By the exterior coating process, necessary areas of the surface of the third intermediate member 440 are covered with an exterior coating material 600. Note that, unlike other manufacturing methods, in this manufacturing method, the inner surfaces of the slits 424 formed by the slit forming process are not covered with the exterior coating material 600.

[0151] 40 to 41B, the third intermediate member 440 (see FIG. 39A) is divided into individual pieces to form coil component members 455. Fig. 40 shows an XY plan view of the third intermediate member 440 shown in Fig. 39A after being divided into individual pieces, Fig. 41A shows a cross section taken along line DD' in Fig. 40, and Fig. 41B shows a cross section taken along line EE' in Fig. 40.

[0152] This dividing process forms slits 425 that run along the X1-X2 direction and penetrate the third intermediate member 440 in the Z1-Z2 direction between the multiple coil portions 10 aligned in the Y1-Y2 direction. The specific means for dividing the coil portions 10 are arbitrary, and examples include cutting with a blade or cutting with a dicing saw. Figures 40 and 41B show a case where cutting with a dicing saw is used as the slit forming process. The surface formed by the slit forming process (the inner surface 425a of the slit 425) is aligned along the first direction (the Z1-Z2 direction). This process increases the volume of the main body 30 and improves its magnetic properties compared to when the inner surface 425a of the slit 425 includes a tapered surface.

[0153] After forming the coil component member 455, as shown in FIG. 42A , the first terminal portion 41 and the second terminal portion 42 are formed on the surface of the coil component member 455, including the third processed surface 450c, on which the exterior coating material 600 is not provided. Because the first exposed lead surface 140 and the second exposed lead surface 240 are exposed from the third processed surface 450c of the coil component member 455, forming the first terminal portion 41 and the second terminal portion 42 on the third processed surface 450c establishes electrical continuity between the coil portion 10 and the first terminal portion 41 and the second terminal portion 42. This completes the coil component 100I. Similar to the coil component 100B (see FIG. 8 ), the coil component 100I has a tapered outer surface 301 over the entire outer surface 30a of the main body 30, and a tapered outer surface 302 over the entire outer surface 30b.

[0154] In the coil device 100I, an exterior coating material 610 may be formed on the inner surface 425a of the slit 425 as shown in FIG. 42B.

[0155] In the coil device 100I, the third processed surface 450c formed by cutting the first intermediate member 420 becomes the tapered outer side surfaces 301, 302 (see FIG. 2), and therefore the side of the third processed surface 450c where the taper approaches the center (specifically, the Z1 side in the Z1-Z2 direction) becomes the mounting surface side. Therefore, the bottom surface 41b of the first terminal portion 41 and the bottom surface 42b of the second terminal portion 42 are provided on the Z1 side. This arrangement is opposite in the Z1-Z2 direction to that of the coil device 100B according to the second embodiment (see FIG. 8).

[0156] In this manufacturing method, if the cutting process for cutting the first intermediate member 420 is performed from the opposite side (the Z2 side in the Z1-Z2 direction), the inclination of the taper of the third processed surface 450c will be opposite to that described above, and the Z2 side in the Z1-Z2 direction will be the mounting surface side. In this case, the bottom surface 41b of the first terminal portion 41 and the bottom surface 42b of the second terminal portion 42 will be provided on the Z2 side, and the resulting coil component 100I will have the same positional relationship as the coil component 100B according to the second embodiment (see FIG. 8).

[0157] As described above, in the manufacturing methods according to the present embodiment (first manufacturing method to fifth manufacturing method), at least one of slit forming processing and groove forming processing is performed on a first intermediate member 420 containing a semi-hardened material 401h that is relatively softer than the binder 403 to obtain a second intermediate member 430, and then a hardening processing is performed to harden the semi-hardened material 401h of the second intermediate member 430. Therefore, the processing load is reduced compared to when a slit forming processing and / or groove forming processing is performed on a third intermediate member 440 containing the binder 403. This realizes improved productivity of coil components 100A to 100I, such as extending the life of tools.

[0158] Furthermore, when a slit is formed by press-cutting the first intermediate member 420 containing the semi-hardened material 401h (the second to fifth manufacturing methods), the magnetic powder 402 is likely to move away from the blade due to plastic deformation of the semi-hardened material 401h. Therefore, processing marks (cut surfaces) are unlikely to appear on the magnetic powder 402 located on the third processed surface 450c formed by press-cutting. When the magnetic powder 402 does not have processing marks, corrosion is unlikely to occur even if the magnetic powder 402 includes a portion made of a metallic material. Therefore, the magnetic properties of the main body 30 containing the magnetic powder 402 are unlikely to change over time.

[0159] Furthermore, when a member (third intermediate member 440) containing binder 403 is divided by fracture processing (second manufacturing method to fourth manufacturing method), the magnetic powder 402 is not cut when it is breakable, so the magnetic powder 402 located on the second processing surface 450b formed by fracture processing is less likely to produce processing marks (cut surface), just like the magnetic powder 402 located on the third processing surface 450c.

[0160] Although the present embodiment has been described above, the present invention is not limited to these examples. For example, materials other than those described above for each component can be used as long as they provide the same effects as those of the present invention. Furthermore, those in which a person skilled in the art appropriately adds, deletes, or modifies components of the above-described embodiments, or appropriately combines features of the configuration examples of the embodiments, are also included within the scope of the present invention as long as they include the gist of the present invention.

[0161] DESCRIPTION OF SYMBOLS 10... Coil portion 11... First spiral conductor portion 12... Inner peripheral end portion 13... Outer peripheral end portion 14... First lead-out portion 20... Coil conductor portion 21... Second spiral conductor portion 22... Inner peripheral end portion 23... Outer peripheral end portion 24... Second lead-out portion 30... Main body portion 30a, 30b, 30c, 30d... Outer surface 30e... First intersecting surface 30f... Second intersecting surface 35... Farthest portion 41... First terminal portion (first external electrode) 41a... Side portion 41b... Bottom surface portion 42... Second terminal portion (second external electrode) 42a... Side portion 42b... Bottom surface portion 50... Exterior coating 60... Exterior coating 71... Dummy electrode 80... Second insulating portion 90... First insulating portion 91... Sheet substrate DESCRIPTION OF SYMBOLS 100A, 100B, 100C, 100D, 100E, 100F, 100G, 100H, 100I... Coil component 140... First drawn exposed surface (first end surface) 200... Coil component 201... First coil conductor portion 202... Second coil conductor portion 240... Second drawn exposed surface (second end surface) 301, 302, 303, 304... Tapered outer surface 401... Hardenable material 401h... Semi-hardened material 402... Magnetic powder 403... Binder 405... Component material 410... First component 420... First intermediate component 421, 422, 423, 424, 425... Slit 425a... Inner surface of slit 430... Second intermediate component 440... Third intermediate component 450a...First processing surface 450b...Second processing surface 450c...Third processing surface 450d...Fourth processing surface 451, 452, 453, 454, 455...Coil component member 500...Coil array sheet 600, 610...External coating material 800...Substrate 810...Electrode 850...Solder 851...Fillet C1, C2, C3, C4, C5...Cavity B1...Blade tool G1, G2, G31, G32...Groove M...Processing marks M1, M2, M3, M4, M5...Mold M11, M21, M31, M41, M51...Upper mold O...Center axis P1, P2, P31, P32...Protrusion P11...Protruding blade VP...Via conductor portion W1, W2...Installation width L1, L2: Length between terminals

Claims

1. A coil component comprising: a coil portion having an annular conductor portion having a central axis along a first direction and two electrical ends; and a main body portion covering the annular conductor portion with first and second intersecting planes aligned in the first direction, and including a binder and magnetic powder held in the binder, wherein the coil portion has: a first end face exposed from a surface of the main body portion and connected to one of the two electrical ends of the annular conductor portion; and a second end face exposed from the surface of the main body portion and connected to the other of the two electrical ends of the annular conductor portion, the first end face being covered by a first external electrode having a portion provided on the second intersecting plane, and the second end face being covered by a second external electrode having a portion electrically separated from the first external electrode on the outside of the main body portion and provided on the second intersecting plane, and an outer surface of the main body portion located between the first intersecting plane and the second intersecting plane has a tapered outer surface that moves away from the central axis the closer it gets to the first intersecting plane.

2. A coil component as claimed in claim 1, wherein said first external electrode and said second external electrode each extend to cover at least a portion of said tapered outer surface.

3. The coil component according to claim 1, wherein said tapered outer surface has a furthest portion in said body portion that is furthest from said central axis.

4. A coil component as described in claim 3, wherein the surface roughness of the farthest portion is greater than the surface roughness of other portions of the tapered outer surface, and both the first external electrode and the second external electrode extend so as to cover at least a portion of the farthest portion.

5. A coil component as described in claim 1, wherein at least one of said first end face and said second end face has a portion exposed from said tapered outer side surface.

6. A coil component as described in claim 1, wherein at least a portion of the first end face is exposed from the second intersecting plane, and at least a portion of the second end face is exposed from a portion of the second intersecting plane different from a portion of the second intersecting plane where at least a portion of the first end face is exposed.

7. A coil component according to claim 1, wherein said tapered outer surface has a portion consisting of a surface that contains a relatively large number of machining marks in said first direction.

8. A coil component as described in claim 7, wherein the magnetic powder is made of a metallic material, and a cut surface of the magnetic powder is not located on a surface that contains a relatively large number of processing marks in the first direction.

9. A coil component comprising: a coil section having an annular conductor section having a central axis along a first direction and two electrical ends; and a main body section covering the annular conductor section with first and second intersecting planes aligned in the first direction, the main body section including a magnetic powder having a portion made of a metallic material and a binder, wherein an outer surface located between the first intersecting plane and the second intersecting plane of the main body section has a surface that includes relatively many processing marks of a component in the first direction, and no cut surface of the magnetic powder is located on the surface that includes relatively many processing marks in the first direction.

10. The coil component according to claim 1 or 9, wherein the binder includes a hardened product of a hardening resin.

11. A coil component according to claim 1 or claim 9, wherein the magnetic powder has a surface that is subjected to an insulating treatment.

12. A method for manufacturing a coil component comprising: a coil section having an annular conductor section having a central axis along a first direction and two electrical ends; and a main body section covering the annular conductor section with first and second intersecting planes aligned in the first direction, and including a binder and magnetic powder held in the binder, the method comprising: forming a first intermediate member including a first member including a semi-hardened product of the binder and the magnetic powder, and the coil section having a portion embedded in the first member; performing at least one of a slit forming process and a groove forming process on the first intermediate member to form a second intermediate member; and forming a third intermediate member by performing a hardening process to harden the semi-hardened product contained in the second intermediate member into the binder.

13. A method for manufacturing a coil component as described in claim 12, wherein the second intermediate member is formed by performing at least the groove forming process on the first intermediate member, and a breaking process is performed on the third intermediate member, in which the third intermediate member is broken from a surface formed by the groove forming process.

14. The method for manufacturing a coil component according to claim 13, wherein the second intermediate member is formed by subjecting the first intermediate member to the slit forming process and the groove forming process.

15. The method for manufacturing a coil component according to claim 13, wherein the third intermediate member is subjected to the slit forming process and then the breaking process.

16. A method for manufacturing a coil component as set forth in claim 13, wherein the first member and one or more of the coil portions are placed in a cavity of a mold provided with at least one of a tool for performing the slit forming process and a tool for performing the groove forming process, and the process for forming the first intermediate member and at least one of the slit forming process and the groove forming process are performed in a single step to form the second intermediate member.

17. A method for manufacturing a coil component as set forth in claim 12, wherein the second intermediate member is formed by subjecting the first intermediate member to the slit forming process, and the third intermediate member is subjected to the slit forming process.

18. A method for manufacturing a coil component according to any one of claims 14 to 17, wherein the third intermediate member is divided after an exterior coating process is performed on the third intermediate member.

19. A method for manufacturing a coil component as described in claim 12, wherein the groove forming process is performed from both the surface side of the first intermediate member corresponding to the first intersecting surface and the surface side corresponding to the second intersecting surface.

20. A method for manufacturing a coil component as set forth in claim 12, further comprising the steps of: dividing the third intermediate member; and applying an exterior coating to the member obtained by the dividing process.

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