Coil component and method for manufacturing same

Abstract

[Problem] To provide a coil component capable of preventing variations in positions of a plurality of coils arranged inside an exterior casing, and a method for manufacturing the coil component. [Solution] A coil component 1 has: a plurality of coils 10; a plurality of inner exterior casings 30 including first magnetic particles and a first resin, each covering at least one of the plurality of coils 10; and an outer exterior casing 40 including second magnetic particles and a second resin and covering the plurality of inner exterior casings 30. Each of the plurality of inner exterior casings 30 has a first surface 30a on which a lead-out portion of one of the plurality of coils 10 is arranged, a second surface 20b facing the first surface 30a, and a connecting surface connecting the first surface 30a and the second surface 30b. At least one of the plurality of inner exterior casings 30 has a protrusion 37 protruding from the connecting surface.

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 plurality of coils arranged in an array have been known. For example, the coil component disclosed in Patent Document 1 has a plurality of coils arranged in an array and a base containing a magnetic material and a resin that covers the plurality of coils, and functions as an inductor. In the coil component disclosed in Patent Document 1, the spacing between the plurality of coils is adjusted to a predetermined spacing inside the exterior body, thereby achieving uniformity in the characteristics of the coil component.

[0003] JP 2023-004497 A

[0004] However, with this type of coil component, it is not easy to arrange the multiple coils inside the exterior body without misalignment, and the positions of the multiple coils inside the exterior body tend to vary.

[0005] The present disclosure provides a coil component that can prevent variations in the positions of multiple coils arranged inside an exterior body, and a method for manufacturing the same.

[0006] A coil component according to one embodiment of the present disclosure comprises: a plurality of coils; a plurality of inner exterior bodies each including a first magnetic particle and a first resin and covering at least one of the plurality of coils; and an outer exterior body including a second magnetic particle and a second resin and covering the plurality of inner exterior bodies, wherein each of the plurality of inner exterior bodies has a first surface on which an extraction portion of one of the plurality of coils is arranged, a second surface opposite the first surface, and a connection surface connecting the first surface and the second surface, and at least one of the plurality of inner exterior bodies has a protrusion protruding from the connection surface.

[0007] A method for manufacturing a coil component according to one embodiment of the present disclosure includes the steps of: preparing a plurality of inner exterior bodies, each having at least one of a plurality of coils covered with a first exterior material including first magnetic particles and a first resin; placing the plurality of inner exterior bodies in a cavity of a mold so that the plurality of inner exterior bodies are in contact with each other via a protrusion formed on at least one of the plurality of inner exterior bodies; filling the cavity with a second exterior material including second magnetic particles and a second resin so that the plurality of inner exterior bodies are covered with the second exterior material; and forming an outer exterior body that covers the plurality of inner exterior bodies.

[0008] FIG. 1A is a perspective view of an example of a coil component according to the first embodiment. FIG. 1B is a perspective view of an example of a coil component schematically showing the surface shape of an outer exterior housing shown in FIG. 1A. FIG. 1C is a perspective view of an example of a coil component schematically showing the surface shape of an inner exterior housing shown in FIG. 1A. FIG. 1D is a perspective view of the inner exterior housing shown in FIG. 1C. FIG. 2A is a cross-sectional view of the coil component shown in FIG. 1A taken along line IIA-IIA. FIG. 2B is a cross-sectional view of the coil component shown in FIG. 1A. FIG. 2C is a cross-sectional view of an example of a modified inner exterior housing shown in FIG. 2B. FIG. 2D is a cross-sectional view of an example of a modified inner exterior housing shown in FIG. 2B. FIG. 2E is a cross-sectional view of an example of a modified inner exterior housing shown in FIG. 2B. FIG. 2F is a cross-sectional view of an example of a modified inner exterior housing shown in FIG. 1A. FIG. 2G is a cross-sectional view of an example of a modified inner exterior housing shown in FIG. 1A. FIG. 3 is a perspective view showing an example of a method for manufacturing the coil component shown in FIG. 1A. FIG. 4 is a perspective view showing an example of a process subsequent to the process shown in FIG. 3. FIG. 5 is a perspective view showing an example of a process subsequent to the process shown in FIG. 4. FIG. 6 is a cross-sectional view of the mold shown in FIG. 5 taken along line VI-VI. FIG. 7 is a cross-sectional view showing an example of a step subsequent to the step shown in FIG. 5. FIG. 8A is a perspective view showing an example of a step subsequent to the step shown in FIG. 7. FIG. 8B is a perspective view showing an example of a step subsequent to the step shown in FIG. 7. FIG. 9 is a perspective view showing an example of a step subsequent to the step shown in FIG. 8A. FIG. 10 is a perspective view showing an example of a step subsequent to the step shown in FIG. 9. FIG. 11 is a perspective view showing an example of a step subsequent to the step shown in FIG. 10. FIG. 12 is a cross-sectional view of the mold shown in FIG. 11 taken along line XII-XII. FIG. 13 is a perspective view showing an example of a step subsequent to the step shown in FIG. 11. FIG. 14A is a perspective view showing an example of a step subsequent to the step shown in FIG. 13. FIG. 14B is a perspective view showing an example of a step subsequent to the step shown in FIG. 13. FIG. 15 is a plan view of an example of a coil component according to the second embodiment. FIG. 16 is a plan view of an example of a coil component according to the third embodiment. FIG. 17A is a plan view of an example of a modified protrusion shown in FIG. 2B. Fig. 17B is a plan view of an example of a modified convex portion shown in Fig. 2B. Fig. 17C is a plan view of an example of a modified convex portion shown in Fig. 2B. Fig. 17D is a plan view of an example of a modified convex portion shown in Fig. 2B. Fig. 17E is a plan view of an example of a modified convex portion shown in Fig. 2B. Fig. 17F is a plan view of an example of a modified convex portion shown in Fig. 2B.Fig. 17G is a plan view of an example of a modified protrusion shown in Fig. 2B. Fig. 17H is a plan view of an example of a modified protrusion shown in Fig. 2B. Fig. 17I is a plan view of an example of a modified protrusion shown in Fig. 2B. Fig. 18 is a plan view of an example of a modified inner exterior body shown in Fig. 1A. Fig. 19 is a plan view of an example of a modified inner exterior body shown in Fig. 1A. Fig. 20 is a plan view of an example of a modified coil component shown in Fig. 16. Fig. 21 is a plan view of an example of a modified coil component shown in Fig. 16.

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the contents shown in the drawings are merely shown schematically and exemplarily to facilitate understanding of the present disclosure, and the appearance, dimensional ratios, etc. may differ from the actual product. Furthermore, the present disclosure is not limited to the following embodiments.

[0010] 1A functions as, for example, an inductor and is mounted in the power supplies of various electrical devices. The coil component 1 has a plurality of coils 10 (two in this embodiment), a plurality of inner exterior bodies 30_1 and 30_2 (two in this embodiment), and an outer exterior body 40. The inner exterior body 30_1 and the inner exterior body 30_2 have the same configuration (shape), but may have different configurations (shapes). Hereinafter, the inner exterior body 30_1 and the inner exterior body 30_2 may be referred to as the inner exterior body 30 without distinction.

[0011] The inner exterior body 30 is formed from an exterior material containing magnetic particles and resin, and covers the multiple coils 10. The inner exterior body 30 is formed, for example, by pouring the exterior material into a cavity of a mold in which the coils 10 are placed, and then compressing and curing the poured material. The inner exterior body 30 can be formed using various molding techniques, such as resin molding, transfer molding, injection molding, and dry molding.

[0012] The particle size of the magnetic particles (first magnetic particles) that make up the inner exterior body 30 is not particularly limited, but is, for example, 1 μm to 50 μm. The magnetic material that makes up the inner exterior body 30 is not particularly limited, but is, for example, ferrite or a metallic magnetic material. The resin (first resin) that makes up the inner exterior body 30 is not particularly limited, but is, for example, an epoxy resin or a phenolic resin. The inner exterior body 30 may contain a filler other than magnetic particles. The relative magnetic permeability of the inner exterior body 30 is not particularly limited, but is, for example, 1 to 20,000.

[0013] The inner exterior body 30 has a first surface 30a on which the lead portions 12a and 12b of the coil 10 are arranged, a second surface 30b opposite the first surface 30a, and one or more connecting surfaces connecting the first surface 30a and the second surface 30b. In the present embodiment, the shape of the inner exterior body 30 (excluding the convex portions 37_1 to 37_3 described below) is a hexahedron. Therefore, the inner 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 connecting surfaces connecting the first surface 30a and the second surface 30b.

[0014] The shape of the inner exterior body 30 (however, the shape excluding the convex portions 37_1 to 37_3 described below) is not limited to a hexahedron, and may be another polyhedron such as an octahedron. Furthermore, the shape of the inner exterior body 30 is not limited to a polyhedron. From the perspective of effective magnetic flux, the shape of the inner exterior body 30 may be a cylindrical body such as a cylinder. In the present disclosure, a cylinder 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 inner exterior body 30 is cylindrical or truncated cone, the inner exterior body 30 is provided with one connecting surface that connects the first surface 30a and the second surface 30b.

[0015] 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 corresponds to the direction in which the first surface 30a and the second surface 30b face each other, and is perpendicular to the X-axis and the Y-axis. Hereinafter, the positive side of the Z-axis will be referred to as the upside, and the negative side of the Z-axis will be referred to as the downside. The size of the inner exterior body 30 is not particularly limited, but for example, the maximum length of the inner exterior body 30 in the X-axis direction is 0.6 mm to 6.5 mm, the maximum length of the inner exterior body 30 in the Y-axis direction is 0.6 mm to 6.5 mm, and the length of the inner exterior body 30 in the Z-axis direction is 0.5 mm to 10.0 mm.

[0016] In the present disclosure, the terms "equal," "comparable," or "similar" do not only refer to a state in which the physical quantities of multiple objects being compared are strictly equal, equivalent, or similar, but also include a state in which there is an error of ±Δ% or less (not particularly limited, for example, Δ=7, 5, or 3) between the physical quantities of multiple objects being compared.

[0017] Furthermore, in the present disclosure, "parallel" does not only refer to strict parallelism, but also includes a state in which there is an error of ±Δθ° (not particularly limited, for example, Δθ=3) or less from strict parallelism. Furthermore, "perpendicular" or "orthogonal" does not only refer to strict perpendicular or perpendicular, but also includes a state in which there is an error of ±Δθ° (not particularly limited, for example, Δθ=3) or less from strict perpendicular or perpendicular.

[0018] The third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f are surfaces perpendicular to the first surface 30a. However, at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f may be an inclined surface that forms an acute angle with the first surface 30a. In the example shown in FIG. 2F, the fourth surface 30d and the sixth surface 30f of the inner exterior body 30 are inclined surfaces that form an acute angle with the first surface 30a. Furthermore, in the example shown in FIG. 2G, the fourth surface 30d and the sixth surface 30f of the inner exterior body 30_1 are inclined surfaces that form an acute angle with the first surface 30a, while the fourth surface 30d and the sixth surface 30f of the inner exterior body 30_2 are surfaces perpendicular to the first surface 30a.

[0019] The inclination angle θ1 of the third surface 30c relative 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°. The same applies to the inclination angle θ2 of the fourth surface 30d relative to the first surface 30a, the inclination angle θ3 of the fifth surface 30e relative to the first surface 30a, and the inclination angle θ4 of the sixth surface 30f relative to the first surface 30a. The inclination angles θ1, θ2, θ3, and θ4 may all be equal or different. By making at least one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f an inclined surface, the orientation of the inner exterior body 30 can be identified from the external shape of the inner exterior body 30, and the inner exterior body 30 can be made more compact.

[0020] For example, the third surface 30c and the fifth surface 30e facing each other may be inclined surfaces, while the fourth surface 30d and the sixth surface 30f facing each other may not be inclined surfaces. Alternatively, the fourth surface 30d and the sixth surface 30f may be inclined surfaces, while the third surface 30c and the fifth surface 30e may not be inclined surfaces.

[0021] 1D , 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.

[0022] 1D , the first ridge 35 a, the second ridge 35 b, the third ridge 35 c, and the fourth ridge 35 d each have an irregularity 32 formed thereon, and the irregularity 32 is formed around the outer periphery of the second surface 30 b. However, the irregularity 32 may be formed on only one, two, or three of these ridges.

[0023] 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.

[0024] 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.

[0025] 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 parallel to the first surface 30a. 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, but the curved portion 31 may be formed on only one, two, or three of these ridges.

[0026] 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.

[0027] The degree of curvature (radius of curvature) of curved portion 31 may increase toward first surface 30a or toward second surface 30b. However, the radius of curvature of curved portion 31 is an index representing the degree of curvature of the outer circumferential surface (planar curve) of inner exterior body 30 at the position of fifth ridge line 35e (or sixth ridge line 35f, seventh ridge line 35g, or eighth ridge line 35h) in a cross section parallel to first surface 30a of inner exterior body 30.

[0028] 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.

[0029] The uneven pattern 33 is formed from one end to the other end of the second surface 30b in the X-axis direction. Furthermore, the uneven pattern 33 is formed from one end to the other end of the second surface 30b in the Y-axis direction. 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 that of the unevenness 32, but may be equal to or greater than that of the unevenness 32. By forming the uneven pattern 33 on the second surface 30b, the orientation of the inner exterior body 30 can be identified from the external shape of the inner exterior body 30.

[0030] As shown in FIG. 1A , the coil 10 is an air-core coil and is made of an insulating-coated wire in which a conductive core wire (in this embodiment, a rectangular wire) is coated with an insulating coating. The material of the coil 10 is not particularly limited, but is, for example, copper. The coil 10 may be made of known winding wire such as AIW (polyamideimide wire), UEW (polyurethane wire), or USTC. The thickness of the wire making up the coil 10 is not particularly limited, but is, for example, 20 μm to 200 μm. The width of the wire is also not particularly limited, but is, for example, 40 μm to 400 μm. The coil 10 has a spirally wound winding portion 11 and lead portions 12 a and 12 b drawn out from the winding portion 11. The winding portion 11 is located inside the inner exterior body 30. The winding axis of the winding portion 11 corresponds to the Z-axis direction. The coil 10 is made of rectangular wire wound edgewise, but may also be made of rectangular wire wound flatwise.

[0031] Lead-out portion 12a is drawn out from the upper end of winding portion 11 inside inner exterior body 30. Lead-out portion 12b is drawn out from the lower end of winding portion 11 inside inner exterior body 30. Lead-out portions 12a and 12b function as terminal electrodes for electrically connecting coil 10 to a land pattern on a mounting board.

[0032] The outer exterior body 40 is formed from an exterior material containing a magnetic material (second magnetic particles) and a resin (second resin), and covers multiple (two in this embodiment) inner exterior bodies 30. The outer exterior body 40 may cover three or more inner exterior bodies 30. The outer exterior body 40 is formed, for example, by pouring an exterior material into a cavity of a mold in which multiple inner exterior bodies 30 are placed, and compressing and curing the poured material. The outer exterior body 40 can be formed using various molding techniques, such as resin molding, transfer molding, injection molding, and dry molding.

[0033] The magnetic particles that make up the outer exterior body 40 may be the same as or different from the magnetic particles that make up the inner exterior body 30. Furthermore, the resin that makes up the outer exterior body 40 may be the same as or different from the resin that makes up the inner 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, silicone (thermosetting) may be used as the second resin. The relative magnetic permeability of the outer exterior body 40 may be the same as, smaller than, or greater than the relative magnetic permeability of the inner exterior body 30.

[0034] 1B, the outer exterior body 40 has a first outer surface 40a on which the lead-out portions 12a and 12b of the coil 10 (FIG. 2A) are arranged, a second outer surface 40b opposite the first outer surface 40a, and one or more connecting outer surfaces connecting the first outer surface 40a and the second outer surface 40b. The direction in which the first outer surface 40a and the second outer surface 40b face each other is the same as the direction in which the first surface 30a and the second surface 30b of the inner exterior body 30 (FIG. 1A) face each other.

[0035] In this embodiment, the outer exterior body 40 has a hexahedral shape. Therefore, the outer exterior body 40 has a third outer surface 40c, a fourth outer surface 40d adjacent to the third outer surface 40c, a fifth outer surface 40e adjacent to the fourth outer surface 40d, and a sixth outer surface 40f adjacent to the fifth outer surface 40e, as connecting outer surfaces connecting the first outer surface 40a and the second outer surface 40b. At least a portion of the first surface 30a of the inner exterior body 30 ( FIG. 2A ) may be exposed from the first outer surface 40a of the outer exterior body 40. In this case, a portion of the first outer surface 40a is formed by at least a portion of the first surface 30a of the inner exterior body 30.

[0036] The shape of the outer exterior body 40 is not limited to a hexahedron, and may be another polyhedron such as an octahedron. Furthermore, the shape of the outer exterior body 40 is not limited to a polyhedron. From the viewpoint of effective magnetic flux, the shape of the outer exterior body 40 may be a columnar shape such as a cylinder. When the outer exterior body 40 is cylindrical or frustoconical, the outer exterior body 40 is provided with one connecting outer surface that connects the first outer surface 40a and the second outer surface 40b.

[0037] 2A , a portion of the outer exterior body 40 extends into the inter-electrode region between the lead-out portion 12 a and the lead-out portion 12 b. Therefore, between the lead-out portion 12 a and the lead-out portion 12 b, at least a portion of the first surface 30 a of the inner exterior body 30 is covered by the outer exterior body 40. Between the lead-out portion 12 a and the lead-out portion 12 b, the first outer surface 40 a of the outer exterior body 40 is located below the first surface 30 a of the inner exterior body 30.

[0038] The outer edge of the first outer surface 40a of the outer exterior body 40 is located below the first surface 30a of the inner exterior body 30. For example, around the draw-out portion 12a, the first outer surface 40a is located below the first surface 30a. Also, around the draw-out portion 12b, the first outer surface 40a is located below the first surface 30a.

[0039] 1B, the outer exterior body 40 may have a surface shape similar to that of the inner exterior body 30 (FIG. 1D). The third outer surface 40c, the fourth outer surface 40d, the fifth outer surface 40e, and the sixth outer surface 40f are inclined surfaces that form acute angles with respect to the first outer surface 40a, but may also be surfaces that are perpendicular to the first outer surface 40a.

[0040] The first ridge 45a located between the second outer surface 40b and the third outer surface 40c is formed with unevenness 42. The second ridge 45b located between the second outer surface 40b and the fourth outer surface 40d is also formed with unevenness 42. The third ridge 45c located between the second outer surface 40b and the fifth outer surface 40e is also formed with unevenness 42. The fourth ridge 45d located between the second outer surface 40b and the sixth outer surface 40f is also formed with unevenness 42.

[0041] The configuration (formation range, shape, etc.) of the irregularities 42 is the same as the configuration of the irregularities 32 described above. A detailed description of the irregularities 42 will be omitted to avoid repetition. The modifications to the irregularities 32 described above can also be applied to the irregularities 42.

[0042] A curved portion 41 is formed on the fifth ridge 45e located between the third outer surface 40c and the fourth outer surface 40d. A curved portion 41 is also formed on the sixth ridge 45f located between the fourth outer surface 40d and the fifth outer surface 40e. A curved portion 41 is also formed on the seventh ridge 45g located between the fifth outer surface 40e and the sixth outer surface 40f. A curved portion 41 is also formed on the eighth ridge 45h located between the sixth outer surface 40f and the third outer surface 40c.

[0043] The configuration (formation area, shape, etc.) of the bending portion 41 is the same as the configuration of the above-described bending portion 31. A detailed description of the bending portion 41 will be omitted to avoid repetition. The above-described modifications to the bending portion 31 can also be applied to the bending portion 41.

[0044] An arbitrary pattern is formed on the second outer surface 40b using a concave-convex pattern 43. The configuration (formation area, shape, etc.) of the concave-convex pattern 43 is the same as the configuration of the above-mentioned concave-convex pattern 33. A detailed description of the concave-convex pattern 43 will be omitted to avoid repetition. The above-mentioned modified examples of the concave-convex pattern 33 can also be applied to the concave-convex pattern 43.

[0045] As shown in FIG. 1C , at least one of the multiple inner exterior bodies 30 (in this embodiment, each of the multiple inner exterior bodies 30) has protrusions 37_1 to 37_3 protruding from the connection surface. Hereinafter, the protrusions 37_1 to 37_3 may be referred to as protrusion 37 without distinction. As shown in FIG. 1D , the protrusions 37 are formed on the third surface 30c, the fourth surface 30d, and the sixth surface 30f of the inner exterior body 30. The protrusions 37 may also be formed on the fifth surface 30e. The protrusions 37 are formed on two or more of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f.

[0046] For example, as shown in Fig. 2C, the protrusions 37 may be formed on two connecting surfaces (the fourth surface 30d and the fifth surface 30e). Although not shown in detail, the protrusions 37 may be formed on only one of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f. Alternatively, the protrusions 37 may be formed on all of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f.

[0047] As shown in FIG. 2B , the protrusion 37_1 is formed on the third surface 30c, the protrusion 37_2 is formed on the fourth surface 30d, and the protrusion 37_3 is formed on the sixth surface 30f. In a cross section (XY cross section) parallel to the first surface 30a, the protrusion 37_1 protrudes in a direction perpendicular to the third surface 30c (Y-axis direction). The protrusion 37_2 protrudes in a direction perpendicular to the fourth surface 30d (X-axis direction). The protrusion 37_3 protrudes in a direction perpendicular to the sixth surface 30f (X-axis direction).

[0048] However, the protrusion 37_1 may protrude in a direction inclined with respect to the direction perpendicular to the third surface 30c (the Y-axis direction). The protrusion 37_2 may protrude in a direction inclined with respect to the direction perpendicular to the fourth surface 30d (the X-axis direction). The protrusion 37_3 may protrude in a direction inclined with respect to the direction perpendicular to the sixth surface 30f (the X-axis direction).

[0049] 2F , in a cross section (X-Z cross section) perpendicular to the first surface 30a and parallel to the protruding direction (X-axis direction) of the convex portion 37_3 of the inner exterior body 30_1, a tip surface 370 located at the tip of the convex portion 37_3 of the inner exterior body 30_1 may be inclined with respect to the direction perpendicular to the first surface 30a (Z-axis direction). Furthermore, in a cross section (X-Z cross section) perpendicular to the first surface 30a and parallel to the protruding direction (X-axis direction) of the convex portion 37_2 of the inner exterior body 30_2, a tip surface 370 located at the tip of the convex portion 37_3 of the inner exterior body 30_2 may be inclined with respect to the direction perpendicular to the first surface 30a (Z-axis direction). In this case, the convex portion 37_3 of the inner exterior body 30_1 and the convex portion 37_2 of the inner exterior body 30_2 are in partial contact with each other via their respective tip surfaces 370. Therefore, as indicated by dots in FIG. 2F, a portion of the outer packaging body 40 fills the space between the protrusion 37_3 of the inner packaging body 30_1 and the protrusion 37_2 of the inner packaging body 30_2.

[0050] 2G, even when the tip surface 370 of the convex portion 37_2 of the inner exterior body 30_2 is perpendicular to the first surface 30a, the convex portion 37_3 of the inner exterior body 30_1 and the convex portion 37_2 of the inner exterior body 30_2 are in partial contact with each other via their respective tip surfaces 370. Therefore, as indicated by dots in FIG. 2G, a portion of the outer exterior body 40 fills the space between the convex portion 37_3 of the inner exterior body 30_1 and the convex portion 37_2 of the inner exterior body 30_2.

[0051] As shown in FIG. 2B , one protrusion 37_1 is formed on the third surface 30c, but multiple protrusions 37_1 may be formed thereon. Furthermore, one protrusion 37_2 is formed on the fourth surface 30d, but multiple protrusions 37_2 may be formed thereon. Furthermore, one protrusion 37_3 is formed on the sixth surface 30f, but multiple protrusions 37_3 may be formed thereon. Furthermore, at least one protrusion 37 may be formed on the fifth surface 30e.

[0052] 2D, two protrusions 37_2 are formed on the fourth surface 30d so as to protrude in a direction perpendicular to the fourth surface 30d, and two protrusions 37_3 are formed on the sixth surface 30f so as to protrude in a direction perpendicular to the sixth surface 30f.

[0053] 2A , the protrusion 37 extends from one end (upper end) to the other end (lower end) of the inner exterior body 30 in a direction perpendicular to the first surface 30a (the Z-axis direction). The protrusion 37 extends continuously from the upper end to the lower end of the inner exterior body 30, but may also extend intermittently. When viewed in a direction parallel to the first surface 30a (the Y-axis direction in FIG. 2A ), the length of the protrusion 37 in the Z-axis direction is equal to the distance between the first surface 30a and the second surface 30b (the height of the inner exterior body 30).

[0054] However, when viewed from a direction parallel to the first surface 30a, the length of the protrusion 37 in the Z-axis direction may be shorter than the distance between the first surface 30a and the second surface 30b. In this case, the protrusion 37 may be located at any position between the upper end and the lower end of the inner exterior body 30. Furthermore, multiple protrusions 37 having a length shorter than the distance between the first surface 30a and the second surface 30b may be arranged at intervals at any position between the upper end and the lower end of the inner exterior body 30.

[0055] 2B , in a cross section (XY cross section) parallel to the first surface 30a, the convex portion 37 has a shape that narrows (tapers) toward the tip of the convex portion 37. The cross-sectional shape of the convex portion 37_1 is substantially semicircular or semielliptical, and the outer peripheral surface of the convex portion 37_1 is curved in an arc shape. In other words, in a cross section parallel to the first surface 30a, the convex portion 37_1 is curved so as to narrow toward the tip of the convex portion 37_1.

[0056] The cross-sectional shape of the protrusions 37_2 and 37_3 is substantially trapezoidal, and the outer peripheral surfaces of the protrusions 37_2 and 37_3 are bent into a trapezoidal shape. In a cross section parallel to the first surface 30a, the tip of the protrusion 37_2 has a flat surface extending in a direction perpendicular to the protrusion direction of the protrusion 37_2 (the Y-axis direction). In addition, in a cross section parallel to the first surface 30a, the tip of the protrusion 37_3 has a flat surface extending in a direction perpendicular to the protrusion direction of the protrusion 37_3 (the Y-axis direction). The flat surface of the protrusion 37_3 of the inner exterior body 30_1 is configured to be able to come into contact with the flat surface of the protrusion 37_2 of the inner exterior body 30_2. These flat surfaces may be inclined with respect to the Y-axis direction.

[0057] The shape of the convex portions 37 of the inner exterior body 30_1 does not necessarily have to match the shape of the convex portions 37 of the inner exterior body 30_2. In the example shown in Fig. 2D, the two convex portions 37_2 formed on the fourth surface 30d of the inner exterior body 30_1 have the same cross-sectional shape as the two convex portions 37_2 formed on the fourth surface 30d of the inner exterior body 30_2, but have different sizes. Furthermore, the cross-sectional shape of each of the two convex portions 37_3 formed on the sixth surface 30f of the inner exterior body 30_1 is trapezoidal, while the cross-sectional shape of each of the two convex portions 37_3 formed on the sixth surface 30f of the inner exterior body 30_2 is semicircular or semi-elliptical.

[0058] The protrusions 37 may have a shape that becomes wider toward the tip of the protrusions 37 in a cross section parallel to the first surface 30a (XY cross section). In the example shown in Fig. 2E, each of the two protrusions 37_3 formed on the sixth surface 30f of the inner exterior body 30_1 has a shape that becomes wider toward the tip. In a cross section parallel to the first surface 30a, each of the two protrusions 37_3 formed on the sixth surface 30f of the inner exterior body 30_1 has a trapezoidal shape.

[0059] In a cross section parallel to the first surface 30a, the cross-sectional shape of the convex portion 37 is not limited to a semicircle, a semi-ellipse, or a trapezoid, but may be a triangle, a square, a rectangle, a pentagon, another polygon, or any other shape.

[0060] As shown in FIG. 2B , the ratio L1 / L2 of the length L1 of the protrusion 37_1 (and the same for the protrusions 37_2 and 37_3) in the protruding direction to the length L2 of the fourth surface 30d of the inner exterior body 30 in the Y-axis direction is not particularly limited, but is, for example, 1 / 10≦L1 / L2≦1 / 3. Furthermore, the ratio L3 / L4 of the length L3 of the protrusion 37_1 (and the same for the protrusions 37_2 and 37_3) in the direction perpendicular to the protruding direction to the length L4 of the third surface 30c of the inner exterior body 30 is not particularly limited, but is, for example, 1 / 10≦L1 / L2≦1 / 3. In this embodiment, L1 is shorter than L3, but L1 may be equal to or greater than L3. Furthermore, L2 is equal to L4, but L2 may be different from L4.

[0061] In the example shown in Fig. 2B, the convex portion 37_1 is located at the center of the third surface 30c in the X-axis direction, the convex portion 37_2 is located at the center of the fourth surface 30d in the Y-axis direction, and the convex portion 37_3 is located at the center of the sixth surface 30e in the Y-axis direction. In the example shown in Fig. 2D, the midpoints of the two convex portions 37_2 in the Y-axis direction are located at the center of the fourth surface 30d in the Y-axis direction. Furthermore, the midpoints of the two convex portions 37_3 in the Y-axis direction are located at the center of the sixth surface 30f in the Y-axis direction.

[0062] As shown in FIG. 2B , any of the multiple protrusions 37 protrudes toward the connecting outer surface. More specifically, in the inner exterior body 30_1, the protrusion 37_1 protrudes toward the third outer surface 40c, and the protrusion 37_2 protrudes toward the fourth outer surface 40d. The protrusion 37_1 is not exposed from the third outer surface 40c and is covered by the outer exterior body 40. In a cross section (XY cross section) parallel to the first surface 30a, a thin layer 46 of the outer exterior body 40 is formed between the tip of the protrusion 37_1 and the third outer surface 40c. The protrusion 37_2 is not exposed from the fourth outer surface 40d and is covered by the outer exterior body 40. In a cross section (XY cross section) parallel to the first surface 30a, a thin layer 46 of the outer exterior body 40 is formed between the tip of the protrusion 37_2 and the fourth outer surface 40d. The average thickness of the thin layer 46 is not particularly limited, but is, for example, 5 to 30 μm.

[0063] Furthermore, in the inner exterior body 30_2, the protrusion 37_1 protrudes toward the third outer surface 40c, and the protrusion 37_3 protrudes toward the sixth outer surface 40f. The protrusion 37_1 is not exposed from the third outer surface 40c and is covered by the outer exterior body 40. In a cross section (XY cross section) parallel to the first surface 30a, a thin layer 46 of the outer exterior body 40 is formed between the tip of the protrusion 37_1 and the third outer surface 40c. The protrusion 37_3 is not exposed from the sixth outer surface 40f and is covered by the outer exterior body 40. In a cross section (XY cross section) parallel to the first surface 30a, a thin layer 46 of the outer exterior body 40 is formed between the tip of the protrusion 37_3 and the sixth outer surface 40f.

[0064] In the inner exterior body 30_1, the protrusion 37_1 may be exposed from the third outer surface 40 c, and the protrusion 37_2 may be exposed from the fourth outer surface 40 d. In the inner exterior body 30_2, the protrusion 37_1 may be exposed from the third outer surface 40 c, and the protrusion 37_3 may be exposed from the sixth outer surface 40 f.

[0065] 1D , the uneven pattern 33 formed on the second surface 30b of the inner exterior body 30 extends to the upper end surfaces of the convex portions 37. Furthermore, the unevenness 32 formed on each of the first ridge portion 35a, the second ridge portion 35b, the third ridge portion 35c, and the fourth ridge portion 35d of the inner exterior body 30 is also formed at the position of the convex portions 37. In other words, the unevenness 32 is formed on the ridge portions located between the upper end surfaces of the convex portions 37 and the outer circumferential surface.

[0066] 1C , the inner exterior body 30_1 and the inner exterior body 30_2 are disposed adjacent to each other in the X-axis direction such that the protrusion 37_3 of the inner exterior body 30_1 faces the protrusion 37_2 of the inner exterior body 30_2. Inside the outer exterior body 40, the protrusion 37_3 of the inner exterior body 30_1 protrudes toward the inner exterior body 30_2. More specifically, inside the outer exterior body 40, the protrusion 37_3 of the inner exterior body 30_1 protrudes toward the protrusion 37_2 of the inner exterior body 30_2.

[0067] Inside the outer exterior body 40, the protrusion 37_3 of the inner exterior body 30_1 is in contact with the protrusion 37_2 of the inner exterior body 30_2. In other embodiments, inside the outer exterior body 40, the protrusion 37_3 of the inner exterior body 30_1 may be spaced apart from the protrusion 37_2 of the inner exterior body 30_2. In this case, a part of the outer exterior body 40 is disposed between the protrusion 37_3 of the inner exterior body 30_1 and the protrusion 37_2 of the inner exterior body 30_2.

[0068] The protrusion 37_3 of the inner exterior body 30_1 has a flat surface parallel to the Y axis as a contact surface with the protrusion 37_2 of the inner exterior body 30_2. The protrusion 37_2 of the inner exterior body 30_2 also has a flat surface parallel to the Y axis as a contact surface with the protrusion 37_3 of the inner exterior body 30_1. Therefore, the protrusion 37_3 of the inner exterior body 30_1 comes into surface contact with the protrusion 37_2 of the inner exterior body 30_2.

[0069] 2D and 2E , in a cross section parallel to the first surface 30 a, the shape of the convex portion 37_3 of the inner exterior body 30_1 may be a trapezoid that narrows or widens toward its tip, and the shape of the convex portion 37_2 of the inner exterior body 30_2 may be a semicircle or semiellipse that narrows toward its tip, thereby enabling the convex portion 37_3 of the inner exterior body 30_1 and the convex portion 37_2 of the inner exterior body 30_2 to be in point contact.

[0070] Although detailed illustrations are omitted, even if the shape of the convex portion 37_3 of the inner outer casing 30_1 and / or the convex portion 37_2 of the inner outer casing 30_2 is a triangle that narrows toward the tip, the convex portion 37_3 of the inner outer casing 30_1 and the convex portion 37_2 of the inner outer casing 30_2 can be in point contact.

[0071] Next, a method for manufacturing the coil component 1 will be described with reference to Figures 3 to 14B. First, a plurality of coils 10 as shown in Figure 3 are prepared. Also, partitioning sections 50 are prepared, and if necessary, the partitioning sections 50 are attached to the base 130 via an adhesive sheet 120. For example, a double-sided adhesive sheet can be used as the adhesive sheet 120.

[0072] The partition unit 50 is made of, for example, metal, but may also be made of a heat-resistant resin or the like. The partition unit 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 cross-sectional shape of the inner exterior body 30 perpendicular to the Z-axis direction. The partition unit 50 is provided with 12 partition spaces 52, but the number of partition spaces 52 is not particularly limited.

[0073] The partition wall 51 has an inner wall surface 51c surrounding each of the multiple partition spaces 52, and recesses 57_1 to 57_3 are formed on the inner wall surface 51c. Hereinafter, the recesses 57_1 to 57_3 may be referred to as recess 57 without distinction. The recess 57 extends from a first end 51a, which is the lower end of the partition wall 51, to a second end 51b, which is the upper end of the partition wall 51. The recess 57_2 is located on one side of the inner wall surface 51c in the X-axis direction, and the recess 57_3 is located on the other side of the inner wall surface 51c in the X-axis direction. The recess 57_1 is located on one side of the inner wall surface 51c in the Y-axis direction (the side from which the lead portions 12a and 12b of the coil 10 are led out). In a plan view, the positions of the recesses 57_1 to 57_3 formed on the inner wall surface 51c correspond to the positions of the protrusions 37_1 to 37_3 formed on the inner exterior body 30 ( FIG. 1D ).

[0074] In a cross section perpendicular to the axial direction (Z-axis direction) of each of the plurality of partition spaces 52, the shape of recess 57_1 corresponds to the shape of protrusion 37_1 ( FIG. 1D ), the shape of recess 57_2 corresponds to the shape of protrusion 37_2, and the shape of recess 57_3 corresponds to the shape of protrusion 37_3. In this way, recess 57 for forming protrusion 37 in at least one of the plurality of inner exterior bodies 30 is formed in partition 50 (inner wall surface 51 c).

[0075] Next, the multiple coils 10 are placed in the multiple partition spaces 52, respectively. 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 coil 10 is 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, and 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, respectively, the lead-out portions 12 a and 12 b of the coils 10 are fixed (adhered) to the adhesive sheet 120 inside each of the multiple partition spaces 52.

[0076] Next, as shown in FIG. 4 , with the multiple coils 10 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. 4 , 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 fillers other than magnetic particles.

[0077] When the partition 50 is placed inside the mold 60 (cavity 62), the partition 50 is moved in the direction shown by the arrow in Fig. 4. This allows a plurality of coils 10 to be placed in the cavity 62, as shown in Fig. 5. The mold 60 is heated before and after placing the partition 50 in the cavity 62. This allows the partition 50 to be removed from the pedestal 130 shown in Fig. 4.

[0078] 6 , inside the cavity 62, the lead-out portions 12a and 12b are arranged on the opening surface side of the cavity 62. At least a portion of the lead-out portion 12a is exposed upward from the opening surface of the cavity 62. In addition, at least a portion of the lead-out portion 12b is exposed upward from the opening surface of the cavity 62.

[0079] 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 partition 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 partition spaces 52, respectively, and open toward the opening surface of the cavity 62. A first end 51a of the partition 51 is close to the bottom surface 64 of the cavity 62. A second end 51b of the partition 51 is close to the opening surface of the cavity 62.

[0080] When the partition portion 50 is accommodated in the cavity 62, the outer casing material 80 filled in the cavity 62 enters the plurality of partition spaces 52. Furthermore, a portion of the outer casing material 80 enters the recesses 57_1 to 57_3 ( FIG. 3 ). In each of the plurality of partition spaces 52, the winding portion 11 is covered with the outer casing material 80, and at least a portion of the lead-out portions 12a and 12b is covered with the outer casing material 80. In this manner, in the present embodiment, the outer casing material 80 is filled into the cavity 62 so that the plurality of coils 10 are covered with the outer casing material 80.

[0081] 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.

[0082] 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.

[0083] Therefore, the above-described process of arranging the plurality of coils 10 in the plurality of partition spaces 52 is equivalent to the process of arranging the plurality of coils 10 in the plurality of partition regions 70. Furthermore, the above-described process of filling the plurality of partition spaces 52 with the outer jacket material 80 is equivalent to the process of filling the plurality of partition regions 70 with the outer jacket material 80.

[0084] In this embodiment, as shown in Fig. 4 , 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. 6 . 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.

[0085] 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.

[0086] 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. 4 is arranged via the connection region 72 so as to span the multiple partition regions 70 shown in FIG. 6.

[0087] Next, the exterior material 80 filled in the cavity 62 shown in FIG. 6 is compressed and cured. More specifically, an upper mold (not shown) is prepared, and the exterior material 80 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 80 filled in the multiple partition areas 70 is compressed and cured, forming multiple inner exterior bodies 30 inside the multiple partition areas 70. Furthermore, the exterior material 80 filled in the recesses 57_1 to 57_3 ( FIG. 3 ) is compressed and cured, forming protrusions 37_1 to 37_3 on the connecting surface of the inner exterior body 30. Furthermore, the exterior material 80 filled in the connection area 72 is compressed and cured, forming a first coupling portion 90 inside the connection area 72. As described above, the multiple partition areas 70 are connected via the connection area 72, and therefore the multiple inner exterior bodies 30 are connected via the first coupling portion 90. In this way, in this embodiment, a first molded body 100 can be formed having a plurality of inner 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 inner exterior bodies 30.

[0088] Next, as shown in FIG. 7 , the partition section 50 with the first molded body 100 formed therein is removed from the mold 60 (cavity 62). Then, the multiple inner 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 inner exterior bodies 30 from the first connecting portion 90. Alternatively, the multiple inner 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 the multiple inner exterior bodies 30 from the first connecting portion 90.

[0089] By breaking the multiple inner exterior bodies 30 at the first connecting portions 90, the multiple inner exterior bodies 30 connected to the first connecting portions 90 are separated into individual pieces, thereby obtaining multiple individual pieces of the multiple inner exterior bodies 30 each having a multiple coils 10 covered by an exterior material 80 as shown in FIG. 8A . In each of the multiple inner exterior bodies 30, a fracture surface having, for example, an uneven shape is formed at the location where the first connecting portion 90 was connected. This fracture surface corresponds to the unevenness 32 formed on 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 inner exterior body 30 shown in FIG. 1D . This fracture surface 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 inner exterior body 30.

[0090] In the manufacturing method of the coil component 1 of this embodiment, when the inner exterior body 30 ( FIGS. 7 and 8A ) is broken from the first connecting portion 90 ( FIGS. 7 and 8B ), the resin peels off along the magnetic particles. Therefore, the inner exterior body 30 is separated from the first connecting portion 90 without cutting the magnetic particles. As a result, asperities 32 are formed on 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 shown in FIG. 1D . Therefore, at least a portion of the asperities 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 asperities 32 are different from so-called burrs. In other words, the asperities 32 are not located outside of a virtual plane that extends from the flat regions of each of the third surface 30 c to the sixth surface 30 f, but are located inside (on the coil 10 side). The manufacturing method of the coil component 1 allows the coil component 1 to be singulated without generating external burrs.

[0091] When a matte pattern is formed on the surface of the release film 110 shown in Figure 4, the matte pattern can be transferred to the second surface 30b of the inner exterior body 30 shown in Figure 1D, thereby forming a concave-convex pattern 33 on the second surface 30b.

[0092] 7 (corresponding to height H3 of connection region 72 shown in FIG. 6 ) 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 multiple inner exterior bodies 30 can be easily broken from the first connecting portion 90. As shown in FIG. 8B , when the multiple inner exterior bodies 30 are broken from the first connecting portion 90, a runner of the first connecting portion 90 having multiple holes formed therein is formed.

[0093] Next, the outer exterior body 40 is formed using the obtained inner exterior body 30. First, as shown in Fig. 9, a partition 150 is prepared, and if necessary, the partition 150 is attached to a base 130 via an adhesive sheet 120. The partition 150 has a similar configuration to the partition 50, except that the width of the partition space 52 in the X-axis direction is wider.

[0094] Next, multiple (two in this embodiment) inner exterior bodies 30 are placed in each of the multiple partition spaces 52. More specifically, the convex portion 37_3 of one inner exterior body 30 is butted against (contacted with) the convex portion 37_2 of the other inner exterior body 30 to form a set of inner exterior bodies 30. This set of inner exterior bodies 30 is then placed in each of the multiple partition spaces 52. Furthermore, the multiple inner exterior bodies 30 are placed in each of the multiple partition spaces 52 so that the convex portions 37_1 and 37_2 of one inner exterior body 30 and the convex portions 37_1 and 37_3 of the other inner exterior body 30 contact the inner wall surface 51 c of the partition portion 150. However, it is not necessary to place inner exterior bodies 30 in all of the partition spaces 52, and it is also possible that no inner exterior body 30 is placed in any of the partition spaces 52. When multiple inner exterior bodies 30 are placed in each of the multiple partition spaces 52, the first surfaces 30a (or the drawer portions 12a and 12b) of the multiple inner exterior bodies 30 are fixed (adhered) to the adhesive sheet 120 inside each of the multiple partition spaces 52.

[0095] Next, as shown in Fig. 10 , with the multiple inner exterior bodies 30 adhered to the adhesive sheet 120, the divider 150 is placed inside a mold (lower mold) 60. As a result, as shown in Fig. 11 , the multiple inner exterior bodies 30 are placed in a cavity 62 filled with an exterior material 180 so that the multiple inner exterior bodies 30 come into contact with each other via the protrusions 37 formed on at least one of the multiple inner exterior bodies 30 (in this embodiment, each of the multiple inner exterior bodies 30). The exterior material 180 filled in the cavity 62 may be the same as or different from the exterior material 80 used to form the inner exterior body 30 shown in Fig. 4 .

[0096] The mold 60 is heated before and after the partition 150 is accommodated in the cavity 62. This allows the partition 150 to be detached from the pedestal 130 shown in FIG.

[0097] 11 , inside the cavity 62, the second surface 30b of the inner exterior body 30 faces the bottom surface 64 ( FIG. 10 ) 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 inner exterior body 30 faces the opening surface of the cavity 62.

[0098] 12 , when the partition portion 150 is accommodated in the cavity 62, the exterior material 180 filled in the cavity 62 enters the multiple partition spaces 52. Then, in each of the multiple partition spaces 52, the multiple inner exterior bodies 30 are covered with the exterior material 180. That is, in the present embodiment, the exterior material 180 is filled in the cavity 62 so that the multiple inner exterior bodies 30 are covered with the exterior material 180. A portion of the exterior material 180 enters the inter-electrode region between the lead portions 12 a and 12 b and fills the periphery of the lead portions 12 a and 12 b. The lead portions 12 a and 12 b are partially exposed from the exterior material 180 (the opening surface of the cavity 62).

[0099] In the present embodiment, as shown in Fig. 10 , a plurality of inner exterior bodies 30 are arranged in each of a plurality of partition spaces 52, and then a partition 150 is housed in the cavity 62, thereby arranging a plurality of inner exterior bodies 30 in each of a plurality of partition areas 70 shown in Fig. 12 . However, the method of arranging a plurality of inner exterior bodies 30 in each of a plurality of partition areas 70 is not limited to this. For example, a partition 150 may be arranged in the cavity 62 to form a plurality of partition areas 70 in the cavity 62, and then a plurality of inner exterior bodies 30 may be arranged in each of the plurality of partition areas 70.

[0100] 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.

[0101] Next, the exterior material 180 filled in the cavity 62 shown in FIG. 12 is compressed and cured. More specifically, an upper mold (not shown) is prepared, and the exterior material 180 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 180 filled in the multiple partition regions 70 is compressed and cured, forming multiple outer exterior bodies 40 inside the multiple partition regions 70. Furthermore, the exterior material 180 filled in the connection region 72 is compressed and cured, forming second coupling portions 190 inside the connection region 72. As described above, the multiple partition regions 70 are connected via the connection region 72, and therefore the multiple outer exterior bodies 40 are connected via the second coupling portions 190. In this way, in this embodiment, a second molded body 200 can be formed, which has multiple outer exterior bodies 40 formed in the multiple partition regions 70 and second coupling portions 190 formed in the connection region 72 and connected to the multiple outer exterior bodies 40.

[0102] Next, as shown in FIG. 13 , the partition portion 150 with the second molded body 200 formed therein is removed from the mold 60 (cavity 62). Then, the multiple outer exterior bodies 40 are 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 outer exterior bodies 40 from the second connecting portion 190. Alternatively, the multiple outer exterior bodies 40 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 the multiple outer exterior bodies 40 from the second connecting portion 190.

[0103] By breaking the multiple outer exterior bodies 40 at the second connecting portion 190, the multiple outer exterior bodies 40 connected to the second connecting portion 190 are separated into individual pieces, thereby obtaining multiple individual pieces of the outer exterior bodies 40 that cover the multiple inner exterior bodies 30, as shown in FIG. 14A . In each of the multiple outer exterior bodies 40, a fracture surface having, for example, an uneven shape is formed at the portion where the second connecting portion 190 was connected. This fracture surface is the unevenness 42 formed on each of the first ridge portion 45 a, the second ridge portion 45 b, the third ridge portion 45 c, and the fourth ridge portion 45 d of the outer exterior body 40 shown in FIG. 1B . This fracture surface may extend to the second outer surface 40 b, the third outer surface 40 c, the fourth outer surface 40 d, the fifth outer surface 40 e, and the sixth outer surface 40 f of the outer exterior body 40.

[0104] The manufacturing method of the coil component 1 of this embodiment includes a step of removing the outer exterior body 40 ( FIGS. 13 and 14A ) from the partition portion 150 ( FIG. 13 ) while breaking it from the second connecting portion 190 ( FIGS. 13 and 14B ). In this step, the resin peels off along the magnetic particles without cutting them, forming irregularities 42 on each of the first ridge portion 45 a, the second ridge portion 45 b, the third ridge portion 45 c, and the fourth ridge portion 45 d shown in FIG. 1B . Thus, when the outer exterior body 40 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 prevents oxidation of the magnetic particles and inhibits rusting of the exterior material without the use of 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.

[0105] Furthermore, at least a portion of the irregularities 42 have a shape that reflects the shape of the magnetic particles (a shape that follows the surface shape of the magnetic particles), and the irregularities 42 are different from so-called burrs. In other words, the irregularities 42 are not located outside of an imaginary plane that is an extension of the flat regions of each of the third outer surface 40c to the sixth outer surface 40f, but are located inside (on the coil 10 side). In this way, the manufacturing method for the coil component 1 of this embodiment can individualize the coil component 1 without generating external burrs.

[0106] When a matte pattern is formed on the surface of the release film 110 (Figure 10), the matte pattern can be transferred to the second outer surface 40b of the outer casing 40 shown in Figure 1B, forming a concave-convex pattern 43 on the second outer surface 40b.

[0107] As shown in FIG. 13 , the outer casing 40 has a resin-rich layer 48. At least a portion of the resin-rich layer 48 is formed around the boundary between at least one of the multiple inner casings 30 and the outer casing 40. In this embodiment, the resin-rich layer 48 is formed along the boundary between at least one of the multiple inner casings 30 and the outer casing 40. The resin-rich layer 48 contains a higher amount of resin (second resin) 47b than regions other than the resin-rich layer 48 (e.g., near the surface of the outer casing 40). The resin-rich layer 48 may contain a higher amount of resin (second resin) 47b as it approaches the boundary between at least one of the multiple inner casings 30 and the outer casing 40. The contents of metal elements (e.g., Fe) constituting the magnetic particles 47a and elements (e.g., C) constituting the resin 47b in the resin-rich layer 48 can be determined based on the results of simple quantitative analysis using cross-sectional EDS. In the resin-rich layer 48, the weight percentage of the metal elements that make up the magnetic particles 47a is lower and the weight percentage of the elements that make up the resin 47b is higher than in other portions (e.g., near the surface of the outer casing 40). The thickness of the resin-rich layer 48 is not particularly limited, but is, for example, 1 μm to 200 μm or 1 μm to 50 μm. The difference in the content of the elements (e.g., C) that make up the resin 47b in the resin-rich layer 48 and the content of the elements (e.g., C) that make up the resin 47b in the region other than the resin-rich layer 48 is not particularly limited, but is, for example, 0.1 wt % to 8.0 wt %, or 0.5 wt % to 1.0 wt %.

[0108] 13 (corresponding to height H3 of connection region 72 shown in FIG. 12 ) 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 multiple outer exterior bodies 40 can be easily broken off from second connecting portion 190. As shown in FIG. 14B , when the multiple outer exterior bodies 40 are broken off from second connecting portion 190, runners of second connecting portion 190 having multiple holes formed therein are formed. In this manner, coil device 1 can be obtained.

[0109] 1A , in the coil device 1 of this embodiment, at least one of the multiple inner exterior bodies 30 (in this embodiment, each of the multiple inner exterior bodies 30) has a protrusion 37 protruding from the connection surface (the third surface 30c, the fourth surface 30d, and the sixth surface 30f). Therefore, the multiple inner exterior bodies 30 can be arranged inside the outer exterior body 40 so that the multiple inner exterior bodies 30 contact each other via the protrusion 37 formed on at least one of the multiple inner exterior bodies 30. In this case, the multiple inner exterior bodies 30 are fixed to each other via the protrusion 37, and the positions of the multiple inner exterior bodies 30 inside the outer exterior body 40 are less likely to vary. This makes it possible to prevent the positions of the multiple coils 10 arranged inside the multiple inner exterior bodies 30 from varying.

[0110] Furthermore, in a direction perpendicular to the first surface 30a (the Z-axis direction), the protrusion 37 extends from one end to the other end of at least one of the multiple inner exterior bodies 30. Therefore, when the multiple inner exterior bodies 30 are brought into contact with each other via the protrusion 37 formed on at least one of the multiple inner exterior bodies 30, a contact area between the multiple inner exterior bodies 30 can be ensured.

[0111] The multiple inner exterior bodies 30 include an inner exterior body 30_1 and an inner exterior body 30_2 arranged adjacent to each other. The inner exterior body 30_1 has a protrusion 37_3 as the protrusion 37. The protrusion 37_3 protrudes toward the inner exterior body 30_2 inside the outer exterior body 40. By bringing the protrusion 37_3 into contact with the inner exterior body 30_2, the inner exterior body 30_1 and the inner exterior body 30_2 are fixed to each other via the protrusion 37_3, and the positions of the inner exterior body 30_1 and the inner exterior body 30_2 inside the outer exterior body 40 are less likely to vary. This makes it possible to prevent variation in the positions of the coils 10 arranged inside the inner exterior body 30_1 and the inner exterior body 30_2.

[0112] Furthermore, the inner exterior body 30_2 has a protrusion 37_2 as the protrusion 37. The protrusion 37_3 of the inner exterior body 30_1 protrudes toward the protrusion 37_2 of the inner exterior body 30_2 inside the outer exterior body 40. By bringing the protrusion 37_3 of the inner exterior body 30_1 into contact with the protrusion 37_2 of the inner exterior body 30_2, the position at which the protrusion 37_3 of the inner exterior body 30_1 comes into contact with the inner exterior body 30_2 is less likely to vary.

[0113] 2D , the protrusions 37_2 of the inner exterior body 30_2 have a shape that narrows toward the tip of the protrusions 37_2 in a cross section parallel to the first surface 30a. This allows the protrusions 37_2 of the inner exterior body 30_2 to come into point contact with the protrusions 37_3 of the inner exterior body 30_1. This makes it less likely that cracks or chips will occur in the protrusions 37_3 of the inner exterior body 30_1 and / or the protrusions 37_2 of the inner exterior body 30_2.

[0114] Furthermore, in a cross section parallel to the first surface 30a, the convex portion 37_2 of the inner exterior body 30_2 is curved so as to become narrower toward the tip of the convex portion 37_2. This makes it easier for the outer exterior body 40 to fit around the contact portion between the convex portion 37_3 of the inner exterior body 30_1 and the convex portion 37_2 of the inner exterior body 30_2, making it less likely that the inner exterior body 30_1 and the inner exterior body 30_2 will become misaligned inside the outer exterior body 40.

[0115] Furthermore, in a cross section parallel to the first surface 30a, the protrusion 37_3 of the inner exterior body 30_1 has, at the tip of the protrusion 37_3, a flat surface that extends in a direction perpendicular to the protrusion direction of the protrusion 37_3 (the Y-axis direction). Therefore, the protrusion 37_2 of the inner exterior body 30_2 comes into stable contact with the flat surface of the protrusion 37_3 of the inner exterior body 30_1. This further reduces variation in the positions of the inner exterior body 30_1 and the inner exterior body 30_2 inside the outer exterior body 40.

[0116] In the example shown in FIG. 2D , the convex portion 37_2 of the inner exterior body 30_2 has a shape that narrows toward the tip of the convex portion 37_2 in a cross section parallel to the first surface 30a. This allows the convex portion 37_2 of the inner exterior body 30_2 to be in point contact with the convex portion 37_3 of the inner exterior body 30_1. This makes it less likely that cracks or chips will occur in the convex portion 37_3 of the inner exterior body 30_1 and / or the convex portion 37_2 of the inner exterior body 30_2. Furthermore, in the example shown in FIG. 2E , the convex portion 37_3 of the inner exterior body 30_1 has a shape that widens toward the tip of the convex portion 37_3 in a cross section parallel to the first surface 30a. This makes it easier for the convex portion 37_3 of the inner exterior body 30_1 to engage with the outer exterior body 40, effectively preventing variation in the position of the inner exterior body 30_1 inside the outer exterior body 40.

[0117] 2F and 2G , in a cross section (XZ cross section) that is perpendicular to the first surface 30a and parallel to the protruding direction of the convex portion 37_3 of the inner exterior body 30_1, a tip surface 370 located at the tip of the convex portion 37_3 of the inner exterior body 30_1 is inclined with respect to the direction perpendicular to the first surface 30a. Therefore, as shown by dots in Fig. 2F , the outer exterior body 40 can easily get between the tip surface 370 of the convex portion 37_3 of the inner exterior body 30_1 and the inner exterior body 30_2, making it difficult for the inner exterior body 30_1 and the inner exterior body 30_2 to become misaligned inside the outer exterior body 40.

[0118] 2D , at least one of the multiple inner exterior bodies 30 has a third surface 30c, a fourth surface 30d, a fifth surface 30e, and a sixth surface 30f that constitute a connecting surface. When viewed from a direction perpendicular to the first surface 30a, along the circumferential direction of at least one of the multiple inner exterior bodies 30, the fourth surface 30d is adjacent to the third surface 30c, the fifth surface 30e is adjacent to the fourth surface 30d, the sixth surface 30f is adjacent to the fifth surface 30e, and the third surface 30c is adjacent to the sixth surface 30f. The third surface 30c, the fourth surface 30d, the fifth surface 30e, or the sixth surface 30f has a plurality of protrusions 37_2 or 37_3. Therefore, the multiple inner exterior bodies 30 can be arranged inside the outer exterior body 40 so that the multiple inner exterior bodies 30 are in contact with each other via the multiple protrusions 37_2 or 37_3 formed on the third surface 30c, the fourth surface 30d, the fifth surface 30e, or the sixth surface 30f. This allows the multiple inner exterior bodies 30 to be fixed to each other via the multiple protrusions 37_2 or 37_3, making it less likely that the positions of the multiple inner exterior bodies 30 will vary inside the outer exterior body 40.

[0119] 1A , two or more of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f each have a protrusion 37. Therefore, three or more inner exterior bodies 30 can be fixed to each other via the protrusion 37 formed on two or more of the third surface 30c, the fourth surface 30d, the fifth surface 30e, and the sixth surface 30f.

[0120] 1A and 1B , the outer exterior body 40 has a first outer surface 40a on which one of the lead-out portions 12a or 12b of the multiple coils 10 is arranged, a second outer surface 40b opposite the first outer surface 40a, and a connecting outer surface connecting the first outer surface 40a and the second outer surface 40b. Any of the multiple protrusions 37 protrudes toward the connecting outer surface. Any of the multiple protrusions 37 may be exposed from the connecting outer surface. By having the protrusions 37 exposed from the connecting outer surface, the orientation of the outer exterior body 40 can be identified from the external shape of the outer exterior body 40.

[0121] 2B , any of the plurality of protrusions 37 protrudes toward the connection outer surface. Any of the plurality of protrusions 37 is not exposed from the connection outer surface and is covered by the outer exterior body 40. This makes it possible to prevent rust, deterioration of characteristics, and even damage to the inner exterior body 30 originating from the protrusions 37 protruding toward the connection outer surface.

[0122] 13 , the outer exterior body 40 has a resin-rich layer 48. At least a portion of the resin-rich layer 48 is formed around the boundary between the outer exterior body 40 and at least one of the multiple inner exterior bodies 30. The resin-rich layer 48 has a higher content of second resin 47b than regions other than the resin-rich layer 48. Therefore, the resin-rich layer 48 can improve adhesion between the outer exterior body 40 and at least one of the multiple inner exterior bodies 30.

[0123] 9 to 11 , the method for manufacturing the coil device 1 of this embodiment includes a step of placing multiple inner exterior bodies 30 in a mold cavity 62 so that the multiple inner exterior bodies 30 contact each other via a protrusion 37 formed on at least one of the multiple inner exterior bodies 30 (in this embodiment, each of the multiple inner exterior bodies 30). Therefore, inside the cavity 62, the multiple inner exterior bodies 30 are fixed to each other via the protrusion 37, making it difficult for the positions of the multiple inner exterior bodies 30 to vary. In this state, the cavity 62 is filled with the exterior material 180 so that the multiple inner exterior bodies 30 are covered by the exterior material 180, thereby forming the outer exterior body 40 while preventing variation in the positions of the multiple inner exterior bodies 30. This prevents variation in the positions of the multiple coils 10 arranged inside the multiple inner exterior bodies 30.

[0124] 3 to 5 , the method for manufacturing the coil device 1 of this embodiment further includes a step of filling the cavity 62 with the exterior material 80 so that the multiple coils 10 are covered with the exterior material 80. The cavity 62 is divided into multiple regions (partition regions 70) by partitions 50. The partitions 50 have recesses 57 formed therein for forming the protrusions 37 in at least one of the multiple inner exterior bodies 30. By filling such a partition 50 with the exterior material 80, it is possible to form at least one inner exterior body 30 having the protrusions 37 formed therein.

[0125] 9 to 11 , the cavity 62 is divided into multiple regions (partition regions 70) by the partitions 150. The multiple inner exterior bodies 30 are housed in the cavity 62 so that any of the multiple protrusions 37_1 to 37_3 contacts the inner wall surface 51 c of the partitions 150. Therefore, inside the cavity 62, any of the multiple inner exterior bodies 30 is fixed to the inner wall surface 51 c via the protrusions 37, making it difficult for the position of any of the multiple inner exterior bodies 30 to vary.

[0126] 15 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.

[0127] The coil device 1A of this embodiment has four inner exterior bodies 30_1 to 30_4 and four coils 10A_1 to 10A_4. Hereinafter, the inner exterior bodies 30_1 to 30_4 may be referred to as the inner exterior body 30 without distinction. Furthermore, the coils 10A_1 to 10A_4 may be referred to as the coils 10A without distinction.

[0128] Coil 10A has a first coil 13 and a second coil 14. First coil 13 has a U-shape and is arranged outside second coil 14 so as to overlap with it. First coil 13 has first legs 130a and 130b and a first connection portion 131. First legs 130a and 130b extend in a direction perpendicular to a mounting substrate (not shown). First connection portion 131 connects first leg 130a and first leg 130b and extends in a direction parallel to the mounting substrate.

[0129] The second coil 14 has second legs 140a and 140b, a second connection portion 141, and second mounting portions 142a and 142b. The second legs 140a and 140b extend perpendicular to a mounting substrate (not shown). The second leg 140a overlaps the first leg 130a, and the second leg 140b overlaps the first leg 130b. The second connection portion 141 connects the second legs 140a and 140b and extends parallel to the mounting substrate. The second connection portion 141 overlaps the first connection portion 131.

[0130] An insulating coating layer is formed on at least a portion of second leg 140a, and second leg 140a is in contact with first leg 130a without conducting electricity. Also, an insulating coating layer is formed on at least a portion of second leg 140b, and second leg 140b is in contact with first leg 130b without conducting electricity. Also, an insulating coating layer is formed on at least a portion of second connection portion 141, and second connection portion 141 is in contact with first connection portion 131 without conducting electricity.

[0131] However, a gap may be formed between the second leg 140a and the first leg 130a. Also, a gap may be formed between the second leg 140b and the first leg 130b. Also, a gap may be formed between the second connecting portion 141 and the first connecting portion 131.

[0132] The second mounting portion 142a extends in a direction parallel to the mounting substrate (not shown) and orthogonal to the second leg portion 140a. The second mounting portion 142b extends in a direction parallel to the mounting substrate and orthogonal to the second portion 140b. The second mounting portions 142a and 142b extend in directions approaching each other.

[0133] Coil 10A_1 is disposed inside inner exterior body 30_1, coil 10A_2 is disposed inside inner exterior body 30_2, coil 10A_3 is disposed inside inner exterior body 30_3, and coil 10A_4 is disposed inside inner exterior body 30_4. In this embodiment, inner exterior body 30 also has protrusion 37. Therefore, in this embodiment, the same effects as in the first embodiment can be obtained.

[0134] 16 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.

[0135] The coil component 1B has cores 20_1 and 20_2, coils 10B_1 and 10B_2, terminal electrodes 140a_1 and 140a_2, and terminal electrodes 140b_1 and 140b_2. Hereinafter, the cores 20_1 and 20_2 may be referred to as core 20 without distinction. The coils 10B_1 and 10B_2 may be referred to as coil 10B without distinction. The terminal electrodes 140a_1 and 140a_2 may be referred to as terminal electrode 140a without distinction. The terminal electrodes 140b_1 and 140b_2 may be referred to as terminal electrode 140b without distinction.

[0136] The core 20 is a T-shaped core made of a composite material containing a magnetic material and a resin. The core 20 is formed by, for example, powder molding, injection molding, or cutting. The material constituting the core 20 may be the same as or different from the material constituting the inner exterior body 30.

[0137] The core 20 has a core portion 21 and a flange portion 22. The core 20 may be a drum core in which flange portions 22 are formed on both axial ends of the core portion 21. The core portion 21 is a columnar body extending perpendicular to a mounting substrate (not shown) and protruding upward from the flange portion 22. The cross-sectional shape of the core portion 21 perpendicular to the axial direction is circular, but may also be elliptical, rectangular, octagonal, other polygonal, or other shapes. The planar shape of the flange portion 22 is rectangular, but may also be other polygonal, circular, elliptical, or other shapes. At least a portion of the core 20 is covered by the inner exterior body 30. The bottom surface of the flange portion 22 may be exposed from the first surface 30a of the inner exterior body 30.

[0138] Coil 10B is made of a round wire and has a spirally wound winding portion 11B and lead-out portions 12aB and 12bB led out from winding portion 11B. Winding portion 11B is disposed in core portion 21 and is covered with inner exterior body 30. Lead-out portions 12aB and 12bB are disposed on the bottom surface of flange portion 22. At least a portion of lead-out portion 12aB is covered with inner exterior body 30. In addition, at least a portion of lead-out portion 12bB is also covered with inner exterior body 30.

[0139] Terminal electrode 140a is provided on one side in the X-axis direction of first surface 30a of inner exterior body 30 so as to cover lead portion 12aB arranged on the bottom surface of flange 22. Terminal electrode 140b is provided on the other side in the X-axis direction of first surface 30a of inner exterior body 30 so as to cover lead portion 12bB arranged on the bottom surface of flange 22. Terminal electrodes 140a and 140b are formed, for example, by a laminated electrode film made of an underlying electrode film and a plating film formed on the underlying electrode film. Lead portions 12aB and 12bB are connected to terminal electrodes 140a and 140b, respectively, by thermocompression bonding, soldering, a conductive adhesive, or the like.

[0140] In this embodiment as well, the inner exterior body 30 has the protrusions 37. Therefore, in this embodiment as well, the same effects as in the first embodiment can be obtained.

[0141] The present disclosure is not limited to the above-described embodiments, and various modifications can be made within the scope of the present disclosure.

[0142] As shown in Figures 17A to 17I, the shape of the convex portion 37 shown in Figure 2B may be modified into various shapes. Although Figures 17A to 17I show modified examples of the convex portion 37_1, these modified examples are also applicable to the convex portions 37_2 and 37_3. These modified examples are also applicable to the second and third embodiments. For example, as shown in Figure 17A, in a plan view, the base end side of the convex portion 37_1 may have a curved shape that becomes wider toward the tip, and the tip side of the convex portion 37_1 may have a curved shape that becomes narrower toward the tip.

[0143] As shown in FIG. 17B, in plan view, the shape of the base end side of the convex portion 37_1 may be quadrilateral (square or rectangular), and the shape of the tip end side of the convex portion 37_1 may be substantially circular or elliptical.

[0144] As shown in FIG. 17C, the shape of the convex portion 37_1 may be quadrilateral (square or rectangle) in plan view.

[0145] 17D, the shape of the protrusion 37_1 may be substantially a parallelogram in a plan view. In the example shown in Fig. 17D, the protrusion 37_1 extends in a direction oblique to a direction perpendicular to the third surface 30c.

[0146] As shown in FIG. 17E, when the shape of the protrusion 37_1 is quadrangular in plan view, two corners located at the tip of the protrusion 37_1 may be rounded.

[0147] As shown in FIG. 17F, when the shape of the protrusion 37_1 is quadrangular in plan view, two corners located at the tip of the protrusion 37_1 may be chamfered to form C-faces.

[0148] As shown in FIG. 17G, in a plan view, the shape of the base end side of the convex portion 37_1 is quadrilateral (square or rectangle), and the shape of the tip end side of the convex portion 37 may be trapezoidal, narrowing toward the tip.

[0149] As shown in FIG. 17H, in a plan view, the shape of the convex portion 37_1 may be a triangle that narrows toward the tip.

[0150] As shown in FIG. 17I, in a plan view, the base end of the convex portion 37_1 may have a quadrilateral (square or rectangular) shape, and the tip end of the convex portion 37 may have a triangular shape that narrows toward the tip.

[0151] The protrusion 37 may be formed on only one of the two inner exterior bodies 30_1 and 30_2 shown in Fig. 1C. For example, as shown in Fig. 18, the protrusion 37 may be formed on only the inner exterior body 30_1. In the example shown in Fig. 18, the protrusion 37_3 formed on the sixth surface 30f of the inner exterior body 30_1 protrudes toward the fourth surface 30d of the inner exterior body 30_2 and is in contact with the fourth surface 30d.

[0152] As shown in FIG. 19, a protrusion 37_3 formed on the sixth surface 30f of the inner exterior body 30_1 may be in contact with the bottom surface of a recess 38 formed on the fourth surface 30d of the inner exterior body 30_2.

[0153] As shown in Fig. 20 , in the third embodiment, coil 10B may be disposed inside inner exterior body 30 so that the winding axis direction of winding portion 11B is parallel to first surface 30a. In Fig. 20 , the winding axis direction of winding portion 11B corresponds to the Y-axis direction. The shape of winding portion 11B 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.

[0154] 21 , terminal electrode 140a may extend from the bottom surface of flange 22 to the side surface of flange 22 (the side surface on the positive Y-axis direction in the example shown in FIG. 21 ). Similarly, terminal electrode 140b may extend from the bottom surface of flange 22 to the side surface of flange 22 (the side surface on the positive Y-axis direction in the example shown in FIG. 21 ). In this case, lead portions 12aB and 12bB can be connected to terminal electrodes 140a and 140b, respectively, at positions corresponding to the side surface of flange 22.

[0155] 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. 1D may be chamfered (cut so as to remove any corners). Furthermore, at least one of the first ridge line portion 45a, the second ridge line portion 45b, the third ridge line portion 45c, and the fourth ridge line portion 45d shown in Fig. 1B may be chamfered (cut so as to remove any corners). Furthermore, irregularities 42 may be formed on the chamfered portions of the inner exterior body 30 or the outer exterior body 40 described above.

[0156] Although the cross-sectional shape of the inner exterior body 30 parallel to the XZ plane shown in FIG. 1A is a trapezoid (quadrilateral), it may be another polygon. For example, the cross-sectional shape may be a hexagon. Furthermore, although the cross-sectional shape of the inner exterior body 30 parallel to the YZ plane is a trapezoid (quadrilateral), it may be another polygon. For example, the cross-sectional shape may be a hexagon. The same applies to the outer exterior body 40 shown in FIG. 1B.

[0157] 1A , in the first embodiment, the multiple inner exterior bodies 30 are arranged along the X axis. However, the multiple inner exterior bodies 30 may be arranged along the Y axis without changing the orientation of the inner exterior bodies 30. Also, the multiple inner exterior bodies 30 may be arranged along the X axis and the Y axis without changing the orientation of the inner exterior bodies 30. The same applies to the second and third embodiments.

[0158] 3 to 14B , in the first embodiment, a method for molding the inner exterior body 30 and the outer exterior body 40 using the partitions 50 and 150 has been described. However, the inner exterior body 30 and the outer exterior body 40 may be molded without using the partitions 50 and 150. For example, the inner exterior body 30 and the outer exterior body 40 can be molded using various molding techniques such as resin molding, transfer molding, injection molding, and dry molding.

[0159] 6 may be an inclined surface that is inclined with respect to the bottom surface 64 of the mold 60, or may be inclined with respect to the axial direction (Z-axis direction) of the partition space 52. In the direction (X-axis direction) perpendicular to the axial direction of the partition space 52 shown in Fig. 6, the distance L between the inner wall surface 51c of the partition wall 51 located on one side and the inner wall surface 51c of the partition wall 51 located on the other side may increase with increasing distance from the bottom surface 64 of the cavity 62 (toward the opening surface of the cavity 62).

[0160] Furthermore, the cross-sectional area perpendicular to the axial direction of each of the multiple partition spaces 52 may increase in a direction away from the bottom surface 64 of the cavity 62 (toward the opening surface of the cavity 62). Furthermore, the opening area of ​​each of the multiple second openings 54 may be larger than the opening area of ​​each of the multiple first openings 53. In this case, when the multiple inner exterior bodies 30 are torn from the first connecting portion 90, the multiple inner exterior bodies 30 can be easily removed from the multiple partition regions 70 via the multiple second openings 54. Furthermore, when the multiple outer exterior bodies 40 are torn from the first connecting portion 190, the multiple outer exterior bodies 40 can be easily removed from the multiple partition regions 70 via the multiple second openings 54.

[0161] 1A , in the first embodiment, the inner exterior body 30 covers one coil 10, but may cover multiple coils 10. The same applies to the second and third embodiments.

[0162] In the first embodiment, a convex portion protruding from the connecting outer surface (at least one of the third outer surface 40c to the sixth outer surface 40f shown in FIG. 1B) of the outer exterior body 40 may be formed. The coil device 1 may further include an exterior body that covers the multiple outer exterior bodies 40 that have convex portions protruding from the connecting outer surface. The same applies to the second and third embodiments.

[0163] This specification discloses the following:

[0164] [Supplementary Note 1] A coil component having a plurality of coils, a plurality of inner exterior bodies including first magnetic particles and a first resin and covering at least one of the plurality of coils, and an outer exterior body including second magnetic particles and a second resin and covering the plurality of inner exterior bodies, wherein each of the plurality of inner exterior bodies has a first surface on which an extraction portion of one of the plurality of coils is arranged, a second surface opposite the first surface, and a connection surface connecting the first surface and the second surface, and at least one of the plurality of inner exterior bodies has a protrusion protruding from the connection surface. [Supplementary Note 2] The coil component according to Supplementary Note 1, wherein the protrusion extends from one end to the other end of at least one of the plurality of inner exterior bodies in a direction perpendicular to the first surface. [Supplementary Note 3] The coil component according to Supplementary Note 1 or 2, wherein the plurality of inner exterior bodies include a first inner exterior body and a second inner exterior body arranged adjacent to each other, wherein the first inner exterior body has a first protrusion as the protrusion, and wherein the first protrusion protrudes toward the second inner exterior body from within the outer exterior body. [Supplementary Note 4] The coil component according to Supplementary Note 3, wherein the second inner exterior body has a second protrusion as the protrusion, and wherein the first protrusion protrudes toward the second protrusion from within the outer exterior body. [Supplementary Note 5] The coil component according to Supplementary Note 4, wherein the first protrusion has a shape that narrows toward the tip of the first protrusion in a cross section parallel to the first surface. [Supplementary Note 6] The coil component according to Supplementary Note 5, wherein the first protrusion is curved so as to narrow toward the tip of the first protrusion in a cross section parallel to the first surface. [Supplementary Note 7] The coil component according to any one of Supplementary Notes 4 to 6, wherein, in a cross section parallel to the first surface, the second convex portion has, at a tip thereof, a flat surface extending in a direction perpendicular to the protruding direction of the second convex portion. [Supplementary Note 8] The coil component according to any one of Supplementary Notes 4 to 7, wherein, in a cross section parallel to the first surface, the second convex portion has a shape that narrows or widens toward the tip of the second convex portion.[Supplementary Note 9] The coil component according to any one of Supplementary Notes 3 to 8, wherein, in a cross section perpendicular to the first surface and parallel to the protruding direction of the first protrusion, a first tip surface located at a tip of the first protrusion is inclined with respect to the direction perpendicular to the first surface. [Supplementary Note 10] The coil component according to any one of Supplementary Notes 1 to 9, wherein at least one of the plurality of inner exterior bodies has a third surface, a fourth surface, a fifth surface, and a sixth surface that constitute the connecting surface, and when viewed from the direction perpendicular to the first surface, along a circumferential direction of at least one of the plurality of inner exterior bodies, 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 the third surface is adjacent to the sixth surface, and the third surface, the fourth surface, the fifth surface, or the sixth surface has a plurality of the protrusions. [Supplementary Note 11] The coil component according to any one of Supplementary Notes 1 to 10, wherein at least one of the plurality of inner exterior bodies has a third surface, a fourth surface, a fifth surface, and a sixth surface that constitute the connecting surface, and when viewed from a direction perpendicular to the first surface, along a circumferential direction of at least one of the plurality of inner exterior bodies, 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 the third surface is adjacent to the sixth surface, and two or more of the third surface, the fourth surface, the fifth surface, and the sixth surface each have the protrusion. [Supplementary Note 12] The coil component according to Supplementary Note 11, wherein the outer exterior body has a first outer surface on which lead-out portions of any of the plurality of coils are arranged, a second outer surface facing the first outer surface, and a connecting outer surface that connects the first outer surface and the second outer surface, and any of the plurality of protrusions protrudes toward the connecting outer surface, and any of the plurality of protrusions is exposed from the connecting outer surface. [Supplementary Note 13] The coil component described in Supplementary Note 11, wherein the outer exterior body has a first outer surface on which an extraction portion of any of the plurality of coils is arranged, a second outer surface opposite to the first outer surface, and a connecting outer surface connecting the first outer surface and the second outer surface, any of the plurality of protrusions protrudes toward the connecting outer surface, and any of the plurality of protrusions is not exposed from the connecting outer surface and is covered by the outer exterior body.[Supplementary Note 14] The coil component according to any one of Supplementary Notes 1 to 13, wherein the outer exterior body has a resin-rich layer, at least a portion of the resin-rich layer is formed around a boundary between the outer exterior body and at least one of the plurality of inner exterior bodies, and the resin-rich layer has a higher content of the second resin than an area other than the resin-rich layer. [Supplementary Note 15] A method for manufacturing a coil component, comprising: preparing a plurality of inner exterior bodies, each having at least one of a plurality of coils covered with a first exterior material containing first magnetic particles and a first resin, placing the plurality of inner exterior bodies in cavities of a mold so that the plurality of inner exterior bodies are in contact with each other via protrusions formed on at least one of the plurality of inner exterior bodies, filling the cavity with the second exterior material so that the plurality of inner exterior bodies are covered with a second exterior material containing second magnetic particles and a second resin, and forming an outer exterior body covering the plurality of inner exterior bodies. [Supplementary Note 16] The method for manufacturing a coil component according to Supplementary Note 15, further comprising a step of filling the cavity with the first external material so that the plurality of coils are covered with the first external material, wherein the cavity is partitioned into a plurality of regions by a first partition, and a recess for forming the protrusion in at least one of the plurality of inner external bodies is formed in the first partition. [Supplementary Note 17] The method for manufacturing a coil component according to Supplementary Note 15 or 16, wherein the cavity is partitioned into a plurality of regions by a second partition, and the plurality of inner external bodies are placed in the cavity so that any of the plurality of protrusions contacts an inner wall surface of the second partition.

[0165] DESCRIPTION OF SYMBOLS 1, 1A, 1B... Coil component 10, 10A, 10A_1 to 10A_4, 10B, 10B_1 to 10B_2... Coil 11, 11B... Winding portion 12a, 12b, 12aB, 12bB... Lead-out portion 13... First coil 130a, 130b... First leg portion 131... First connection portion 14... Second coil 140a, 140b... Second leg portion 141... Second connection portion 142a, 142b... Second mounting portion 20, 20_1, 20_2... Core 21... Core portion 22... Flange portion 30, 30_1 to 30_4... Inner exterior body 30a to 30f... First surface to sixth surface 31... Curved portion 32... Concave and recess 33... Concave and recess pattern 35a to 35h...First ridge line portion to eighth ridge line portion 37, 37_1 to 37_3...Convex portion 370...Tip surface 38...Concave portion 40...Outer exterior body 40a to 40f...First outer surface to sixth outer surface 41...Curved portion 42...Concave and recessed portion 43...Concave and recessed pattern 45a to 45h...First ridge line portion to eighth ridge line portion 46...Thin layer 47a...Magnetic particles 47b...Resin 48...Resin-rich layer 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 57, 57_1 to 57_3...Concave portion 60...Mold DESCRIPTION OF SYMBOLS 61...Main body 62...Cavity 63...Inner wall 64...Bottom surface 70...Partition region 72...Connection region 80, 180...Sheathing material 90...First connecting portion 100...First molded body 110...Release film 120...Adhesive sheet 130...Pedestal 140a, 140a_1, 140a_2, 140b, 140b_1, 140b_2...Terminal electrode 190...Second connecting portion 200...Second molded body

Claims

1. A coil component comprising: a plurality of coils; a plurality of inner exterior bodies each including a first magnetic particle and a first resin and covering at least one of the plurality of coils; and an outer exterior body including a second magnetic particle and a second resin and covering the plurality of inner exterior bodies, wherein each of the plurality of inner exterior bodies has a first surface on which an extraction portion of one of the plurality of coils is arranged, a second surface opposite the first surface, and a connection surface connecting the first surface and the second surface, and at least one of the plurality of inner exterior bodies has a protrusion protruding from the connection surface.

2. The coil component according to claim 1, wherein the protrusion extends from one end to the other end of at least one of the plurality of inner exterior bodies in a direction perpendicular to the first surface.

3. A coil component as described in claim 1 or 2, wherein the multiple inner exterior bodies include a first inner exterior body and a second inner exterior body arranged adjacent to each other, the first inner exterior body has a first convex portion as the convex portion, and the first convex portion protrudes from inside the outer exterior body toward the second inner exterior body.

4. A coil component according to claim 3, wherein the second inner exterior body has a second protrusion as the protrusion, and the first protrusion protrudes toward the second protrusion inside the outer exterior body.

5. A coil component according to claim 4, wherein the first protrusion has a shape that narrows toward the tip of the first protrusion in a cross section parallel to the first surface.

6. A coil component according to claim 5, wherein the first protrusion is curved so that the width thereof narrows toward the tip of the first protrusion in a cross section parallel to the first surface.

7. A coil component according to claim 6, wherein, in a cross section parallel to the first surface, the second convex portion has a flat surface at the tip of the second convex portion that extends in a direction perpendicular to the protruding direction of the second convex portion.

8. A coil component according to claim 5, wherein the second protrusion has a shape that narrows or widens toward the tip of the second protrusion in a cross section parallel to the first surface.

9. A coil component as described in claim 3, wherein in a cross section perpendicular to the first surface and parallel to the protruding direction of the first convex portion, a first tip surface located at the tip of the first convex portion is inclined with respect to the direction perpendicular to the first surface.

10. A coil component as described in claim 1 or 2, wherein at least one of the plurality of inner exterior bodies has a third surface, a fourth surface, a fifth surface, and a sixth surface that constitute the connecting surface, and when viewed from a direction perpendicular to the first surface, along the circumferential direction of at least one of the plurality of inner exterior bodies, 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 the third surface is adjacent to the sixth surface, and the third surface, the fourth surface, the fifth surface, or the sixth surface has a plurality of the protrusions.

11. A coil component as described in claim 1 or 2, wherein at least one of the plurality of inner exterior bodies has a third surface, a fourth surface, a fifth surface, and a sixth surface that constitute the connecting surface, and when viewed from a direction perpendicular to the first surface, along the circumferential direction of at least one of the plurality of inner exterior bodies, 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 the third surface is adjacent to the sixth surface, and at least two of the third surface, the fourth surface, the fifth surface, and the sixth surface each have the convex portion.

12. A coil component as described in claim 11, wherein the outer exterior body has a first outer surface on which an extraction portion of any of the plurality of coils is arranged, a second outer surface opposite the first outer surface, and a connecting outer surface connecting the first outer surface and the second outer surface, wherein any of the plurality of protrusions protrudes toward the connecting outer surface, and any of the plurality of protrusions is exposed from the connecting outer surface.

13. A coil component as described in claim 11, wherein the outer exterior body has a first outer surface on which an extraction portion of any of the plurality of coils is arranged, a second outer surface opposite the first outer surface, and a connecting outer surface connecting the first outer surface and the second outer surface, any of the plurality of protrusions protruding toward the connecting outer surface, and any of the plurality of protrusions not exposed from the connecting outer surface but covered by the outer exterior body.

14. A coil component as described in claim 1 or 2, wherein the outer exterior body has a resin-rich layer, at least a portion of the resin-rich layer is formed around the boundary between the outer exterior body and at least one of the plurality of inner exterior bodies, and the resin-rich layer has a higher content of the second resin than areas other than the resin-rich layer.

15. A method for manufacturing a coil component, comprising the steps of: preparing a plurality of inner exterior bodies, each having at least one of a plurality of coils covered with a first exterior material containing first magnetic particles and a first resin; placing the plurality of inner exterior bodies in a cavity of a mold so that the plurality of inner exterior bodies contact each other via a protrusion formed on at least one of the plurality of inner exterior bodies; filling the cavity with a second exterior material containing second magnetic particles and a second resin so that the plurality of inner exterior bodies are covered with the second exterior material; and forming an outer exterior body that covers the plurality of inner exterior bodies.

16. A method for manufacturing a coil component as described in claim 15, further comprising a step of filling the cavity with the first exterior material so that the plurality of coils are covered by the first exterior material, the cavity being divided into a plurality of regions by a first partition portion, and the first partition portion having a recess formed therein for forming the protrusion on at least one of the plurality of inner exterior bodies.

17. A method for manufacturing a coil component as described in claim 15 or 16, wherein the cavity is divided into multiple regions by second partitions, and multiple inner exterior bodies are housed in the cavity so that any one of the multiple protrusions contacts the inner wall surface of the second partition.

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