Coil component and method for manufacturing same

Abstract

[Problem] To provide: a coil component with excellent inductance characteristics; and a method for manufacturing the same. [Solution] A coil component 1 comprises: at least one coil; at least one first exterior body 30 that includes first magnetic particles and a first resin, and that covers the at least one coil; a second exterior body 140 that includes second magnetic particles and a second resin, and that covers the at least one first exterior body 30; and at least one terminal electrode 40a that is exposed from a first exterior surface 140a of the second exterior body 140, and that is connected to a lead-out portion of the at least one coil. The at least one first exterior body 30 is a columnar body or a polyhedral body, and includes: a first surface 30a and a second surface 30b opposing each other along a direction perpendicular to the first exterior surface 140a; and one or more connection surfaces connecting the first surface 30a and the second surface 30b. A first uneven section 32 is formed in at least a portion of a ridge line part positioned between the second surface 30b and the connection surface(s).

Description

Coil component and manufacturing method thereof

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

[0002] Coil components having a coil disposed inside an exterior body have been known for some time. For example, the coil component disclosed in Patent Document 1 has a polyhedral (hexahedral) exterior body and a coil located inside the exterior body, and functions as an inductor. The coil component disclosed in Patent Document 1 can adjust inductance characteristics depending on the type of exterior material constituting the exterior body.

[0003] Japanese Patent Application Laid-Open No. 2003-168610

[0004] However, in recent years, there has been a demand for further improvement in the inductance characteristics of coil components.

[0005] The present disclosure provides a coil component with excellent inductance characteristics and a method for manufacturing the same.

[0006] (1) A coil component according to one embodiment of the present disclosure comprises: at least one coil; at least one first exterior body including first magnetic particles and a first resin and covering the at least one coil; a second exterior body including second magnetic particles and a second resin and covering the at least one first exterior body; and at least one terminal electrode exposed from a first outer surface of the second exterior body and connected to an extraction portion of at least one of the coils, wherein at least one of the first exterior bodies is a column or polyhedron and has a first surface and a second surface facing each other along a direction perpendicular to the first outer surface, and one or more connection surfaces connecting the first surface and the second surface, and a first irregularity is formed on at least a portion of a ridge portion located between the second surface and the connection surface.

[0007] (2) In the coil component of (1) above, at least one of the first outer casings may be a hexahedron having a third surface, a fourth surface, a fifth surface, and a sixth surface connecting the first surface and the second surface, and the first irregularity may be formed on at least one of a first ridge portion located between the second surface and the third surface, a second ridge portion located between the second surface and the fourth surface, a third ridge portion located between the second surface and the fifth surface, and a fourth ridge portion located between the second surface and the sixth surface.

[0008] (3) In the coil component of (2) above, at least one of the third surface, the fourth surface, the fifth surface, and the sixth surface may be an inclined surface.

[0009] (4) In the coil component of (3) above, the third surface is adjacent to the sixth surface, the fourth surface is adjacent to the third surface, the fifth surface is adjacent to the fourth surface, and the sixth surface is adjacent to the fifth surface. Each of the third surface and the fifth surface, or each of the fourth surface and the sixth surface, may be an inclined surface.

[0010] (5) In any of the coil components (2) to (4) above, at least one of the fifth ridge portion located between the third surface and the fourth surface, the sixth ridge portion located between the fourth surface and the fifth surface, the seventh ridge portion located between the fifth surface and the sixth surface, and the eighth ridge portion located between the sixth surface and the third surface may have a curved portion that is curved in a cross section perpendicular to a direction perpendicular to the first surface, and the radius of curvature of the curved portion may increase toward one side in the direction perpendicular to the first surface.

[0011] (6) In any of the coil components (1) to (5) above, the second surface may have an arbitrary pattern formed by a concave-convex pattern.

[0012] (7) In any of the coil components (1) to (6) above, the second outer casing may be a column or a polyhedron, and may have the first outer surface, a second outer surface facing the first outer surface, and one or more connecting outer surfaces connecting the first outer surface and the second outer surface, and a second irregularity may be formed on at least a portion of a ridge portion located between the second outer surface and the connecting outer surface.

[0013] (8) A method for manufacturing a coil component according to one embodiment of the present disclosure includes: a step of preparing a plurality of coils; a step of arranging the plurality of coils in a plurality of partition areas defined by partition sections and accommodating the plurality of coils in a cavity of a mold; a step of filling the plurality of partition areas with a first exterior material containing first magnetic particles and a first resin, and filling at least a portion of a connection area connecting adjacent partition areas with the first exterior material; a step of forming a first molded body having a plurality of first exterior bodies formed in the plurality of partition areas and first connecting sections formed in the connection area and connected to the plurality of first exterior bodies; a step of removing the plurality of first exterior bodies from the partition sections while breaking them at the first connecting sections; and a step of covering at least one of the first exterior bodies with a second exterior material containing second magnetic particles and a second resin, and forming a second exterior body covering at least one of the first exterior bodies.

[0014] (9) In the method for manufacturing a coil component according to (8) above, the connection region may have a gap formed between the partition portion and a bottom surface of the cavity that faces the partition portion.

[0015] (10) In the method for manufacturing a coil component of (8) or (9) above, the partition portion may have a plurality of bottomless cylindrical partition spaces surrounded by partition walls, and a plurality of first openings formed on one side of the plurality of partition spaces and opening toward the bottom surface of the cavity, and the first connecting portion may be pressed against the opening edges of the plurality of first openings to break the plurality of first outer casings from the first connecting portion.

[0016] (11) In the method for manufacturing a coil component of (10) above, the partition wall may have a first end close to the bottom surface of the cavity and a second end opposite the first end, and the first connecting portion may be pressed against the first end in a direction from the first end toward the second end to break the plurality of first outer casings from the first connecting portion.

[0017] (12) In the method for manufacturing a coil component according to (10) or (11) above, the cross-sectional area of ​​each of the partition spaces perpendicular to the axial direction may increase with increasing distance from the bottom surface of the cavity.

[0018] (13) In the manufacturing method of any of the coil components (10) to (12) above, the distance between the inner wall surface of the partition located on one side and the inner wall surface of the partition located on the other side in a direction perpendicular to the axial direction of the partition space may increase as the distance from the bottom surface of the cavity increases.

[0019] (14) In the method for manufacturing a coil component according to any one of (10) to (13) above, the partition portion may have a plurality of second openings that open on the opposite side to the plurality of first openings, the opening areas of the plurality of second openings may be equal to or greater than the opening areas of the plurality of first openings, and the plurality of first outer casings may be removed from the plurality of partition areas via the plurality of second openings.

[0020] (15) In the method for manufacturing a coil part of (8) or (9) above, the partition portion may have a plurality of cylindrical partition spaces with bottoms surrounded by partition walls, a plurality of bottom walls formed on one side of the plurality of partition spaces, and a plurality of through holes penetrating the plurality of bottom walls, and the first connecting portion may be pressed against the opening edges of the plurality of through holes to break the plurality of first outer casings from the first connecting portion.

[0021] (16) In the method for manufacturing a coil component according to any one of (8) to (15) above, the method may further include the steps of preparing a plurality of cores each having a core portion and a flange portion formed at one axial end of the core portion, and providing a plurality of the coils on the plurality of core portions, and arranging a plurality of the coils together with the plurality of the cores in a plurality of the partition areas.

[0022] (17) In the method for manufacturing a coil component according to (16) above, a plurality of the coils may be arranged in a plurality of the partition regions together with a plurality of the cores so that end faces of a plurality of the flange portions are exposed from the partition portion.

[0023] (18) In the method for manufacturing a coil component according to any one of (8) to (17) above, the method may further include a step of placing a release film on the bottom surface of the cavity, and the release film may be placed across the plurality of partition areas via the connection area.

[0024] (19) The method for manufacturing a coil component according to any one of (8) to (18) above may include the steps of: accommodating a plurality of first exterior bodies in a cavity of a mold by placing at least one of the first exterior bodies in each of the plurality of partition areas; filling the plurality of partition areas with the second exterior material, and filling at least a portion of a connection area that connects adjacent partition areas with the second exterior material; forming the second molded body having a plurality of second exterior bodies formed in the plurality of partition areas and second connecting portions that are formed in the connection area and are connected to the plurality of second exterior bodies; and removing the plurality of second exterior bodies from the partition area while breaking them at the second connecting portions.

[0025] FIG. 1A is a perspective view of an example of a coil component according to a first embodiment. FIG. 1B is a perspective view of an example of a coil component, schematically illustrating the surface shape of the second exterior housing shown in FIG. 1A. FIG. 1C is a perspective view of an example of a coil component, schematically illustrating the surface shape of the first exterior housing shown in FIG. 1A. FIG. 1D is a perspective view of an example of a coil component according to a second embodiment. FIG. 1E is a perspective view of an example of a coil component, typically illustrating the surface shape of the second exterior housing shown in FIG. 1D. FIG. 1F is a perspective view of an example of a coil component, typically illustrating the surface shape of the first exterior housing shown in FIG. 1D. FIG. 2A is a cross-sectional view taken along line IIA-IIA of the coil component shown in FIG. 1A. FIG. 2B is a cross-sectional view taken along line IIB-IIB of the coil component shown in FIG. 1D. FIG. 3A is a perspective view of an example of a core provided with a coil and terminal electrodes. FIG. 3B is a perspective view of an example of a modified core shown in FIG. 3A. FIG. 4 is a perspective view showing an example of a method for manufacturing the coil component shown in FIG. 1A. FIG. 5 is a perspective view showing an example of a process subsequent to the process shown in FIG. 4. FIG. 6 is a perspective view showing an example of a step subsequent to the step shown in FIG. 5. FIG. 7A is a cross-sectional view taken along line VIIA-VIIA of the mold shown in FIG. 6. FIG. 7B is a cross-sectional view of an example of a modified partition shown in FIG. 7A. FIG. 7C is a cross-sectional view of another modified partition shown in FIG. 7A. FIG. 7D is a cross-sectional view of an example of a modified partition shown in FIG. 7C. FIG. 8 is a cross-sectional view showing an example of a step subsequent to the step shown in FIG. 6. FIG. 9A is a perspective view showing an example of a step subsequent to the step shown in FIG. 8. FIG. 9B is a perspective view showing an example of a step subsequent to the step shown in FIG. 8. FIG. 10 is a perspective view showing an example of a step subsequent to the step shown in FIG. 9A. FIG. 11 is a perspective view showing an example of a step subsequent to the step shown in FIG. 10. FIG. 12 is a perspective view showing an example of a step subsequent to the step shown in FIG. 11. FIG. 13 is a perspective view showing an example of a step subsequent to the step shown in FIG. 12. FIG. 14A is a cross-sectional view taken along line XIVA-XIVA of the mold shown in FIG. 13. FIG. 14B is a cross-sectional view of the mold in a manufacturing process of the coil component of the second embodiment. Fig. 15A is a cross-sectional view showing an example of a step subsequent to the step shown in Fig. 13. Fig. 15B is a cross-sectional view of a second molded body in the manufacturing process of the coil component of the second embodiment. Fig. 16A is a perspective view showing an example of a step subsequent to the step shown in Fig. 15A. Fig. 16B is a perspective view showing an example of a step subsequent to the step shown in Fig. 15A.Fig. 17A is a perspective view of an example of a coil component according to the third embodiment. Fig. 17B is a perspective view of an example of a coil component according to the fourth embodiment. Fig. 18 is a perspective view showing an example of a method for manufacturing the coil component shown in Fig. 17A. Fig. 19 is a perspective view showing an example of a step subsequent to the step shown in Fig. 18. Fig. 20 is a perspective view showing an example of a step subsequent to the step shown in Fig. 19. Fig. 21 is a perspective view of the first exterior body shown in Fig. 20, as viewed from the mounting surface side. Fig. 22 is a perspective view of an example of a modified version of the coil component shown in Fig. 1A. Fig. 23 is a perspective view of an example of a modified version of the coil component, schematically showing the surface shape of the second exterior body shown in Fig. 22. Fig. 24 is a perspective view of another modified version of the coil component shown in Fig. 1A.

[0026] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the contents shown in the drawings are merely schematic and illustrative for understanding the present disclosure, and the appearance and dimensional ratios may differ from the actual product. Furthermore, the present disclosure is not limited to the following embodiments.

[0027] (First Embodiment) The coil component 1 of the first embodiment shown in FIG. 1A functions as, for example, an inductor and is mounted in the power supply of various electrical devices. The coil component 1 includes at least one coil 10 (in this embodiment, multiple coils), at least one first exterior body 30_1 and 30_2 (in this embodiment, multiple first exterior bodies), a second exterior body 140, terminal electrodes 40a1-40a2, and terminal electrodes 40b1-40b2. The first exterior body 30_1 and the first exterior body 30_2 have the same configuration. Hereinafter, the first exterior body 30_1 and the first exterior body 30_2 may be referred to as the first exterior body 30 without distinction. Furthermore, the terminal electrodes 40a1 and 40a2 may be referred to as the terminal electrode 40a without distinction. Furthermore, the terminal electrodes 40b1 and 40b2 may be referred to as the terminal electrode 40b without distinction.

[0028] The first exterior body 30 is formed of an exterior material containing a magnetic material (magnetic particles) and a resin, and seals (coats) the coil 10. In this embodiment, the first exterior body 30 includes a core (T-shaped core) 20 as a component thereof. That is, the first exterior body 30 has the core 20 and a core coating portion 36 ( FIG. 2A ) that covers the core 20. The first exterior body 30 is formed, for example, by pouring an exterior material into a mold cavity in which the core 20 is placed, and compressing and curing the poured material. Note that the step of placing the core 20 in the mold cavity may be omitted, and the core 20 may be omitted from the first exterior body 30. The first exterior body 30 can be formed using various molding techniques, such as resin molding, transfer molding, injection molding, and dry molding.

[0029] The particle size of the magnetic particles (first magnetic particles) forming the first exterior body 30 is not particularly limited, but is, for example, 1 μm to 50 μm. The magnetic material forming the first exterior body 30 is not particularly limited, but is, for example, ferrite or a metallic magnetic material. The resin (first resin) forming the first exterior body 30 is not particularly limited, but is, for example, an epoxy resin or a phenolic resin. The relative magnetic permeability of the first exterior body 30 is not particularly limited, but is, for example, 1 to 20,000.

[0030] The first exterior body 30_1 has a first surface 30a on which the terminal electrodes 40a1 and 40b1 are arranged, a second surface 30b opposite the first surface 30a, and one or more connection surfaces connecting the first surface 30a and the second surface 30b. The same applies to the first exterior body 30_2. In this embodiment, the first exterior body 30 is a hexahedron. Therefore, the first exterior body 30 has a third surface 30c, a fourth surface 30d adjacent to the third surface 30c, a fifth surface 30e adjacent to the fourth surface 30d, and a sixth surface 30f adjacent to the fifth surface 30e, as connection surfaces connecting the first surface 30a and the second surface 30b. As shown in FIG. 2A , in this embodiment, the first exterior body 30 includes a core 20, and an end surface 22a of the core 20 is exposed from the first surface 30a of the first exterior body 30. Therefore, a part of the first surface 30 a is configured by the end surface 22 a of the core 20 .

[0031] The shape of the first exterior body 30 is not limited to a hexahedron, and may be another polyhedron, such as an octahedron. Furthermore, the shape of the first exterior body 30 is not limited to a polyhedron. From the perspective of effective magnetic flux, the shape of the first exterior body 30 may be a cylindrical body, such as a circular cylinder. In the present disclosure, a cylindrical body also includes a solid body in which the first surface 30a and the second surface 30b are not congruent, such as a truncated cone. When the first exterior body 30 is cylindrical or truncated cone, the first exterior body 30 is provided with one connecting surface that connects the first surface 30a and the second surface 30b.

[0032] 1A , the X-axis corresponds to the direction in which the fourth surface 30d and the sixth surface 30f face each other. The Y-axis corresponds to the direction in which the third surface 30c and the fifth surface 30e face each other. The Z-axis is an axis perpendicular to the X-axis and the Y-axis. The Z-axis corresponds to the direction in which the first surface 30a and the second surface 30b face each other. The size of the first exterior body 30 is not particularly limited, but for example, the length of the first exterior body 30 in the X-axis direction is 0.6 mm to 6.5 mm, the length of the first exterior body 30 in the Y-axis direction is 0.6 mm to 6.5 mm, and the length of the first exterior body 30 in the Z-axis direction is 0.5 mm to 5.0 mm.

[0033] The third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f may be inclined surfaces that form acute angles with the first surface 30a. The inclination angle θ1 of the third surface 30c with respect to the first surface 30a is not particularly limited, but is, for example, 60°≦θ1<90°. The inclination angle θ1 may be, for example, 75°≦θ1≦85°. However, the third surface 30c does not have to be an inclined surface, and the inclination angle θ1 of the third surface 30c with respect to the first surface 30a may be 90°. The same applies to the inclination angle θ2 of the fourth surface 30d with respect to the first surface 30a, the inclination angle θ3 of the fifth surface 30e with respect to the first surface 30a, and the inclination angle θ4 of the sixth surface 30f with respect to the first surface 30a. Note that the inclination angles θ1, θ2, θ3, and θ4 may all be equal or different.

[0034] By making at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f a sloped surface, the orientation of the first exterior body 30 can be identified from the external shape of the first exterior body 30. Therefore, for example, when forming terminal electrodes 40a and 40b on the first exterior body 30, it becomes easier to identify the electrode formation surface of the first exterior body 30 (in this embodiment, the first surface 30a). Furthermore, by making at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f a sloped surface, the first exterior body 30 can be made more compact.

[0035] In the present embodiment, the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f are each inclined surfaces, but any one, two, or three of these surfaces may be inclined surfaces. For example, the mutually opposing third surface 30c and the fifth surface 30e may each be inclined surfaces, while the mutually opposing fourth surface 30d and the sixth surface 30f may not be inclined surfaces. Alternatively, the mutually opposing fourth surface 30d and the sixth surface 30f may each be inclined surfaces, while the third surface 30c and the fifth surface 30e may not be inclined surfaces. Forming inclined surfaces on the first exterior body 30 in this manner facilitates mold removal from a mold when molding the first exterior body 30, making it easier to remove the exterior body 30 from the mold.

[0036] 1C , the first ridge 35a located between the second surface 30b and the third surface 30c has an unevenness 32. The second ridge 35b located between the second surface 30b and the fourth surface 30d has an unevenness 32. The third ridge 35c located between the second surface 30b and the fifth surface 30e has an unevenness 32. The fourth ridge 35d located between the second surface 30b and the sixth surface 30f has an unevenness 32.

[0037] In the example shown in FIG. 1C , the first ridge 35 a, the second ridge 35 b, the third ridge 35 c, and the fourth ridge 35 d each have an asperity 32 formed thereon, and the asperity 32 is formed around the entire periphery of the second surface 30 b. However, the asperity 32 may be formed on only one, two, or three of these ridges. The manufacturing method of the coil component 1 described below includes a step of removing the first outer casing 30 ( FIGS. 8 and 9A ) from the partition 50 ( FIG. 8 ) while breaking it from the first connecting portion 90 ( FIGS. 8 and 9B ). In this step, the resin peels off along the magnetic particles without cutting them, forming the asperity 32 on each of the first ridge 35 a, the second ridge 35 b, the third ridge 35 c, and the fourth ridge 35 d. In this way, when the first exterior body 30 is broken from the first connecting portion 90, the resin peels off along the magnetic particles, so the magnetic particles are not cut and no new surfaces are created. This makes it possible to prevent oxidation of the magnetic particles and suppress rusting of the exterior material without using a rust inhibitor. Furthermore, by suppressing deterioration of the exterior material due to rust and preventing a decrease in the soft magnetic properties of the coil component 1, the inductance characteristics of the coil component 1 can be improved.

[0038] In the first ridge portion 35 a, the irregularities 32 are formed continuously or intermittently from one end to the other end of the first ridge portion 35 a in the X-axis direction. However, the irregularities 32 may be formed locally in a part of the first ridge portion 35 a (for example, the center or end in the X-axis direction). The same applies to the irregularities 32 formed in the third ridge portion 35 c.

[0039] The irregularities 32 are formed continuously or intermittently on the second ridge portion 35b from one end to the other in the Y-axis direction. However, the irregularities 32 may be formed locally on a part of the second ridge portion 35b (for example, the center or end in the Y-axis direction). The same applies to the irregularities 32 formed on the fourth ridge portion 35d.

[0040] The irregularities 32 may be formed not only on the first ridge 35a, the second ridge 35b, the third ridge 35c, and the fourth ridge 35d, but also around these ridges. For example, the irregularities 32 may also be formed on the outer edge of the second surface 30b. In this case, the irregularities 32 may be formed up to a position spaced a distance W1 (see the enlarged view in FIG. 1C ) inward from the first ridge 35a in the Y-axis direction. The distance W1 is, for example, 0.5 μm to 300 μm, or 0.5 μm to 40 μm. The irregularities 32 may also be formed up to a position spaced a distance W1 inward from the second ridge 35b in the X-axis direction. The irregularities 32 may also be formed up to a position spaced a distance W1 inward from the third ridge 35c in the Y-axis direction. Alternatively, the irregularities 32 may be formed up to a position spaced a distance the same as the distance W1 inward in the X-axis direction from the fourth ridge line portion 35d.

[0041] Alternatively, the irregularities 32 may also be formed at the end of each of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f on the positive Z-axis side. In this case, the irregularities 32 may be formed up to a position spaced a distance W2 (see the enlarged view in FIG. 1C ) from the first ridge 35a toward the negative Z-axis direction. The distance W2 may be, for example, 10 μm to 300 μm, or 20 μm to 200 μm, or 50 μm to 100 μm. Note that the distance W2 may be the same as the height H3 (thickness of the first connecting portion 90) of the connection region 72 in FIG. 7A (described later), and may be, for example, 10 μm to 50 μm, or 20 μm to 40 μm. Furthermore, the irregularities 32 may also be formed up to a position spaced a distance similar to the distance W2 toward the negative Z-axis direction from the second ridge 35b. Alternatively, the irregularities 32 may be formed up to a position spaced a distance W2 from the third ridge 35c in the negative Z-axis direction, or up to a position spaced a distance W2 from the fourth ridge 35d in the negative Z-axis direction.

[0042] In a manufacturing method of the coil component 1 described below, in the process of removing the first outer casing 30 (FIGS. 8 and 9A) from the partition 50 (FIG. 8) while breaking it at the first connecting portion 90 (FIGS. 8 and 9B), the magnetic particles are not cut but the resin peels off along the magnetic particles, forming irregularities 32 on each of the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d. Therefore, at least a portion of the irregularities 32 has a shape that reflects the shape of the magnetic particles (a shape that follows the surface shape of the magnetic particles), and the irregularities 32 are different from so-called burrs. In other words, the irregularities 32 are not located outside but inside (on the coil 10 side) a virtual plane that extends the flat regions of each of the third surface 30c to the sixth surface 30f. This manufacturing method of the coil component 1 allows the coil component 1 to be singulated without generating external burrs.

[0043] A curved portion 31 is formed on the fifth ridge 35e located between the third surface 30c and the fourth surface 30d. A curved portion 31 is also formed on the sixth ridge 35f located between the fourth surface 30d and the fifth surface 30e. A curved portion 31 is also formed on the seventh ridge 35g located between the fifth surface 30e and the sixth surface 30f. A curved portion 31 is also formed on the eighth ridge 35h located between the sixth surface 30f and the third surface 30c. The curved portion 31 is curved in a cross section perpendicular to a direction orthogonal to the first surface 30a (the Z-axis direction). In the example shown in FIG. 1C , a curved portion 31 is formed on each of the fifth ridge 35e, the sixth ridge 35f, the seventh ridge 35g, and the eighth ridge 35h. However, the curved portion 31 may be formed on only one, two, or three of these ridges.

[0044] In the fifth ridge portion 35e, the curved portion 31 is formed continuously or intermittently from one end to the other end in the extension direction of the fifth ridge portion 35e. However, the curved portion 31 may be formed locally in a portion of the fifth ridge portion 35e (e.g., the center or end portion in the extension direction of the fifth ridge portion 35e). The same applies to the curved portions 31 formed in the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h. Forming the curved portion 31 in at least one of the fifth ridge portion 35e, the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h prevents magnetic flux from concentrating around these ridge portions, thereby improving the inductance characteristics of the coil device 1.

[0045] The degree of curvature (radius of curvature) of the curved portion 31 may increase toward one side in the Z-axis direction. In the example shown in Fig. 1C, the radius of curvature of the curved portion 31 decreases toward the second surface 30b, but the radius of curvature of the curved portion 31 may decrease toward the first surface 30a. However, the radius of curvature of the curved portion 31 is an index representing the degree of curvature of the outer circumferential surface (planar curve) of the first exterior body 30 at the position of the fifth ridge line 35e (or the sixth ridge line 35f, the seventh ridge line 35g, or the eighth ridge line 35h) in a cross section of the first exterior body 30 perpendicular to the Z-axis. By increasing the radius of curvature of the curved portion 31 toward one side in the Z-axis direction in at least one of the fifth ridge portion 35e, the sixth ridge portion 35f, the seventh ridge portion 35g, and the eighth ridge portion 35h, it is possible to prevent magnetic flux from concentrating on one side in the extension direction of these ridge portions, and improve the inductance characteristics of the coil component 1.

[0046] The second surface 30b may have any desired pattern formed by a concave-convex pattern 33. The concave-convex pattern 33 is formed by a plurality of convex portions and / or a plurality of concave portions. These convex portions and / or concave portions may be formed regularly at a predetermined pitch along the X-axis and / or Y-axis. However, the concave-convex pattern 33 may also be a collection of randomly arranged convex portions and / or concave portions. The heights of the plurality of convex portions forming the concave-convex pattern 33 may be uniform or may vary. The depths of the plurality of concave portions forming the concave-convex pattern 33 may be uniform or may vary. The heights of the plurality of convex portions or the depths of the plurality of concave portions forming the concave-convex pattern 33 are not particularly limited, but are, for example, 0.1 μm to 40 μm.

[0047] The uneven pattern 33 is formed from one end to the other in the X-axis direction of the second surface 30b. The uneven pattern 33 is also formed from one end to the other in the Y-axis direction of the second surface 30b. However, the uneven pattern 33 may be formed locally on the second surface 30b. The unevenness (e.g., surface roughness) of the uneven pattern 33 is smaller than the unevenness of the unevenness 32, but may be equal to or greater than the unevenness of the unevenness 32.

[0048] By forming the uneven pattern 33 on the second surface 30b, the orientation of the first exterior body 30 can be identified from the external shape of the first exterior body 30. Furthermore, by forming the uneven pattern 33 in a slit shape on the second surface 30b, in a manufacturing method for a coil component described below, the first exterior body 30 (FIGS. 8 and 9A) can be easily removed from the partition portion 50 (FIG. 8) while being broken off from the first connecting portion 90 (FIGS. 8 and 9B). Note that the uneven pattern 33 may be formed on the first surface 30a.

[0049] As shown in FIG. 1A , the core 20 has a core portion 21 and a flange portion 22. The core 20 is a T-shaped core and is formed from a composite material containing a magnetic material and a resin. The core 20 is formed, for example, by powder compaction, injection molding, or machining. The material forming the core 20 may be the same as or different from the material forming the first exterior body 30. The relative permeability of the core 20 may be the same as or different from the relative permeability of the first exterior body 30. For example, the core 20 may be formed from a material with a higher relative permeability than the first exterior body 30.

[0050] The core portion 21 has a cylindrical shape and protrudes from the center of the flange portion 22. The core portion 21 may protrude from the center of the flange portion 22 at a position offset in the radial direction thereof. The core portion 21 is located inside the first exterior body 30. The shape of the core portion 21 is not limited to the shape shown in Fig. 1A and may be, for example, a square prism, an octagonal prism, or any other polygonal prism.

[0051] The flange portion 22 has a flat rectangular parallelepiped shape (flat plate shape) and is formed at one axial end of the core portion 21. The flange portion 22 may be disposed parallel to the second surface 30b of the first exterior body 30. As shown in FIG. 2A , a portion of the flange portion 22 may be exposed from the first surface 30a. The shape of the flange portion 22 is not limited to the shape shown in FIG. 1A . For example, the planar shape of the flange portion 22 may be circular, octagonal, or another polygonal shape. Note that either the core portion 21 or the flange portion 22 may be omitted from the core 20.

[0052] The thermal expansion coefficient of the core 20 (at least one of the flange portion 22 and the core portion 21) may be equal to or different from the thermal expansion coefficient of the first exterior body 30. The thermal expansion coefficient of the core 20 (at least one of the flange portion 22 and the core portion 21) may be smaller than or larger than the thermal expansion coefficient of the first exterior body 30.

[0053] When the core portion 21 is formed of an annealed metal, the thermal expansion coefficient of the core portion 21 is, for example, 10 ppm / K or more and 20 ppm / K or less. When the core portion 21 is formed of a composite material containing a magnetic material and a resin, the thermal expansion coefficient of the core portion 21 is, for example, 20 ppm / K or more and 60 ppm / K or less. The thermal expansion coefficient of the first exterior body 30 is, for example, 15 ppm / K. The difference between the thermal expansion coefficient of the core portion 21 and the thermal expansion coefficient of the first exterior body 30 may be, for example, 2 ppm / K or more, or 5 ppm / K or more. The difference between the thermal expansion coefficient of the core portion 21 and the thermal expansion coefficient of the first exterior body 30 may be, for example, 45 ppm / K or less, or 10 ppm / K or less. In this case, it is possible to prevent cracks from occurring in the first exterior body 30 around the core portion 21 due to the thermal expansion coefficient of the core portion 21.

[0054] An example of a method for making the thermal expansion coefficient of the core portion 21 smaller than the thermal expansion coefficient of the first exterior body 30 is to perform an annealing treatment on the core portion 21. When the core portion 21 contains magnetic particles and a resin, the annealing treatment on the core portion 21 reduces the resin content, thereby reducing the thermal expansion coefficient of the core portion 21.

[0055] Note that by forming core 20 from a material different from that of first exterior body 30, the thermal expansion coefficient of core portion 21 may be made smaller than that of first exterior body 30. Alternatively, in a case where core 20 and first exterior body 30 both contain magnetic particles and resin, the thermal expansion coefficient of core portion 21 may be made smaller than that of first exterior body 30 by making the resin content in core 20 smaller than that of first exterior body 30.

[0056] As shown in FIG. 1A , the coil 10 has a winding portion 11 wound into a coil shape and lead-out portions 12a and 12b drawn out from the winding portion 11. The winding portion 11 is located inside the first exterior body 30 and is provided on the outer circumferential surface of the core portion 21. The winding portion 11 is formed, for example, by winding a wire around the core portion 21. However, if the coil 10 is an air-core coil, the winding portion 11 may be fitted into the core portion 21. The wire forming the winding portion 11 can be, for example, a conductive core wire made of copper or the like, such as a rectangular wire, a round wire, a twisted wire, a Litz wire, or a braided wire, or an insulating-coated wire in which such a conductive core wire is covered with an insulating coating. Specifically, known winding wires such as AIW (polyimide wire), UEW (polyurethane wire), and USTC can be used. The wire diameter is not particularly limited, but for round wires, it is, for example, 50 μm to 2 mm. In the case of a rectangular wire, for example, the wire thickness is 20 μm to 200 μm and the wire width is 40 μm to 400 μm. As shown in Figure 2A, the number of layers in the winding axis direction of the winding part 11 is, for example, three, and the number of layers in the radial direction is, for example, three. The winding axis direction of the winding part 11 corresponds to the Z-axis direction.

[0057] 1A , lead-out portions 12a and 12b respectively constitute one end and the other end of the wire forming coil 10 and are spaced apart in the X-axis direction. Lead-out portion 12a may be drawn from one end of winding portion 11 in the Z-axis direction inside first exterior body 30 toward third surface 30c of first exterior body 30. Lead-out portion 12a may also be drawn further toward first surface 30a inside first exterior body 30. Similarly, lead-out portion 12b may be drawn from the other end of winding portion 11 in the Z-axis direction inside first exterior body 30 toward third surface 30c of first exterior body 30. Lead-out portion 12b may also be drawn further toward first surface 30a inside first exterior body 30.

[0058] The terminal electrodes 40a1 and 40b1 are formed on the first surface 30a of the first exterior body 30_1 and are spaced apart in the X-axis direction. The terminal electrodes 40a2 and 40b2 are formed on the first surface 30a of the first exterior body 30_2 and are spaced apart in the X-axis direction. The terminal electrode 40a is connected to the lead portion 12a, and the terminal electrode 40b is connected to the lead portion 12b. The terminal electrodes 40a and 40b are formed, for example, by a laminated electrode film including a base electrode film and a plating film formed on the base electrode film. The base electrode film is a conductive paste film containing, but is not limited to, a metal such as Sn, Ag, Ni, or Cu, or an alloy thereof. The plating film is, but is not limited to, a metal such as Sn, Au, Ni, Pt, Ag, or Pd, or an alloy thereof.

[0059] As shown in Fig. 3A, the terminal electrodes 40a and 40b have, for example, a flat plate shape and a rectangular shape in a plan view. The thickness of each of the terminal electrodes 40a and 40b is, for example, 3 μm to 100 μm. As shown in Fig. 2A, in this embodiment, the end surface 22a of the flange portion 22 is exposed from the first surface 30a, and therefore at least a portion of the terminal electrode 40a and at least a portion of the terminal electrode 40b are formed on the end surface 22a of the flange portion 22.

[0060] Terminal electrode 40a is formed on first surface 30a so as to cover lead portion 12a arranged on first surface 30a. Similarly, terminal electrode 40b is formed on first surface 30a so as to cover lead portion 12b arranged on first surface 30a. Note that lead portion 12a may be connected to terminal electrode 40a by thermocompression bonding, soldering, a conductive adhesive, or the like. Similarly, lead portion 12b may be connected to terminal electrode 40b by thermocompression bonding, soldering, a conductive adhesive, or the like.

[0061] 1A , a portion of terminal electrode 40a may extend over at least one of the third surface 30c, the fourth surface 30d, and the fifth surface 30e of first exterior body 30. A portion of terminal electrode 40b may extend over at least one of the third surface 30c, the fifth surface 30e, and the sixth surface 30f of first exterior body 30. Lead portions 12a and 12b may be connected to terminal electrodes 40a and 40b at positions corresponding to at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f.

[0062] The second exterior body 140 is formed from an exterior material containing a magnetic material (second magnetic particles) and a resin (second resin), and seals (coats) at least one (in this embodiment, multiple, for example, two) first exterior bodies 30. The second exterior body 140 is formed, for example, by pouring an exterior material into a cavity of a mold in which at least one first exterior body 30 is placed, and then compressing and curing the poured exterior material. The second exterior body 140 can be formed using various molding techniques, such as resin molding, transfer molding, injection molding, and dry molding.

[0063] The magnetic particles that make up second exterior body 140 may be the same as or different from the magnetic particles that make up first exterior body 30. Furthermore, the resin that makes up second exterior body 140 may be the same as or different from the resin that makes up first exterior body 30. For example, permalloy may be used as the second magnetic particles, and epoxy resin may be used as the second resin. Furthermore, for example, silicone (thermosetting) may be used as the second resin.

[0064] 1B , second exterior body 140 has first outer surface 140a on which terminal electrodes 40a and 40b are exposed, second outer surface 140b opposite first outer surface 140a, and one or more connecting outer surfaces connecting first outer surface 140a and second outer surface 140b. The direction in which first outer surface 140a and second outer surface 140b face each other is the same as the direction in which first surface 30a and second surface 30b of first exterior body 30 ( FIG. 1A ) face each other, that is, the Z-axis direction.

[0065] In the present embodiment, the second exterior body 140 is a hexahedron. Therefore, the second exterior body 140 has a third exterior surface 140c, a fourth exterior surface 140d adjacent to the third exterior surface 140c, a fifth exterior surface 140e adjacent to the fourth exterior surface 140d, and a sixth exterior surface 140f adjacent to the fifth exterior surface 140e, as connecting exterior surfaces connecting the first exterior surface 140a and the second exterior surface 140b. At least a portion of the first surface 30a of the first exterior body 30 may be exposed from the first exterior surface 140a of the second exterior body 140. In this case, the portion of the first exterior surface 140a is formed by at least a portion of the first surface 30a of the first exterior body 30.

[0066] The shape of the second exterior body 140 is not limited to a hexahedron, and may be another polyhedron, such as an octahedron. Furthermore, the shape of the second exterior body 140 is not limited to a polyhedron. From the viewpoint of effective magnetic flux, the shape of the second exterior body 140 may be a columnar shape, such as a cylinder. When the second exterior body 140 is cylindrical or frustoconical, the second exterior body 140 has one connecting outer surface that connects the first outer surface 140a and the second outer surface 140b.

[0067] 2A , a portion of the second exterior body 140 extends into the inter-electrode region between the terminal electrodes 40a and 40b. Therefore, at least a portion of the first surface 30a of the first exterior body 30 is covered by the second exterior body 140 between the terminal electrodes 40a and 40b. Between the terminal electrodes 40a and 40b, the first outer surface 140a of the second exterior body 140 is located below (on the negative side of the Z axis) the contact surface between the terminal electrode 40a and the first surface 30a of the first exterior body 30. Furthermore, between the terminal electrodes 40a and 40b, the first outer surface 140a of the second exterior body 140 is located below the contact surface between the terminal electrode 40b and the first surface 30a of the first exterior body 30.

[0068] The outer edge of the first outer surface 140a of the second exterior body 140 is located below the contact surface between the terminal electrode 40a and the first surface 30a of the first exterior body 30. For example, around the terminal electrode 40a, the first outer surface 140a is located below the contact surface between the terminal electrode 40a and the first surface 30a of the first exterior body 30. Furthermore, the outer edge of the first outer surface 140a of the second exterior body 140 is located below the contact surface between the terminal electrode 40b and the first surface 30a of the first exterior body 30. For example, around the terminal electrode 40b, the first outer surface 140a is located below the contact surface between the terminal electrode 40b and the first surface 30a of the first exterior body 30.

[0069] In FIG. 1B , the second exterior body 140 has a surface shape similar to that of the first exterior body 30 ( FIG. 1C ). That is, the third exterior surface 140c, the fourth exterior surface 140d, the fifth exterior surface 140e, and the sixth exterior surface 140f are inclined surfaces that form acute angles with the first exterior surface 140a. The configuration of the inclined surfaces of the second exterior body 140 (such as the inclination angle of the inclined surfaces and the type of outer surface on which the inclined surfaces are formed) is the same as the configuration of the inclined surfaces of the first exterior body 30 described above. A detailed description of the inclined surfaces of the second exterior body 140 will be omitted to avoid duplication. The modifications to the inclined surfaces of the first exterior body 30 described above can also be applied to the inclined surfaces of the second exterior body 140.

[0070] By making at least one of third outer surface 140c, fourth outer surface 140d, fifth outer surface 140e, and sixth outer surface 140f a sloped surface, it is possible to identify the orientation of second outer body 140 from the external shape of second outer body 140. Furthermore, by making at least one of third outer surface 140c, fourth outer surface 140d, fifth outer surface 140e, and sixth outer surface 140f a sloped surface, it is possible to reduce the size of second outer body 140.

[0071] 1B , a first ridge portion 145a located between the second outer surface 140b and the third outer surface 140c is formed with an unevenness 142. A second ridge portion 145b located between the second outer surface 140b and the fourth outer surface 140d is also formed with an unevenness 142. A third ridge portion 145c located between the second outer surface 140b and the fifth outer surface 140e is also formed with an unevenness 142. A fourth ridge portion 145d located between the second outer surface 140b and the sixth outer surface 140f is also formed with an unevenness 142.

[0072] In the example shown in FIG. 1B , the first ridge 145a, the second ridge 145b, the third ridge 145c, and the fourth ridge 145d each have an asperity 142 formed thereon, and the asperity 142 is formed around the entire circumference of the second surface 30b. However, the asperity 142 may be formed on only one, two, or three of these ridges. The manufacturing method of the coil component 1 described below includes a step of removing the second exterior body 140 ( FIGS. 15A and 16A ) from the partition 150 ( FIG. 15A ) while breaking it from the second connecting portion 190 ( FIGS. 15A and 16B ). In this step, the resin peels off along the magnetic particles without cutting them, forming the asperity 142 on each of the first ridge 145a, the second ridge 145b, the third ridge 145c, and the fourth ridge 145d. In this way, when the second exterior body 140 is broken from the second connecting portion 190, the resin peels off along the magnetic particles, so the magnetic particles are not cut and no new surfaces are created. This makes it possible to prevent oxidation of the magnetic particles and suppress rusting of the exterior material without using a rust inhibitor. Furthermore, by suppressing deterioration of the exterior material due to rust and preventing a decrease in the soft magnetic properties of the coil component 1, the inductance characteristics of the coil component 1 can be improved.

[0073] The configuration (formation range, shape, etc.) of the irregularities 142 is the same as the configuration of the aforementioned irregularities 32. A detailed description of the irregularities 142 will be omitted to avoid repetition. The above-described modified examples of the irregularities 32 can also be applied to the irregularities 142.

[0074] In a manufacturing method of the coil component 1 described below, in the process of removing the second exterior body 140 (FIGS. 15A and 16A) from the partition 150 (FIG. 15A) while breaking it at the second connecting portion 190 (FIGS. 15A and 16B), the magnetic particles are not cut but the resin peels off along the magnetic particles, forming irregularities 142 on each of the first ridge portion 145a, the second ridge portion 145b, the third ridge portion 145c, and the fourth ridge portion 145d. Therefore, at least a portion of the irregularities 142 has a shape that reflects the shape of the magnetic particles (a shape that follows the surface shape of the magnetic particles), and the irregularities 142 are different from so-called burrs. In other words, the irregularities 142 are not located outside but inside (on the coil 10 side) a virtual plane that extends the flat regions of each of the third outer surface 140c to the sixth outer surface 140f. This manufacturing method of the coil component 1 allows the coil component 1 to be singulated without generating external burrs.

[0075] A curved portion 141 is formed on a fifth ridge portion 145e located between the third outer surface 140c and the fourth outer surface 140d. A curved portion 141 is also formed on a sixth ridge portion 145f located between the fourth outer surface 140d and the fifth outer surface 140e. A curved portion 141 is also formed on a seventh ridge portion 145g located between the fifth outer surface 140e and the sixth outer surface 140f. A curved portion 141 is also formed on an eighth ridge portion 145h located between the sixth outer surface 140f and the third outer surface 140c. The curved portion 141 is curved in a cross section perpendicular to a direction orthogonal to the first outer surface 140a (the Z-axis direction). 1B , curved portions 141 are formed on each of fifth ridge portion 145e, sixth ridge portion 145f, seventh ridge portion 145g, and eighth ridge portion 145h, but curved portions 141 may be formed on only one, two, or three of these ridge portions. By forming curved portion 141 on at least one of fifth ridge portion 145e, sixth ridge portion 145f, seventh ridge portion 145g, and eighth ridge portion 145h, magnetic flux is prevented from concentrating around these ridge portions, thereby improving the inductance characteristics of coil device 1.

[0076] The configuration (formation area, shape, etc.) of the bending portion 141 is the same as the configuration of the above-described bending portion 31. A detailed description of the bending portion 141 will be omitted to avoid repetition. The above-described modifications to the bending portion 31 can also be applied to the bending portion 141.

[0077] An arbitrary design is formed on the second outer surface 140b using a concave-convex pattern 143. The concave-convex pattern 143 is formed of a plurality of convex portions and / or a plurality of concave portions. These convex portions and / or concave portions may be formed regularly at a predetermined pitch along the X-axis and / or Y-axis. However, the concave-convex pattern 143 may also be a collection of randomly arranged convex portions and / or concave portions.

[0078] The configuration (formation area, shape, etc.) of the concave-convex pattern 143 is the same as the configuration of the above-described concave-convex pattern 33. A detailed description of the concave-convex pattern 143 will be omitted to avoid repetition. The above-described modified examples of the concave-convex pattern 33 can also be applied to the concave-convex pattern 143.

[0079] By forming concave-convex pattern 143 on second outer surface 140b, the orientation of second outer housing 140 can be identified from the external shape of second outer housing 140. Furthermore, by forming concave-convex pattern 143 in a slit shape on second outer surface 140b, second outer housing 140 ( FIGS. 15A and 16A ) can be easily removed from partition portion 150 ( FIG. 15A ) while being torn off from second connecting portion 190 ( FIGS. 15A and 16B ) in a manufacturing method for a coil component, which will be described later. Note that concave-convex pattern 143 may also be formed on first outer surface 140a.

[0080] 4 to 16B, a method for manufacturing the coil component 1 will be described. First, a plurality of coils 10 and a plurality of cores 20 shown in Fig. 4 are prepared. In this embodiment, the plurality of coils 10 are fixed to the plurality of cores 20, respectively, mainly from the viewpoint of preventing misalignment of the plurality of coils 10, but the plurality of cores 20 is not essential.

[0081] Next, a plurality of winding portions 11 are fitted into the plurality of core portions 21, respectively, or wire is wound around the plurality of core portions 21, thereby providing a plurality of coils 10 on the plurality of core portions 21. In each of the plurality of coils 10, the lead-out portions 12a and 12b of the coil 10 may be disposed on the end surface 22a of the flange portion 22.

[0082] Furthermore, the partition 50 is prepared, and if necessary, the partition 50 is attached to the base 130 via the adhesive sheet 120. For example, a double-sided adhesive sheet can be used as the adhesive sheet 120. In this case, by exposing the adhesive sheet 120 to a heated atmosphere, the partition 50 can be peeled off from the adhesive sheet 120 and separated from the base 130. However, instead of the adhesive sheet 120, an adhesive or the like may be used to adhere the partition 50 to the base 130. Alternatively, the partition 50 may be fixed to the base 130 by mechanical or magnetic means.

[0083] The partition portion 50 is made of, for example, metal, but may also be made of a heat-resistant resin or the like. The partition portion 50 has a partition wall 51 and a plurality of partition spaces 52. The plurality of partition spaces 52 are bottomless cylindrical spaces surrounded by the partition wall 51. The plurality of partition spaces 52 may be arranged in a matrix along the X-axis and the Y-axis. The cross-sectional shape of each of the plurality of partition spaces 52 perpendicular to the axial direction (Z-axis direction) corresponds to the shape of the end surface 22a of the flange portion 22 and is rectangular, but may be other polygonal shapes, circular, or the like. The partition portion 50 is provided with 20 partition spaces 52, but the number of partition spaces 52 is not particularly limited.

[0084] Next, the multiple cores 20 each having the multiple coils 10 are placed in the multiple partition spaces 52, respectively, so that the multiple coils 10 are placed in the multiple partition spaces 52. In this embodiment, each of the multiple coils 10 is placed in each of the multiple partition spaces 52. However, it is not necessary to place a coil 10 in all of the partition spaces 52, and it is also possible that no coils 10 are placed in any of the partition spaces 52. In each of the multiple partition spaces 52, one axial side of the partition space 52 is closed by the adhesive sheet 120. On the other hand, the other axial side of the partition space 52 is open. Therefore, when the multiple coils 10 are placed in the multiple partition spaces 52 together with the multiple cores 20, the end surface 22 a of the core 20 is fixed (adhered) to the adhesive sheet 120 inside each of the multiple partition spaces 52.

[0085] Next, as shown in FIG. 5 , with the multiple cores 20 adhered to the adhesive sheet 120, the partition section 50 is placed inside a mold (lower mold) 60. Here, the mold 60 has a main body 61 and a cavity 62 formed in the main body 61. The cavity 62 is a space (recess) surrounded by an inner wall 63 and a bottom surface 64. If necessary, a release film 110 is placed on the bottom surface 64 of the cavity 62. In the example shown in FIG. 5 , the release film 110 is placed along the inner wall 63 and the bottom surface 64 of the cavity 62 so as to be in close contact with them. The outer edge of the release film 110 may be positioned outside the opening edge of the cavity 62. After the release film 110 is placed in the cavity 62, the cavity 62 is filled with an outer casing material 80. A fluid material is used as the outer casing material 80. For example, a composite magnetic material using a thermoplastic resin or a thermosetting resin as a binder is used as the outer casing material 80. The exterior material 80 may contain a filler or the like.

[0086] When the partition portion 50 is placed inside the mold 60 (cavity 62), the partition portion 50 is moved in the direction shown by the arrow in Fig. 5. This allows a plurality of coils 10 to be placed in the cavity 62 together with a plurality of cores 20, as shown in Fig. 6. The mold 60 is heated before and after placing the partition portion 50 in the cavity 62. This reduces the connection strength between the adhesive sheet 120 and the partition portion 50, allowing the partition portion 50 to be detached from the base 130 shown in Fig. 5.

[0087] 7A , inside the cavity 62, the top of the core 21 faces the bottom surface 64 of the cavity 62 and is disposed at a position spaced apart from the bottom surface 64. The end surface 22 a of the flange 22 faces the opening surface of the cavity 62 and is disposed so as to be flush with the opening surface of the cavity 62. That is, in this embodiment, the plurality of coils 10 are disposed together with the plurality of cores 20 in the plurality of partition spaces 52 so that the end surfaces 22 a of the plurality of flanges 22 are exposed from the partitions 50.

[0088] The partition 50 further has a plurality of first openings 53 and a plurality of second openings 54. The plurality of first openings 53 are formed on one side of the plurality of partitioned spaces 52, respectively, and open toward a bottom surface 64 of the cavity 62. The plurality of second openings 54 are open on the opposite side of the plurality of first openings 53 in the Z-axis direction. The plurality of second openings 54 are formed on the other side of the plurality of partitioned spaces 52, respectively, and open toward the opening surface of the cavity 62. The partition 51 has a first end 51a close to the bottom surface 64 of the cavity 62 and a second end 51b opposite the first end 51a in the Z-axis direction.

[0089] When the partition portion 50 is accommodated in the cavity 62, the exterior material 80 filled in the cavity 62 enters the plurality of partition spaces 52. Then, in each of the plurality of partition spaces 52, the winding portion 11 is covered with the exterior material 80, and at least a portion of the lead-out portions 12a and 12b are covered with the exterior material 80. Furthermore, the core portion 21 is covered with the exterior material 80, and at least a portion of the flange portion 22 is covered with the exterior material 80. Note that the end surface 22a and the lead-out portions 12a and 12b arranged on the end surface 22a may be exposed from the exterior material 80 (the opening surface of the cavity 62).

[0090] The partition 50 is accommodated inside the mold 60 so that the position of the second end 51b of the partition 51 is equal to the position of the opening surface of the cavity 62. Because the height H1 of the partition 51 is smaller than the depth H2 of the cavity 62, the first end 51a of the partition 51 is disposed at a position spaced a distance H3 from the bottom surface 64. By accommodating the partition 50 in the cavity 62, a plurality of partition areas 70 defined (partitioned) by the partition 50 (partition 51) are formed inside the cavity 62 at positions corresponding to the plurality of partition spaces 52.

[0091] The partition region 70 extends in the Z-axis direction from the opening surface of the cavity 62 to the bottom surface 64 of the cavity 62, and the height (depth) of the partition region 70 is H2. On the other hand, the partition space 52 extends in the Z-axis direction from the opening surface of the cavity 62 to a position corresponding to the first end 51a of the partition wall 51, and the height (depth) of the partition space 52 is H1. Therefore, the partition region 70 includes the partition space 52. In other words, the partition region 70 is a region formed by virtually extending the partition space 52 along the inner wall surface 51c of the partition wall 51 to the position of the bottom surface 64.

[0092] Therefore, the above-mentioned process of arranging the plurality of coils 10 together with the plurality of cores 20 in the plurality of partition spaces 52 is equivalent to the process of arranging the plurality of coils 10 together with the plurality of cores 20 in the plurality of partition regions 70. Furthermore, the above-mentioned process of filling the plurality of partition spaces 52 with the outer casing material 80 is equivalent to the process of filling the plurality of partition regions 70 with the outer casing material 80.

[0093] In this embodiment, as shown in Fig. 5 , a plurality of coils 10 are arranged in each of a plurality of partition spaces 52, and then the partition unit 50 is housed in the cavity 62, thereby arranging a plurality of coils 10 in each of a plurality of partition regions 70 shown in Fig. 7A . However, the method of arranging a plurality of coils 10 in a plurality of partition regions 70 is not limited to this. For example, a plurality of coils 10 may be arranged in each of the plurality of partition regions 70 after the partition unit 50 is arranged in the cavity 62 to form a plurality of partition regions 70 in the cavity 62.

[0094] By disposing the partition portion 50 inside the cavity 62, a connection region 72 is formed inside the cavity 62 in addition to multiple partition regions 70. The connection region 72 is a region sandwiched between the first end 51a of the partition wall 51 and the bottom surface 64 of the cavity 62. The connection region 72 has a gap formed between the first end 51a and the bottom surface 64, and connects adjacent partition regions 70 to each other. The height H3 of the connection region 72 (gap height) is, for example, 10 μm≦H3≦50 μm, or 20 μm≦H3≦40 μm.

[0095] One adjacent partition region 70 and the other adjacent partition region 70 are connected via a connection region 72. The connection region 72 extends along the bottom surface 64 and connects the end of one adjacent partition region 70 (partition space 52) in the Z-axis direction to the end of the other adjacent partition region 70 (partition space 52) in the Z-axis direction. Therefore, the exterior material 80 is filled into the multiple partition regions 70 and also into at least a portion of the connection region 72 that connects the adjacent partition regions 70 to each other. The exterior material 80 may be filled into the connection region 72 without any gaps, or may be filled so that gaps remain. Although detailed illustration is omitted, the release film 110 shown in FIG. 5 is arranged via the connection region 72 so as to span the multiple partition regions 70 shown in FIG. 7A.

[0096] The inner wall surface 51c of the partition wall 51 is an inclined surface that is inclined with respect to the bottom surface 64 of the mold 60 and is inclined with respect to the axial direction (Z-axis direction) of the partition space 52. The inclination angle θ5 of the inner wall surface 51c with respect to the first end 51a of the partition wall 51 (similar to the inclination angle of the inner wall surface 51c with respect to the bottom surface 64 of the mold 60) corresponds to the inclination angle θ1 of the third surface 30c with respect to the first surface 30a of the first exterior body 30 shown in FIG. 1A . The inner wall surface 51c does not have to be an inclined surface, and the inclination angle θ5 of the inner wall surface 51c with respect to the bottom surface 64 of the mold 60 may be 90°. 7A , in a direction perpendicular to the axial direction of partition space 52 (X-axis direction), distance L between inner wall surface 51c of partition wall 51 located on one side and inner wall surface 51c of partition wall 51 located on the other side increases with increasing distance from bottom surface 64 of cavity 62 (toward the opening surface of cavity 62). Note that distance L corresponds to the length of first exterior body 30 shown in FIG. 1A in the X-axis direction. The minimum value of distance L may be smaller than the length of end surface 22a of flange portion 22 in the X-axis direction (however, if end surface 22a is circular, the diameter).

[0097] The cross-sectional area perpendicular to the axial direction of each of the plurality of partition spaces 52 increases in a direction away from the bottom surface 64 of the cavity 62 (toward the opening surface of the cavity 62). The cross-sectional area corresponds to the cross-sectional area of ​​the first exterior body 30 shown in Fig. 1A in a cross section perpendicular to the Z axis. Furthermore, the opening area of ​​each of the plurality of second openings 54 is larger than the opening area of ​​each of the plurality of first openings 53.

[0098] Next, the exterior material 80 filled in the cavity 62 shown in FIG. 7A is compressed and cured. More specifically, an upper mold (not shown) is prepared, and the exterior material 80 is compressed and cured using a mold (lower mold) 60 and the upper mold at a predetermined mold temperature for a predetermined time. As a result, the exterior material 80 filled in the multiple partition regions 70 is compressed and cured, forming multiple first exterior bodies 30 inside the multiple partition regions 70. Furthermore, the exterior material 80 filled in the connection region 72 is compressed and cured, forming first coupling portions 90 inside the connection region 72. As described above, the multiple partition regions 70 are connected via the connection region 72, and therefore the multiple first exterior bodies 30 are connected via the first coupling portions 90. In this manner, in this embodiment, a first molded body 100 can be formed, which has multiple first exterior bodies 30 formed in the multiple partition regions 70 and first coupling portions 90 formed in the connection region 72 and coupled to the multiple first exterior bodies 30.

[0099] Next, as shown in FIG. 8 , the partition section 50 with the first molded body 100 formed therein is removed from the mold die 60 (cavity 62). Then, the multiple first exterior bodies 30 are removed from the partition section 50 while being broken from the first connecting portion 90. For example, a jig may be used to press the first connecting portion 90 against the first end 51 a of the partition wall 51 in a direction from the first end 51 a toward the second end 51 b, thereby breaking the multiple first exterior bodies 30 from the first connecting portion 90. As described above, the opening area of ​​each of the multiple second openings 54 is larger than the opening area of ​​each of the multiple first openings 53. Therefore, the multiple first exterior bodies 30 can be easily removed from the multiple partition regions 70 through the multiple second openings 54. Alternatively, the multiple first exterior bodies 30 may be broken from the first connecting portion 90 by pressing the first connecting portion 90 against the opening edges of the multiple first openings 53. Alternatively, a cutting tool may be used to cut off the multiple first exterior bodies 30 from the first connecting portion 90 .

[0100] By breaking the multiple first exterior bodies 30 at the first connecting portion 90, the multiple first exterior bodies 30 connected to the first connecting portion 90 are separated into individual pieces, thereby obtaining the multiple individual pieces of the first exterior bodies 30 as shown in FIG. 9A . In each of the multiple first exterior bodies 30, a fracture surface having, for example, an uneven shape is formed at the portion where the first connecting portion 90 was connected. These fracture surfaces correspond to the unevenness 32 formed on the first ridge portion 35 a, the second ridge portion 35 b, the third ridge portion 35 c, and the fourth ridge portion 35 d of the first exterior body 30 shown in FIG. 1C . These fracture surfaces may extend to the second surface 30 b, the third surface 30 c, the fourth surface 30 d, the fifth surface 30 e, and the sixth surface 30 f of the first exterior body 30. Note that the method of forming the unevenness 32 on the first exterior body 30 is not limited to this. For example, the asperities 32 may be formed on at least one of the first ridgeline portion 35a, the second ridgeline portion 35b, the third ridgeline portion 35c, and the fourth ridgeline portion 35d of the first exterior body 30 by applying a physical load, such as by polishing or grinding. Forming the asperities 32 by polishing or grinding the first exterior body 30 creates new surfaces on the magnetic particles. On the other hand, when the first exterior body 30 is broken from the first connecting portion 90, the resin peels off along the magnetic particles, so the magnetic particles are not cut and new surfaces are not created. This prevents rust on the surface of the first exterior body 30 without using a rust inhibitor. Furthermore, by suppressing deterioration of the first exterior body 30 due to rust, the soft magnetic properties of the coil component 1 can be prevented from deteriorating.

[0101] When a matte finish pattern is formed on the surface of the release film 110 ( FIG. 5 ), the matte finish pattern can be transferred to the second surface 30b of the first exterior body 30 shown in FIG. 1C , forming a concave-convex pattern 33 on the second surface 30b. Note that the method for forming the concave-convex pattern 33 on the first exterior body 30 is not limited to this. For example, the concave-convex pattern 33 may be formed on the second surface 30b by applying a physical load to the second surface 30b, such as by polishing or grinding. Forming the concave-convex pattern 33 by polishing or grinding the second surface 30b creates new surfaces on the magnetic particles. On the other hand, the second surface 30b of the first exterior body 30 to which the matte finish pattern of the release film 110 is transferred does not have new surfaces on the magnetic particles. This prevents rust on the surface of the first exterior body 30 without the use of a rust inhibitor. Furthermore, by suppressing deterioration of the first exterior body 30 due to rust, the soft magnetic properties of the coil component 1 can be prevented from deteriorating.

[0102] 8 (corresponding to height H3 of connection region 72 shown in FIG. 7A ) is relatively thin, for example, 10 μm or more and 50 μm or less (or 20 μm or more and 40 μm or less), and therefore the multiple first exterior bodies 30 can be easily broken from the first connecting portion 90. As shown in FIG. 9B , when the multiple first exterior bodies 30 are broken from the first connecting portion 90, runners of the first connecting portion 90 having multiple holes formed therein are formed.

[0103] Next, as shown in FIG. 10 , terminal electrodes 40a and 40b are formed on the first surface 30a of each of the multiple first exterior bodies 30. The formation of the terminal electrodes 40a and 40b is not particularly limited, and can be performed by a paste method, a plating method, sputtering, screen printing, or the like. For example, the terminal electrodes 40a and 40b may be formed on the first surface 30a so as to cover the lead portions 12a and 12b. Alternatively, the terminal electrodes 40a and 40b may be formed in advance on the end surface 22a of the flange portion 22 of the core 20, and the lead portions 12a and 12b may be connected to these terminal electrodes 40a and 40b. In this manner, the first exterior body 30 can be obtained.

[0104] Next, the second exterior body 140 is formed using the obtained first exterior body 30. First, as shown in Fig. 11 , the partition section 150 is prepared, and if necessary, the partition section 150 is attached to the base 130 via an adhesive sheet 120. The partition section 150 has a similar configuration to the partition section 50, except that the width of the partition space 52 in the X-axis direction is configured to be wider.

[0105] Next, at least one first exterior body 30 (in this embodiment, multiple, for example, two) is placed in each of the multiple partition spaces 52. However, it is not necessary to place a first exterior body 30 in all of the partition spaces 52, and it is also possible that no first exterior body 30 is placed in any of the partition spaces 52. When at least one first exterior body 30 is placed in each of the multiple partition spaces 52, the first surface 30a (or terminal electrodes 40a and 40b) of at least one first exterior body 30 is fixed (adhered) to the adhesive sheet 120 inside each of the multiple partition spaces 52.

[0106] Next, as shown in Fig. 12 , with the plurality of first exterior bodies 30 adhered to the adhesive sheet 120, the partition portion 150 is placed inside a mold (lower mold) 60. As a result, the plurality of first exterior bodies 30 are placed in a cavity 62 filled with an exterior material 180, as shown in Fig. 13 . The exterior material 180 filled in the cavity 62 of the mold 60 may be the same as or different from the exterior material 80 used to form the first exterior body 30 shown in Fig. 5 .

[0107] The mold 60 is heated before and after the partition 150 is accommodated in the cavity 62. This reduces the connection strength between the adhesive sheet 120 and the partition 150, allowing the partition 150 to be detached from the base 130 shown in FIG.

[0108] 13 , inside the cavity 62, the second surface 30b of the first exterior body 30 faces the bottom surface 64 ( FIG. 12 ) of the cavity 62 and is disposed at a position spaced apart from the bottom surface 64. In addition, the first surface 30a of the first exterior body 30 faces the opening surface of the cavity 62.

[0109] 14A , when the partition portion 150 is accommodated in the cavity 62, the exterior material 180 filling the cavity 62 enters the multiple partition spaces 52. In each of the multiple partition spaces 52, the multiple first exterior bodies 30 are covered with the exterior material 180. A portion of the exterior material 180 enters the inter-electrode region between the terminal electrodes 40a and 40b and fills the periphery of the terminal electrodes 40a and 40b. The exterior material 180 may be the same as or different from the exterior material 80 that constitutes the first exterior body 30. The terminal electrodes 40a and 40b are at least partially exposed from the exterior material 180 (the opening surface of the cavity 62).

[0110] 12 , in the present embodiment, at least one first exterior body 30 is placed in each of the plurality of partitioned spaces 52, and then the partition unit 150 is housed in the cavity 62, thereby placing at least one first exterior body 30 in each of the plurality of partitioned regions 70 shown in FIG. 14A . However, the method of placing at least one first exterior body 30 in each of the plurality of partitioned regions 70 is not limited to this. For example, the partition unit 150 may be placed in the cavity 62 to form the plurality of partitioned regions 70 in the cavity 62, and then at least one first exterior body 30 may be placed in each of the plurality of partitioned regions 70.

[0111] By disposing the partition portion 150 inside the cavity 62, a connection region 72 is formed inside the cavity 62 in addition to the plurality of partition regions 70. The exterior material 180 is filled into the plurality of partition regions 70, and also into at least a portion of the connection region 72 that connects adjacent partition regions 70 to each other. The exterior material 180 may be filled into the connection region 72 without any gaps, or may be filled so that gaps remain.

[0112] Next, the exterior material 180 filled in the cavity 62 shown in FIG. 14A is compressed and cured. More specifically, an upper mold (not shown) is prepared, and the exterior material 180 is compressed and cured using the mold (lower mold) 60 and the upper mold at a predetermined mold temperature for a predetermined time. As a result, the exterior material 180 filled in the multiple partition regions 70 is compressed and cured, and multiple second exterior bodies 140 are formed inside the multiple partition regions 70. Furthermore, the exterior material 180 filled in the connection region 72 is compressed and cured, and second coupling portions 190 are formed inside the connection region 72. As described above, the multiple partition regions 70 are connected via the connection region 72, and therefore the multiple second exterior bodies 140 are connected via the second coupling portions 190. In this way, in this embodiment, a second molded body 200 can be formed having a plurality of second outer bodies 140 formed in a plurality of partition regions 70 and a second connecting portion 190 formed in the connection region 72 and connected to the plurality of second outer bodies 140.

[0113] Next, as shown in FIG. 15A , the partition portion 150 with the second molded body 200 formed therein is removed from the mold die 60 (cavity 62). The multiple second exterior bodies 140 are then removed from the partition portion 150 while being broken from the second connecting portion 190. For example, a jig may be used to press the second connecting portion 190 against the first end 51 a of the partition wall 51 in a direction from the first end 51 a toward the second end 51 b, thereby breaking the multiple second exterior bodies 140 from the second connecting portion 190. As described above, the opening area of ​​each of the multiple second openings 54 is larger than the opening area of ​​each of the multiple first openings 53. Therefore, the multiple second exterior bodies 140 can be easily removed from the multiple partition regions 70 through the multiple second openings 54. Alternatively, the multiple second exterior bodies 140 may be broken from the second connecting portion 190 by pressing the second connecting portion 190 against the opening edges of the multiple first openings 53. Alternatively, a cutting tool may be used to cut off the multiple second exterior bodies 140 from the second connecting portion 190 .

[0114] By breaking the second exterior bodies 140 at the second connecting portions 190, the second exterior bodies 140 connected to the second connecting portions 190 can be separated into individual pieces, thereby obtaining the individual pieces of the second exterior bodies 140 as shown in FIG. 16A . In each of the second exterior bodies 140, a fracture surface having, for example, an uneven shape is formed at the portion where the second connecting portions 190 were connected. This fracture surface corresponds to the unevenness 142 formed on each of the first ridge portion 145 a, the second ridge portion 145 b, the third ridge portion 145 c, and the fourth ridge portion 145 d of the second exterior body 140 shown in FIG. 1B . This fracture surface may extend to the second outer surface 140 b, the third outer surface 140 c, the fourth outer surface 140 d, the fifth outer surface 140 e, and the sixth outer surface 140 f of the second exterior body 140. Note that the method for forming the irregularities 142 on the second exterior body 140 is not limited to this. For example, the irregularities 142 may be formed on at least one of the first ridge line portion 145 a, the second ridge line portion 145 b, the third ridge line portion 145 c, and the fourth ridge line portion 145 d of the second exterior body 140 by applying a physical load by polishing, grinding, or the like to these ridge line portions.

[0115] When a matte pattern is formed on the surface of release film 110 ( FIG. 12 ), the matte pattern can be transferred to second outer surface 140 b of second exterior body 140 shown in FIG. 1B , thereby forming concave-convex pattern 143 on second outer surface 140 b. Note that the method of forming concave-convex pattern 143 on second exterior body 140 is not limited to this. For example, concave-convex pattern 143 may be formed on second outer surface 140 b by applying a physical load to second outer surface 140 b by polishing, grinding, or the like.

[0116] 15A (corresponding to height H3 of connection region 72 shown in FIG. 14A ) is relatively thin, for example, 10 μm or more and 50 μm or less (or 20 μm or more and 40 μm or less), so that the plurality of second exterior bodies 140 can be easily broken from second connecting portion 190. As shown in FIG. 16B , when the plurality of second exterior bodies 140 are broken from second connecting portion 190, runners of second connecting portion 190 having a plurality of holes formed therein are formed. In this manner, coil device 1 can be obtained.

[0117] As shown in Figures 7A, 8, 9A, and 9B, in this embodiment, multiple first exterior bodies 30 are removed from the partition section 50 while being broken from the first connecting section 90. Therefore, to obtain multiple individual pieces of the first exterior body 30, it is not necessary to cut the first compact 100 with a cutting tool, and the process of cutting the first compact 100 can be omitted. This avoids problems associated with cutting the first compact 100, such as loss of the exterior material 80 constituting the first exterior body 30 due to magnetic particles falling off during cutting, rust on the surface of the first exterior body 30 due to oxidation of newly formed surfaces on the magnetic particles, deterioration of the first exterior body 30 due to rust, and cracks occurring at the cut portion. As a result, a coil component 1 with excellent inductance characteristics and reliability can be manufactured. Furthermore, the cost required for the exterior material 80 can be reduced.

[0118] Furthermore, in this embodiment, fracture surfaces having irregularities 32 ( FIG. 1C ) can be formed between (at the connection between) the plurality of first exterior bodies 30 and the first coupling portion 90. In particular, in this embodiment, such fracture surfaces can be formed around each of the first ridge portion 35 a, the second ridge portion 35 b, the third ridge portion 35 c, and the fourth ridge portion 35 d of the first exterior body 30 without creating new surfaces on the magnetic particles.

[0119] Furthermore, in this embodiment, multiple first exterior bodies 30 can be manufactured collectively. This makes it possible to avoid problems that arise from the individual manufacturing of the first exterior bodies 30, such as the problem of variations in the volume of the first exterior bodies 30 due to variations in the amount of exterior material 80 put into the cavity 62. As a result, it is possible to manufacture coil components 1 that have excellent inductance characteristics and reliability. Furthermore, the production efficiency of the coil components 1 can be improved.

[0120] 7A , the connection region 72 has a gap formed between the partition portion 50 and the bottom surface 64 of the cavity 62 facing the partition portion 50. This allows the exterior material 80 to flow between the multiple partition regions 70 via the gap. This makes it possible to uniformize the amount of exterior material 80 filled into the multiple partition regions 70, and prevents variation in the volume of the multiple first exterior bodies 30.

[0121] The partition unit 50 also has a plurality of partition spaces 52 surrounded by partition walls 51, and a plurality of first openings 53 formed on one side of the plurality of partition spaces 52 and opening toward the bottom surface 64 of the cavity 62. The first connecting portions 90 are pressed against the opening edges 53 a of the plurality of first openings 53 to break the plurality of first exterior bodies 30 from the first connecting portions 90. Therefore, the plurality of first exterior bodies 30 can be broken from the first connecting portions 90 while the first molded bodies 100 are housed in the partition unit 50. This makes it possible to omit the step of removing the first molded bodies 100 (the combined body of the plurality of first exterior bodies 30 and the first connecting portions 90) from the partition unit 50, thereby simplifying the process of dividing the plurality of first exterior bodies 30 into individual bodies.

[0122] Furthermore, the partition wall 51 has a first end 51a that is close to the bottom surface 64 of the cavity 62 and a second end 51b that is opposite the first end 51a. The first connecting portion 90 is pressed against the first end 51a in a direction from the first end 51a toward the second end 51b, thereby breaking the multiple first exterior bodies 30 from the first connecting portion 90. As a result, the multiple first exterior bodies 30 that have broken from the first connecting portion 90 are released to the outside of the partition portion 50, making it easier to remove the multiple first exterior bodies 30 from the partition portion 50.

[0123] Furthermore, the cross-sectional area perpendicular to the axial direction (Z-axis direction) of each of the plurality of partition spaces 52 increases with increasing distance from the bottom surface 64 of the cavity 62. Therefore, when the first connecting portion 90 is pressed against the first end 51 a of the partition wall 51 (or against the opening edges 53 a of the plurality of first openings 53) in a direction away from the bottom surface 64 of the cavity 62 (a direction from the first end 51 a toward the second end 51 b), the plurality of first exterior bodies 30 that have broken off from the first connecting portion 90 can be reliably removed from the plurality of partition spaces 52 at the second end 51 b side.

[0124] Furthermore, in a direction perpendicular to the axial direction of the partitioned space 52 (the X-axis direction), a distance L between an inner wall surface 51 c of the partition wall 51 located on one side and an inner wall surface 51 c of the partition wall 51 located on the other side increases with increasing distance from the bottom surface 64 of the cavity 62. Therefore, the distance between the inner wall surfaces 51 c is greater on the second end 51 b side than on the first end 51 a side, and as a result, the cross-sectional area perpendicular to the axial direction of the partitioned space 52 is larger. Therefore, when the first connecting portion 90 is pressed against the first end 51 a of the partition wall 51 (or against the opening edges 53 a of the plurality of first openings 53) in a direction away from the bottom surface 64 of the cavity 62 (the direction from the first end 51 a toward the second end 51 b), the plurality of first exterior bodies 30 broken off from the first connecting portion 90 can be reliably removed from the plurality of partitioned spaces 52 at the second end 51 b side.

[0125] Furthermore, the partition unit 50 has a plurality of second openings 54 that open on the opposite side to the plurality of first openings 53, and the opening area of ​​each of the plurality of second openings 54 is equal to or greater than the opening area of ​​each of the plurality of first openings 53. Then, the plurality of first exterior bodies 30 are removed from the plurality of partition regions 70 through the plurality of second openings 54. By making the opening area of ​​the second openings 54 equal to or greater than the opening area of ​​the first openings 53, when the first connecting unit 90 is pressed against the opening edges 53 a of the plurality of first openings 53, the plurality of individual pieces of the first exterior bodies 30 can be reliably removed from the second openings 54.

[0126] The manufacturing method of the coil component 1 of this embodiment further includes a step of preparing a plurality of cores 20 each having a core portion 21 and a flange portion 22, and a step of providing a plurality of coils 10 on the plurality of core portions 21, and arranging the plurality of coils 10 together with the plurality of cores 20 in the plurality of partition regions 70. As a result, the coils 10 are fixed to the cores 20, and therefore, displacement of the coils 10 in the partition regions 70 can be prevented.

[0127] Furthermore, in this embodiment, the multiple coils 10 are arranged in the multiple partition regions 70 together with the multiple cores 20 so that the end faces 22a of the multiple flange portions 22 are exposed from the partition portion 50. This makes it difficult for the outer casing material 80 filled in the partition regions 70 to adhere to the end faces 22a of the flange portions 22. This allows the terminal electrodes 40a and 40b to be formed on the end faces 22a of the flange portions 22 without being hindered by the outer casing material 80. Furthermore, if the terminal electrodes 40a and 40b have already been formed on the end faces 22a of the flange portions 22, it is possible to prevent the outer casing material 80 filled in the partition regions 70 from adhering to the terminal electrodes 40a and 40b.

[0128] The manufacturing method for the coil component 1 of this embodiment also includes a step of arranging a release film 110 on the bottom surface 64 of the cavity 62. The release film 110 is then arranged across the plurality of partition regions 70, via the connection region 72. Therefore, as shown in Figures 7A and 8, when the partition portion 50 on which the first molded body 100 is formed is removed from the cavity 62, the first molded body 100 is easily separated from the bottom surface 64 of the cavity 62. This makes it possible to facilitate the operation of removing the partition portion 50 on which the first molded body 100 is formed from the cavity 62.

[0129] Furthermore, in the coil component 1 of this embodiment, the irregularities 32 are formed on at least a portion of the first ridge portion 35a located between the second surface 30b and the third surface 30c. Therefore, angularity of the first exterior body 30 around the first ridge portion 35a can be reduced. Similarly, the irregularities 32 formed on at least a portion of the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d can also reduce angularity of the first exterior body 30 around each of these ridge portions. Furthermore, since the irregularities 32 formed on at least a portion of these ridge portions originate from magnetic particles, the inductance characteristics of the coil component 1 can be improved. In particular, in this embodiment, the magnetic particles are less susceptible to external loads such as cutting and can maintain their original shape, so that the irregularities 32 having an irregular surface that follows the surface shape of the magnetic particles can be formed on the above-mentioned ridge portions.

[0130] 14A , in the manufacturing method of the coil device 1 of this embodiment, at least one (in this embodiment, multiple, for example, two) first exterior housings 30 having at least one coil 10 disposed therein are covered with an exterior material 180 containing magnetic particles and resin, thereby forming a second exterior housing 140 that covers the at least one first exterior housing 30. Also, as shown in FIG. 1A , the coil device 1 of this embodiment has at least one first exterior housing 30 that contains magnetic particles and resin and covers at least one (in this embodiment, multiple, for example, two) coil 10, and a second exterior housing 140 that contains magnetic particles and resin and covers the at least one first exterior housing 30. Therefore, the inductance characteristics of the coil device 1 can be improved depending on the type of exterior material 180 (the material constituting the second exterior housing 140). Furthermore, the environmental resistance (oil resistance, solvent resistance, water resistance, moisture resistance, acid resistance, alkali resistance, rust resistance, and heat resistance) of the coil component 1 can be improved depending on the type of exterior material 180. Furthermore, the mechanical strength and electrical insulation of the coil component 1 can be improved and magnetic leakage from the coil 10 can be prevented depending on the type of exterior material 180. Furthermore, the adhesion of the second exterior body 140 to the first exterior body 30 can be improved depending on the type of exterior material 180.

[0131] Furthermore, by forming the unevenness 32 on the first exterior body 30, the first exterior body 30 and the second exterior body 140 can be firmly connected via the unevenness 32. This can improve the adhesion between the first exterior body 30 and the second exterior body 140.

[0132] 15A , 16A , and 16B , the manufacturing method of coil device 1 of this embodiment includes a step of removing multiple second exterior bodies 140 from partition portion 150 while breaking them from second connecting portion 190. Therefore, as shown in FIG. 1B , in coil device 1 of this embodiment, irregularities 142 are formed on at least a portion of ridge portions 145 a to 145 d located between second outer surface 140 b and the connecting outer surface. This allows second exterior body 140 to be prevented from becoming angular around first ridge portion 145 a, similar to first exterior body 30. Similarly, around second ridge portion 145 b, third ridge portion 145 c, and fourth ridge portion 145 d, irregularities 142 formed on at least a portion of these ridge portions allow for prevention of angularity in second exterior body 140. Furthermore, the unevenness 142 formed on at least a portion of these ridge portions 145a to 145d originates from magnetic particles, thereby improving the inductance characteristics of the coil component 1. In particular, in this embodiment, the magnetic particles are less susceptible to external loads such as cutting and can maintain their original shape, so that it is possible to form the unevenness 142 having an uneven surface that follows the surface shape of the magnetic particles on the above-mentioned ridge portions 145a to 145d.

[0133] 1D has the same configuration as the coil component 1 of the first embodiment, except for the following points: The same reference numerals are used to designate the same components as those of the coil component 1 of the first embodiment, and detailed descriptions thereof will be omitted.

[0134] 1D to 1F, coil device 1A of this embodiment has a second exterior body 140A. As shown in Fig. 2B, second exterior body 140A differs from second exterior body 140 of the first embodiment in that second exterior body 140A covers a single first exterior body 30. The surface shape of second exterior body 140A is similar to the surface shape of second exterior body 140 of the first embodiment. That is, as shown in Fig. 1E, second exterior body 140A has concave-convex portions 142, curved portions 141, and concave-convex pattern 143.

[0135] The coil component 1A shown in FIG. 1D is manufactured, for example, as follows. Below, the manufacturing method of the coil component 1A will be described, focusing only on the differences from the manufacturing method of the coil component 1 of the first embodiment. As shown in FIGS. 11 to 14A , in the first embodiment, multiple (two) first exterior bodies 30 were arranged in the partition spaces 52. On the other hand, as shown in FIG. 14B , in the present embodiment, one first exterior body 30 is arranged in each of the multiple partition spaces 52 (partition regions 70). When the exterior material 180 filled in the cavity 62 is compressed and cured, a second molded body 200 can be formed, which has multiple second exterior bodies 140A formed in the multiple partition regions 70 and second connecting portions 190 formed in the connection region 72 and connected to the multiple second exterior bodies 140A.

[0136] 15B, the partition section 150 in which the second molded body 200 is formed is removed from the mold 60 (cavity 62). Then, the multiple second exterior bodies 140A are removed from the partition section 150 while being broken away from the second connecting section 190. This separates the multiple second exterior bodies 140A connected to the second connecting section 190, thereby obtaining individual pieces of the second exterior body 140A that cover the single first exterior body 30 as shown in FIG. 1D. In this embodiment, the same effects as in the first embodiment can be obtained.

[0137] 17A has the same configuration as the coil component 1 of the first embodiment, except for the following points: The same reference numerals are used to designate the same components as those of the coil component 1 of the first embodiment, and detailed descriptions thereof will be omitted.

[0138] As shown in Fig. 17A, the coil device 1B has a coil 10B. The coil 10B differs from the coil 10 of the first embodiment (Fig. 1A) in that the coil 10B is formed of a flat coil. The coil 10A is formed by edgewise winding a flat coil, but it may also be formed by flatwise winding a flat coil.

[0139] 21 , a portion of the lead-out portion 12a of the coil 10B is exposed from the first surface 30a of the first exterior body 30. Similarly, a portion of the lead-out portion 12b of the coil 10B is exposed from the first surface 30a of the first exterior body 30. In this embodiment, the portion of the lead-out portion 12a exposed from the first surface 30a and the portion of the lead-out portion 12b exposed from the first surface 30a function as terminal electrodes. However, if necessary, terminal electrodes 40a and 40b as shown in FIG. 1A may be formed on the first surface 30a.

[0140] 1A, the coil component 1B of this embodiment does not include a core 20 inside the first exterior body 30. When the coil 10B is formed as a flat coil, it is possible to prevent the coil 10B from shifting its position inside the first exterior body 30 even without fixing the coil 10B to the core 20. However, if necessary, the coil component 1B may include a core 20 and the coil 10B may be fixed to the core 20.

[0141] Next, a method for manufacturing the coil component 1B will be described with reference to Figures 18 to 21. Below, only a method for forming the first exterior body 30 of the coil component 1B will be described. The method for forming the second exterior body 140 of the coil component 1B is similar to the method for forming the second exterior body 140 of the first embodiment, and therefore a detailed description thereof will be omitted. First, a plurality of coils 10B shown in Figure 18 are prepared. Next, the plurality of coils 10B are respectively placed in the plurality of partition spaces 52 of the partition section 50. When the plurality of coils 10B are respectively placed in the plurality of partition spaces 52, the lead-out portions 12a and 12b are fixed (adhered) to the adhesive sheet 120 inside each of the plurality of partition spaces 52.

[0142] Next, as shown in Fig. 19 , with the lead-out portions 12a and 12b of each of the plurality of coils 10B adhered to the adhesive sheet 120, the partition portion 50 is housed inside the mold 60. This allows the plurality of coils 10B to be housed in the cavity 62. The mold 60 is heated before and after the partition portion 50 is housed in the cavity 62. This reduces the connection strength between the adhesive sheet 120 and the partition portion 50, allowing the partition portion 50 to be detached from the base 130 shown in Fig. 18 .

[0143] 19 , inside the cavity 62, the lead-out portions 12a and 12b face the opening surface of the cavity 62. The lead-out portions 12a and 12b are arranged so as to be exposed from the opening surface of the cavity 62. That is, in this embodiment, the multiple coils 10B are arranged in the multiple partition spaces 52 so that the lead-out portions 12a and 12b of each of the multiple coils 10B are exposed from the partition portions 50. As a result, the outer jacket material 80 filled in the cavity 62 enters the partition spaces 52 so as to cover the winding portion 11, and the lead-out portions 12a and 12b are exposed from the outer jacket material 80.

[0144] Next, as in the first embodiment, the exterior material 80 filled in the cavity 62 is compressed and hardened to form a first molded body 100 (see FIG. 15A ) having a plurality of first exterior bodies 30 formed in a plurality of partition regions 70 and a first connecting portion 90 formed in the connection region 72 and connected to the plurality of first exterior bodies 30. Next, the plurality of first exterior bodies 30 are broken at the first connecting portion 90, thereby obtaining the coil device 1B shown in FIGS. 20 and 21 .

[0145] This embodiment also provides the same effects as the first embodiment. Additionally, in this embodiment, the terminal electrodes 40a and 40b ( FIG. 1A ) can be omitted from the coil component 1B, simplifying the configuration and manufacturing process of the coil component 1B. Furthermore, because the coil 10B is formed as a flat coil, it is possible to prevent the coil 10B from shifting position inside the first exterior body 30. Furthermore, it is possible to increase the value of the current flowing through the coil 10B.

[0146] 17B has the same configuration as the coil component 1B of the third embodiment, except for the following points: The same reference numerals are used to designate the same components as those of the coil component 1B of the third embodiment, and detailed descriptions thereof will be omitted.

[0147] 17B , coil device 1C of the present embodiment has second exterior body 140C. Second exterior body 140C differs from second exterior body 140 of the third embodiment in that second exterior body 140C covers a single first exterior body 30. The surface shape of second exterior body 140C is similar to the surface shape of second exterior body 140 of the third embodiment. In the present embodiment as well, effects similar to those of the third embodiment can be obtained.

[0148] The present disclosure is not limited to the above-described embodiments, and various modifications can be made within the scope of the present disclosure.

[0149] In the first embodiment, as shown in FIG. 3B, the core 20 may be a drum core in which flanges 22 are formed on both axial ends of the core portion 21.

[0150] In the first embodiment, as shown in Fig. 7B , the inclined surface may be omitted from the inner wall surface 51c of the partition wall 51. That is, the inner wall surface 51c may be arranged parallel to the Z axis. In this case, the opening area of ​​each of the plurality of first openings 53 is equal to the opening area of ​​each of the plurality of second openings 54. The configuration of the partition section 50 shown in Fig. 7B may be applied to the partition section 150 shown in Figs. 14A and 14B .

[0151] In the above-described first embodiment, as shown in FIG. 7C , the partition section 50 may have a plurality of cylindrical partition spaces 52 with bottoms surrounded by partition walls 51, a plurality of bottom walls 55 formed on one side of the plurality of partition spaces 52, and a plurality of through holes 56 penetrating the plurality of bottom walls 55.

[0152] Each of the plurality of bottom walls 55 extends parallel to the bottom surface 64 of the cavity 62. The planar shape of each of the plurality of bottom walls 55 corresponds to the cross-sectional shape perpendicular to the axial direction of each of the plurality of partition spaces 52, and is, for example, rectangular. Each of the plurality of bottom walls 55 is formed so as to close one side of each of the plurality of partition spaces 52 (the side opposite to the second opening 54). The planar shape of each of the plurality of through holes 56 is, for example, circular. However, the planar shape of the through holes 56 may also be square, rectangular, or another polygonal shape. The through holes 56 are formed in the center of the bottom walls 55, but the positions of the through holes 56 may be changed as appropriate.

[0153] The connection region 72 is formed between the first end 51 a of the partition wall 51 and the bottom surface 64 of the cavity 62, and between the bottom wall 55 and the bottom surface 64 of the cavity 62. Thus, the connection region 72 is formed over the entire area of ​​the bottom surface 64. The connection region 72 is connected to the plurality of partition spaces 52 via the plurality of through holes 56.

[0154] 7C , the exterior material 80 filled in the cavity 62 is compressed and cured to form the first molded body 100. The first molded body 100 has a plurality of first exterior bodies 30 formed in the plurality of partition spaces 52, a plurality of protrusions 34 formed in the plurality of through holes 56 and connected to the plurality of first exterior bodies 30, and a first coupling portion 90 formed in the connection region 72 and connected to the plurality of protrusions 34. In other words, the plurality of first exterior bodies 30 and the first coupling portion 90 are connected via the plurality of protrusions 34.

[0155] For example, by pressing the first connecting portion 90 against the opening edges 56a of the plurality of through holes 56, the plurality of first exterior bodies 30 can be broken from the first connecting portion 90. At this time, the plurality of first exterior bodies 30 each have a plurality of protrusions 34 integrally formed therewith. Therefore, the plurality of protrusions 34 may be removed (broken) as necessary. In this case, traces of the protrusions 34 (through holes 56) remain on each of the plurality of first exterior bodies 30 broken from the first connecting portion 90. This can be used as an identifier to identify the orientation of the first exterior body 30. The configuration of the divider 50 shown in FIG. 7C may also be applied to the divider 150 shown in FIGS. 14A and 14B .

[0156] As shown in Fig. 7D, the inner wall surface 51c of the partition wall 51 shown in Fig. 7C may be an inclined surface that is inclined with respect to the bottom surface 64 of the mold 60. The inclination angle of the inner wall surface 51c with respect to the first end 51a of the partition wall 51 (similar to the inclination angle of the inner wall surface 51c with respect to the bottom surface 64 of the mold 60) is not particularly limited, but may be the same as θ5 shown in Fig. 7A, and when the inner wall surface 51c is an inclined surface, it is 60° or more and less than 90°. The configuration of the partition unit 50 shown in Fig. 7D may be applied to the partition unit 150 shown in Figs. 14A and 14B.

[0157] In each of the above embodiments, at least one of the first ridge line portion 35a, the second ridge line portion 35b, the third ridge line portion 35c, and the fourth ridge line portion 35d shown in FIG. 1C may be chamfered (cut so that no corners remain). In this case, at least one of the chamfered first ridge line portion 35a, the second ridge line portion 35b, the third ridge line portion 35c, and the fourth ridge line portion 35d may have an irregularity 32 formed thereon. Furthermore, the intersection of the first ridge line portion 35a, the second ridge line portion 35b, and the fifth ridge line portion 35e shown in FIG. 1C may be chamfered, and the irregularity 32 may be formed at that portion. Furthermore, the intersection of the second ridge line portion 35b, the third ridge line portion 35c, and the sixth ridge line portion 35f may be chamfered, and the irregularity 32 may be formed at that portion. Furthermore, the intersection of third ridge portion 35c, fourth ridge portion 35d, and seventh ridge portion 35g may be chamfered, and this portion may further include irregularities 32. Furthermore, the intersection of first ridge portion 35a, fourth ridge portion 35d, and eighth ridge portion 35h may be chamfered, and this portion may further include irregularities 32. The above-described modified examples of first exterior body 30 may also be applied to second exterior body 140 shown in FIG. 1B.

[0158] In each of the above embodiments, the cross-sectional shape of the first exterior body 30 parallel to the XZ plane shown in FIG. 1A is trapezoidal (quadrilateral), but it may be another polygon. For example, the cross-sectional shape may be hexagonal. Furthermore, the cross-sectional shape of the first exterior body 30 parallel to the YZ plane is trapezoidal (quadrilateral), but it may be another polygon. For example, the cross-sectional shape may be hexagonal. The same applies to the second exterior body 140 shown in FIG. 1B.

[0159] In the first embodiment, as shown in FIG. 22 , the coil 10 may be disposed inside the first exterior body 30 so that the winding axis direction of the winding portion 11 is parallel to the first surface 30a. In FIG. 22 , the winding axis direction of the winding portion 11 corresponds to the Y-axis direction. The shape of the winding portion 11 as viewed from the winding axis direction is a rectangle with its long side in the X-axis direction, but it may also be a square, another polygon, a circle, an ellipse, or the like. The lead-out portions 12a and 12b are directly led out from the winding portion 11 toward the first surface 30a and are disposed on the surface of the first surface 30a. A portion of the lead-out portion 12a may be embedded in the first exterior body 30, and a portion of the lead-out portion 12b may be embedded in the first exterior body 30.

[0160] The cross-sectional shape of the first external housing 30 parallel to the XY plane is rectangular, but may also be square, another polygon, circle, ellipse, or the like. The coil component 1 shown in FIG. 22 does not include a core 20 ( FIG. 1A ). This simplifies the configuration of the coil component 1, and also eliminates the step of placing multiple coils 10 on the core 20 ( FIG. 4 ) in the manufacturing process of the coil component 1. However, from the perspective of preventing displacement of the coil 10 in the manufacturing process of the coil component 1, the coil component 1 may also include a core 20 (a flat core without a winding core portion 21 as shown in FIG. 1A ).

[0161] As shown in FIG. 23 , in this modification, the first ridge 145 a, the second ridge 145 b, the third ridge 145 c, and the fourth ridge 145 d of the second exterior body 140 each have an asperity 142. Although detailed illustrations are omitted, the first ridge 35 a, the second ridge 35 b, the third ridge 35 c, and the fourth ridge 35 d of the first exterior body 30 also have an asperity 32. Therefore, in this modification, the magnetic particles do not generate new surfaces in the asperities 32 and 142. This prevents oxidation of the magnetic particles and inhibits rusting of the exterior material without the use of a rust inhibitor. Furthermore, by inhibiting deterioration of the exterior material due to rust and preventing a decrease in the soft magnetic properties of the coil component 1, the inductance characteristics of the coil component 1 can be improved.

[0162] In the first embodiment, as shown in FIG. 24 , the terminal electrode 40a may extend from the end surface 22a of the flange 22 to the side surface of the flange 22 (the side surface on the positive Y-axis direction in the example shown in FIG. 24 ). Similarly, the terminal electrode 40b may extend from the end surface 22a of the flange 22 to the side surface of the flange 22 (the side surface on the positive Y-axis direction in the example shown in FIG. 24 ). In this case, the lead portions 12a and 12b can be connected to the terminal electrodes 40a and 40b, respectively, at positions corresponding to the side surface of the flange 22. Therefore, compared to the case where the lead portions 12a and 12b are connected to the terminal electrodes 40a and 40b, respectively, at positions corresponding to the end surface 22a of the flange 22, as shown in FIG. 1A , it is easier to ensure flatness of the bottoms of the terminal electrodes 40a and 40b located on the end surface 22a, and the connection strength of the terminal electrodes 40a and 40b to the land pattern of the mounting board (not shown) can be improved.

[0163] 1A , in the first embodiment, the second exterior body 140 covers two first exterior bodies 30, but the second exterior body 140 may cover three or more first exterior bodies 30. The same applies to the third embodiment.

[0164] In the first embodiment described above, the multiple first exterior bodies 30 are arranged along the X axis. However, the multiple first exterior bodies 30 may be arranged along the Y axis without changing the orientation of the first exterior bodies 30. Also, the multiple first exterior bodies 30 may be arranged along the X axis and the Y axis without changing the orientation of the first exterior bodies 30. The same applies to the third embodiment described above.

[0165] In the first embodiment, the first exterior body 30_1 and the first exterior body 30_2 have the same configuration (shape), but they may have different configurations (shapes). The same applies to the third embodiment.

[0166] 11 to 15A , in the first embodiment, the first exterior body 30, on which the terminal electrodes 40a and 40b have been formed, is placed in the partition space 52 to form the second exterior body 140. However, the first exterior body 30, on which the terminal electrodes 40a and 40b have not been formed, may be placed in the partition space 52, and the terminal electrodes 40a and 40b may be formed on the first exterior body 30 and / or the second exterior body 140 after the second exterior body 140 has been formed.

[0167] 11 to 16B, in the first embodiment, the method for molding the second molded body 140 using the partition 50 has been described. However, the second molded body 140 may be molded without using the partition 50. For example, the second exterior body 140 can be molded using various molding techniques such as resin molding, transfer molding, injection molding, and dry molding.

[0168] DESCRIPTION OF SYMBOLS 1, 1A, 1B, 1C... Coil component 10, 10B... Coil 11... Winding portion 12a, 12b... Lead-out portion 20... Core 21... Core portion 22... Flange portion 22a... End surface 30, 30_1, 30_2... First exterior body 30a to 30f... First surface to sixth surface 31... Curved portion 32... Unevenness 33... Unevenness pattern 34... Convex portion 35a to 35h... First ridge portion to eighth ridge portion 36... Core coating portion 40a, 40b, 40a1, 40b1, 40a2, 40b2... Terminal electrode 50, 150... Partition portion 51... Partition wall 51a... First end 51b... Second end 51c... Inner wall surface 52... Partition space 53... First opening 53a...opening edge 54...second opening 55...bottom wall 56...through hole 56a...opening edge 60...mold 61...main body 62...cavity 63...inner wall 64...bottom surface 70...partition region 72...connection region 80, 180...exterior material 90...first connecting portion 100...first molded body 110...release film 120...adhesive sheet 130...base 140, 140A, 140C...second exterior body 140a to 140f...first outer surface to sixth outer surface 141...curved portion 142...unevenness 143...unevenness pattern 145a to 145h...first ridge portion to eighth ridge portion 190...second connecting portion 200...second molded body

Claims

1. A coil component comprising: at least one coil; at least one first exterior body comprising first magnetic particles and a first resin and covering at least one of the coils; a second exterior body comprising second magnetic particles and a second resin and covering at least one of the first exterior bodies; and at least one terminal electrode exposed from a first outer surface of the second exterior body and connected to an extraction portion of at least one of the coils, wherein at least one of the first exterior bodies is a column or polyhedron and has a first surface and a second surface facing each other in a direction perpendicular to the first outer surface, and one or more connection surfaces connecting the first surface and the second surface, and wherein a first irregularity is formed on at least a portion of a ridge portion located between the second surface and the connection surface.

2. The coil component according to claim 1, wherein at least one of the first exterior bodies is a hexahedron and has a third surface, a fourth surface, a fifth surface, and a sixth surface connecting the first surface and the second surface, and the first irregularities are formed on at least one of a first ridge line portion located between the second surface and the third surface, a second ridge line portion located between the second surface and the fourth surface, a third ridge line portion located between the second surface and the fifth surface, and a fourth ridge line portion located between the second surface and the sixth surface.

3. The coil component according to claim 2, wherein at least one of the third surface, the fourth surface, the fifth surface, and the sixth surface is an inclined surface.

4. A coil component according to claim 3, wherein the third surface is adjacent to the sixth surface, the fourth surface is adjacent to the third surface, the fifth surface is adjacent to the fourth surface, the sixth surface is adjacent to the fifth surface, and each of the third surface and the fifth surface, or each of the fourth surface and the sixth surface, is an inclined surface.

5. A coil component as set forth in any one of claims 2 to 4, wherein at least one of a fifth ridge line portion located between the third surface and the fourth surface, a sixth ridge line portion located between the fourth surface and the fifth surface, a seventh ridge line portion located between the fifth surface and the sixth surface, and an eighth ridge line portion located between the sixth surface and the third surface has a curved portion that is curved in a cross section perpendicular to a direction orthogonal to the first surface, and the radius of curvature of the curved portion increases toward one side in the direction orthogonal to the first surface.

6. A coil component according to any one of claims 1 to 4, wherein the second surface has an arbitrary pattern formed thereon using a concave-convex pattern.

7. A coil component according to any one of claims 1 to 4, wherein the second exterior body is a column or a polyhedron, and has the first outer surface, a second outer surface opposing the first outer surface, and one or more connecting outer surfaces connecting the first outer surface and the second outer surface, and a second irregularity is formed on at least a portion of a ridge line located between the second outer surface and the connecting outer surface.

8. A method for manufacturing a coil component, comprising: a step of preparing a plurality of coils; a step of arranging the plurality of coils in a plurality of partition areas defined by partition sections, and accommodating the plurality of coils in a cavity of a mold; a step of filling the plurality of partition areas with a first exterior material containing first magnetic particles and a first resin, and filling at least a portion of a connection area connecting adjacent partition areas with the first exterior material; a step of forming a first molded body having a plurality of first exterior bodies formed in the plurality of partition areas and first connecting sections formed in the connection area and connected to the plurality of first exterior bodies; a step of removing the plurality of first exterior bodies from the partition sections while breaking them at the first connecting sections; and a step of covering at least one of the first exterior bodies with a second exterior material containing second magnetic particles and a second resin, and forming a second exterior body covering at least one of the first exterior bodies.

9. A method for manufacturing a coil component according to claim 8, wherein the connection region has a gap formed between the partition and a bottom surface of the cavity that faces the partition.

10. A method for manufacturing a coil component as described in claim 8 or 9, wherein the partition portion has a plurality of bottomless cylindrical partition spaces surrounded by partition walls, and a plurality of first openings formed on one side of the plurality of partition spaces and opening toward the bottom surface of the cavity, and the first connecting portion is pressed against the opening edges of the plurality of first openings to break the plurality of first outer casings from the first connecting portion.

11. A method for manufacturing a coil component as described in claim 10, wherein the partition has a first end close to the bottom surface of the cavity and a second end opposite the first end, and the first connecting portion is pressed against the first end in a direction from the first end toward the second end, thereby breaking the plurality of first exterior bodies at the first connecting portion.

12. A method for manufacturing a coil component according to claim 10, wherein the cross-sectional area of ​​each of the plurality of partition spaces perpendicular to the axial direction increases with increasing distance from the bottom surface of the cavity.

13. A method for manufacturing a coil component as described in claim 10, wherein the distance between the inner wall surface of the partition located on one side and the inner wall surface of the partition located on the other side in a direction perpendicular to the axial direction of the partition space increases with increasing distance from the bottom surface of the cavity.

14. A method for manufacturing a coil component as described in claim 10, wherein the partition section has a plurality of second openings that open on the opposite side to the plurality of first openings, the opening areas of the plurality of second openings are equal to or greater than the opening areas of the plurality of first openings, and the plurality of first outer casings are taken out from the plurality of partition areas via the plurality of second openings.

15. A method for manufacturing a coil component as described in claim 8 or 9, wherein the partition portion has a plurality of cylindrical partition spaces with bottoms surrounded by partition walls, a plurality of bottom walls formed on one side of the plurality of partition spaces, and a plurality of through holes penetrating the plurality of bottom walls, and the first connecting portion is pressed against the opening edges of the plurality of through holes to break the plurality of first outer casings from the first connecting portion.

16. A method for manufacturing a coil component as claimed in claim 8 or 9, further comprising the steps of: preparing a plurality of cores each having a core portion and a flange portion formed at one axial end of the core portion; and providing a plurality of the coils on a plurality of the core portions; and arranging a plurality of the coils together with a plurality of the cores in a plurality of the partition areas.

17. A method for manufacturing a coil component according to claim 16, wherein a plurality of the coils are arranged in a plurality of the partition areas together with a plurality of the cores so that the end faces of a plurality of the flange portions are exposed from the partition portion.

18. A method for manufacturing a coil component according to claim 8 or 9, further comprising the step of placing a release film on the bottom surface of the cavity, wherein the release film is placed across the plurality of partition areas, via the connection areas.

19. A method for manufacturing a coil component as described in claim 8 or 9, comprising the steps of: accommodating a plurality of first exterior bodies in a cavity of a mold by placing at least one of the first exterior bodies in each of the plurality of partition areas; filling the plurality of partition areas with the second exterior material and filling at least a portion of a connection area that interconnects adjacent partition areas with the second exterior material; forming the second molded body having a plurality of second exterior bodies formed in the plurality of partition areas and second connecting portions formed in the connection area and connected to the plurality of second exterior bodies; and removing the plurality of second exterior bodies from the partition areas while breaking them at the second connecting portions.

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