JP7816631B2 - Coil component and manufacturing method thereof - Google Patents

Description

The present disclosure relates to coil components and methods for manufacturing the same.

A conventional coil component is described in JP 2021-150314 A (Patent Document 1). This coil component has an annular core, a resin cap that covers part of the core, and a coil wound around the core and cap. The coil includes multiple straight pin members and multiple bent pin members, which are alternately connected to form a spiral coil, and the multiple straight pin members include an endmost straight pin member located at the axial end of the coil.

Japanese Patent Application Laid-Open No. 2021-150314

However, in the conventional coil components described above, the most distal straight pin member is connected to the bent pin member in a cantilevered manner, which can cause the posture of the most distal straight pin member to become unstable, potentially destabilizing the connection between the most distal straight pin member and the bent pin member. This can potentially reduce the reliability of the connection between the most distal straight pin member and the bent pin member.

For example, when assembling a coil, the second end of the most distal straight pin member is connected to the bent pin member by welding or other means without restraining the first end of the most distal straight pin member, which means the most distal straight pin member is connected to the bent pin member in an unstable position. This could reduce the reliability of the connection between the most distal straight pin member and the bent pin member.

Therefore, the object of this disclosure is to provide a coil component and a manufacturing method thereof that can improve the connection reliability between the endmost straight pin member and the bent pin member.

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

In this embodiment, the most distal straight pin member faces the first surface of the first portion, the first end of the most distal straight pin member contacts the protrusion, and the second end of the most distal straight pin member is connected to the bent pin member away from the first surface. This results in the first end of the most distal straight pin member being supported by the protrusion, and the second end of the most distal straight pin member being supported by the bent pin member. In other words, the most distal straight pin member is connected to the bent pin member in a doubly supported beam state. This stabilizes the posture of the most distal straight pin member, and stabilizes the connection between the most distal straight pin member and the bent pin member. This improves the connection reliability between the most distal straight pin member and the bent pin member.

For example, when assembling the coil, the first end of the most distal straight pin member can be supported on the protrusion, and the second end of the most distal straight pin member can be connected to the bent pin member by welding or other means, allowing the most distal straight pin member to be connected to the bent pin member in a stable position. This improves the connection reliability between the most distal straight pin member and the bent pin member.

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

Preferably, in one embodiment of the coil component,
further comprising an electrode terminal connected to the coil;
The endmost straight pin member is connected to the electrode terminal.

According to the above embodiment, the most-end straight pin member is connected to the electrode terminal. This stabilizes the posture of the most-end straight pin member, thereby stabilizing the connection between the most-end straight pin member and the electrode terminal. This improves the connection reliability between the most-end straight pin member and the electrode terminal.

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

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

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

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

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

According to the above embodiment, the second end of the most distal straight pin member is spaced apart from the first surface, so that the heat generated when connecting the most distal straight pin member and the electrode terminal by welding or the like is less likely to be transmitted to the core cover portion, thereby reducing deterioration of the core cover portion due to heat.

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

According to the above embodiment, the heat generated when connecting the most distal straight pin member and the electrode terminal by welding or the like is less likely to be transmitted by the protrusion portion and less likely to be transmitted by the core cover portion.

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

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

Preferably, in one embodiment of the coil component,
a mounting base for mounting the electrode terminal,
The core cover portion and the mounting base portion are integrally molded into a single piece.

In the above embodiment, the core cover and mounting base are integrated, so the core stored in the core cover is supported by the mounting base, stabilizing the position of the core. Furthermore, the number of parts that make up the coil component can be reduced, simplifying the manufacturing process for the coil component.

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

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

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

Preferably, in one embodiment of the method for manufacturing a coil component, the method further includes a step of connecting an electrode terminal to the endmost straight pin member and connecting the electrode terminal to the coil.

According to the above embodiment, the most-end straight pin member is connected to the electrode terminal. This stabilizes the posture of the most-end straight pin member, thereby stabilizing the connection between the most-end straight pin member and the electrode terminal. This improves the connection reliability between the most-end straight pin member and the electrode terminal.

Preferably, in one embodiment of the method for manufacturing a coil component, the process of forming the coil includes connecting the ends of each straight pin member and each bent pin member while fitting each straight pin member and each bent pin member into a groove portion of a jig.

According to the above embodiment, the straight pin members and the bent pin members can be connected while positioning them, thereby improving the connection reliability of the straight pin members and the bent pin members.

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

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

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

According to the above embodiment, the straight pin members and bent pin members can be connected while being positioned, thereby improving the connection reliability between the straight pin members and bent pin members. Furthermore, the electrode terminal can be connected to the outermost straight pin member while being positioned, thereby improving the connection reliability between the outermost straight pin member and the electrode terminal.

Preferably, in one embodiment of the method for manufacturing a coil component,
the step of forming the coil includes connecting the ends of the straight pin members and the ends of the bent pin members while exposing the ends of the straight pin members and the ends of the bent pin members from holes in the jig;
The step of forming the electrode terminal includes connecting the electrode terminal to the end straight pin member while exposing the end straight pin member and the electrode terminal from the hole of the jig.

According to the above embodiment, the connection between the straight pin member and the bent pin member and the connection between the endmost straight pin member and the electrode terminal can be performed in a single step while the jig remains attached.

One aspect of the coil component and its manufacturing method disclosed herein can improve the connection reliability between the endmost straight pin member and the bent pin member.

FIG. 2 is a top perspective view showing the coil component of the first embodiment. FIG. FIG. 2 is a bottom perspective view showing the inside of the coil component. FIG. FIG. 2 is a schematic cross-sectional view of a coil component. 6 is a cross-sectional view taken along the line VI-VI in FIG. 1. FIG. 10 is a top perspective view of a connection portion between an endmost straight pin member and a bent pin member in the first coil. FIG. FIG. FIG. 2 is a bottom view of the coil component excluding the bottom plate portion. 11 is a cross-sectional view taken along the line XI-XI of FIG. 10. FIG. 2 is a perspective view of a jig used in the manufacturing method of the coil component. FIG. 10 is a bottom view showing a state in which the jig is used in the manufacturing method of the coil component. FIG. 14 is a perspective view of FIG. 13 with the core and base case omitted.

The coil component and its manufacturing method, which are one aspect of the present disclosure, are described in detail below with reference to the illustrated embodiments. Note that some of the drawings are schematic and may not reflect actual dimensions or proportions.

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

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

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

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

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

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

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

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

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

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

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

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

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

The core 3 is composed of, for example, a ceramic core such as ferrite, or a magnetic core made from iron-based powder molding or nanocrystalline foil. The core 3 has a first end face 301 and a second end face 302 that face each other in the central axis direction, as well as an inner peripheral surface 303 and an outer peripheral surface 304. The first end face 301 is the lower end face of the core 3 and is located on the bottom plate portion 21 side. The second end face 302 is the upper end face of the core 3. The short end portion 32 has a convex portion on the second end face 302. In other words, the region of the second end face 302 located at the short end portion 32 is located higher in the Z direction than the region of the second end face 302 located at the long end portion 31.

The cross section of the core 3 perpendicular to the circumferential direction as viewed from the central axis direction is rectangular. The first end face 301 and the second end face 302 are disposed perpendicular to the central axis direction of the core 3. The inner peripheral surface 303 and the outer peripheral surface 304 are disposed parallel to the central axis direction of the core 3. In this specification, "perpendicular" does not necessarily mean a completely perpendicular state, but also includes a substantially perpendicular state. Furthermore, "parallel" does not necessarily mean a completely parallel state, but also includes a substantially parallel state.

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

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

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

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

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

The first coil 41 and the second coil 42 are spirally wound around the core 3 and the core cover part 60 along the circumferential direction of the core 3 as viewed from the central axis direction of the core 3. Specifically, the first coil 41 is wound around one longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal axis direction of the core 3, and the second coil 42 is wound around the other longitudinal portion 31 of the core 3 and the core cover part 60 along the longitudinal axis direction of the core 3. The winding axis of the first coil 41 and the winding axis of the second coil 42 run parallel to each other. The first coil 41 and the second coil 42 are symmetrical with respect to the longitudinal axis of the core 3.

The number of turns of the first coil 41 is the same as the number of turns of the second coil 42. The winding direction of the first coil 41 around the core 3 is opposite to the winding direction of the second coil 42 around the core 3. In other words, the winding direction of the first coil 41 from the first electrode terminal 51 to the second electrode terminal 52 is opposite to the winding direction of the second coil 42 from the third electrode terminal 53 to the fourth electrode terminal 54.

The first to fourth electrode terminals 51 to 54 are connected so that a common mode current flows in the same direction in the first coil 41, from the first electrode terminal 51 to the second electrode terminal 52, and in the second coil 42, from the third electrode terminal 53 to the fourth electrode terminal 54. When a common mode current flows in the first coil 41, a first magnetic flux is generated in the core 3 by the first coil 41. When a common mode current flows in the second coil 42, a second magnetic flux is generated in the core 3 in a direction that reinforces the first magnetic flux within the core 3. Therefore, the first coil 41 and core 3, and the second coil 42 and core 3, act as inductance components, eliminating noise from the common mode current.

The first coil 41 is formed by connecting multiple pin members by welding, such as laser welding or spot welding. Note that Figure 3 does not depict the multiple pin members actually welded together, but rather the state in which the multiple pin members are assembled. Furthermore, the method of connecting the multiple pin members is not limited to welding; other connection methods, such as soldering or conductive adhesive, may also be used. For simplicity's sake, the following description will be given assuming that welding is used as the method of connecting the multiple pin members.

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

The first coil 41 includes, from one end to the other, an endmost straight pin member 411 on one end side (one), multiple sets of bent pin members 410 and straight pin members 412, and an endmost straight pin member 411 on the other end side (the other). In this embodiment, the endmost straight pin member 411 and the straight pin member 412 have the same shape. However, this is not limited thereto, and the endmost straight pin member 411 and the straight pin member 412 may have different shapes. For example, the length in the extension direction of the endmost straight pin member 411 may be shorter than the length in the extension direction of the straight pin member 412.

Regarding the spring index of the bending pin member 410, as shown in Figure 5, when the bending pin member 410 is positioned along the second end face 302, inner peripheral surface 303, and outer peripheral surface 304 of the core 3, the spring index Ks of the bending pin member 410 is less than 3.6 for the radius of curvature R1 of the bending pin member 410 located at the corner of the outer peripheral surface 304 of the core 3 and the radius of curvature R2 of the bending pin member 410 located at the corner of the inner peripheral surface 303 of the core 3. The spring index Ks can be expressed as the radius of curvature R1, R2 of the bending pin member divided by the wire diameter r of the bending pin member. As such, the bending pin member 410 has high rigidity and is difficult to bend.

The bent pin members 410 and straight pin members 412 are alternately connected by welding, such as laser welding or spot welding. One end of a straight pin member 412 is connected to one end of a bent pin member 410, and the other end of the straight pin member 412 is connected to one end of another bent pin member 410. By repeating this process, multiple bent pin members 410 and straight pin members 412 are connected, and the connected multiple bent pin members 410 and straight pin members 412 are arranged spirally on the core 3. In other words, one set of bent pin members 410 and straight pin members 412 forms one turn.

The bent pin members 410 are arranged parallel to each other along the second end face 302, inner peripheral surface 303, and outer peripheral surface 304 of the core 3. The imaginary line connecting both ends of the bent pin members 410 in the extension direction extends in the X direction, tilted slightly in the Y direction when viewed from the central axis of the core 3. In other words, the bent pin members 410 are arranged so that the plane containing the center line of the bent pin members 410 is tilted slightly in the Y direction with respect to the plane (XZ plane) perpendicular to the axial direction of the first coil 41. The straight pin members 412 are arranged parallel to each other along the first end face 301 of the core 3. The straight pin members 412 extend in the X direction. The endmost straight pin members 411 are arranged parallel to each other along the first end face 301 of the core 3. The endmost straight pin members 411 extend in a direction parallel to the straight pin members 412.

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

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

Like the first coil 41, the second coil 42 is composed of multiple pin members. That is, the second coil 42 includes, from one end to the other, a straight pin member 421 at one end, multiple sets of bent pin members 420 and straight pin members 422, and a straight pin member 421 at the other end. The bent pin members 420 and straight pin members 422 are alternately connected and wound around the core 3. That is, the multiple bent pin members 420 and straight pin members 422 are connected, and the connected multiple bent pin members 420 and straight pin members 422 are spirally wound around the core 3.

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

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

As shown in FIG. 3, the first coil 41 and the second coil 42 (pin members 410-412, 420-422) preferably each include a conductor portion and a coating that covers a portion of the conductor portion. The conductor portion is, for example, a copper wire, and the coating is, for example, a polyamideimide resin. The thickness of the coating is, for example, 0.02 to 0.04 mm.

The endmost straight pin members 411, 421 are composed of uncoated conductor portions 411a, 421a. The straight pin members 412, 422 are composed of uncoated conductor portions 412a, 422a. The bent pin members 410, 420 are composed of conductor portions 410a, 420a and coatings 410b, 420b.

At one end and the other end of the bent pin members 410, 420, the conductor portions 410a, 420a are exposed from the coatings 410b, 420b. That is, the endmost straight pin members 411, 421, the straight pin members 412, 422, and the bent pin members 410, 420 are welded to each other, for example, at the exposed conductor portions 411a, 421a, 412a, 422a, 410a, 420a. These conductor portions not covered by the coating, i.e., the conductor portions exposed (without the coating), are electrically conductive to the outside.

Figure 6 is a cross-sectional view taken along line VI-VI of Figure 1. The dummy terminal 55 is omitted from Figure 6. As shown in Figure 6, in the first coil 41, the ends of adjacent pin members are welded together at a welded portion. A welded portion refers to a portion that melts during welding and then solidifies. Specifically, the first coil 41 has a first welded portion 81 and a second welded portion 82. More specifically, in adjacent turns of the first coil 41, the straight pin member 412 and the bent pin member 410 of one turn form a first welded portion 81, where one conductor portion 412a of the straight pin member 412 is welded to the conductor portion 410a of the bent pin member 410. The straight pin member 412 and the bent pin member 410 of the other turn form a second welded portion 82, where the other conductor portion 412a of the straight pin member 412 is welded to the conductor portion 410a of the bent pin member 410.

Note that Figure 6 illustrates a turn composed of the straight pin member 412 and the bent pin member 410 of the first coil 41, but the same applies to a turn composed of the endmost straight pin member 411 and the bent pin member 410. Specifically, the endmost straight pin member 411 is welded to the conductor portion 410a of the bent pin member 410 connected to the conductor portion 411a, forming the first welded portion 81 or the second welded portion 82.

The second coil 42 has a third weld 83 and a fourth weld 84. As with the first coil 41, in adjacent turns of the second coil 42, the straight pin member 422 and the bent pin member 420 of one turn are welded at one conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member 420, forming the third weld 83. The straight pin member 422 and the bent pin member 420 of the other turn are welded at the other conductor portion 422a of the straight pin member 422 and the conductor portion 420a of the bent pin member, forming the fourth weld 84. Furthermore, the most distal straight pin member 421 is welded at the conductor portion 420a of the bent pin member 420 connected to its conductor portion 421a, forming the third weld 83 or the fourth weld 84. The third welded portion 83 and the fourth welded portion 84 of the second coil 42 have the same configuration as the first welded portion 81 and the second welded portion 82 of the first coil 41, and therefore a description thereof will be omitted.

The core cover portion 60 is located between the conductor portions and welded portions of the coils 41 and 42 that are exposed from the coating and the core 3. This ensures more reliable insulation between the conductor portions and welded portions of the coils 41 and 42 and the core 3.

The core cover portion 60 is provided over the first end face 301 of the core 3, a portion of the inner peripheral surface 303 of the core 3, and a portion of the outer peripheral surface 304 of the core 3. The core cover portion 60 has an inner peripheral portion 60a facing the inner peripheral surface 303 of the core 3, an outer peripheral portion 60b facing the outer peripheral surface 304 of the core 3, and a bottom portion 60c facing the first end face 301 of the core 3. The bottom portion 60c is an example of the "first portion" described in the claims. The bottom portion 60c has a first surface 60c1 opposite the first end face 301.

The core 3 is connected to the core cover part 60 via a core adhesive member 91. By connecting the core adhesive member 91 to a part of the core 3, the stress on the core 3 received from the core cover part 60 is reduced, thereby suppressing deterioration of the magnetic properties of the core 3. In other words, it is possible to suppress a decrease in inductance value caused by magnetostriction. Note that the core cover part 60 may not be connected to the core 3 via the core adhesive member 91, but may simply be fitted into the core 3.

The core adhesive member 91 is provided between the first end face 301 of the core 3 and the bottom 60c of the core cover part 60. This reduces the effect of magnetostriction on the core 3 while ensuring a stable attachment of the core cover part 60 to the core 3.

Examples of materials for the core adhesive member 91 include soft resins such as urethane resin and silicone resin. By using such soft resins, the effects of magnetostriction can be reduced.

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

As shown in Figure 6, the conductor portions of the coils 41, 42 that are exposed from the coating are arranged in the recess 215 so as to be located on the first main surface 210a side. The coil adhesive member 90 is fixed in the recess 215 to adhere the coils 41, 42 to the bottom plate portion 21 and cover at least a portion of the conductor portions of the coils 41, 42 that are exposed from the coating. Preferably, the coil adhesive member 90 covers all of the conductor portions.

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

Because the coil adhesive member 90 is fixed within the recess 215 of the bottom plate portion 21, the coil adhesive member 90 is stably fixed to the bottom plate portion 21, thereby enabling the coils 41, 42 to be stably fixed to the bottom plate portion 21. Furthermore, because the coil adhesive member 90 covers the conductor portions of the coils 41, 42 that are exposed from the coating, problems such as electrical shorts with the outside can be prevented. Furthermore, if the coil component 1 is subjected to external forces such as vibration or shock, the coil adhesive member 90 absorbs the shock and protects the coils 41, 42.

An example of a material for the coil adhesive member 90 is silicone resin. Using silicone resin can improve reflow heat resistance and mechanical strength.

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

As shown in Figure 7, the endmost straight pin member 411 has a rectangular cross section. The cross-sectional shape of the endmost straight pin member 411 is not particularly limited and may be circular, elliptical, or any other polygonal shape other than rectangular.

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

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

The bending pin member 410 has a circular cross section. However, the cross-sectional shape of the bending pin member 410 may be elliptical, polygonal, or other shapes. The end face 410ef of the first end 410e1 of the bending pin member 410 is flat. The end face 410ef is perpendicular to the center line 410c of the first end 410e1. Similarly, the end face of the second end (not shown) of the bending pin member 410 is flat. The end face is perpendicular to the center line of the second end.

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

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

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

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

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

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

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

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

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

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

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

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

(Positional relationship between the protrusion, the most straight pin member, and the electrode terminal)
Fig. 10 is a bottom view of the coil component excluding the bottom plate portion. Fig. 11 is a cross-sectional view taken along line XI-XI in Fig. 10. For convenience, the first to fourth electrode terminals 51 to 54 are indicated by two-dot chain lines in Fig. 10.

As shown in Figures 10 and 11, in the first coil 41, the endmost straight pin member 411 on the first electrode terminal 51 side faces the first surface 60c1 (first region 60c11) of the bottom 60c. The first end 411e1 of the endmost straight pin member 411 contacts the first protrusion 621. The second end 411e2 of the endmost straight pin member 411 is spaced from the first surface 60c1 (first region 60c11) and connected to the first end 410e1 of the bent pin member 410. The first end 411e1 and the second end 411e2 each correspond to 1/3 of the length of the endmost straight pin member 411 in the extension direction.

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

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

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

As shown in Figures 10 and 11, the outermost straight pin member 411 is connected to the first electrode terminal 51. This stabilizes the posture of the outermost straight pin member 411, thereby stabilizing the connection between the outermost straight pin member 411 and the first electrode terminal 51. This improves the connection reliability between the outermost straight pin member 411 and the first electrode terminal 51.

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

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

Preferably, the endmost straight pin member 411 and the first electrode terminal 51 are connected by welding. This improves connection strength compared to connections made by soldering.

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

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

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

10, the second end 411e2 of the endmost straight pin member 411 on the second electrode terminal 52 side is connected to the second electrode terminal 52. As a result, the second end 411e2 of the endmost straight pin member 411 is spaced apart from the first surface 60c1, making it difficult for heat generated when connecting the endmost straight pin member 411 and the second electrode terminal 52 by welding or the like to propagate to the core cover part 60, thereby reducing thermal deterioration of the core cover part 60.

Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the second protrusion 622 is spaced apart from the second electrode terminal 52. As a result, the heat generated when connecting the outermost straight pin member 411 and the second electrode terminal 52 by welding or the like is less likely to be transmitted by the second protrusion 622, and less likely to be transmitted by the core cover portion 60.

Preferably, the endmost straight pin member 421 and the second electrode terminal 52 are connected by welding. This improves connection strength compared to connections made by soldering.

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

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

In addition, since the second end 421e2 of the endmost straight pin member 421 is separated from the first surface 60c1, the heat generated when connecting the endmost straight pin member 421 and the bent pin member 420 by welding or the like is less likely to be transmitted to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

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

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

Preferably, the endmost straight pin member 421 and the third electrode terminal 53 are connected by welding. This improves connection strength compared to connections made by soldering.

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

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

In addition, since the second end 421e2 of the endmost straight pin member 421 is separated from the first surface 60c1, the heat generated when connecting the endmost straight pin member 421 and the bent pin member 420 by welding or the like is less likely to be transmitted to the core cover part 60, thereby reducing deterioration of the core cover part 60 due to heat.

10, the second end 421e2 of the endmost straight pin member 421 on the fourth electrode terminal 54 side is connected to the fourth electrode terminal 54. As a result, the second end 421e2 of the endmost straight pin member 421 is spaced apart from the first surface 60c1, so that the heat generated when connecting the endmost straight pin member 421 and the fourth electrode terminal 54 by welding or the like is less likely to propagate to the core cover part 60, thereby reducing thermal deterioration of the core cover part 60.

Furthermore, when viewed from a direction perpendicular to the first surface 60c1, the fourth protrusion 624 is spaced apart from the fourth electrode terminal 54. As a result, the heat generated when connecting the outermost straight pin member 421 and the fourth electrode terminal 54 by welding or the like is less likely to be transmitted by the fourth protrusion 624, and less likely to be transmitted by the core cover portion 60.

Preferably, the endmost straight pin member 421 and the fourth electrode terminal 54 are connected by welding. This improves connection strength compared to connections made by soldering.

(Method for manufacturing coil components)
Next, a method for manufacturing the coil component 1 will be described.

Referring to Figure 4, the annular core 3 is stored in the core cover portion 60 of the base case 22 so that the first end face 301 located in the central axis direction of the core 3 is covered. This is called the core storage process.

Then, referring to Figure 10, a plurality of straight pin members 411, 412, 421, 422 and a plurality of bent pin members 410, 420 are arranged around the core 3 and the core cover part 60 so that the ends of each straight pin member 411, 412, 421, 422 and the ends of each bent pin member 410, 420 are positioned on the first surface 60c1 side of the core cover part 60. This is called the pin member arrangement process.

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

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

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

Then, the ends of each straight pin member 411, 412, 421, 422 are connected to the ends of each bent pin member 410, 420 to form coils 41, 42 in which each straight pin member 411, 412, 421, 422 is alternately connected to each bent pin member 410, 420. This is called the coil formation process.

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

The above coil forming process includes supporting the first end portions 411e1, 421e1 of the most distal straight pin members 411, 421 on the first to fourth protrusion portions 621 to 624, and separating the second end portions 411e2, 421e2 of the most distal straight pin members 411, 421 from the first surface 60c1 and connecting them to the bent pin members 410, 420.

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

Then, the first to fourth electrode terminals 51 to 54 are connected to the endmost straight pin members 411, 421, and the electrode terminals 51 to 54 are connected to the coils 41, 42. This is called the electrode terminal connecting process.

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

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

According to the manufacturing method of the coil component 1 described above, while the first ends 411e1, 421e1 of the outermost straight pin members 411, 421 are supported by the first to fourth protrusions 621-624, the second ends 411e2, 421e2 of the outermost straight pin members 411, 421 can be connected to the bent pin members 410, 420, allowing the outermost straight pin members 411, 421 to be connected to the bent pin members 410, 420 in a stable position. This improves the connection reliability between the outermost straight pin members 411, 421 and the bent pin members 410, 420.

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

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

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

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

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

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

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

Figure 13 is a bottom view showing the jig being used in the manufacturing method of the coil component. Figure 14 is a perspective view of Figure 13 with the core and base case omitted.

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

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

Therefore, the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420 can be connected to the bent pin members 410, 420 while positioning them, thereby improving the connection reliability of the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420.

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

Specifically, as shown by the black circles in Figure 13, the connection points between the ends of each straight pin member 411, 412, 421, 422 and the ends of each bent pin member 410, 420 are exposed from the first to fourth hole portions 141 to 144. Then, for example, a welding tool is inserted through the first to fourth hole portions 141 to 144 to weld the above-mentioned connection points.

Therefore, while the jig 100 remains attached, all straight pin members 411, 412, 421, 422 and all bent pin members 410, 420 can be connected in a single step.

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

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

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

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

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

Therefore, while the jig 100 remains attached, the connection between the straight pin members 411, 412, 421, 422 and the bent pin members 410, 420 and the connection between the endmost straight pin members 411, 421 and the first to fourth electrode terminals 51 to 54 can be performed in a single process.

(Other embodiments)
The present disclosure is not limited to the above-described embodiments, and design modifications are possible within the scope of the present disclosure.

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

The core cover and mounting base are integrated, but they may be separate, or the core cover and mounting base may be spaced apart. The mounting base may also be omitted, with the electrode terminal attached to the bottom plate.

The shape of the case and the shape of the core are not limited to the first embodiment and can be modified. Furthermore, the number of coils is not limited to the first embodiment and can be modified. Furthermore, the number of electrode terminals is not limited to the first embodiment and can be modified.

The present disclosure includes the following aspects.
<1>
an annular core;
a core cover portion that covers at least a portion of the core;
a coil wound around the core and the core cover,
the core has a first end surface and a second end surface facing each other in a central axis direction,
the core cover portion has a first portion facing the first end surface, the first portion having a protrusion on a first surface opposite to the first end surface,
the coil includes a plurality of straight pin members and a plurality of bent pin members, the straight pin members and the bent pin members being alternately connected to form the spiral of the coil, and the plurality of straight pin members include an endmost straight pin member located at an end on at least one side in the axial direction of the coil,
a coil component, wherein the outermost straight pin member faces the first surface of the first portion, a first end of the outermost straight pin member contacts the protrusion, and a second end of the outermost straight pin member is spaced from the first surface and connected to the bent pin member.
<2>
further comprising an electrode terminal connected to the coil;
The coil component according to <1>, wherein the outermost straight pin member is connected to the electrode terminal.
<3>
The coil component according to <2>, wherein the first end of the outermost straight pin member is connected to the electrode terminal.
＜4＞
The coil component according to <3>, wherein the protrusion overlaps the electrode terminal when viewed from a direction perpendicular to the first surface.
<5>
The coil component according to <2>, wherein the second end of the outermost straight pin member is connected to the electrode terminal.
<6>
The coil component according to <5>, wherein the protrusion is spaced apart from the electrode terminal when viewed in a direction perpendicular to the first surface.
＜７＞
The coil component according to any one of <2> to <6>, wherein the outermost straight pin member and the electrode terminal are connected by welding.
＜8＞
a mounting base for mounting the electrode terminal,
The coil component according to any one of <2> to <7>, wherein the core cover portion and the mounting base portion are an integrally molded product.
＜９＞
a step of housing the annular core in a core cover portion so that a first end face of the core located in a central axis direction is covered;
a step of arranging a plurality of straight pin members and a plurality of bent pin members around the core and the core cover portion such that an end of each straight pin member and an end of each bent pin member are located on a first surface side of the core cover portion opposite the first end surface;
and connecting an end of each of the straight pin members to an end of each of the bent pin members to form a coil in which the straight pin members and the bent pin members are alternately connected,
The step of arranging the straight pin members and the bent pin members includes: making an endmost straight pin member, which is located at an end on at least one side of the coil in the axial direction, of the plurality of straight pin members face the first surface; and making a first end of the endmost straight pin member contact a protrusion provided on the first surface;
The method for manufacturing a coil component includes, in the process of forming the coil, supporting the first end of the outermost straight pin member on the protrusion portion, and connecting the second end of the outermost straight pin member to the bent pin member while separating it from the first surface.
<10>
The method for manufacturing a coil component according to <9>, further comprising the step of connecting an electrode terminal to the outermost straight pin member and connecting the electrode terminal to the coil.
<11>
The method for manufacturing a coil component according to <9> or <10>, wherein the step of forming the coil includes connecting an end of each of the straight pin members and each of the bent pin members with an end of each of the straight pin members and each of the bent pin members while the straight pin members and each of the bent pin members are fitted into grooves of a jig.
<12>
The method for manufacturing a coil component according to <11>, wherein the step of forming the coil includes connecting the ends of the straight pin members and the ends of the bent pin members while exposing the ends of the straight pin members and the ends of the bent pin members from holes in the jig.
<13>
the step of forming the coil includes connecting an end of each of the straight pin members and an end of each of the bent pin members in a state in which the straight pin members and the bent pin members are fitted into grooves of a jig;
The method for manufacturing a coil component according to <10>, wherein the step of connecting the electrode terminal includes connecting the electrode terminal to the outermost straight pin member in a state where a positioning protrusion of the jig is inserted into a slit portion of the electrode terminal.
<14>
the step of forming the coil includes connecting the ends of the straight pin members and the ends of the bent pin members while exposing the ends of the straight pin members and the ends of the bent pin members from holes in the jig;
<14> The method for manufacturing a coil component according to <13>, wherein the step of forming the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while exposing the endmost straight pin member and the electrode terminal from the hole portion of the jig.

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

Claims (14)

an annular core;
a core cover portion that covers at least a portion of the core;
a coil wound around the core and the core cover,
the core has a first end surface and a second end surface facing each other in a central axis direction,
the core cover portion has a first portion facing the first end surface, the first portion having a protrusion on a first surface opposite to the first end surface,
the coil includes a plurality of straight pin members and a plurality of bent pin members, the straight pin members and the bent pin members being alternately connected to form the spiral of the coil, and the plurality of straight pin members include an endmost straight pin member located at an end on at least one side in the axial direction of the coil,
a coil component, wherein the outermost straight pin member faces the first surface of the first portion, a first end of the outermost straight pin member contacts the protrusion, and a second end of the outermost straight pin member is spaced from the first surface and connected to the bent pin member. further comprising an electrode terminal connected to the coil;
The coil component according to claim 1 , wherein the outermost straight pin member is connected to the electrode terminal. The coil component described in claim 2, wherein the first end of the outermost straight pin member is connected to the electrode terminal. The coil component described in claim 3, wherein the protrusion overlaps the electrode terminal when viewed in a direction perpendicular to the first surface. The coil component of claim 2, wherein the second end of the outermost straight pin member is connected to the electrode terminal. The coil component described in claim 5, wherein the protrusion is spaced apart from the electrode terminal when viewed in a direction perpendicular to the first surface. A coil component according to any one of claims 2 to 6, wherein the outermost straight pin member and the electrode terminal are connected by welding. a mounting base for mounting the electrode terminal,
The coil component according to claim 2 , wherein the core cover portion and the mount portion are an integrally molded product. a step of housing the annular core in a core cover portion so that a first end face of the core located in a central axis direction is covered;
a step of arranging a plurality of straight pin members and a plurality of bent pin members around the core and the core cover portion such that an end of each straight pin member and an end of each bent pin member are located on a first surface side of the core cover portion opposite the first end surface;
and connecting an end of each of the straight pin members to an end of each of the bent pin members to form a coil in which the straight pin members and the bent pin members are alternately connected,
The step of arranging the straight pin members and the bent pin members includes: making an endmost straight pin member, which is located at an end on at least one side of the coil in the axial direction, of the plurality of straight pin members face the first surface; and making a first end of the endmost straight pin member contact a protrusion provided on the first surface;
The method for manufacturing a coil component includes, in the process of forming the coil, supporting the first end of the outermost straight pin member on the protrusion portion, and connecting the second end of the outermost straight pin member to the bent pin member while separating it from the first surface. The method for manufacturing a coil component described in claim 9 further comprises the step of connecting an electrode terminal to the outermost straight pin member and connecting the electrode terminal to the coil. The method for manufacturing a coil component described in claim 9 or 10, wherein the step of forming the coil includes connecting the ends of each straight pin member and each bent pin member while fitting each straight pin member and each bent pin member into a groove in a jig. The method for manufacturing a coil component described in claim 11, wherein the step of forming the coil includes connecting the ends of each straight pin member and each bent pin member while exposing the ends of each straight pin member and each bent pin member from the hole in the jig. the step of forming the coil includes connecting an end of each of the straight pin members and an end of each of the bent pin members in a state in which the straight pin members and the bent pin members are fitted into grooves of a jig;
11. The method for manufacturing a coil component according to claim 10, wherein the step of connecting the electrode terminal includes connecting the electrode terminal to the outermost straight pin member with a positioning protrusion of the jig inserted into a slit portion of the electrode terminal. the step of forming the coil includes connecting the ends of the straight pin members and the ends of the bent pin members while exposing the ends of the straight pin members and the ends of the bent pin members from holes in the jig;
14. The method for manufacturing a coil component according to claim 13, wherein the step of forming the electrode terminal includes connecting the electrode terminal to the endmost straight pin member while exposing the endmost straight pin member and the electrode terminal from the hole portion of the jig.