Coil component

Abstract

A coil component (1) comprises a coil (10), a plurality of cores (20), and a base (30). The coil (10) is a member that is formed in a helical shape. The plurality of cores (20) are members that are combined with the coil (10). The base (30) is a member that holds the plurality of cores (20). The plurality of cores (20) are aligned in the alignment direction. The plurality of cores (20) are arranged in a manner being sandwiched between one part and the other part of the base (30) in the alignment direction.

Description

Coil component

[0001] The present invention relates to a coil component.

[0002] In a coil component, there may be a case where two or more cores are arranged side by side in a predetermined direction so as to be in contact with or close to each other. Regarding this type of technology, Patent Document 1 below discloses a composite component (100) having two E-shaped cores (20A, 20B). The two E-shaped cores (20A, 20B) are arranged such that their central portions (22) and wall portions (24) are in contact with each other and are fixed with an epoxy-based adhesive or the like. Further, the two E-shaped cores (20A, 20B) are fixed on a resin base (10) with an epoxy-based adhesive or the like.

[0003] Japanese Patent Application Laid-Open No. 2020-174112

[0004] However, there was room for improvement in keeping a plurality of cores in contact with or close to each other during the manufacturing process or after the manufacture of the coil component. For example, in Patent Document 1, after the manufacture of the composite component (100), in order to maintain the state in which the two E-shaped cores (20A, 20B) are held such that the central portions (22) and the wall portions (24) are in contact with each other, it is necessary to fix the two E-shaped cores (20A, 20B) with an epoxy-based resin. Also, in the manufacturing process of the composite component (100), until the two E-shaped cores (20A, 20B) are fixed with an epoxy-based resin, it is necessary to hold the two E-shaped cores (20A, 20B) with a jig or the like such that the central portions (22) and the wall portions (24) are in contact with each other. Thus, there may be a case where work is required to maintain a state in which a plurality of cores are in contact with or close to each other during the manufacturing process or after the manufacture of the coil component.

[0005] The present invention has been made in view of the above problems, and provides a coil component in which it is easy to keep a plurality of cores in contact with or close to each other during the manufacturing process or after the manufacture of the coil component.

[0006] The coil component of the present invention comprises a spirally formed coil, a plurality of cores combined with the coil, and a base that holds the plurality of cores, wherein the plurality of cores are arranged in a direction and are positioned sandwiched between a part and another part of the base in that direction.

[0007] According to the coil component of the present invention, multiple cores are arranged sandwiched between parts of the base and other parts in the direction of alignment. Therefore, it is easy to keep the multiple cores in contact with or close to each other during or after the manufacturing process of the coil component.

[0008] The aforementioned objectives, as well as other objectives, features, and advantages, will become even clearer from the preferred embodiments described below and the accompanying drawings.

[0009] This is a perspective view of a coil component according to the first embodiment of the present invention. This is an exploded perspective view of a coil component according to the first embodiment. This is a right side view of a coil component according to the first embodiment. The core is shown by a dashed line, and the outer shape of the coil is shown by a solid line. This is a front view of a coil component according to the first embodiment. The outer shape of the core is shown by a dashed line, and the internal structure of the core is shown by a dotted line. The outer shapes of the coil and terminals in the brazing material are shown by dotted lines. This is a top view of a coil component according to the first embodiment. This is a cross-sectional view of the section along the dashed line in Figure 3, viewed in the direction of arrow VI-VI. Figure 7(a) is an enlarged view of the area within frame X shown by the dashed line in Figure 6. Figure 7(b) is a view of the front end of the coil component from above. In Figure 7(b), the buffer member is omitted from the illustration, and the core is shown by a dashed line. This is a cross-sectional view of a coil component at the center in the left-right direction according to the first embodiment. Figure 9(a) is a perspective view of a base according to the second embodiment of the present invention. Figure 9(b) is a right side view of a base according to the second embodiment.

[0010] The various components of the coil component of the present invention do not need to be independent entities; it is permissible for multiple components to be formed as a single member, for one component to be formed from multiple members, for one component to be part of another component, for parts of one component to overlap with parts of another component, and so on. Furthermore, while the method for manufacturing the coil component of the present invention may be described using multiple steps described in order, the order of description does not limit the order or timing of the execution of the multiple steps. For this reason, when implementing the method for manufacturing the coil component of the present invention, the order of the multiple steps can be changed to the extent that it does not impede the content, and some or all of the execution timing of the multiple steps may overlap with each other.

[0011] Embodiments of the present invention will be described below with reference to the drawings. In each drawing, corresponding components are denoted by the same reference numeral, and redundant explanations will be omitted as appropriate. In this embodiment, the directions of front, back, left, right, up, and down are defined and described as shown in the figures. However, this is defined for convenience in order to briefly explain the relative relationships of the components and does not limit the direction during manufacturing or use of the product implementing the present invention. The up and down direction is the direction perpendicular to the mounting surface, which will be described later, and in the up and down direction, the side facing the mounting surface is called the down side and the side facing the top surface is called the up side. The up and down direction coincides with the height direction of the coil component. The front and back direction coincides with the alignment direction and the axial direction of the coil, which will be described later. The left and right direction may also be called the width direction. Furthermore, in this invention, a plane means a shape that is physically formed with a plane as the target, and it is not necessary for it to be a geometrically perfect plane.

[0012] <First Embodiment> (Coil Component) Figure 1 is a perspective view showing an example of a coil component 1 according to the first embodiment of the present invention.

[0013] First, an overview of the coil component 1 of this embodiment will be described. The coil component 1 comprises a coil 10, a plurality of cores 20, and a base 30. The coil 10 is a spirally formed member. The plurality of cores 20 are members that are combined with the coil 10. The base 30 is a member that holds the plurality of cores 20. The plurality of cores 20 are arranged in a parallel direction. In addition, the plurality of cores 20 are arranged sandwiched between a part and another part of the base 30 in the parallel direction. With the above configuration, it is easy to keep the plurality of cores 20 in contact with or close to each other during or after the manufacturing process of the coil component 1. For example, during the manufacturing process of the coil component 1, the plurality of cores 20 can be kept close to or in contact with each other by inserting them between a part and another part of the base 30. Specifically, after inserting the plurality of cores 20 between a part and another part of the base 30, the plurality of cores 20 are naturally maintained in a state of being close to or in contact with each other. Furthermore, after the manufacturing of the coil component 1, the multiple cores 20 are positioned sandwiched between a part and another part of the base 30, so that the multiple cores 20 are maintained in close proximity or in contact with each other. Note that during or after the manufacturing process of the coil component 1, other materials (for example, the tape 50 in this embodiment, or adhesive) may be used to assist in maintaining the contact or proximity of the multiple cores 20 with each other. Even with such assistance, the above configuration makes it easier to maintain the contact or proximity of the multiple cores 20 with each other during or after the manufacturing process of the coil component 1.

[0014] Next, the coil component 1 of this embodiment will be described in detail. The coil component 1 is an electronic component having a coil 10. An electronic component is a component that can constitute part of an electronic circuit. Examples of coil component 1 include transformers, antennas, or inductors. In this embodiment, the coil component 1 is mounted on a mounting substrate (not shown) so as to make contact with the mounting portion 64 (particularly its lower surface) of the terminal 60, which will be described later.

[0015] The coil component 1 has a mounting surface on which it can be mounted. The mounting surface of the coil component 1 is the surface that is substantially parallel to the mounting substrate when the coil component 1 is mounted on the mounting substrate. As will be described later, in this embodiment, the coil component 1 is surface-mounted on the mounting substrate. When the coil component 1 is surface-mounted on the mounting substrate in this way, the mounting surface of the coil component 1 is the region of the coil component 1 that is in surface contact with the mounting substrate, and more specifically, it is the lower surface of the mounting portion 64 of the terminal 60, which will be described later. Alternatively, if the terminal 60 is pin-shaped, the mounting surface of the coil component 1 is the surface of the coil component 1 that is parallel to the mounting substrate, and specifically, it is the lower surface of the coil component 1 (for example, the lower surface of the base 30).

[0016] The coil 10 is a component formed from a conductive material in a helical shape. In this embodiment, the coil 10 is an edgewise coil in which flat wires with a flattened cross-section (a rectangular or elliptical cross-section) are arranged in a helical shape. The coil 10 may also be formed from round wires with a circular cross-section. Here, "formed in a helical shape" means that the conductive material forms at least one loop. The coil 10 is not limited to the manufacturing method and may be any conductive material formed in a helical shape. For example, the coil 10 may be formed from a conductive material in a helical shape such that the winding shaft portion is hollow. In this case, after the helical coil is formed, a core 20 may be inserted into the hollow portion of the coil. The inner surface of the coil 10 and the core 20 (particularly the circumferential surface of the middle leg 24, which will be described later) may be spaced apart or in contact. Alternatively, the coil 10 may be formed by winding a conductive material (coil wire) around the core 20. In this case, the coil wire in the coil 10 may be pressed against the core 20 (particularly the middle leg 24) or may be in contact with it. The coil wire may be embedded in the core 20.

[0017] The coil component 1 may have one or more coils 10. In this embodiment, the coil component 1 has two coils 10 (a first coil 11 and a second coil 12). In this embodiment, the helical direction of the first coil 11 with respect to its axial direction (left-hand screw direction = counterclockwise) is opposite to the helical direction of the second coil 12 with respect to its axial direction (right-hand screw direction = clockwise). Alternatively, the helical direction of the first coil 11 with respect to its axial direction and the helical direction of the second coil 12 with respect to its axial direction may be the same. In the helical shape of the coil 10, the direction in which the central axis of the helical shape extends is called the axial direction of the coil 10, or simply the axial direction. In this embodiment, both the axial direction of the first coil 11 and the axial direction of the second coil 12 coincide with the front-rear direction. In this embodiment, the first coil 11 and the second coil 12 are arranged side by side in the front-rear direction with their end faces facing each other. In other words, the rear end face of the first coil 11 faces the front end face of the second coil 12. Furthermore, in this embodiment, as will be described later, the internal space of the first core 21 and the internal space of the second core 22 are connected in the front-rear direction, so the rear end surface of the first coil 11 directly faces the rear end surface of the second coil 12. Here, "the rear end surface of the first coil 11 directly faces the rear end surface of the second coil 12" means that the rear end surface of the first coil 11 faces the front end surface of the second coil 12 when no other member is sandwiched between the rear end surface of the first coil 11 and the front end surface of the second coil 12.

[0018] In this embodiment, the end portion of the conductive material forming the coil 10 is drawn out from the coil 10 as a lead portion 13. That is, the lead portion 13 is the lead wire of the coil 10. In this embodiment, both ends of the conductive material forming the coil 10 are drawn out, and both ends are drawn outward in the axial direction. Specifically, the lead portions 13 of the first coil 11 are drawn forward, and the lead portions 13 of the second coil 12 are drawn backward. Here, of the two lead portions 13, 13 drawn out from one coil 10, one lead portion 13a is drawn out from the end face on the central side in the front-rear direction of the coil 10, and the other lead portion 13b is drawn out from the outside in the front-rear direction of the coil 10. In this embodiment, as shown in Figure 3, the lead portions 13 are drawn out downward from each of the end faces of the coil 10 in the axial direction. Specifically, the base end of the lead portion 13 extends along the vertical direction. Figure 3 is a right-side view of the coil component 1 with the coil 10 exposed, excluding the core 20 and tape 50. The outer shape of the core 20 is shown by a dashed line. Figure 4 is a front view of the coil component 1 with the coil 10 exposed, excluding the core 20 and tape 50, similar to Figure 3. The outer shape of the core 20 is shown by a dashed line, and the internal structure of the core 20 is shown by a dotted line. The pull-out portion 13 is bent in the middle, and the tip of the pull-out portion 13 extends along the front-to-back direction. In other words, the tip of the pull-out portion 13 extends along the upper surface 32a of the base portion 32, which will be described later.

[0019] The core 20 is a component formed from a magnetic material. In this embodiment, the core 20 is a so-called EP core, as will be described later. The core 20 may be a so-called I-core, E-core, U-core, or a core of other shape. In this embodiment, the multiple cores 20 have the same shape as each other, but in other embodiments, the multiple cores 20 may have different shapes as well.

[0020] Multiple cores 20 are combined with a coil 10. That is, at least one or all of the multiple cores 20 are combined with a coil 10. When we say that a core 20 is combined with a coil 10, we mean that at least a part of the core 20 is engaged with at least a part of the coil 10. Specifically, the coil 10 is inserted into a recess formed in the core 20, or at least a part of the core 20 is inserted into the inner diameter side of the coil 10. In this embodiment, the coil 10 is inserted into a recess formed in the core 20 (a recess defined by the peripheral wall portion 26, which will be described later), and a part of the core 20 (the middle leg 24, which will be described later) is inserted into the inner diameter side of the coil 10.

[0021] As shown in Figure 2, in this embodiment, the core 20 includes a peripheral wall portion 26 that covers at least a part of the circumferential surface of the coil 10. Specifically, the peripheral wall portion 26 covers a portion of the circumferential surface of the coil 10 that faces upward and to the sides (left and right). In this embodiment, the core 20 also includes a covering portion 23 that covers the end face of the coil 10. In this embodiment, a recess is formed by the peripheral wall portion 26 and the covering portion 23, and the coil 10 is housed in this recess. In this embodiment, the core 20 also has a middle leg 24. The middle leg 24 in this embodiment protrudes axially from the covering portion 23. The middle leg 24 is positioned inside the coil 10. In this embodiment, the peripheral wall portion 26 (including the insertion portion 28 described later), the covering portion 23, and the middle leg 24 are integrally formed. In this embodiment, as shown in Figure 4, the entire circumferential surface of the coil 10 is spaced apart from the core 20 (particularly the circumferential wall portion 26), and the entire inner circumferential surface on the inner diameter side of the coil 10 is spaced apart from the core 20 (particularly the middle leg portion 24). Alternatively, the circumferential surface of the coil 10 may be in contact with the core 20 (particularly the circumferential wall portion 26), and the inner circumferential surface on the inner diameter side of the coil 10 may be in contact with the core 20 (particularly the middle leg portion 24).

[0022] As shown in Figure 2, the core 20 in this embodiment includes an insertion portion 28 which is positioned between a part of the base 30 and another part of it, as will be described later. The insertion portion 28 in this embodiment is a part of the peripheral wall portion 26. Specifically, the insertion portion 28 in this embodiment is the lower end of the peripheral wall portion 26. More specifically, in this embodiment, the peripheral wall portion 26 has a notch formed on the outer side in the front-rear direction (the side on which the covering portion 23 is positioned). The insertion portion 28 is located on the inner side of the peripheral wall portion 26 in the front-rear direction relative to the notch (on the opening side of the recess formed by the covering portion 23 and the peripheral wall portion 26).

[0023] As shown in Figure 2, the coil component 1 comprises two or more cores 20. In this embodiment, the coil component 1 comprises two cores 20 (a first core 21 and a second core 22). In this embodiment, the two cores 20 have the same shape as each other. The two cores 20 are combined such that their respective recesses are in communication. That is, the two cores 20 are combined such that the protruding ends of their respective middle legs 24 and the open ends of their respective peripheral wall portions 26 are close together. In this embodiment, the two cores 20 are in contact at their respective middle legs 24 and their respective peripheral wall portions 26. Alternatively, a gap sheet may be placed between the two cores 20, and the gap sheet may be sandwiched between the respective middle legs 24 and between the respective peripheral wall portions 26 of the two cores 20.

[0024] As shown in Figure 3 or Figure 5, the multiple cores 20 are arranged in a predetermined alignment direction. In this embodiment, the alignment direction is the lateral direction perpendicular to the vertical direction. More specifically, in this embodiment, the alignment direction is the front-to-back direction (axial direction).

[0025] The base 30 holds a plurality of cores 20. The base 30 is made of an insulating material. In this embodiment, the base 30 is made of resin. Examples of resins used to form the base 30 include LCP (Liquid Crystal Polymer) or TAP (Thermoplastic Amorphous Polymer). The base 30 holds the cores 20 directly or indirectly. Holding the cores 20 means supporting the cores 20 directly or indirectly. In this embodiment, the base 30 holds the cores 20 directly. Specifically, the cores 20 are placed directly on the base 30 (particularly the pedestal portion 32), and the cores 20 are supported by the base 30. In this embodiment, as will be described later, a plurality of cores 20 are sandwiched between the base 30 (a pair of upright portions 34, 34, described later), and the plurality of cores 20 are held by the base 30. Alternatively, the cores 20 may be indirectly held by the base 30 via other members.

[0026] As described above, the multiple cores 20 are arranged sandwiched between parts of the base 30 and other parts in the alignment direction (front-to-back direction). In other words, parts of the base 30 or other parts are arranged on one side and the other side of the multiple cores 20 in the alignment direction. Specifically, at least a part of each of the multiple cores 20 (each insertion portion 28 of the multiple cores 20) is arranged sandwiched between parts of the base 30 and other parts in the alignment direction. In this embodiment, parts of the base 30 and other parts overlap with each other in the alignment direction, and at least a part of each of the multiple cores 20 overlaps with parts of the base 30 and other parts respectively in the alignment direction. Alternatively, parts of the base 30 and other parts do not have to overlap in the alignment direction. For example, even if parts of the base 30 and other parts do not overlap when viewed in the alignment direction, it is sufficient that parts of the base 30 or other parts are arranged on one side and the other side of the multiple cores 20 in the alignment direction. Specifically, even if the base 30 only has the first upright portion 34b1 (see Figure 2) and the second upright portion 34c2 (see Figure 2) described later, the two cores 20 can be said to be arranged sandwiched between the first upright portion 34b1 and the second upright portion 34c2 in the direction of alignment.

[0027] Here, when multiple cores 20 are arranged sandwiched between a part and another part of the base 30 in the alignment direction, the cores 20 adjacent to the part of the base 30 or the other part (hereinafter referred to as "part of the base 30, etc.") in the alignment direction may be in contact with the part of the base 30, etc., as described later, or they may be slightly separated. That is, the cores 20 adjacent to the part of the base 30, etc. in the alignment direction are in contact with or close to the part of the base 30, etc. When the cores 20 adjacent to the part of the base 30, etc. in the alignment direction are close to the part of the base 30, etc., it is preferable that the distance between them in the alignment direction (front-to-back direction) is small. Specifically, it is preferable that the distance between them is smaller than the thickness of the insertion portion 28 (the dimension of the insertion portion 28 in the left-to-right direction). More preferably, if the corners of the cores 20 (especially the insertion portion 28) are R-chamfered, the distance between them is smaller than the radius of curvature of the R-chamfer. Alternatively, more preferably, the separation distance is smaller than the thickness of the tape 50 (first tape 51 or second tape 52) described later. In other words, it is preferable that the separation distance is extremely small relative to the insertion portion 28, and that the insertion portion 28, which is sandwiched by a part of the base 30, does not substantially shift position in the alignment direction.

[0028] In this embodiment, as shown in Figure 1 or Figure 2, the coil component 1 has a terminal 60. The terminal 60 is made of a conductive material such as metal. The terminal 60 is connected to the lead-out portion 13 and is electrically connected to the coil 10. In this embodiment, the terminal 60 is an input / output terminal connected to a mounting substrate (not shown). In this embodiment, the terminal 60 is a surface-mount terminal that makes surface contact with the mounting substrate. Instead of this embodiment, the terminal 60 may be a terminal of another shape, such as a pin-shaped terminal.

[0029] The terminal 60 in this embodiment is attached to the base 30. The terminal 60 in this embodiment is formed by bending a plate-shaped conductive material into a horizontal U-shape. The terminal 60 is attached to the base 30 by sandwiching the base 30 (particularly the pedestal portion 32 described later) in the vertical direction with its U-shape. Alternatively, the terminal 60 may be attached to the base 30 by being embedded in the base 30 or the like. The terminal 60 in this embodiment has a mounting portion 64 that makes surface contact with the mounting substrate. The lower surface of the mounting portion 64 makes surface contact with the mounting substrate. In this embodiment, the mounting portion 64 is arranged along the lower surface of the base 30.

[0030] In this embodiment, one end of the terminal 60 is electrically connected to the tip of the lead-out portion 13. Specifically, one end of the terminal 60 is positioned along the upper surface 32a of the base 30 (base portion 32), and the tip of the lead-out portion 13 is placed on the upper surface of the said end of the terminal 60. In this embodiment, one end of the terminal 60 is brazed to the tip of the lead-out portion 13 with a brazing material 70 such as solder. Alternatively, one end of the terminal 60 and the tip of the lead-out portion 13 may be electrically connected by another method such as welding. Also, in this embodiment, the tip of the lead-out portion 13 is crimped and fixed by a crimping portion 62 which is part of the terminal 60. Specifically, as shown in Figure 4, the crimping portion 62 extends upward from one end of the terminal 60 and is bent to follow the upper surface of one end of the lead-out portion 13. One end of the lead-out portion 13 is held between one end of the terminal 60 and the tip of the crimping portion 62 in the vertical direction.

[0031] In this embodiment, as shown in Figure 2, the coil component 1 has a tape 50. The tape 50 fixes the multiple cores 20 to each other, or the cores 20 to other members. In this embodiment, the coil component 1 has two tapes 50 (first tape 51 and second tape 52). Alternatively, the coil component 1 may have only one tape 50, or three or more tapes 50, or may not have any tape 50 at all. As shown in Figure 1 or Figure 8, the first tape 51 helps to maintain a state in which the multiple cores 20 are close together or in contact in the direction of alignment. Specifically, the first tape 51 is attached around the sides of the multiple cores 20. More specifically, the first tape 51 is attached around the sides of the multiple cores 20 at a position above the upper end of the upright portion 34, which will be described later. Therefore, the first tape 51 is not attached to the base 30. The second tape 52 fixes the multiple cores 20 to the base 30. Furthermore, the second tape 52 assists in maintaining a state in which the multiple cores 20 are close together or in contact in the direction of alignment. Specifically, the second tape 52 is attached around a part of the base 30 (the upright portion 34, which will be described later) and the sides of the multiple cores 20. In this embodiment, the first tape 51 is narrower than the second tape 52. The first tape 51 is attached to the inner layer side of the second tape 52 so as to overlap it. In this embodiment, the upper end of the first tape 51 is positioned along the upper end of the second tape 52. In other words, the upper end of the first tape 51 is positioned at approximately the same height as the upper end of the second tape 52. In contrast, the lower end of the first tape 51 is positioned above the lower end of the second tape 52.

[0032] In this embodiment, as shown in Figure 4, each end of the core 20 in the width direction (left-right direction) is located further inward in the width direction than the ends of the base 30 (especially the upright portion 34) in the width direction. As a result, after the first tape 51 has been wound around the multiple cores 20, the thickness of the first tape 51 makes the outer surface of the first tape 51 and the outer surface of the base 30 substantially flush. This allows the second tape 52 to be wound smoothly around the multiple cores 20 and the base 30 (upright portion 34). In this embodiment, as shown in Figure 8, each end of the core 20 in the alignment direction (front-back direction) is located further inward in the alignment direction than the ends of the base 30 (upright portion 34) in the alignment direction. As a result, the second tape 52 can be wound smoothly around the multiple cores 20 and the base 30 (upright portion 34) even after the first tape 51 has been wound around the multiple cores 20.

[0033] In this embodiment, as shown in Figure 2, the base 30 comprises a pedestal portion 32 and at least a pair of upright portions 34, 34. The pedestal portion 32 is located on one side in the vertical direction of the core 20, which is the mounting surface side (lower side). The vertical direction is perpendicular to the mounting surface. Specifically, at least a part of the pedestal portion 32 is located below at least one of the multiple cores 20. That is, a part of the pedestal portion 32 may be located above the lowest end of the core 20. Therefore, the upright portions 34, which will be described later, may rise from a part of the pedestal portion 32 that is located below the core 20, or they may rise from a part of the pedestal portion 32 that is located above the lowest end of the core 20. In this embodiment, the entire pedestal portion 32 is located below each of the multiple cores 20 (their lower ends). In this embodiment, the pedestal portion 32 is a member on which the coil 10 and the core 20 are placed. Specifically, the base portion 32 in this embodiment is a plate-shaped member that extends in the front-rear direction and the left-right direction.

[0034] The upright portion 34 extends from the base portion 32 (its upper surface 32a) to the top side (upper side) in the vertical direction. The top side in the vertical direction is the opposite side from one side in the vertical direction. The pair of upright portions 34, 34 are arranged in a parallel direction. Here, the top surface of the coil component 1 is the upper surface of the coil component 1 (the upper surface of the core 20 in this embodiment). In this embodiment, the pair of upright portions 34 are arranged to overlap in the parallel direction. Alternatively, the pair of upright portions 34 may be arranged in offset positions in the parallel direction. In this embodiment, the upright portion 34 has a rectangular prism shape with a rectangular cross-section. Alternatively, the cross-section of the upright portion 34 may have another shape, such as a circle. In this embodiment, the dimensions of the upright portion 34 in the parallel direction (front-to-back direction) are larger than the dimensions of the upright portion 34 in the width direction (left-to-right direction). This allows the upright portion 34 to hold multiple cores 20 well while keeping the dimensions of the coil component 1 in the width direction down. In this embodiment, the pair of upright sections 34, 34 are a total of two upright sections 34, 34, each spaced apart in the direction of alignment. Alternatively, if one upright section 34 and two upright sections 34 are spaced apart in the direction of alignment, these three upright sections 34 may be referred to as a pair of upright sections.

[0035] As described above, the multiple cores 20 are arranged sandwiched between parts of the base 30 in the direction of alignment. Specifically, as shown in Figure 3, in this embodiment, the multiple cores 20 are arranged sandwiched between a pair of upright portions 34, 34 in the direction of alignment (front-to-back direction). In other words, each insertion portion 28 of the multiple cores 20 is arranged sandwiched between a pair of upright portions 34, 34 in the direction of alignment. In this embodiment, the insertion portion 28 of the core 20 is inserted between the pair of upright portions 34. Specifically, the insertion portion 28 is inserted between the pair of upright portions 34 such that the upright portion 34 fits into a notch formed in the core 20 (peripheral wall portion 26). In this embodiment, the height dimension of the insertion portion 28 is approximately the same as the protruding dimension of the upright portion 34. Therefore, the core 20 (especially the covering portion 23) is in contact with the upper surface of the upright portion 34. Alternatively, the core 20 may not have a notch formed in it, and parts of multiple cores 20, including the covering portion 23, may be arranged between a pair of upright portions 34.

[0036] In this embodiment, the base 30 has two pairs of upright sections 34 (a pair of first upright sections 34b, 34b and a pair of second upright sections 34c, 34c). The first pair of upright sections (a pair of first upright sections 34b, 34b) and the second pair of upright sections (a pair of second upright sections 34c, 34c) are spaced apart from each other in the width direction. The width direction is perpendicular to the alignment direction and the vertical direction, respectively. In other words, one of the pair of first upright sections 34b, 34b, one first upright section 34b1 and one of the pair of second upright sections 34c, 34c, one second upright section 34c1 are spaced apart from each other in the width direction. Also, the other first upright section 34b2 of the pair of first upright sections 34b, 34b, and the other second upright section 34c2 of the pair of second upright sections 34c, 34c are also spaced apart from each other in the width direction. In this embodiment, the first upright portion 34b and the second upright portion 34c, which are spaced apart in the width direction, are positioned to overlap in the width direction. Alternatively, the first upright portion 34b and the second upright portion 34c, which are spaced apart in the width direction, may not overlap in the width direction and may be positioned offset in the front-rear direction. In this embodiment, the shape of the base 30 when viewed from above is rectangular. The upright portions 34 (each of the two pairs of upright portions 34) in this embodiment are formed at the corners (each of the four corners) of the rectangular base 30. As described above, the multiple cores 20 can be held well by being sandwiched between two pairs of upright portions 34 that are spaced apart in the width direction. Instead of this embodiment, the base 30 may have only one pair of upright portions 34, or it may have three or more pairs of upright portions 34. Furthermore, if the base 30 has only a pair of upright portions 34, the pair of upright portions 34 may be located in the center of the base 30 in the width direction, or they may be located at the ends of the base 30 in the width direction.

[0037] Here, an example of a method for manufacturing the coil component 1 in this embodiment will be described. The coil component 1 may be manufactured by a method other than that described below. In this embodiment, as shown in Figure 2, first, a plurality of coils 10 and a plurality of cores 20 are assembled. In this embodiment, the coils 10 are placed in recesses of the cores 20, but are not fixed to the cores 20. Specifically, within the recess, the coils 10 are movable within the range of the gap between the coil 10 and the peripheral wall portion 26 or the middle leg 24. Also, within the recess, the coils 10 are movable in the axial direction within the range of the gap between the coil 10 and the covering portion 23 or other coils 10. Alternatively, the coils 10 may be fixed to the cores 20 by adhesive or the like. Next, the first tape 51 is wound around the plurality of cores 20 so that the plurality of cores 20 are in close proximity or in contact with each other. Next, the plurality of cores 20 and the plurality of coils 10 are attached to the base 30. Terminals 60 are attached to the base 30. Specifically, the multiple cores 20 and multiple coils 10 (and lead-out sections 13) move downward toward the base 30 and are placed on the base 30. More specifically, the insertion section 28 of the core 20 is inserted between a pair of upright sections 34. The lead-out sections 13 and the cores 20 are also placed on the base 30 (base section 32). The tip of the lead-out section 13 is also placed on the terminal 60. After the lead-out section 13 is placed on the terminal 60, the lead-out section 13 is crimped by the crimping section 62. Finally, the second tape 52 is wound around the upright sections 34 and the multiple cores 20.

[0038] In this embodiment, as shown in Figures 3 and 7(b), each of the pair of upright portions 34, 34 is in contact with a plurality of cores 20. Specifically, the side surface of the upright portion 34 (the surface facing inward in the direction of alignment) is in contact with the side surface of the core 20 adjacent to the upright portion 34 in the direction of alignment. In this embodiment, the side surface of the upright portion 34 is in surface contact with the side surface of the core 20 adjacent to the upright portion 34 in the direction of alignment. If the upright portion 34 has a projection 34a, as will be described later in the second embodiment, the tip of the projection 34a or the end face at the tip is in contact with the core 20 adjacent to the upright portion 34 in the direction of alignment. The upright portion 34 is pressed against the core 20 as will be described later, but it may simply be in contact with the core 20.

[0039] In this embodiment, each of the pair of upright portions 34, 34 is in pressure contact with a plurality of cores 20 (particularly the insertion portion 28). In this embodiment, before the cores 20 are placed on the base 30, the total dimensions of the plurality of cores 20 in the alignment direction (front-to-back direction) are greater than the distance between the pair of upright portions 34 in the alignment direction. Therefore, when the plurality of cores 20 are inserted between the pair of upright portions 34, each of the pair of upright portions 34 is in pressure contact with the adjacent core 20 in the alignment direction in an inward direction. Furthermore, because each of the pair of upright portions 34 is in pressure contact with the adjacent core 20 in the alignment direction in an inward direction, the plurality of cores 20 aligned in the alignment direction are biased toward each other. In this embodiment, the first core 21 exerts a backward biasing force on the second core 22, and the second core 22 exerts a forward biasing force on the first core 21. In this embodiment, the first core 21 is in contact with the second core 22, and the rear end surface of the first core 21 is in pressure contact with the front end surface of the second core 22. In an alternative to this embodiment, if a gap sheet is placed between the first core 21 and the second core 22, then each of the first core 21 and the second core 22 biases the second core 22 or the first core 21 via the gap sheet. In other words, the gap sheet is sandwiched and held between the first core 21 and the second core 22.

[0040] In this embodiment, as shown in Figure 4, in the width direction (left-right direction), the lead-out portion 13 (particularly its tip) drawn out from the coil 10 is positioned between one of the pair of first upright portions 34b, 34b and one of the pair of second upright portions 34c, 34c. With this configuration, the coil 10 can be positioned in the left-right direction by the upright portions 34 during the manufacturing process of the coil component 1. Alternatively, even after the manufacturing of the coil component 1, the positional displacement of the coil 10 in the left-right direction can be restricted by the upright portions 34. Specifically, the two lead-out portions 13a and 13b (particularly their tips) are arranged side by side in the width direction (left-right direction), and both of the two lead-out portions 13a and 13b are positioned between the first upright portion 34b1 and the second upright portion 34c1. More specifically, the two extension sections 13a and 13b overlap in the width direction with the first upright section 34b1 and the second upright section 34c1. In this embodiment, an extension section 13 is also positioned between the first upright section 34b2 and the second upright section 34c2. This allows for positioning of each of the two coils 10, or for restricting misalignment.

[0041] In this embodiment, as shown in Figure 4, the upright portion 34 (its side surface) and the pull-out portion 13 (particularly the side surface of its tip) are spaced apart in the width direction. In this embodiment, each of the two upright portions 34 (one first upright portion 34b and one second upright portion 34c) that are spaced apart in the width direction (left-right direction) is spaced apart from the pull-out portion 13 adjacent to it in the width direction. Alternatively, of the two upright portions 34 that are spaced apart in the width direction, one upright portion 34 may be spaced apart from the pull-out portion 13 adjacent to it in the width direction, while the other upright portion 34 may be in contact with (abutting against) the pull-out portion 13 adjacent to it in the width direction. In this embodiment, the distance D1 between the upright portion 34 and the pull-out portion 13 in the width direction is smaller than the sum of the distance D2 between the middle leg 24 and the coil 10 (its inner surface) and the distance D3 between the peripheral wall portion 26 and the coil 10 (its inner surface) in the width direction. Preferably, the distance D1 between the upright portion 34 and the pull-out portion 13 in the width direction is smaller than the distance D2 between the middle leg 24 and the coil 10 in the width direction. Alternatively, the distance D1 between the upright portion 34 and the pull-out portion 13 in the width direction is smaller than the distance D3 between the peripheral wall portion 26 and the coil 10. This allows the upright portion 34 to position the coil 10 well. Alternatively, both of the two upright portions 34 that are spaced apart in the width direction (one first upright portion 34b and one second upright portion 34c) may be in contact with the pull-out portion 13 adjacent to the upright portion 34 in the width direction.

[0042] Furthermore, in this embodiment, as shown in Figure 4, the side surface of the upright portion 34 facing inward in the width direction is located further inward in the width direction than a portion of the core 20 located above the upright portion 34. Specifically, the side surface of the upright portion 34 facing inward in the width direction is located further inward in the width direction than a surface (the inner surface of the peripheral wall portion 26) of a portion of the core 20 (a portion of the peripheral wall portion 26) that covers the side of the coil 10. More specifically, in this embodiment, the width dimension (dimension in the width direction) of a portion of the core 20 (a portion of the peripheral wall portion 26) that covers the side of the coil 10 is smaller than the dimension of the upright portion 34 in the width direction. As a result, the side surface of the upright portion 34 facing inward in the width direction is located further inward in the width direction than a surface (the inner surface of the peripheral wall portion 26) of a portion of the core 20 that covers the side of the coil 10.

[0043] In this embodiment, as shown in Figure 3, the base 30 is provided with a partition portion 36. The partition portion 36 is a part that protrudes from the base portion 32 (particularly its upper surface 32a) toward the top surface (upper side) in the vertical direction between the two coils 10. As a result, when the two coils 10 are placed on the base 30 from above during the manufacturing process of the coil component 1, the partition portion 36 can separate the two coils 10 into a front side and a rear side. Specifically, as described above, during the manufacturing process of the coil component 1, the coils 10 are not fixed to the core 20 and are movable in the axial direction relative to the core 20. Therefore, during the manufacturing process of the coil component 1, there are cases where the two coils 10 are placed on the base 30 with the two coils 10 positioned biased toward either the front or rear side of the core 20. At this time, during the process of placing the two coils 10 on the base 30 from above, the partition portion 36 can separate the two coils 10 into front and rear sides. The protruding dimension of the partition portion 36 (the dimension from the upper surface of the base portion 32 to the protruding end in the vertical direction) is preferably greater than the thickness dimension of the drawer portion 13. More specifically, the protruding dimension of the partition portion 36 is preferably greater than the dimension of the tip of the drawer portion 13 in the vertical direction.

[0044] In the present embodiment, as shown in FIG. 3, the partition portion 36 is disposed between the lead-out portions 13 drawn from each of the two coils 10. Specifically, as described above, the lead-out portion 13 drawn downward from the coil 10 is bent approximately 90 degrees midway and extends along the upper surface of the base 30. The partition portion 36 is disposed between the bent portions of the lead-out portions 13 drawn from each of the two coils 10.

[0045] In the present embodiment, as shown in FIG. 2, the partition portion 36 is a rib extending in the left-right direction. Instead of the present embodiment, the partition portion 36 may be a dot-shaped protrusion or may be formed by a plurality of protrusions. In the present embodiment, the partition portion 36 includes a first portion 36a and a second portion 36b which are two ribs. Instead of the present embodiment, the partition portion 36 may include only the first portion 36a or only the second portion 36b. The first portion 36a and the second portion 36b are respectively located on both sides of a rib 38 described later in the width direction (left-right direction). The first portion 36a and the second portion 36b are located so as to overlap in the width direction. In other words, the first portion 36a and the second portion 36b extend on the same straight line. As shown in FIG. 3, the first portion 36a is disposed between one lead-out portion 13 (lead-out portion 13a) of each of the two coils 10 in the front-rear direction. Also, the second portion 36b is disposed between one lead-out portion 13 (lead-out portion 13b) of each of the two coils 10 in the front-rear direction.

[0046] In the present embodiment, the dimension of the partition portion 36 in the arrangement direction decreases from the base side (lower end side) to the protruding end (upper end side) of the partition portion 36. Since the dimension of the upper part of the partition portion 36 is small and the dimension of the lower part of the partition portion 36 is large in this way, when two coils 10 are arranged on the base 30 from above, the two coils 10 can be well separated front and back. More specifically, in the present embodiment, the dimension of the partition portion 36 in the arrangement direction gradually decreases from the base side to the protruding end of the partition portion 36. In other words, the side surface of the partition portion 36 (the surface facing the outside in the front-rear direction in the partition portion 36) is an inclined surface that slopes outward in the front-rear direction downward. As a result, when the coil 10 (particularly the bent portion of the lead-out portion 13) from above toward the base 30 hits the inclined surface of the partition portion 36, the bent portion of the lead-out portion 13 slides on the inclined surface, and the coil 10 is arranged at a desired position in the front-rear direction.

[0047] In the present embodiment, as shown in FIG. 3, the protruding end of the partition portion 36 is located on the mounting surface side (lower side) of the coil 10 than one end (coil lower end 10a) on the mounting surface side (lower side) of the peripheral surface of the coil 10. In other words, the protruding end of the partition portion 36 is located below the entire coil 10. As a result, in the process of arranging two coils 10 on the base 30 from above, it is possible to prevent the peripheral surface of the coil 10 from accidentally colliding with the partition portion 36 (particularly the protruding end). Thereby, it is possible to prevent an unexpected external force from being applied to the partition portion 36 by the peripheral surface of the coil 10 and the partition portion 36 from being deformed or damaged.

[0048] In the present embodiment in which the convex strip 38 described later is provided on the base 30, as shown in FIG. 4, the protruding end of the partition portion 36 is located below the upper surface 38a of the convex strip 38. More specifically, as will be described later, the upper surface 38a of the convex strip 38 is formed in a concave shape. The protruding end of the partition portion 36 is located below the bottom of the upper surface 38a formed in a concave shape in the convex strip 38. As a result, even if the coil 10 (particularly its peripheral surface) contacts the upper surface 38a of the convex strip 38 in the manufacturing process of the coil component 1 as will be described later, it is unlikely that the peripheral surface of the coil 10 contacts the protruding end of the partition portion 36.

[0049] In this embodiment, as shown in Figure 7(b), a portion of the core 20 is positioned on both outer sides of the partition portion 36 in the width direction (left-right direction). With this configuration, the partition portion 36 can be used to position the core 20 in the width direction during the manufacturing process of the coil component 1. Alternatively, the partition portion 36 can be used to suppress misalignment of the core 20 after the manufacturing of the coil component 1. Specifically, a portion of the core 20 is positioned on the outer side in the width direction of the first portion 36a and the second portion 36b. In this embodiment, the insertion portion 28 of the core 20 is positioned on the outer side in the width direction of the first portion 36a and the second portion 36b.

[0050] In this embodiment, the partition portion 36 and a part of the core 20 (insertion portion 28) are spaced apart in the width direction. More specifically, in this embodiment, the partition portion 36 (first portion 36a and second portion 36b) is spaced apart in the width direction from the parts of the core 20 (insertion portions 28) located on both outer sides of the partition portion 36, respectively. Alternatively, the partition portion 36 may be spaced apart in the width direction from one insertion portion 28 located outside the partition portion 36, but may be in contact with the other insertion portions 28. When the partition portion 36 is spaced apart from a part of the core 20, it is preferable that the distance between the partition portion 36 and a part of the core 20 (insertion portion 28) in the width direction is smaller than the distance between the circumferential surface of the coil 10 and a part of the core 20 (insertion portion 28) in the width direction when viewed from above. This allows the partition portion 36 to effectively position the core 20 or suppress misalignment of the core 20. Alternatively, the partition portion 36 (first portion 36a and second portion 36b) may be in contact with a portion of the core 20 (insertion portion 28) located on both outer sides of the partition portion 36.

[0051] In this embodiment, as shown in Figure 6, a cushioning member 40 is positioned between the base portion 32 and the core 20. Specifically, the cushioning member 40 is positioned between the base portion 32 and the core 20 in the vertical direction. The cushioning member 40 has a rigidity less than that of the base portion 32. In this embodiment, the cushioning member 40 is made of resin. Specifically, the cushioning member 40 can be made of a soft resin material, specifically a soft epoxy resin or silicone rubber. With the above configuration, for example, when the coil component 1 is shaken vertically due to vibration, the core 20 may receive an unexpected external force from the base portion 32. At this time, because the cushioning member 40, which has a rigidity less than that of the base portion 32, is positioned between the base portion 32 and the core 20, deformation or damage to the core 20 can be effectively suppressed.

[0052] In this embodiment, during the manufacturing process of the coil component 1, the cushioning member 40 is pre-placed on the base 30 (base portion 32), and the coil 10 and core 20 are placed on the base 30. In this embodiment, the curing of the resin cushioning member 40 is performed after the placement of the coil 10 and core 20. As a result, the cushioning member 40 adheres well to the coil 10 or core 20. Alternatively, the curing of the cushioning member 40 may be performed before the placement of the coil 10 and core 20. In this embodiment, as shown in Figure 7(a), the surface of the cushioning member 40 is recessed along the outer shape of the core 20 or coil 10. As a result, the cushioning member 40 holds the core 20 and coil 10 well.

[0053] In this embodiment, as shown in Figure 7(a), the upper surface 32a of the base portion 32 and the core 20 (its lower surface) are spaced apart in the vertical direction. This further suppresses deformation or damage to the core 20 by the cushioning member 40. Alternatively, the distance between the upper surface 32a of the base portion 32 and the core 20 in the vertical direction may be smaller than the depth dimension of the recess 32b, which will be described later. This prevents the core 20 from floating more than necessary from the base 30. Alternatively, the distance between the upper surface 32a of the base portion 32 and the core 20 in the vertical direction may be larger than the depth dimension of the recess 32b, which will be described later. This prevents the core 20 from unexpectedly colliding with the base portion 32. In an alternative to this embodiment, the upper surface of the base portion 32 may be in contact with the lower surface of the core 20.

[0054] In this embodiment, similarly, the upper surface 32a of the base portion 32 and the drawer portion 13 are spaced apart in the vertical direction. The distance between the upper surface 32a of the base portion 32 and the drawer portion 13 in the vertical direction may be smaller or larger than the depth dimension of the recess 32b, which will be described later. Alternatively, the upper surface 32a of the base portion 32 may be in contact with the lower surface of the drawer portion 13.

[0055] In this embodiment, as shown in Figure 7(a) or Figure 7(b), the cushioning member 40 is locally positioned on the upper surface 32a of the base portion 32. In other words, the recess 32b, which will be described later, is locally formed on the upper surface 32a of the base portion 32. Specifically, the cushioning member 40 is located below the insertion portion 28. More specifically, as shown in Figure 7(b), the cushioning member 40 is positioned below the central part of the insertion portion 28 in the alignment direction (front-to-back direction), and the cushioning member 40 is not positioned below the ends of the insertion portion 28 in the alignment direction. Furthermore, the cushioning member 40 is positioned closer to the coil 10 side (closer to the inside in the width direction) relative to the center of the insertion portion 28 in the width direction (left-to-right direction). More specifically, the cushioning member 40 is positioned below a part of the inside in the width direction of the insertion portion 28, and the cushioning member 40 is not positioned below a part of the outside in the width direction of the insertion portion 28.

[0056] In this embodiment, as shown in Figure 7(a) or Figure 7(b), a recess 32b is formed in the upper surface 32a of the base portion 32. The recess 32b is recessed downward from the upper surface 32a of the base portion 32. As shown in Figure 7(a), a part of the cushioning member 40 is placed inside the recess 32b, and another part of the cushioning member 40 is placed so as to protrude from the recess 32b toward the top surface of the base portion 32a. By forming a recess 32b in the base portion 32 in this way, and by having the cushioning member 40 extend into the interior of the recess 32b, the thickness dimension (dimension in the vertical direction) of the cushioning member 40 can be increased by the depth dimension of the recess 32b. This improves the cushioning performance of the cushioning member 40 (the characteristic of absorbing shocks and vibrations and reducing damage to the core). Furthermore, in the manufacturing process of the coil component 1, by filling the recess 32b with the cushioning member 40, it is possible to suppress the unexpected lateral flow of the cushioning member 40 before hardening. In this embodiment, a portion of the cushioning member 40 that is located above the upper surface 32a of the base portion 32 (the dimension from the upper surface of the base portion 32 to the upper end of the cushioning member 40 in the vertical direction) is greater than the depth of the recess 32b. This allows the cushioning performance of the cushioning member 40 to be effectively utilized.

[0057] In this embodiment, as shown in Figure 7(b), the dimensions of the recess 32b in the left-right direction are larger than the dimensions of the recess 32b in the front-back direction. Specifically, in this embodiment, the shape of the recess 32b when viewed from above is an ellipse with the left-right direction as its longitudinal direction.

[0058] In this embodiment, as shown in Figure 7(a), the recess 32b overlaps with the pull-out section 13 (pull-out section 13a) and the core 20 in the vertical direction. The buffer member 40 is positioned between the core 20 and the base section 32, and between the pull-out section 13 and the base section 32. In this embodiment, as shown in Figure 7(b), the area of ​​the region in the recess 32b that overlaps with the pull-out section 13 (first region 32c) is smaller than the area of ​​the region in the recess 32b that overlaps with the core 20 (particularly a part of the core 20 that is placed on the base section 32; in this embodiment, the insertion section 28) (second region 32d). The first region 32c is the region of the recess 32b that overlaps with the pull-out section 13 when viewed along the vertical direction. The second region 32d is the region of the recess 32b that overlaps with the core 20 when viewed along the vertical direction. As described above, by arranging the cushioning member 40 between the drawer section 13 and the base section 32, when the coil component 1 is shaken vertically due to vibration or the like, the drawer section 13 can be subjected to unexpected external force from the base section 32, which can effectively suppress deformation or damage to the drawer section 13 or the coil 10. Furthermore, the coil 10 may generate heat when the coil component 1 is used. Since the area of ​​the first region 32c is smaller than the area of ​​the second region 32d, the thermal history of the cushioning member 40 due to the heat generated by the coil 10 can be minimized, thereby suppressing unexpected damage or deformation of the cushioning member 40. This allows the cushioning performance of the cushioning member 40 to be maintained well.

[0059] In this embodiment, a buffer member 40 is placed between one of the two extensions 13a and 13b drawn from a single coil 10 and the base portion 32. In contrast, no buffer member 40 is placed between the other extension 13b and the base portion 32. As shown in Figure 7(b), this is because the extension 13b is drawn from the outer end face in the front-rear direction of the coil 10. In other words, the extension 13b is located outside the recess 32b in the front-rear direction. By reducing the area of ​​the buffer member 40 that contacts the extension 13 in this way, it is possible to suppress the decrease in the buffering performance of the buffer member 40 due to heat from the coil 10.

[0060] In this embodiment, as shown in Figures 2 and 4, the base 30 is provided with a protrusion 38. The protrusion 38 projects vertically from the base portion 32 toward the top surface and extends in the direction of alignment. The upper surface 38a of the protrusion 38, which faces the top surface (upward side), is formed in a concave shape along the circumferential surface of the coil 10. More specifically, the upper surface 38a of the protrusion 38 is formed in a concave groove shape that extends in the axial direction of the coil 10. With the above configuration, when the coil 10 and core 20 are placed on the base 30 during the manufacturing process of the coil component 1, even if the coil 10 is not in the desired position relative to the core 20, the upper surface 38a of the protrusion 38 can correct the coil 10 to the desired position. In other words, even when the coil 10 is in a position where its axial direction is tilted relative to the middle leg 24 of the core 20, the upper surface 38a of the protrusion 38 appropriately contacts the circumferential surface of the coil 10 during the process of placing the coil 10 on the base 30, thereby enabling the coil 10 to assume the desired position.

[0061] In this embodiment, as shown in Figure 8, the upper surface 38a of the protrusion 38 is spaced vertically apart from the circumferential surface of the coil 10. Specifically, at least the bottom of the upper surface 38a of the concave-shaped protrusion 38 is spaced vertically apart from the circumferential surface of the coil 10. In this embodiment, the entire upper surface 38a of the concave-shaped protrusion 38 is spaced vertically apart from the circumferential surface of the coil 10. That is, there are gaps 38b and 38c between the upper surface 38a of the protrusion 38 and the circumferential surfaces of the two coils 10, respectively. The coil component 1 includes a continuous gap portion 38d. This continuous gap portion 38d includes two gaps 38b and 38c and extends from the first coil 11 to the second coil 12 in the direction of alignment (front-to-back direction). Specifically, the continuous gap portion 38d extends from the front end of the first coil 11 to the rear end of the second coil 12 in the front-to-back direction. With the above configuration, during the manufacturing process of the coil component 1, the dimensions of the continuous gap 38d (especially the dimensions in the vertical direction) can be observed visually or by camera photography to confirm whether the coil 10 and the lead portion 13 have been processed into the desired shape, or whether the coil 10 and the lead portion 13 are placed on the base 30 in the desired orientation. For example, if the bending shape (bending angle, etc.) of the bent portion of the lead portion 13 is not in the desired configuration, the dimensions of the continuous gap 38d in the vertical direction may become smaller or larger than the range of predetermined values. Alternatively, in this embodiment, as described above, during the manufacturing process of the coil component 1, the coil 10 is not fixed to the core 20, and the coil 10 and core 20 are placed on the base 30 by gripping and manipulating the core 20 with a jig or the like. In such a case, the coil 10, which is not gripped by a jig or the like, may be placed on the base 30 in an orientation different from the desired orientation. At this time, it is possible to confirm whether the coil 10 is placed on the base 30 in the desired position by checking whether the dimensions of the continuous gap portion 38d in the vertical direction are within a predetermined range.

[0062] In this embodiment, as shown in Figure 4, the continuous void portion 38d is visible from the outside of the coil component 1 when viewed along the alignment direction (front-to-back direction). In other words, the continuous void portion 38d communicates with the outside of the coil component 1 in the front-to-back direction. That is, the continuous void portion 38d communicates with the outside of the coil component 1 in the front-to-back direction without any other members in between. Specifically, in this embodiment, the lower end of a portion (covering portion 23) that covers the end face of the coil 10 in the core 20 is located above the lower end (lower end 10a) of the circumferential surface of the coil 10. In other words, the lower end and lead portion 13 of the coil 10 are exposed from the core 20 (especially the covering portion 23).

[0063] In this embodiment, the protrusion 38 and its upper surface 38a extend from the first coil 11 to the second coil 12 in the direction of alignment. Specifically, the upper surface 38a of the protrusion 38 extends from the front end of the first coil 11 to the rear end of the second coil 12 in the front-rear direction. A continuous gap 38d is defined on the upper surface 38a of the protrusion 38. Because the protrusion 38 extends continuously from the first coil 11 to the second coil 12 in this way, when the coil 10 and the core 20 are placed on the base 30 in the manufacturing process of the coil component 1 without the coil 10 being fixed to the core 20, the coil 10 is placed on the base 30 in the desired position by the upper surface 38a of the protrusion 38. That is, even if the coil 10 is not fixed to the core 20 and is positioned in a slightly misaligned position in the front-rear direction, the coil 10 can be supported by the upper surface 38a of the protrusion 38, which extends continuously from the first coil 11 to the second coil 12, and return to the desired position.

[0064] Alternatively, the protrusion 38 may be interrupted in the middle in the front-to-back direction. For example, the protrusion 38 may be formed from two protrusions located below the first coil 11 and the second coil 12, and these two protrusions may be spaced apart in the front-to-back direction.

[0065] <Second Embodiment> Figure 9(a) is a perspective view showing an example of the base 30 in the coil component 1 according to this embodiment. First, an overview of the coil component 1 of this embodiment will be described.

[0066] The coil component 1 of this embodiment is characterized in that, similar to the first embodiment, the plurality of cores 20 are arranged sandwiched between a part of the base 30 and other parts in the alignment direction (front-to-back direction).

[0067] Next, the coil component 1 of this embodiment will be described in detail. The base 30 of this embodiment differs from the first embodiment in that a projection 34a is formed on the upright portion 34. Specifically, as shown in Figure 9(b), the pair of upright portions 34, 34 have projections 34a that protrude inward in the direction of alignment (front-to-back direction). The protruding end of the projection 34a is in contact with the core 20 (see Figure 2). Inward in the direction of alignment means the side where the pair of upright portions 34 face each other. In other words, the inward direction in the direction of alignment of one upright portion 34 of the pair of upright portions 34 is the direction that points towards the other upright portion 34 with respect to that one upright portion 34. Because the projection 34a is formed on the upright portion 34 in this way, the upright portion 34 can make good contact with the core 20.

[0068] In the manufacturing process of the coil component 1 of this embodiment, when the core 20 is inserted between the pair of upright portions 34, 34, the core 20 interferes with the protruding end of the projection 34a and breaks the protruding end as it is inserted between the pair of upright portions 34, 34. As a result, the core 20 is well biased inward in the alignment direction by the upright portions 34 (especially the projection 34a).

[0069] In this embodiment, a projection 34a is formed on each of the pair of upright portions 34. Alternatively, the projection 34a may be formed on only one of the pair of upright portions 34, and the other upright portion 34 may not have a projection 34a.

[0070] As shown in Figure 9(b), the projection 34a in this embodiment is a convex ridge extending in the vertical direction. More specifically, the projection 34a in this embodiment extends from the upper end to the lower end of the upright portion 34. Alternatively, the projection 34a in this embodiment may be a convex ridge formed only on a part of the upright portion 34 in the vertical direction (for example, the central portion). Furthermore, the projection height of the projection 34a in this embodiment gradually increases from the upper end to the lower end. That is, the shape of the projection 34a when viewed from the side is a right triangle. This makes it easy to insert the core 20 between the pair of upright portions 34, 34. Alternatively, the projection 34a may be a point-shaped projection.

[0071] In this embodiment, a base portion 32 is located below the projection 34a, and the lower end of the projection 34a is integrally formed with the base portion 32. Alternatively, the base portion 32 may not be located below the projection 34a. For example, notches may be formed in the area between the regions where each of the pair of upright portions 34 is formed in the base portion 32, and the area may be hollow. When the core 20 is inserted between the pair of upright portions 34, 34 while interfering with the protruding end of the projection 34a and destroying the protruding end, a part of the destroyed projection 34a may fall below the projection 34a. Because there is no base portion 32 below the projection 34a, the part of the destroyed projection 34a does not remain on the base portion 32 but is naturally discharged to the outside of the coil component 1.

[0072] It should be noted that the present invention is not limited to the embodiments described above, and includes various modifications, improvements, and other forms as long as the objectives of the present invention are achieved. The following modifications can be combined as appropriate. In the embodiments described above, the multiple cores 20 were arranged sandwiched between a pair of upright portions 34, 34 extending upward from the base portion 32 in the alignment direction, but this is not limited to this. The multiple cores 20 may be sandwiched in the alignment direction by portions of the base 30 other than the upright portions 34. For example, if the base 30 has wall portions that cover the left and right sides of the multiple cores 20, the multiple cores 20 may be sandwiched in the alignment direction by portions that extend from the wall portions in the left and right directions.

[0073] The above embodiments encompass the following technical concepts: (1) A coil component comprising a spirally formed coil, a plurality of cores combined with the coil, and a base that holds the plurality of cores, wherein the plurality of cores are arranged in a vertical direction, and are positioned between a part of the base and another part in the vertical direction. (2) The coil component according to (1), wherein the coil component has a mounting surface on which the coil component can be mounted, the base has a pedestal portion located on the mounting surface side, which is one side of the vertical direction perpendicular to the mounting surface, relative to the cores, the base has at least a pair of upright portions extending from the pedestal portion to the top surface side, which is opposite to the one side in the vertical direction, the pair of upright portions are arranged in the vertical direction, and the plurality of cores are positioned between the pair of upright portions in the vertical direction. (2-1) The coil component according to (2), wherein the dimensions of the upright portions in the vertical direction are greater than the dimensions of the upright portions in the width direction. (3) The coil component according to (2), wherein each of the pair of upright portions is in contact with the plurality of cores, and the plurality of cores are sandwiched between the pair of upright portions and in contact with each other. (4) The coil component according to (3), wherein each of the pair of upright portions is pressed against the plurality of cores, and the plurality of cores are biased against each other. (5) The coil component according to (3) or (4), wherein the upright portions have projections that protrude inward in the direction of alignment, and the protruding ends of the projections are in contact with the cores. (6) The coil component according to any one of (2) to (5), wherein the base has two pairs of upright portions, the first pair of upright portions and the second pair of upright portions are spaced apart from each other in the width direction which is perpendicular to the alignment direction and the vertical direction, and in the width direction, a pull-out portion drawn out from the coil is positioned between one of the first pair of upright portions and one of the second pair of upright portions.(6-1) The coil component according to (6), wherein the distance between the upright portion and the pull-out portion in the width direction is smaller than the sum of the distance between the middle leg and the coil and the distance between the peripheral wall portion and the coil in the width direction. (6-2) The coil component according to (6), wherein the side surface of the upright portion facing inward in the width direction is located inward in the width direction than the surface of a part of the core covering the side of the coil facing inward in the width direction. (7) The coil component according to any one of (1) to (6), wherein the coil component has two coils arranged in the direction of alignment, the coil component has a mounting surface on which the coil component can be mounted, the base has a pedestal portion located on the mounting surface side which is one side in the vertical direction which is perpendicular to the mounting surface, and the base has a partition portion between the two coils which protrudes from the pedestal portion toward the top surface side which is opposite to the one side in the vertical direction. (7-1) The coil component according to (7), wherein the protruding dimension of the partition portion is greater than the thickness dimension of the pull-out portion. (8) The coil component according to (7), wherein the dimension of the partition portion in the direction of arrangement decreases from the root side of the partition portion to the protruding end. (8-1) The coil component according to (8), wherein the side surface of the partition portion is a slope that inclines outward in the front-rear direction toward downward. (9) The coil component according to (7) or (8), wherein the protruding end of the partition portion is located toward the mounting surface side of one end of the circumferential surface of the coil toward the mounting surface side. (9-1) The coil component according to (9), wherein the protruding end of the partition portion is located below the upper surface of the convex ridge formed on the base. (10) The coil component according to any one of (7) to (9), wherein a part of the core is arranged on both outer sides of the partition portion in the width direction, which is a direction perpendicular to the direction of arrangement and the up-down direction, respectively. (10-1) The coil component according to (10), wherein the partition portion is spaced apart from a part of the core in the width direction, and the distance between the partition portion and a part of the core in the width direction is smaller than the distance between the circumferential surface of the coil and a part of the core in the width direction when viewed from above.(11) The coil component according to any one of (1) to (10), wherein the coil component has a mounting surface on which the coil component can be mounted, the base has a base portion located on the mounting surface side, which is one side in the vertical direction perpendicular to the mounting surface, relative to the core, and a cushioning member having less rigidity than the rigidity of the base portion is disposed between the base portion and the core. (11-1) The coil component according to (11), wherein the upper surface of the base portion and the core are spaced apart in the vertical direction. (12) The coil component according to (11), wherein a recess is formed on the upper surface of the base portion, a part of the cushioning member is disposed inside the recess, and another part of the cushioning member is disposed protruding from the recess toward the top surface side, which is opposite to the one side in the vertical direction relative to the upper surface. (12-1) The coil component according to (12), wherein the thickness dimension of a part of the cushioning member located above the upper surface of the base portion is greater than the depth dimension of the recess. (13) The coil component according to (12), wherein the recess overlaps with the extension portion drawn out from the coil and the core in the vertical direction, the buffer member is disposed between the core and the base portion and between the extension portion and the base portion, and the area of ​​the region in the recess that overlaps with the extension portion is smaller than the area of ​​the region in the recess that overlaps with the core. (14) The coil component according to any one of (1) to (13), wherein the coil component has two coils arranged in the direction of alignment, the coil component has a mounting surface on which the coil component can be mounted, the base has a base portion located on the mounting surface side, which is one side in the vertical direction perpendicular to the mounting surface, relative to the core, the base has a protrusion projecting from the base portion toward the top surface side, which is opposite to the one side in the vertical direction, and extending in the direction of alignment, the upper surface of the protrusion facing toward the top surface is formed in a concave shape along the circumferential surface of the coil, there is a gap between the upper surface of the protrusion and the circumferential surfaces of each of the two coils, and the coil component includes a continuous gap portion extending from the first coil to the second coil in the direction of alignment, including the two gaps.(14-1) The coil component according to (14), wherein the continuous void is visible from the outside of the coil component when viewed along the direction of alignment. (15) The coil component according to (14), wherein the protrusion and the upper surface of the protrusion extend from the first coil to the second coil in the direction of alignment, and the continuous void is defined on the upper surface of the protrusion.

Claims

1. A coil component comprising a spirally formed coil, a plurality of cores combined with the coil, and a base that holds the plurality of cores, wherein the plurality of cores are arranged in a direction and are sandwiched between a part and another part of the base in that direction.

2. The coil component according to claim 1, wherein the coil component has a mounting surface on which the coil component can be mounted, the base has a pedestal portion located on the mounting surface side, which is one side in the vertical direction perpendicular to the mounting surface, relative to the core, the base has at least a pair of upright portions extending from the pedestal portion to the top surface side, which is opposite to the one side in the vertical direction, the pair of upright portions are arranged in the direction of alignment, and the plurality of cores are arranged sandwiched between the pair of upright portions in the direction of alignment.

3. The coil component according to claim 2, wherein each of the pair of upright portions is in contact with the plurality of cores, and the plurality of cores are sandwiched between the pair of upright portions and in contact with each other.

4. The coil component according to claim 3, wherein each of the pair of upright portions is in pressure contact with the plurality of cores, and the plurality of cores are biased toward each other.

5. The coil component according to claim 3 or 4, wherein the upright portion has a projection that protrudes inward in the direction of alignment, and the protruding end of the projection is in contact with the core.

6. The coil component according to any one of claims 2 to 5, wherein the base has two pairs of upright portions, the first pair of upright portions and the second pair of upright portions are spaced apart from each other in the width direction which is perpendicular to the alignment direction and the vertical direction, and in the width direction, a pull-out portion drawn out from the coil is positioned between one of the first pair of upright portions and one of the second pair of upright portions.

7. The coil component according to any one of claims 1 to 6, wherein the coil component has two coils arranged in the direction of alignment, the coil component has a mounting surface on which the coil component can be mounted, the base has a pedestal portion located on the mounting surface side, which is one side in the vertical direction perpendicular to the mounting surface, relative to the core, and the base has a partition portion between the two coils that protrudes from the pedestal portion toward the top surface side, which is the opposite side in the vertical direction.

8. The coil component according to claim 7, wherein the dimensions of the partition portion in the direction of arrangement decrease from the base side to the protruding end of the partition portion.

9. The coil component according to claim 7 or 8, wherein the protruding end of the partition portion is located closer to the mounting surface than one end of the circumferential surface of the coil on the mounting surface side.

10. The coil component according to any one of claims 7 to 9, wherein a portion of the core is arranged on both outer sides of the partition portion in the width direction, which is a direction perpendicular to the alignment direction and the vertical direction, respectively.

11. The coil component according to any one of claims 1 to 10, wherein the coil component has a mounting surface on which the coil component can be mounted, the base has a pedestal portion located on the mounting surface side, which is one side of the core in the vertical direction perpendicular to the mounting surface, and a cushioning member having less rigidity than the rigidity of the pedestal portion is disposed between the pedestal portion and the core.

12. The coil component according to claim 11, wherein a recess is formed on the upper surface of the base portion, a part of the cushioning member is disposed inside the recess, and another part of the cushioning member is disposed to protrude from the recess toward the top surface, which is opposite to the one side in the vertical direction from the upper surface.

13. The coil component according to claim 12, wherein the recess overlaps with the extension portion drawn out from the coil and the core in the vertical direction, the buffer member is disposed between the core and the base portion and between the extension portion and the base portion, and the area of ​​the region in the recess that overlaps with the extension portion is smaller than the area of ​​the region in the recess that overlaps with the core.

14. The coil component according to any one of claims 1 to 13, wherein the coil component has two coils arranged in the direction of alignment, the coil component has a mounting surface on which the coil component can be mounted, the base has a base portion located on the mounting surface side, which is one side of the vertical direction perpendicular to the mounting surface, relative to the core, the base has a protrusion projecting from the base portion toward the top surface side, which is opposite to the one side in the vertical direction, and extending in the direction of alignment, the upper surface of the protrusion facing toward the top surface is formed in a concave shape along the circumferential surface of the coil, there is a gap between the upper surface of the protrusion and the circumferential surfaces of each of the two coils, and the coil component includes a continuous gap portion extending from the first coil to the second coil in the direction of alignment, including the two gaps.

15. The coil component according to claim 14, wherein the protrusion and the upper surface of the protrusion extend from the first coil to the second coil in the direction of alignment, and the continuous gap is defined on the upper surface of the protrusion.

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