JP2011040598A - Coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component which is enhanced in adhesive strength between a first core and a second core. <P>SOLUTION: The coil component includes a drum core 2 having a second collar part 22 connected to one axial end of a core part 23 and an exterior core 3 bonded to the drum core 2 with an adhesive 10B. The second collar part 22 has a second arcuate part 22E bonded to the adhesive 10B and a second external surface 22B crossing the second arcuate part 22E at one axial end of the drum core 2. The exterior core 3 has a first internal surface 4A bonded to the second arcuate part 22E with the adhesive 10B and a second end surface 4C crossing the first internal surface 4A at one end of the exterior core 3 and positioned nearby the second external surface 22B, and a projection part 41 having one end positioned on the second end surface 4C and extending in an axial direction is provided on the first internal surface 4A, and the second end surface 4C protrudes from the second external surface 22B to form a level difference. The adhesive 10B covers one end part of the projection part 41 in the level difference to bond the drum core 2 and exterior core 3 together. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a coil component, and in particular, a coil component including a first core and a second core disposed around the first core and bonded to the first core with an adhesive.

  Conventionally, a coil component including a drum core that is a first core and an exterior core that is a second core disposed around the drum core has been known. As shown in Patent Document 1, the drum core and the exterior core are bonded to each other by applying the resin to the adhesive surface in advance and attaching the drum core and the exterior core together.

JP 2004-207396 A

  In general, ferrite or the like that is a base material of the core does not have good wettability with respect to the adhesive. Therefore, in the coil component, it is preferable that the adhesive area to which the adhesive between the drum core and the exterior core adheres is large. However, since the coil component is required to be downsized such as a low profile, there is a possibility that sufficient adhesive strength cannot be obtained in this case. Then, an object of this invention is to provide the coil components with which the adhesive strength of a 1st core and a 2nd core was raised more.

  In order to solve the above-described problem, the present invention provides a first core having a core part around which a winding is wound, and a first hook part and a second hook part respectively connected to both axial ends of the core part. Provided is a coil component including a core, a second core bonded to the first core via an adhesive, and a pair of terminal electrodes to which both ends of the winding are respectively connected. In this coil component, the first core includes a first core bonding surface that is respectively defined on the outer periphery of the first collar part and the outer periphery of the second collar part and adheres to the adhesive, and the first collar part and the second collar part. It has a first core end surface that is defined as one of the ends and is one end of the first core in the axial direction and intersects the first core bonding surface. The second core has a second core adhesive surface that faces the first core adhesive surface and adheres to the adhesive, and is an end of the second core in the axial direction and intersects the second core adhesive surface in the vicinity of the first core end surface. And a second core end face. Either one or both of the first core bonding surface and the second core bonding surface protrudes from the first core bonding surface or the second core bonding surface, and one end is positioned on the first core end surface or the second core end surface. Protrusions extending in the direction are provided. The pair of terminal electrodes is provided on either the first core end surface or the second core end surface, respectively. The first core end surface and the second core end surface are the first core end surface and the second core end surface where the first core end surface and the second core end surface intersect the first core end surface and the second core end surface. It is comprised so that a level | step difference may be protruded in an axial direction from the location which cross | intersects a 1st core adhesion surface or a 2nd core adhesion surface in either one of a core end surface. The adhesive is interposed between the first core bonding surface and the second core bonding surface, and is disposed so as to cover one end of the protruding portion and straddle the first core and the second core in the step.

  According to such a configuration, an adhesive fillet is formed in the step. This fillet is formed to straddle either one of the first core bonding surface and the second core bonding surface, one of the first core end surface and the second core end surface, and the end of the protrusion. As a result, the bonding area can be increased, and the bonding strength between the first core and the second core can be increased. Moreover, since the step is formed on the first core end surface and the second core end surface where the terminal electrode is not provided, adhesion of the adhesive to the terminal electrode is suppressed.

  In the coil component having the above-described configuration, it is preferable that one of the first core end surface and the second core end surface provided with the pair of terminal electrodes is a surface that protrudes most in the axial direction.

  According to such a configuration, since the surface on which the terminal electrode is provided reliably comes into surface contact with the mounting substrate, mounting defects can be reduced.

  The pair of terminal electrodes is preferably provided on the first core. According to such a configuration, the terminal core is provided on the first core, and the second core can be bonded to the first core in a state where the end of the winding is connected to the terminal electrode. Become.

  The first core has a shape in which the longitudinal direction and the short direction are defined on the end surface of the first core, and the pair of terminal electrodes are respectively provided at one end and the other end of the first core end surface in the short direction. Preferably it is.

  According to such a structure, since the distance of the location mounted on a mounting board | substrate can be shortened, the rigidity with respect to the bending which generate | occur | produces in a mounting board | substrate is improved.

  The first core intersects the first core end surface and has a first core peripheral surface including the first core adhesion surface, and the second core intersects the second core end surface and includes the second core adhesion surface. A pair of terminal electrodes each having a second core peripheral surface are provided across the first core end surface and the first core peripheral surface, respectively, or provided across the second core end surface and the second core peripheral surface, respectively. It is preferable that both ends of each are connected to the pair of terminal electrodes on the first core peripheral surface or the second core peripheral surface.

  According to such a configuration, since the connecting portion is not provided on the end face side of the first core and the second core, it is suppressed that the protrusion due to the connecting portion is formed on the end face portion. This can reduce the height of the coil component.

  The second core is composed of a plurality of split cores each having a second core end face and a second core adhesion surface, and the pair of terminal electrodes are provided on the first core, respectively, It is preferable that the portions connected to both ends are respectively positioned between the plurality of divided cores.

  Moreover, it is preferable that a pair of terminal electrode is arrange | positioned in the outline which mutually connects the surrounding surface which makes an outline among several division | segmentation cores in the cross section orthogonal to an axial direction.

  According to such a structure, since a connection location is located between division | segmentation cores, it is suppressed that a connection location contacts other electronic components etc., and a connection location can be protected.

  The first core end surface is either the first collar portion or the second collar portion, and is also defined in the other end position of the first core in the axial direction. The second core end surface is the other end position of the second core. And a step is formed between the first core end surface at the other end position and the second core end surface at the other end position. It is preferable that the adhesive is located on the end surface of the second core and is disposed so as to cover the other end portion of the protruding portion and straddle the first core and the second core within the step at the other end position.

  According to such a structure, since the fillet by an adhesive agent can be drawn also on the other end side of the first core and the second core, the adhesive strength can be further increased.

  According to the coil component of the present invention, the adhesive strength between the first core and the second core can be further increased.

The disassembled perspective view of the coil components which concern on embodiment of this invention. The top perspective view of the coil component which concerns on embodiment of this invention. The bottom perspective view of the coil component concerning an embodiment of the invention. Sectional drawing along the IV-IV line of FIG. Explanatory drawing which concerns on glass layer formation of the coil components which concern on embodiment of this invention. The top view in the state which combined the drum core and exterior core of the coil components which concern on embodiment of this invention. Sectional drawing along the VII-VII line of FIG. The top view of the state which started filling UV curing resin between the 2nd collar part of the coil components which concern on embodiment of this invention, and an exterior core. The top view of the state which finished filling UV curing resin between the 2nd collar part of the coil components which concern on embodiment of this invention, and an exterior core. Sectional drawing of the state filled with a thermosetting resin between the upper collar part and exterior core of the coil components which concern on embodiment of this invention.

  Hereinafter, a coil component according to an embodiment of the present invention will be described with reference to FIGS. A coil component 1 shown in FIG. 1 is mainly composed of a drum core 2, an exterior core 3, a winding 6, and a terminal electrode 7, and has a small outer dimension of about 2.0 to 5.0 mm. It is a product.

  The drum core 2, which is the first core, is provided with conductivity using a magnetic material containing manganese, for example, Mn-Zn ferrite as a base material. As shown in FIGS. 1 and 4, the substantially cylindrical core portion 23 is provided. And a first flange portion 21 and a second flange portion 22 that are provided coaxially at both ends in the central axis direction of the core portion 23. The first collar portion 21 and the second collar portion 22 have the same shape and are configured such that the projection shapes match in the axial direction of the core portion 23.

  As shown in FIG. 4, one end of the core part 23 is connected to the first collar part 21 and the first inner surface 21 </ b> A facing the second collar part 22, and the drum core 2 in the axial direction of the core part 23. A first outer surface 21B which is an end surface of the first end surface and is a smooth surface, and a first peripheral surface 21C which is located between the first inner surface 21A and the first outer surface 21B and intersects the first outer surface 21B is defined. Yes. As shown in FIG. 1, the first peripheral surface 21C is composed of a pair of first arc portions 21E, 21E connecting the pair of first straight portions 21D, 21D and the pair of first straight portions 21D, 21D. Moreover, in the 1st collar part 21, the maximum distance from one 1st circular arc part 21E to the other 1st circular arc part 21E becomes longer than the distance from one 1st linear part 21D to the other 1st linear part 21D. It is configured. In the first flange portion 21, the first outer surface 21B acts as a suction surface (upper surface) when the coil component 1 is sucked and mounted, and the first arc portions 21E and 21E are bonded to the outer core 3. Acts as a core bonding surface.

  The other end of the core portion 23 is connected to the second flange portion 22 and the second inner surface 22A facing the first flange portion 21 and the other end side end surface of the drum core 2 in the axial direction of the core portion 23. A second outer surface 22B that is the first core end surface and is a smooth surface, and a second peripheral surface 22C that is located between the second inner surface 22A and the second outer surface 22B and intersects the second outer surface 22B. ing. The second outer surface 22B is configured to be substantially parallel to the first outer surface 21B, and the second peripheral surface 22C is a pair connecting the pair of second straight portions 22D and 22D and the pair of second straight portions 22D and 22D. Second arc portions 22E and 22E.

  In the second collar portion 22, the maximum distance from one second arc portion 22E to the other second arc portion 22E is longer than the distance from one second linear portion 22D to the other second linear portion 22D. It is comprised so that it may become. Therefore, a direction from one second arc portion 22E to the other second arc portion 22E is defined as a longitudinal direction, and a direction from one second linear portion 22D to the other second linear portion 22D is defined as a short direction. To do. In the second flange portion 22, the second outer surface 22B acts as a mounting surface (lower surface) mounted on a substrate (not shown) when the coil component 1 is sucked and mounted, and the second arc portions 22E and 22E are exterior parts. It acts as a first core bonding surface bonded to the core 3.

  The core portion 23 has a core portion peripheral surface 23A located between the first inner surface 21A and the second inner surface 22A. In the drum core 2, a space 2 a (FIG. 4) in which the winding 6 is accommodated is formed in a portion surrounded by the winding core peripheral surface 23 </ b> A, the first inner surface 21 </ b> A, and the second inner surface 22 </ b> A.

  The drum core 2 having the above-described configuration is made of a conductive material, and insulation is achieved by coating the surface with an insulating glass layer 8 (FIG. 4). When the glass layer 8 is coated on the drum core 2, as shown in FIG. 5, a plurality of drum cores 2 are provided in a barrel 9 that includes a spray nozzle 91 at the center and rotates around the axis of the spray nozzle 91 as a rotation axis. To accommodate. The spray nozzle 91 is configured to be able to spray a glass slurry in which fine powder glass, a binder, or the like is suspended.

  In this state, glass slurry is sprayed from the spray nozzle 91 and sprayed onto the drum core 2 for coating. After the glass slurry layer is formed on the drum core 2, dry air of about 70 degrees is put into the barrel 9 to dry the glass slurry layer formed on the drum core 2. Thereby, a layer of glass fine powder is formed on the drum core 2. Thereafter, the drum core 2 is fired, and unnecessary binder components are volatilized and burned to melt (soften) the glass powder, thereby forming the glass layer 8 having a smooth surface.

  In the drum core 2, the core part peripheral surface 23A, the first inner surface 21A, and the second inner surface 22A are surfaces that define a space 2a that is a recess. Further, since the coating method is merely spray coating, the sprayed glass slurry is not sucked and adhered by the drum core 2 itself as in, for example, electrostatic coating. Therefore, compared with the 1st outer surface 21B and the 1st peripheral surface 21C of the 1st collar part 21, and the 2nd outer surface 22B and the 2nd circumferential surface 22C of the 2nd collar part 22, the glass slurry sprayed in the space 2a. Is difficult to adhere. Therefore, as shown in FIG. 4, the thickness of the glass layer 8 in the space 2a (the core portion peripheral surface 23A, the first inner surface 21A, and the second inner surface 22A) is thinner than the first outer surface 21B and the like. Become. Specifically, the average thickness of the glass layer 8 on the first outer surface 21B and the like is about 10 μm, whereas the average thickness of the glass layer 8 on the first inner surface 21A and the second inner surface 22A is about 5 μm. The average thickness of the glass layer 8 on the core peripheral surface 23A is about 3 μm, and the outer peripheral portion of the drum core 2 such as the first outer surface 21B is directed to the core peripheral surface 23A, which is the inner side of the drum core 2. The glass layer 8 is thin.

  Although the winding 6 is accommodated in the space 2a, the space 2a can be made large by thinning the glass layer 8 in the space 2a. Therefore, the number of turns of the winding 6 can be increased, or a large-diameter winding 6 can be used, so that the characteristics of the coil component 1 can be improved.

  As shown in FIG. 1, the outer core 3 is composed of a first divided core 4 and a second divided core 5, and the first divided core 4 and the second divided core 5 have the same shape. Therefore, in the following description, the first divided core 4 will be described as a representative, and the description of the second divided core 5 will be omitted unless otherwise specified.

  The first split core 4 is made of a magnetic material containing nickel, for example, Ni—Zn ferrite as a base material, and has insulating properties. As shown in FIG. 4, the first peripheral surface 21C and the second peripheral surface 22C The first inner surface 4A facing the first inner surface 4A intersecting the first inner surface 4A and being mounted on the drum core 2, the first end surface 4B positioned in the vicinity of the first outer surface 21B, and the first inner surface 4A intersecting the first inner surface 4A and mounted on the drum core 2. And a second end face 4C located in the vicinity of the second outer surface 22B. 4 A of 1st inner surfaces are comprised by the circular arc shape along the 1st circular arc part 21E and the 2nd circular arc part 22E, The circular arc direction length is the circumferential direction length of the 1st circular arc part 21E and the 2nd circular arc part 22E. It is comprised so that it may become substantially the same. The first inner surface 4A functions as a second core bonding surface bonded to the first arc portion 21E and the second arc portion 22E, and the second end surface 4C functions as a second core end surface.

  As shown in FIG. 4, the first end surface 4B and the second end surface 4C are configured to be smooth and parallel to each other. In the first split core 4, the distance from the first end face 4 </ b> B to the second end face 4 </ b> C (the thickness of the first split core 4) is the axial direction of the drum core 2 coated with the glass layer 8 and includes the glass layer 8. The distance between the first outer surface 21B and the second outer surface 22B (thickness of the drum core 2) is slightly shorter.

  As shown in FIG. 1, a first protrusion 41 and a second protrusion 42 are provided on the first inner surface 4 </ b> A at positions substantially near both ends in the arc direction. The first projecting portion 41 and the second projecting portion 42 are in the direction in which the first split core 4 is mounted on the drum core 2 and coincides with the axial direction of the drum core 2 (the thickness direction of the first split core 4). And is configured to protrude from the first inner surface 4A toward the first peripheral surface 21C and the second peripheral surface 22C.

  Since the 1st projection part 41 and the 2nd projection part 42 can be comprised with sufficient dimensional accuracy, it is prescribed | regulated by the 1st projection part 41 and the 2nd projection part 42, and the drum core 2 and the exterior core 3 (1st division | segmentation core) 4), the dimensional accuracy of the space (adhesive filling spaces 4a, 4b, 5a, 5b described later) is also increased. By increasing the dimensional accuracy, the magnetic gap between the drum core 2 and the outer core 3 is stabilized, so that the direct current superimposition characteristics of the coil component 1 can be stably improved.

  The leading end portions in the projecting direction of the first projecting portion 41 and the second projecting portion 42 are configured to have an R shape in a cross section orthogonal to the axial direction, and the first ridge line is the apex of the R shape portion. The second arc portions 21E and 22E are configured to come into contact with each other. Therefore, when the first protrusion 41 and the second protrusion 42 are in contact with the first and second arc portions 21E and 22E, respectively, a single point in the cross section perpendicular to the axial direction in contact with the R-shaped portion at the tip. A very narrow gap is formed. In the second end face 4C, an application area to which a UV curable resin 10B described later is dropped and applied is defined around the vicinity of the first protrusion 41 and the vicinity of the second protrusion 42, respectively. The coated area includes each of the end surface of the first protruding portion 41 and the end surface of the second protruding portion 42 that are flush with the second end surface 4C, and the coated region includes the first protruding portion. 41 and the second projecting portion 42 are respectively defined on both side surfaces with the top of each projecting portion having a substantially bowl shape as a boundary.

  As shown in FIG. 1, the second divided core 5 also has a second inner surface 5A, a first end surface 5B, and a second end surface 5C having the same shape as the first divided core 4, and the second inner surface 5A includes A first protrusion 51 and a second protrusion 52 are provided.

  As shown in FIG. 3, the terminal electrode 7 is made of nickel and tin after a silver paste is applied and baked on the surface of the glass layer 8 of the second flange portion 22 in a state where the glass layer 8 is formed on the drum core 2. As shown in FIGS. 3 and 6, the first electrode 71 connected to one end of the winding 6 by thermocompression bonding and the other end of the winding 6 connected by thermocompression bonding are formed. It is comprised from the 2nd electrode 72 wired. By forming the terminal electrode 7 on the drum core 2, the exterior core 3 can be mounted on the drum core 2 in a state where the winding 6 is wound around the core portion 23 and connected to the terminal electrode 7. This configuration facilitates the manufacture of the coil component 1.

  The first electrode 71 is disposed across the second outer surface 22B and one second linear portion 22D of the second peripheral surface 22C, and one end of the winding 6 is connected at the position of the first second linear portion 22D. Yes. The second electrode 72 is disposed across the second outer surface 22B and the other second linear portion 22D of the second peripheral surface 22C, and the other end of the winding 6 is connected at the other second linear portion 22D position. ing. When the coil component 1 is mounted on a substrate (not shown) by arranging the terminal electrode 7 on the pair of second straight portions 22D and 22D that are short in the second flange portion 22, one mounting location The distance from the (first electrode 71) to the other mounting location (second electrode 72) can be shortened. Thereby, the rigidity with respect to the bending which generate | occur | produces in the mounting substrate which is not shown in figure is improved, and it is suppressed that the coil component 1 is damaged.

  Further, since the terminal electrode 7 is provided on the surface of the glass layer 8, insulation between the drum core 2 is maintained. The terminal electrode 7 may be provided by bonding a copper metal fitting to the second flange portion 22 after the glass layer 8 is formed.

  The drum core 2, the first divided core 4 and the second divided core 5 in a state where the winding 6 is wound and connected to the terminal electrode 7 are flush with the first outer surface 21B and the first end surfaces 4B and 5B. The thermosetting resin 10A, which is an adhesive based on a thermosetting epoxy resin, and the UV curable resin 10B, which is an adhesive based on an ultraviolet curable resin. Glue together.

  Hereinafter, a method of bonding the drum core 2 and the exterior core 3 with the thermosetting resin 10A and the UV curable resin 10B will be described. First, as described above, the drum core 2 in which the glass layer 8 is formed and the terminal electrode 7 is formed and the winding 6 is wound and connected, and the outer core 3 (the first divided core 4 and the second divided core). 5) is prepared (element body preparation step).

  Next, as shown in FIG. 6, the first inner surface 4 </ b> A of the first divided core 4 faces one of the first arc portion 21 </ b> E and the second arc portion 22 </ b> E, and the second inner portion of the second divided core 5. The drum core 2 and the outer core 3 are arranged so that the inner surface 5A faces the other first arc portion 21E and the second arc portion 22E (core arrangement step). By arranging in this way, as shown in FIG. 7, an adhesive filling space 4a and an adhesive filling space 4b are defined between the first inner surface 4A and the first arc portion 21E and the second arc portion 22E, respectively. The adhesive filling space 5a and the adhesive filling space 5b are respectively defined between the second inner surface 5A and the first arc portion 21E and the second arc portion 22E.

  In the core arrangement step, as shown in FIG. 7, the first end surface 4 </ b> B of the first divided core 4, the first end surface 5 </ b> B of the second divided core 5, and the first of the drum core 2 are formed on the upper surface of the table S on which the bonding operation is performed. One outer surface 21B is in contact with each other, and these surfaces are arranged on the same surface. As described above, since the thickness of the first divided core 4 and the second divided core 5 is thinner than the thickness of the drum core 2, when the first end surface 4B, the first end surface 5B, and the first outer surface 21B are arranged flush, The second outer surface 22B of the drum core 2 protrudes from the second end surface 4C and the second end surface 5C, and steps are formed between the second outer surface 22B, the second end surface 4C, and the second end surface 5C.

  Next, as shown in FIG. 8, the UV curable resin 10 </ b> B is dropped from a nozzle (not shown) onto each application region of the second end surface 4 </ b> C and the second end surface 5 </ b> C (application step). The UV curable resin 10B has a viscosity of 300 to 10000 mPa · s, preferably 1000 to 5000 mPa · s at the time of application, and generally shows a liquid state with high fluidity. As described above, the coated area includes the end surfaces of the first protrusion 41 and the second protrusion 42, and the first protrusion 41, the second protrusion 42, and the second arc portion 22E. Since a very narrow gap is formed between the first and the second inner surface 4A, as shown in FIG. 9, the UV curable resin 10B dropped and applied to the application region is caused by capillary action from the gap. And filled in the adhesive filling space 4b between the second arc portion 22E (ultraviolet curable resin filling step).

  Capillary phenomenon is used to fill the UV curable resin 10B, so that even when the coil surface 1 is a small coil component 1 and the adhesive surface is narrow, the capillary tube can be obtained simply by dropping and applying an appropriate amount of adhesive to the application area. Depending on the phenomenon, an appropriate amount can be injected and filled into the adhesive filling space. Therefore, even if a dimensional error occurs between the drum core 2 and the exterior core 3 without being affected by the area of the surface to which the adhesive adheres, a suitable amount of adhesive is filled into the adhesive filling space, The exterior core 3 can be bonded.

  In addition, since the application regions are defined on both side surfaces with the tops of the first protrusion 41 and the second protrusion 42 in contact with the second arcuate portion 22E as the boundary, the adhesive filling space 4b. The space between the first protrusion 41 and the second protrusion 42 and the space outside this space are preferably filled.

  Since the second outer surface 22B protrudes and forms the above-mentioned step as compared with the second end surface 4C and the second end surface 5C where the application area is defined as described above, the second arc portion intersecting the second outer surface 22B. 22E becomes a wall, and the UV curable resin 10B applied to the application area is prevented from flowing out to the second outer surface 22B. In this way, by suppressing the outflow of the UV curable resin 10B to the second outer surface 22B, it is possible to prevent the UV curable resin 10B from adhering to the terminal electrode 7 and to suppress poor connection when the terminal electrode 7 is mounted. Can do.

  After each of the adhesive filling spaces 4b and 5b is filled with the UV curable resin 10B, the filled UV curable resin 10B is irradiated with ultraviolet rays by an ultraviolet irradiation device (not shown) (ultraviolet irradiation step). Since the coil component 1 is small as described above, the UV curable resin 10B filled in the adhesive filling spaces 4b and 5b is instantaneously cured by the irradiation of ultraviolet rays, and the drum core 2 and the exterior core 3 are bonded. In the adhesion with the UV curable resin 10B, since no external force is applied to the drum core 2 and the exterior core 3 other than dropping the UV curable resin 10B, the drum core 2 and the exterior core 3 move from a state where they are placed on the table S. That is suppressed. Therefore, a shift between the drum core 2 and the outer core 3 is suppressed.

  Since the UV curable resin 10B has high fluidity as described above, it can be suitably filled even if the space in which the coil component 1 is small is filled is narrow. The cured UV curable resin 10B is interposed between the first inner surface 4A and the second arc portion 22E, covers the first protrusion 41 and the second protrusion 42 within the above-described step, and the drum core 2 and the exterior. A fillet 10 </ b> C is formed so as to straddle the core 3. In this way, by forming the fillet 10C with the UV curable resin 10B and bonding the drum core 2 and the exterior core 3, it is possible to increase the bonding area and increase the bonding strength.

  Next, as shown in FIG. 10, the drum core 2 and the outer core 3 are reversed so that the second outer surface 22 </ b> B is placed on the upper surface of the table S. In this state, the thermosetting resin 10A is placed on the adhesive filling spaces 4a and 5a, and then the thermosetting resin 10A is filled into the adhesive filling spaces 4a and 5a with a spatula (not shown) (thermosetting). Resin filling step). Thereafter, the drum core 2 and the outer core 3 are moved into a heating furnace (not shown) and heated to heat and cure the thermosetting resin 10A (heating step). Since the drum core 2 and the outer core 3 are already bonded with the UV curable resin 10B, a new misalignment or the like occurs between the drum core 2 and the outer core 3 when the thermosetting resin 10A is filled and heated. There is no. Since the adhesion by the thermosetting resin 10A is strong, the drum core 2 and the exterior core 3 can be reliably adhered together with the adhesion by the UV curable resin 10B.

  By the above process, the bonding between the drum core 2 and the outer core 3 is completed, and the coil component 1 is completed. In the coil component 1 completed by bonding by the above method, as shown in FIG. 9, the second outer surface 22B on which the terminal electrode 7 is provided protrudes compared to the first end surfaces 4B and 5B. According to such a configuration, since the second outer surface 22B is in surface contact with a substrate (not shown) with certainty, mounting defects can be reduced.

  The pair of second linear portions 22D and 22D provided with the first electrode 71 and the second electrode 72 are located between the first divided core 4 and the second divided core 5, respectively, and FIG. 3, as shown in FIG. 6, the first divided core 4 and the second divided core 5 are arranged in a contour that connects the peripheral surfaces forming the outer contour. According to such a configuration, the first electrode 71 and the second electrode 72 provided in the pair of second linear portions 22D and 22D are suppressed from contacting other electronic components and the like, and the pair of second linear portions It is possible to protect the connecting portion formed in 22D and 22D.

  The coil component and the method for manufacturing the coil component of the present invention are not limited to the above-described embodiments, and various improvements and modifications can be made within the scope described in the claims. For example, in the thermosetting resin filling step, the adhesive filling spaces 4a and 5a are filled by pushing the thermosetting resin 10A with a spatula or the like. However, the viscosity is not limited to this, and the viscosity is the same as that of the UV curable resin 10B. The provided thermosetting resin 10A may be prepared, and the adhesive filling spaces 4a and 5a may be filled with an adhesive by a capillary phenomenon as in the case of the UV curable resin 10B. Further, the viscosity of the UV curable resin 10B is not necessarily required to exhibit the above viscosity at room temperature, and it is sufficient to show the viscosity in the ultraviolet curable resin filling step. Further, the step between the drum core 2 and the outer core 3 is formed only on one side in the axial direction of the core portion 23. However, the step is not limited to this and is formed on both sides, and an adhesive fillet is formed on both steps. May be. According to such a configuration, since the bonding area can be further increased, the drum core and the exterior core can be bonded more firmly. In the present embodiment, the coil part in which the protrusion is provided on the exterior core side and the terminal electrode is provided on the drum core side has been described. However, the present invention is not limited thereto, and the protrusion is only on the drum core side, or the drum core side and the exterior core. The terminal electrode may be provided on both of the outer core and the terminal electrode.

DESCRIPTION OF SYMBOLS 1 .. Coil components 2 .. Drum core 2a .. Space 3 .. Outer core 4 .. First division core 4A ... First inner surface 4B ... First end surface 4C ... Second end surfaces 4a, 4b, 5a, 5b · · Adhesive filling space 5 · · Second divided core 5A · · Second inner surface 5B · · First end surface 5C · · Second end surface 6 · · Winding 7 · · Terminal electrode 8 · · Glass layer 9 · · Barrel 10A ·· Thermosetting resin 10B · · UV curable resin 10C · · Fillet 21 · · First collar 21A · · First inner surface 21B · · First outer surface 21C · · First circumferential surface 21D · · First linear portion 21E・ ・ First arc part 22 ・ ・ Second collar part 22A ・ ・ Second inner surface 22B ・ ・ Second outer surface 22C ・ ・ Second circumferential surface 22D ・ ・ Second straight part 22E ・ ・ Second arc part 23 ・ ・Core portion 23A..Core portion peripheral surface 41..First projection portion 42..Second projection portion 51..First projection Origin 52 ·· Second projection 71 · · First electrode 72 · · Second electrode 91 · · Spray nozzle

Claims (8)

A first core having a core part around which the winding is wound, and a first collar part and a second collar part respectively connected to both axial ends of the core part;
A second core bonded to the first core via an adhesive;
A pair of terminal electrodes to which both ends of the winding are respectively connected;
The first core includes a first core bonding surface that is defined on an outer periphery of the first flange portion and an outer periphery of the second flange portion and adheres to the adhesive, and the first and second flange portions. And having a first core end surface that is one end of the first core in the axial direction and intersects the first core bonding surface,
The second core has a second core adhesive surface facing the first core adhesive surface and adhering to the adhesive, and one end of the second core in the axial direction and intersecting the second core adhesive surface. And a second core end face located in the vicinity of the first core end face,
Either or both of the first core adhesive surface and the second core adhesive surface protrude from the first core adhesive surface or the second core adhesive surface, and one end is the first core end surface or the second core Protrusions located on the core end face and extending in the axial direction are provided,
The pair of terminal electrodes are provided on either the first core end surface or the second core end surface,
The first core end surface and the second core end surface are such that a portion of the first core end surface or the second core end surface that intersects the first core bonding surface or the second core bonding surface is The first core end surface and the second core end surface are configured to protrude in the axial direction from the first core bonding surface or the point intersecting the second core bonding surface to form a step.
The adhesive is interposed between the first core adhesive surface and the second core adhesive surface, covers the one end portion of the protrusion within the step, and connects the first core and the second core. Coil parts characterized by being arranged to straddle.   2. The coil component according to claim 1, wherein one of the first core end surface and the second core end surface provided with the pair of terminal electrodes is a surface that protrudes most in the axial direction. .   The coil component according to claim 1, wherein the pair of terminal electrodes are provided on the first core. The first core has a shape in which a longitudinal direction and a short direction are defined on the end surface of the first core,
4. The coil component according to claim 3, wherein the pair of terminal electrodes are respectively provided at one end and the other end of the first core end surface in the short direction. The first core has a first core peripheral surface that intersects the first core end surface and includes the first core bonding surface;
The second core has a second core peripheral surface intersecting the second core end surface and including the second core bonding surface,
The pair of terminal electrodes are respectively provided across the first core end surface and the first core peripheral surface, or are respectively provided across the second core end surface and the second core peripheral surface,
The both ends of the winding are connected to the pair of terminal electrodes on the first core peripheral surface or the second core peripheral surface, respectively. The coil component described. The second core is composed of a plurality of split cores each having a second core end surface and a second core adhesion surface,
Each of the pair of terminal electrodes is provided on the first core, and a portion of the pair of terminal electrodes connected to both ends of the winding is positioned between the plurality of divided cores. The coil component according to claim 5, wherein the coil component is a coil component.   The pair of terminal electrodes are arranged within a contour that connects peripheral surfaces of the plurality of divided cores to each other in a cross section perpendicular to the axial direction. The coil component according to any one of the above. The first core end surface is the other one of the first collar portion and the second collar portion, and is also defined at the other end position of the first core in the axial direction. Also defined at the other end position of the two cores, the step is formed between the first core end surface at the other end position and the second core end surface at the other end position,
The other end of the protrusion is located on the first core end face at the other end position or the second core end face at the other end position. The coil component according to any one of claims 1 to 7, wherein the coil component is disposed so as to cover the other end portion and straddle the first core and the second core.

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