Patent Description:
<CIT> relates to a coil device and discloses a core body comprising a central core, a pot core having a side wall surrounding the central core, and a lid core that covers an upper part of the coil part and an upper part of the central core, wherein the coil part is interposed between the outer peripheral surface of the central core and the inner peripheral surface of the pot core, and is placed on the underside of the lid core.

Another coil component is described in <CIT> and discloses all features of the preamble of claim <NUM>.

The coil component that is described in <CIT> has a core molding (a core mold or a molded core), a coil, and a metal terminal. Specifically, the core molding is formed of a magnetic substance material. The coil has an embedded part that is embedded into the core molding and a protruding part that protrudes from the core molding. Further, the metal terminal is electrically connected to the protruding part. The core molding has a mounting surface, an upper surface, and a side surface. Specifically, the upper surface faces the opposite direction as the mounting surface. The side surface is orthogonal to the mounting surface and the upper surface. The metal terminal has a first planar part, a second planar part, and a third planar part. Specifically, the first planar part is arranged along the side surface of the core molding. The second planar part is connected to an upper end of the first planar part and is arranged along the upper surface of the core molding. Further, the third planar part is connected to a lower end of the first planar part and is arranged along the mounting surface of the core molding. A recessed part is formed in the upper surface of the core molding. The second planar part of the metal terminal is arranged at the recessed part.

The coil components explained above may be subjected to a vacuum and held by a mounter that has a suction nozzle during, for example, a mounting process.

According to the investigation and experiments of the inventors of the present application, there is room for improvement in the configuration of the coil component that is described in <CIT> from the view point of the mounter performing the suction more stably.

The present application attempts to solve the above problem and achieve the above improvement. An object of the present application is to provide a coil component that has a configuration that enables a mounter to perform a suction more stably.

According to the present invention as claimed in claim <NUM>, a coil component includes a core body, a coil, and a metal terminal. The core body is formed of a magnetic material. The core body has a mounting surface, an upper surface, the upper surface and the mounting surface being outwardly opposite to each other, and a first side surface joining (crossing) the mounting surface and the upper surface. The coil has an embedded part embedded in the core body, and a first protruding part protruding from the core body. The metal terminal is electrically connected to the first protruding part of the coil. The metal terminal has a first plate arranged along the first side surface of the core body, a second plate continuously connected to an upper end of the first plate and arranged along the upper surface of the core body, and a third plate continuously connected to a lower end of the first plate and arranged along the mounting surface of the core body. Further, a leading edge of the second plate is recessed toward the upper end of the first plate to form a first arc-shaped part. The upper surface of the core body has a first recess in which the second plate is arranged. The first recess has a second arc-shaped part at a portion facing the first arc-shaped part. The second arc-shaped part extends along a contour of the first arc-shaped part.

According to the present application, a suction by a mounter can be performed more stably.

Embodiments according to the present application are explained below with reference to <FIG>. In regards to the embodiments, redundant explanations with respect to the same configurations are omitted but the same reference numerals are used for labeling in the drawings.

As shown in any drawing among <FIG>, a coil component <NUM> according to the embodiments of the present application has a core body <NUM> (alternately, a core, a core molding, a core mold, or a molded core), a coil <NUM>, and a metal terminal(s) <NUM>. Specifically, the core body <NUM> is formed of (made of or includes) a magnetic substance material (magnetic material). The coil <NUM> has an embedded part <NUM> that is embedded in the core body <NUM> (for instance, shown in <FIG> and <FIG>) and a protruding part(s) (a first protruding part <NUM> and a second protruding part <NUM>, for instance, shown in <FIG>) that protrudes from the core body <NUM>. Further, the metal terminal <NUM> is electrically connected to the protruding part of the coil <NUM>.

The core body <NUM> has a mounting surface <NUM> (for instance, shown in <FIG>), an upper surface <NUM>, and a side surface(s). Specifically, the upper surface <NUM> faces an opposite side to the mounting surface <NUM>. In other words, the mounting surface <NUM> and the upper surface <NUM> are outwardly opposite to each other. The side surfaces join (cross) (or are orthogonal to) the mounting surface <NUM> and the upper surface <NUM>. For instance, the side surfaces are a front surface <NUM>, a rear surface <NUM>, a left side surface <NUM>, a right side surface <NUM>, a front left surface <NUM>, a rear left surface <NUM>, a rear right surface <NUM>, and a front right surface <NUM>.

The metal terminal <NUM> has a first planar part (first plate) <NUM>, a second planar part (second plate) <NUM>, and a third planar part (third plate) <NUM>. Specifically, the first planar part <NUM> is arranged along the side surface of the core body <NUM>. The second planar part <NUM> is continuously connected to an upper end (edge) of the first planar part <NUM> and is arranged along the upper surface <NUM> of the core body <NUM>. Further, the third planar part <NUM> is continuously connected to a lower end (edge) of the first planar part <NUM> and is arranged along the mounting surface <NUM> of the core body <NUM>. The first, second, and third planar parts <NUM>, <NUM>, and <NUM> are integrally formed. In other words, a monolithic member (monolithic metal plate) configures the first, second, and third planar parts <NUM>, <NUM>, and <NUM>.

A leading edge (tip edge or forefront edge) of the second planar part <NUM> is a first recess-shaped part (first arc-shaped part or first arc part) 52a (for instance, shown in <FIG>). Specifically, the first recess-shaped part 52a is hollowed (recessed or depressed) toward an upper end (edge) side of the first planar part <NUM> and the leading edge of the first recess-shaped part 52a is formed to be in a planar shape (arc-planar shape). The upper edge side of the first planar part <NUM> is a base end side of the second planar part <NUM>. A recessed part <NUM> is formed in the upper surface <NUM> of the core body <NUM>. The second planar part <NUM> is arranged in the recessed part <NUM> of the upper surface <NUM>. A second recess-shaped part (second arc-shaped part or second arc part) 30a (for instance, shown in <FIG>) of the recessed part <NUM> corresponds to or is formed along the first recess-shaped part 52a. The second recess-shaped part 30a is formed to be in a planar shape (arc-planar shape) along the planar shape of the first recess-shaped part 52a. In other words, the second recess-shaped part 30a of the recessed part <NUM> extends along a configuration (shape) of the first recess-shaped part 52a as shown in <FIG>, <FIG>, <FIG>, and <FIG>.

According to the embodiment of the present application, because the first recess-shaped part 52a and the second recess-shaped part 30a are provided, the area of a region that can be sucked (subject to a vacuum) by a suction nozzle of a mounter (not shown) can be sufficiently secured and ensured on the upper surface <NUM>. Note that because a suction nozzle (a suction area of the suction nozzle) is generally in a circular shape (such as "R2" shown in <FIG>), the sucked region is efficiently secured on the upper surface <NUM> of the core body <NUM>. As a result, the suction of the coil component <NUM> by the mounter can be performed more stably.

The coil component <NUM> according to the embodiments of the present application is explained in detail below. The core body <NUM> is formed by a compression molding of powders including a magnetic substance material. During the process of the compression molding, the embedded part <NUM> of the coil <NUM> is embedded into the core body <NUM>.

The shape of the core body <NUM> is not particularly limited. However, for instance, the core body <NUM> has the mounting surface <NUM>, the upper surface <NUM>, and a plurality of side surfaces that are respectively orthogonal to the mounting surface <NUM> and the upper surface <NUM>. The mounting surface <NUM> is formed to be flat except for, for instance, a pair of second recessed parts <NUM> described below. The upper surface <NUM> is formed to be flat except for, for instance, a pair of (first) recessed parts <NUM>. Further, the upper surface <NUM> is arranged in parallel to the mounting surface <NUM>.

For instance, the side surfaces of the core body <NUM> has the front surface <NUM>, the rear surface <NUM>, the left side surface <NUM>, and the right side surface <NUM>. Specifically, the rear surface <NUM> is arranged in parallel to the front surface <NUM> and faces the opposite side to the front surface <NUM>. The left side surface <NUM> is orthogonal to the front surface <NUM> and the rear surface <NUM>. Further, the right side surface <NUM> is arranged in parallel to the left side surface <NUM> and faces the opposite side to the left side surface <NUM>.

The core body <NUM> has, for instance, the front left surface <NUM>, the rear left surface <NUM>, the rear right surface <NUM>, and the front right surface <NUM> as the side surfaces. Specifically, the front left surface <NUM> is arranged between the front surface <NUM> and the left side surface <NUM> and connects the front surface <NUM> with the left side surface <NUM>. The rear left surface <NUM> is arranged between the left side surface <NUM> and the rear surface <NUM> and connects the left side surface <NUM> with the rear surface <NUM>. The rear right surface <NUM> is arranged between the rear surface <NUM> and the right side surface <NUM> and connects the rear surface <NUM> with the right side surface <NUM>. Further, the front right surface <NUM> is arranged between the right side surface <NUM> and the front surface <NUM> and connects the right side surface <NUM> with the front surface <NUM>. The front left surface <NUM> is, for instance, tilted relative to each of the front surface <NUM> and the left side surface <NUM> at an angle of <NUM> degrees. The rear left surface <NUM> is, for instance, tilted relative to each of the left side surface <NUM> and the rear surface <NUM> at an angle of <NUM> degrees. The rear right surface <NUM> is, for instance, tilted relative to each of the rear surface <NUM> and the right side surface <NUM> at an angle of <NUM> degrees. Further, the front right surface <NUM> is, for instance, tilted relative to each of the right side surface <NUM> and the front surface <NUM> at an angle of <NUM> degrees. For instance, all of the rear left surface <NUM>, the rear right surface <NUM>, and the front right surface <NUM> have the same shapes and the same sizes (the same areas). However, with respect to a width dimension, the front left surface <NUM> is smaller than the rear left surface <NUM>, the rear right surface <NUM>, and the front right surface <NUM> as shown in <FIG>. With respect to an area, the front left surface <NUM> is smaller than the rear left surface <NUM>, the rear right surface <NUM>, and the front right surface <NUM>.

Each of the front surface <NUM>, the rear surface <NUM>, the left side surface <NUM>, the right side surface <NUM>, the front left surface <NUM>, the rear left surface <NUM>, the rear right surface <NUM>, and the front right surface <NUM> is, for instance, formed to be flat.

In the present embodiment, a pair of left and right (first) recessed parts <NUM> is formed on the upper surface <NUM>. A pair of left and right second recessed parts <NUM> is formed on the mounting surface <NUM>.

As an example, the coil <NUM> is configured by a single round wire. In this case, the coil <NUM> has the embedded part <NUM> that is configured by winding the (single) round wire and a pair of protruding parts (the first protruding part <NUM> and the second protruding part <NUM>) that protrude toward an outside in the radial direction from the embedded part <NUM>. An axis direction of the coil <NUM> is in the vertical direction. The first protruding part <NUM> is configured by one end of the (single) round wire. The second protruding part <NUM> is configured by the other end of the (single) round wire. The first protruding part <NUM> and the second protruding part <NUM> horizontally protrude from the embedded part <NUM>. For instance, the first protruding part <NUM> and the second protruding part <NUM> mutually protrude in the opposite directions from the embedded part <NUM>. The first protruding part <NUM> horizontally protrudes from, for instance, the lower part of the rear left surface <NUM> of the core body <NUM>. The second protruding part <NUM> horizontally protrudes from, for instance, the lower part of the front right surface <NUM> of the core body <NUM>. For instance, the protruding direction of the first protruding part <NUM> protruded from the rear left surface <NUM> is orthogonal to the rear left surface <NUM>. The protruding direction of the second protruding part <NUM> protruded from the front right surface <NUM> is orthogonal to the front right surface <NUM>.

Further, the coil <NUM> is not limited to be configured by the single round wire according to the embodiments of the present application. However, the coil <NUM> may be, for instance, an edgewise coil that is configured by winding a flat wire.

As shown in <FIG>, the metal terminal <NUM> is, for instance, configured by a folding process of a single metal plate.

The metal terminal <NUM> has the first planar part (first plate) <NUM>, the second planar part (second plate) <NUM>, and the third planar part (third plate) <NUM> that are respectively formed to be a flat-shaped plate. The second planar part <NUM> is continuously connected to the upper end of the first planar part <NUM> and is substantially orthogonal to the first planar part <NUM>. The third planar part <NUM> is continuously connected to the lower end of the first planar part <NUM> and is substantially orthogonal to the first planar part <NUM>. The second planar part <NUM> and the third planar part <NUM> are located at opposite positions to each other and are substantially parallel to each other (refer to <FIG>).

As shown in <FIG> and <FIG>, the first planar part(s) <NUM> is, for instance, formed to be in a rectangular shape that is vertically long.

As shown in <FIG>, the second planar part(s) <NUM> is, for instance, formed to be in a rectangular shape that is longer in a front-rear direction than in a right-left direction in the plan view. However, the leading edge(s) of the second planar part(s) <NUM> is the first recess-shaped part(s) (first arc-shaped part or first arc part) 52a as explained above. Further, it is preferred that a lateral width dimension (in the sight-left direction) of the second planar part(s) <NUM> is, for instance, more than two times of a plate thickness of the metal terminal <NUM>. It is also preferred that the lateral width dimension (in the sight-left direction) of the second planar part(s) <NUM> is, for instance, more than three times of the plate thickness of the metal terminal <NUM>. As a result of setting the dimensions of the second planar part <NUM> as explained above, the bending (folding) process of the metal terminal <NUM> to form the second planar part <NUM> can be stably performed.

As shown in <FIG>, the third planar part(s) <NUM> is, for instance, formed to be in a rectangular shape that is longer in the front-rear direction than in the right-left direction in the plan view.

Further, as shown in <FIG>, <FIG>, and <FIG>, the metal terminal <NUM> has a fourth planar part (fourth plate) <NUM> and a fifth planar part (fifth plate) <NUM>. Specifically, the fourth planar part <NUM> is continuously connected to a side edge 51a of the first planar part <NUM> and joins (crosses) the first planar part <NUM>. The fifth planar part <NUM> is continuously connected to a leading edge (tip edge or forefront edge) 54a of the fourth planar part <NUM> and joins (crosses) the fourth planar part <NUM>. Because the fourth planar part <NUM> and the fifth planar part <NUM> are formed by the bending (folding) process of the metal terminal <NUM>, the side edge 51a and the leasing edge 54a are folds or ridges of the metal terminal <NUM>. The fourth planar part <NUM> and the fifth planar part <NUM> are also respectively formed to be a flat-shaped plate. As shown in such as <FIG>, each of the fourth planar part <NUM> and the fifth planar part <NUM> is, for instance, formed to be in a rectangular shape that is vertically long.

In the plan view, an angle between the first planar part <NUM> and the fourth planar part <NUM> is, for instance, set to be <NUM> degrees (refer to such as <FIG>). In the plan view, an angle between the fourth planar part <NUM> and the fifth planar part <NUM> is, for instance, set to be <NUM> degrees (refer to such as <FIG>).

The first planar part <NUM>, the fourth planar part <NUM>, and the fifth planar part <NUM> are respectively vertically arranged or extend in the vertical (up and down) direction. The second planar part <NUM> and the third planar part <NUM> are respectively substantially horizontally arranged or substantially extend in the horizontal direction.

A welded piece (welded strip) <NUM> is formed at a lower end part of the fifth planar part <NUM>. The welded piece(s) <NUM> is welded to the protruding part(s) (the first protruding part <NUM> and the second protruding part <NUM>) of the coil <NUM> (refer to such as <FIG>).

In the present embodiment, the coil component <NUM> has a pair of left and right metal terminals (first and second metal terminals) <NUM>. For instance, the pair of metal terminals <NUM> are mutually formed to be in the same shapes and the same sizes.

The first planar part <NUM> of one (the left side) of the metal terminals <NUM> is arranged along the left side surface <NUM>. The second planar part <NUM> of this metal terminal <NUM> is arranged at or in the recessed part <NUM> on the left side. The third planar part <NUM> of this metal terminal <NUM> is arranged at or in the second recessed part <NUM> on the left side. The fourth planar part <NUM> of this metal terminal <NUM> on the left side is, for instance, arranged along the rear left surface <NUM>. Further, the fifth planar part <NUM> of this metal terminal <NUM> substantially vertically raises relative to (substantially uprises with respect to or substantially stands from) the rear left surface <NUM>.

The first planar part <NUM> of the other (the right side) of the metal terminals <NUM> is arranged along the right side surface <NUM>. The second planar part <NUM> of this metal terminal <NUM> is arranged at or in the recessed part <NUM> on the right side. The third planar part <NUM> of this metal terminal <NUM> is arranged at or in the second recessed part <NUM> on the right side. The fourth planar part <NUM> of this metal terminal <NUM> on the right side is, for instance, arranged along the front right surface <NUM>. Further, the fifth planar part <NUM> of this metal terminal <NUM> substantially vertically raises relative to (substantially uprises with respect to or substantially stands from) the front right surface <NUM>.

As explained above, the second recessed parts <NUM> at or in which the third planar parts <NUM> are arranged are formed on the mounting surface <NUM>.

Further, the fourth planar parts <NUM> are arranged along the side surfaces of the core body <NUM>. The fifth planar parts <NUM> raise relative to the side surfaces of the core body <NUM>.

Further, because the fifth planar parts <NUM> raise from the side surfaces of the core body <NUM>, the satisfactory or excellent heat dissipation from the fifth planar parts <NUM> can be realized. It is preferred that the vertical dimension (length) of each of the fifth planar parts <NUM> is half or more of the vertical dimension (length or height) of the core body <NUM>. It is more preferred that the vertical dimension (length) of each of the fifth planar parts <NUM> is two thirds or more of the vertical dimension (length or height) of the core body <NUM>.

For instance, the metal terminal <NUM> is adhered and fixed to the core body <NUM>. For instance, as shown in <FIG>, the first planar part <NUM> is in surface contact with the side surface of the core body <NUM> and is surface-joined to the core body <NUM> by an adhesive.

The welded piece <NUM> of the metal terminal <NUM> on the left side is welded to one of the protruding parts (the first protruding part <NUM>) of the coil <NUM>. Similarly, the welded piece <NUM> of the metal terminal <NUM> on the right side is welded to the other of the protruding parts (the second protruding part <NUM>) of the coil <NUM>.

For instance, the welded piece <NUM> and the first protruding part <NUM> of the metal terminal <NUM> on the left side are mutually welded at a first welding part <NUM> that is in a spherical shape. Similarly, the welded piece <NUM> and the second protruding part <NUM> of the metal terminal <NUM> on the right side are mutually welded at a second welding part <NUM> that is in a spherical shape.

As shown in <FIG> and <FIG>, the recessed part <NUM> on the left side of the pair of left and right recessed parts <NUM> is arranged at the left end of the upper surface <NUM>. The recessed part <NUM> on the right side is arranged at the right end of the upper surface <NUM>.

For instance, each of the recessed parts <NUM> is configured with a first step <NUM> (a bottom surface), a first tilted (inclined) surface (wall) <NUM> (an upper tilted surface), a second step <NUM>, a second tilted surface <NUM>, and a pair of vertical surfaces (walls) <NUM>. Specifically, the first tilted surface <NUM> is arranged at the peripheral edge of the recessed part <NUM>. The second step <NUM> is arranged at a lower step as compared with the first step <NUM>. Further, the second tilted surface <NUM> is arranged between the first step <NUM> and the second step <NUM> and is tilted downward toward the side of the second step <NUM> from the side of the first step <NUM>.

The first step <NUM> occupies the most of the plane area of the recessed part <NUM>. A bottom surface of the first step <NUM> is substantially horizontally arranged. However, in the present embodiment, the first step <NUM> increases in depth as it becomes far from the side surface of the core body <NUM>.

The left edge of the first step <NUM> of the recessed part <NUM> on the left side linearly extends in the front-rear direction. Each of the front and rear edges of the first step <NUM> of the recessed part <NUM> on the left side linearly extends in the right-left direction. The second step <NUM> of the recessed part <NUM> on the left side linearly extends in the front-rear direction along the left edge of the first step <NUM> of the recessed part <NUM> on the left side, and at the same time, is substantially horizontally arranged. The left edge of the second step <NUM> of the recessed part <NUM> on the left side serves as the upper edge of the left side surface <NUM> at a position where the recessed part <NUM> on the left side is formed.

Similarly, the right edge of the first step <NUM> of the recessed part <NUM> on the right side linearly extends in the front-rear direction. Each of the front and rear edges of the first step <NUM> of the recessed part <NUM> on the right side linearly extends in the right-left direction. The second step <NUM> of the recessed part <NUM> on the right side linearly extends in the front-rear direction along the right edge of the first step <NUM> of the recessed part <NUM> on the right side, and at the same time, is substantially horizontally arranged. The right edge of the second step <NUM> of the recessed part <NUM> on the right side serves as the upper edge of the right side surface <NUM> at a position where the recessed part <NUM> on the right side is formed.

In the plan view, the second tilted surface <NUM> is arranged between the first step <NUM> and the second step <NUM>.

The second tilted surface <NUM> of the recessed part <NUM> on the left side extends in the front-rear direction along the left edge of the first step <NUM> of the recessed part <NUM> on the left side and is tilted downward toward the left side.

The first tilted surface <NUM> of the recessed part <NUM> on the left side is continuously arranged along the right edge, the front edge, and the rear edge of this recessed part <NUM>.

Similarly, the second tilted surface <NUM> of the recessed part <NUM> on the right side extends in the front-rear direction along the right edge of the first step <NUM> of the recessed part <NUM> on the right side and is tilted downward toward the right side.

Similarly, the first tilted surface <NUM> of the recessed part <NUM> on the right side is continuously arranged along the left edge, the front edge, and the rear edge of this recessed part <NUM>.

Each of the first tilted surfaces <NUM> is tilted to a direction in which the recessed part <NUM> becomes smaller (narrow) toward the depth direction (downward) of each of the recessed parts <NUM>. In other words, each of the first tilted surfaces <NUM> is tilted downward and inward with respect to the recessed part <NUM>. The first tilted surface <NUM> works as a draft angle when the core body <NUM> is pulled (taken out) from a mold after being formed by a molding process.

At each of the recessed parts <NUM>, the lower end of the first tilted surface <NUM> is positioned at the same height position as the bottom surface of the first step <NUM>. The vertical surfaces <NUM>, which are vertically arranged, are respectively arranged between both ends of the second step <NUM> and the second tilted surface <NUM> in the front-rear direction and the lower end of the first tilted surface <NUM>.

The planar shape of the recessed part <NUM> corresponds to the planar shape of the second planar part <NUM>. Each of the second planar parts <NUM> enters into each of the recessed parts <NUM>.

Further, as explained above, the leading edge of the second planar part <NUM> of the metal terminal <NUM> is the first recess-shaped part 52a. The first recess-shaped part 52a is hollowed (recessed or depressed) toward the upper edge side of the first planar part <NUM> and is formed to be in the planar shape.

In other words, in the plan view, a right edge (the leading edge) of the second planar part <NUM> of the metal terminal <NUM> on the left side is hollowed toward the left side. A left edge (the leading edge) of the second planar part <NUM> of the metal terminal <NUM> on the right side is hollowed toward the right side. More specifically, the right edge of the second planar part <NUM> of the metal terminal <NUM> on the left side is hollowed toward the left side in a circular arc shape (in an arc shape). The left edge of the second planar part <NUM> of the metal terminal <NUM> on the right side is hollowed toward the right side in the circular arc shape (in the arc shape).

Further, both ends of the leading edge of the second planar part <NUM> (in the present embodiment, the front and rear ends of the right edge of the second planar part <NUM> on the left side and the front and rear ends of the left edge of the second planar part <NUM> on the right side) are respectively formed to be in a projecting circular arc shape toward the outside of the second planar part <NUM>.

Further, with respect to the recessed part <NUM>, the portions that correspond to both ends of the leading edge of the second planar part <NUM> are respectively formed to be in the circular arc shape along both ends of the leading edge of the second planar part <NUM>. As a result, in the configuration in which the second recess-shaped part 30a is formed at the recessed part <NUM> according to the present embodiment, such as a chipping of the core body <NUM> can be suppressed, and at the same time, an interference of the second planar part <NUM> with the core body <NUM> can also be suppressed.

Further, as explained above, with respect to each of the recessed parts <NUM>, the portion of the recessed parts <NUM> that corresponds to the first recess-shaped part 52a is the second recess-shaped part 30a that is formed to be in the planar shape along the first recess-shaped part 52a.

In other words, the planar shape of the right edge of the first step <NUM> of the recessed part <NUM> on the left side and the planar shape of the portion that is arranged along the right edge of the first step <NUM> of the first tilted surface <NUM> of the recessed part <NUM> on the left side are formed to be in the recessed shape that is hollowed toward the left side and is in a circular arc shape.

Similarly, the planar shape of the left edge of the first step <NUM> of the recessed part <NUM> on the right side and the planar shape of the portion that is arranged along the left edge of the first step <NUM> of the first tilted surface <NUM> of the recessed part <NUM> on the right side are formed to be in the recessed shape that is hollowed toward the right side and is in a circular arc shape.

Further, the second recess-shaped part 30a of the recessed part <NUM> on the left side and the second recess-shaped part 30a of the recessed part <NUM> on the right side are mutually arranged on the same circumference in the plan view. In other words, these (two of) second recess-shaped parts 30a extend along the same circumference of a circle R1 (see <FIG>) (are concentrically arranged) on the upper surface <NUM> of the core body <NUM> in the plan view.

As explained above, the pair of recessed parts <NUM> are formed in the upper surface <NUM>. The coil <NUM> has the pair of protruding parts (the first protruding part <NUM> and the second protruding part <NUM>). The coil component <NUM> has the pair of metal terminals <NUM>. One of the pair of metal terminals <NUM> is electrically connected to one of the pair of protruding parts. The other of the pair of metal terminals <NUM> is electrically connected to the other of the pair of protruding parts. The second planar part <NUM> of one of the pair of metal terminals <NUM> is arranged at or in one of the pair of recessed parts <NUM>. The second planar part <NUM> of the other of the pair of metal terminals <NUM> is arranged at or in the other of the pair of recessed parts <NUM>. The second recess-shaped part 30a of one of the pair of recessed parts <NUM> and the second recess-shaped part 30a of the other of the pair of recessed parts <NUM> are mutually arranged on the same circumference in the plan view. In other words, these (two of) second recess-shaped parts 30a extend along the same circumference of a circle R1 (see <FIG>) (are concentrically arranged) on the upper surface <NUM> of the core body <NUM> in the plan view.

As a result, the circular region being surrounded by the second recess-shaped parts 30a of the pair of recessed parts <NUM> on the upper surface <NUM> can be excellently sucked by a suction nozzle of a mounter.

Specifically, as shown in <FIG>, the circular region being surrounded by two second recess-shaped parts 30a corresponds to the circle R1. Further, a circle R2 corresponds to, for example, a periphery of the suction nozzle of the mounter or the sucked region.

As shown in <FIG>, the second recessed part <NUM> on the left side of a pair of left and right second recessed parts <NUM> is arranged at the left end of the mounting surface <NUM>. The second recessed part <NUM> on the right side is arranged at the right end of the mounting surface <NUM>.

For instance, each of the second recessed parts <NUM> is configured with a first step <NUM> (a bottom surface), a first tilted surface (wall) <NUM> (a lower tilted surface), a pair of front and rear second tilted surfaces (walls) <NUM> (lower tilted surfaces), a second step <NUM>, a third tilted surface <NUM>, and a pair of vertical surfaces (walls) <NUM>. Specifically, the first tilted surface <NUM> and the pair of front and rear second tilted surfaces <NUM> are arranged at a peripheral edge of second recessed part <NUM>. The second step <NUM> is arranged in the upward position (on the side of the upper surface <NUM>) as compared with the first step <NUM>. Further, the third tilted surface <NUM> is arranged between the first step <NUM> and the second step <NUM> and is tilted (tilted upward) toward the side of the second step <NUM> from the side of the first step <NUM>.

The first step <NUM> occupies the most of the plane area of the second recessed part <NUM>. A bottom surface of the first step <NUM> is substantially horizontally arranged. But, in the present embodiment, the first step <NUM> increases in depth as it becomes far from the side surface of the core body <NUM>. However, the bottom surface of the first step <NUM> is not limited to the above configuration and may be arranged horizontally (to be parallel to the mounting surface <NUM>).

Each of the left and right edges of the first step <NUM> of the second recessed part <NUM> on the left side linearly extends in the front-rear direction. Each of the front and rear edges of the first step <NUM> of the second recessed part <NUM> on the left side linearly extends in the right-left direction. The second step <NUM> of the second recessed part <NUM> on the left side linearly extends in the front-rear direction along the left edge of the first step <NUM> of the second recessed part <NUM> on the left side, and at the same time, is substantially horizontally arranged. The left edge of the second step <NUM> of the second recessed part <NUM> on the left side serves as the lower edge of the left side surface <NUM> at a position where the second recessed part <NUM> on the left side is formed.

Similarly, each of the left and right edges of the first step <NUM> of the second recessed part <NUM> on the right side linearly extends in the front-rear direction. Each of the front and rear edges of the first step <NUM> of the second recessed part <NUM> on the right side linearly extends in the right-left direction. The second step <NUM> of the second recessed part <NUM> on the right side linearly extends in the front-rear direction along the right edge of the first step <NUM> of the second recessed part <NUM> on the right side, and at the same time, is substantially horizontally arranged. The right edge of the second step <NUM> of the second recessed part <NUM> on the right side serves as the lower edge of the right side surface <NUM> at a position where the second recessed part <NUM> on the right side is formed.

In the plan view, the third tilted surface <NUM> is arranged between the first step <NUM> and the second step <NUM>.

The third tilted surface <NUM> of the second recessed part <NUM> on the left side extends in the front-rear direction along the left edge of the first step <NUM> of the second recessed part <NUM> on the left side and is tilted upward toward the left side. The first tilted surface <NUM> of the second recessed part <NUM> on the left side extends in the front-rear direction along the right edge of this second recessed part <NUM>. The second tilted surface <NUM> at the front side of the second recessed part <NUM> on the left side extends in the right-left direction along the front edge of the second recessed part <NUM> on the left side. The second tilted surface <NUM> at the rear side of the second recessed part <NUM> on the left side extends in the right-left direction along the rear edge of the second recessed part <NUM> on the left side.

Similarly, the third tilted surface <NUM> of the second recessed part <NUM> on the right side extends in the front-rear direction along the right edge of the first step <NUM> of the second recessed part <NUM> on the right side and is tilted upward toward the right side. The first tilted surface <NUM> of the second recessed part <NUM> on the right side extends in the front-rear direction along the left edge of this second recessed part <NUM>. The second tilted surface <NUM> at the front side of the second recessed part <NUM> on the right side extends in the right-left direction along the front edge of the second recessed part <NUM> on the right side. The second tilted surface <NUM> at the rear side of the second recessed part <NUM> on the right side extends in the right-left direction along the rear edge of the second recessed part <NUM> on the right side.

With respect to each of the second recessed parts <NUM>, the first tilted surface <NUM> and the pair of second tilted surfaces <NUM> are tilted to a direction in which the second recessed part <NUM> becomes smaller toward the depth direction (upward) of each of the second recessed parts <NUM>. The first tilted surface <NUM> and the pair of second tilted surfaces <NUM> work as draft angles when the core body <NUM> is pulled (taken out) from a mold after being formed by s molding process.

At each of the second recessed parts <NUM>, the upper end of each of the second tilted surfaces <NUM> is positioned at the same height position as the bottom surface of the first step <NUM>. The vertical surfaces <NUM>, which are vertically arranged, are respectively arranged between both ends of the second step <NUM> and the third tilted surface <NUM> in the front-rear direction and the upper ends of the second tilted surfaces <NUM>.

The planar shape of the second recessed part <NUM> corresponds to the planar shape of the third planar part <NUM>. Each of the third planar parts <NUM> enters into each of the second recessed parts <NUM>.

As shown in <FIG>, for instance, the second planar part <NUM> is spaced apart from the bottom surface of the recessed part <NUM>. On the other hand, the third planar part <NUM> comes in contact with the bottom surface of the second recessed part <NUM>, or alternatively, a distance between the third planar part <NUM> and the bottom surface of the second recessed part <NUM> is smaller than a distance between the second planar part <NUM> and the bottom surface of the recessed part <NUM>.

As a result, since the third planar parts <NUM> work as mounting terminals, a position accuracy of the third planar parts <NUM> can be improved. In addition, as mentioned above, the interferences between the second planar parts <NUM> and the recessed parts <NUM> (the core body <NUM>) can be suppressed.

When the metal terminal(s) <NUM> is attached on (is assembled to) the core body <NUM>, for instance, the second planar part <NUM> is joined (caulked) by being pressed downward. The second step <NUM> and the second tilted surface <NUM> are respectively arranged at the boundary part between the upper surface <NUM> and the left side surface <NUM> and at the boundary part between the upper surface <NUM> and the right side surface <NUM>. Therefore, when the metal terminal <NUM> is attached on (is assembled to) the core body <NUM> and the second planar part <NUM> is joined (caulked) (by being pressed downward), the interferences between the second planar parts <NUM> and the core body <NUM> can be suppressed. Further, as explained above, the first step <NUM> increases in depth as it becomes far from the side surface. Therefore, after the second planar part <NUM> is joined (caulked) to the core body <NUM>, it is possible to suppress a case in which the second planar part <NUM> is detached from the recessed part <NUM> toward the outside. That is, it is possible to respectively suppress cases in which the second planar part <NUM> on the left side is detached from the recessed part <NUM> on the left side in the left direction and the second planar part <NUM> on the right side is detached from the recessed part <NUM> on the right side in the right direction.

Further, the second step <NUM> and the third tilted surface <NUM> are respectively arranged at the boundary part between the mounting surface <NUM> and the left side surface <NUM> and at the boundary part between the mounting surface <NUM> and the right side surface <NUM>. Therefore, when the metal terminal(s) <NUM> is attached on (is assembled to) the core body <NUM>, the interferences between the third planar parts <NUM> and the core body <NUM> can be suppressed.

As explained above, the first tilted surface <NUM> of the recessed part <NUM> is tilted to the direction in which the recessed part <NUM> becomes smaller toward the depth direction (downward) of the recessed part <NUM>. Similarly, the first tilted surface <NUM> and the pair of second tilted surfaces <NUM> of the second recessed part <NUM> are tilted to the direction in which the second recessed part <NUM> becomes smaller toward the depth direction (upward) of the second recessed part <NUM>.

However, in the present embodiment, the tilt angle of the first tilted surface <NUM> is steeper (more acute) (closer to <NUM> degrees) than the tilt angle of each of the first tilted surface <NUM> and the second tilted surfaces <NUM>.

As explained above, the upper tilted surface (the first tilted surface <NUM>), which is tilted to the direction in which the recessed part <NUM> becomes smaller toward the depth direction of the recessed part <NUM>, is formed on the peripheral edge of the recessed part <NUM>. The lower tilted surfaces (the first tilted surface <NUM> and the second tilted surfaces <NUM>), which are tilted to the direction in which the second recessed part <NUM> becomes smaller toward the depth direction of the second recessed part <NUM>, are formed on the peripheral edge of the second recessed part <NUM>. The tilt angle of the upper tilted surface is steeper (more acute) than the tilt angle of each of the lower tilted surfaces.

As a result, the area of the sucked region that can be sucked by a suction nozzle of a mounter can be secured more sufficiently on the upper surface <NUM> of the core body <NUM>.

As shown in <FIG>, a width dimension W1 (for instance, a width dimension in the front-rear direction) of the upper end of the first planar part <NUM> is smaller than a width dimension W2 (for instance, a width dimension in the front-rear direction) of the lower end of the first planar part <NUM>. Therefore, the joining process (attaching process) (caulking process) of the second planar part <NUM> can be performed easily.

Further, the dimension of the second planar part <NUM> is smaller than the dimension of the third planar part <NUM> in the radial direction of the coil component <NUM>. Therefore, the area of the sucked region that can be sucked by the suction nozzle of the mounter can be secured more sufficiently on the upper surface <NUM> of the core body <NUM>.

Further, the first protruding part <NUM> and the second protruding part <NUM> of the coil <NUM> protrude from the lower part of the core body <NUM>. The first protruding part <NUM> and the second protruding part <NUM> are respectively electrically connected to each of the metal terminals <NUM> at the lower part of the coil component <NUM>. Therefore, the distance between each of the first protruding part <NUM> and the second protruding part <NUM> and each of the third planar parts <NUM>, which are mounting terminals, can be shorten. As a result, a direct current resistance (DCR) of the coil component <NUM> is decreased.

In addition, the first protruding part <NUM>, the second protruding part <NUM>, the first welding part <NUM>, and the second welding part <NUM> are arranged at the lower part of the coil component <NUM>. Therefore, since a position of a center of gravity of the coil component <NUM> can be more lowered, a vibration resistance of the coil component <NUM> can be improved.

Further, applications or uses of the coil component <NUM> are not particularly limited. However, for instance, the coil component <NUM> according to the embodiments of the present application can be used as an inductor assembled in a vehicle.

The embodiments of the coil component are explained with reference to the drawings. However, these embodiments are examples of the present invention. Thus, it will be apparent that the same may be varied in many ways.

Claim 1:
A coil component (<NUM>) comprising:
a core body (<NUM>) formed of compressed molded powders including a magnetic material, the core body having:
a mounting surface (<NUM>);
an upper surface (<NUM>) , the upper surface and the mounting surface being outwardly opposite to each other; and
a first side surface (<NUM>) joining the mounting surface and the upper surface (<NUM>);
a coil (<NUM>) having:
an embedded part (<NUM>) embedded in the core body (<NUM>); and
a first protruding part (<NUM>) protruding from the core body (<NUM>); and
a first metal terminal (<NUM>) electrically connected to the first protruding part (<NUM>) of the coil (<NUM>), the first metal terminal (<NUM>) having:
a first plate (<NUM>) arranged along the first side surface (<NUM>) of the core body (<NUM>);
a second plate (<NUM>) continuously connected from an upper end of the first plate (<NUM>) and arranged along the upper surface (<NUM>) of the core body (<NUM>); and
a third plate (<NUM>) continuously connected from a lower end of the first plate (<NUM>) and arranged along the mounting surface (<NUM>) of the core body (<NUM>),
characterized in that a leading edge of the second plate (<NUM>) is recessed toward the upper end of the first plate (<NUM>) to form a first arc-shaped part (52a), and
the upper surface (<NUM>) of the core body (<NUM>) has a first recess (<NUM>) in which the second plate (<NUM>) is arranged,
the first recess (<NUM>) has a second arc-shaped part (30a) facing the first arc-shaped part (52a), and the second arc-shaped part (30a) extends along a contour of the first arc-shaped part (52a).