Patent ID: 11935689
Assignee: TAIYO YUDEN CO., LTD.
Field: Electrical machinery, apparatus, energy (Electrical engineering)
Classification: CPC H  Y | IPC H

Claim 0:
1. A method for manufacturing a coil component, comprising steps of:
(i) preparing a core member having a pillar part;
(ii) forming terminal electrodes each constituted by an electrode layer formed on a surface of the core member, and a conductive layer covering the electrode layer;
(iii) forming a coil part by winding a coil conductive wire covered with an insulating sheath layer around the pillar part; and
(iv) physically and electrically connecting ends of the coil part and the terminal electrodes, respectively, by thermocompression bonding wherein the ends of the coil part are heated and compressed, thereby deforming the ends of the coil part into flat-shaped connection end parts and bonding the flat-shaped connection end parts to the terminal electrodes, respectively,
wherein, in step (ii), the conductive layer is formed at a thickness which is smaller than a thickness of each flat-shaped connection end part, and
in step (iv), the thermocompression bonding comprises: pressing each end of the coil part toward the terminal electrode with a planar heater member whereby the end of the coil part penetrates the conductive layer and is deformed on the electrode layer into the flat-shaped connection end part, thereby bonding the flat-shaped connection end part to the terminal electrode; and then retracting the heater member to move away from the connection end part,
wherein:
each connection end part has a first principle face facing a surface of the electrode layer and electrically connected thereto, a second principle face on a side opposite to the first principle face, exposed and projecting from a surface of the conductive layer, and a side face connecting the first principle face and the second principle face;
the conductive layer has a flat area having a first thickness, and a skirt area provided continuously between the flat area and the side face in a direction perpendicular to the thickness direction and having a second thickness greater than the first thickness; and
the skirt area slopes onto the side face, the first thickness is smaller than the thickness of the connection end part, and the second thickness decreases from a position at the side face toward the flat area in a direction away from the side face.