Inductor, reorganized inductor and method of manufacturing the same

Abstract

The inductor (1) comprises a magnetic layer (2) and a plurality of wires (3) embedded in the magnetic layer (2) and extending in the longitudinal direction. The plurality of wires (3) are arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction. The magnetic layer (2) includes a plurality of wire arrangement sections (7) in which the wires (3) are regularly arranged in parallel, and a margin section (8) in which the wires (3) are omitted, which is arranged between adjacent wire arrangement sections (7) in the parallel direction of the wires (3).

Description

Technology Field

[0001] The present invention relates to an inductor, a singulated inductor, and a method for manufacturing the same. Background Technology

[0002] An inductor is known having a magnetic layer and a plurality of wires embedded in the magnetic layer (see, for example, Patent Document 1 below). In the inductor described in Patent Document 1, the plurality of wires are arranged in parallel at equal intervals in the transverse direction. The magnetic layer contains magnetic particles. Prior art literature

[0003] Japanese Patent Publication No. 2020-150057 The problem to be solved

[0004] Depending on the application and purpose, there are cases where a redesigned inductor smaller in size than the inductor is manufactured by cutting the magnetic layer between adjacent wires in the thickness direction.

[0005] In the inductor described in Patent Document 1, when the distance between two adjacent wires is short, if the magnetic layer between the two adjacent wires is cut, the distance from one end surface of the magnetic layer in the reorganized inductor after cutting to the end wire positioned at one end in the transverse direction becomes excessively short.

[0006] If that happens, the amount of magnetic particles existing between one end surface and the end wiring in the magnetic layer becomes excessively small. Consequently, there is a problem in that the inductance of the remodeled inductor decreases.

[0007] On the other hand, if the distance between two adjacent wires is long, there is a problem in that the reorganization of the inductor after cutting cannot be achieved.

[0008] The present invention provides a reorganized inductor that suppresses the reduction of inductance and promotes miniaturization, a method for manufacturing the same, and an inductor used therein. means of solving the problem

[0009] The present invention (1) comprises a magnetic layer and a plurality of wires embedded in the magnetic layer and extending in the longitudinal direction, wherein the plurality of wires are arranged in parallel at a predetermined interval in a direction perpendicular to the longitudinal direction, and the magnetic layer comprises a plurality of wire arrangement portions in which the wires are regularly arranged in parallel, and a margin portion that is arranged between adjacent wire arrangement portions in the parallel direction of the wires and has the wires omitted.

[0010] In this inductor, wiring is omitted in the margin portion of the magnetic layer. Therefore, if the margin portion is cut along the longitudinal direction, sufficient distance can be secured between the cut end surface of the magnetic layer and the wiring adjacent to the cut end surface. Consequently, the amount of magnetic component existing between the cut end surface and the wiring in the magnetic layer becomes sufficient. As a result, the decrease in inductance of the reorganized inductor after cutting can be suppressed.

[0011] Meanwhile, in the wiring arrangement section, the wiring is arranged in a regular parallel manner. Therefore, the wiring can be arranged compactly in the remodeled inductor. As a result, the remodeled inductor can be miniaturized after cutting.

[0012] Therefore, in this inductor, the decrease in inductance of the remodeled inductor after cutting can be suppressed, while at the same time, the remodeled inductor can be miniaturized.

[0013] In addition, the present invention (2) includes an inductor described in (1), wherein the plurality of wires are arranged in parallel at equal intervals in the wiring arrangement portion.

[0014] In the wiring arrangement section of this inductor, multiple wires are arranged in parallel at equal intervals. Therefore, the wiring can be arranged more compactly by the wiring arrangement section. In addition, the inductance of each wire can be made equal. As a result, the reorganized inductor after cutting can be made even more compact, while the inductance of each wire can be made equal.

[0015] In addition, the present invention (3) includes a method for manufacturing a reorganized inductor comprising a first process for preparing an inductor described in (1) or (2) and a second process for cutting off the margin portion.

[0016] In the method for manufacturing a remodeled inductor, the margin portion is cut, so that the distance between the cut end surface of the magnetic layer and the wiring adjacent to the cut end surface can be sufficiently secured. Therefore, the amount of magnetic component existing between the cut end surface and the wiring in the magnetic layer becomes sufficient. As a result, the decrease in the inductance of the remodeled inductor after the second process can be suppressed.

[0017] Meanwhile, in the wiring arrangement section, the wiring is arranged in a regular parallel manner. Therefore, the wiring can be arranged compactly in the remodeled inductor. As a result, the remodeled inductor can be miniaturized after the second process.

[0018] Therefore, in this method of manufacturing a remodeled inductor, it is possible to manufacture a remodeled inductor that can achieve miniaturization while suppressing the decrease in inductance.

[0019] The present invention (4) comprises a magnetic layer and a plurality of wires embedded in the magnetic layer and extending in the longitudinal direction, wherein the plurality of wires are arranged in parallel at a predetermined interval in a direction perpendicular to the longitudinal direction, and the magnetic layer includes a wire arrangement portion in which the wires are regularly arranged in parallel, and the wires include end wires arranged at one end of the wire arrangement portion in the parallel direction of the wires, and in the parallel direction, the distance from one end surface of the magnetic layer to the end wires is 0.2 mm or more and 7 mm or less.

[0020] In this remodeled inductor, since the distance from one end surface of the magnetic layer to the end wiring is 0.2 mm or more, the amount of magnetic component existing between the cut end surface and the end wiring in the magnetic layer becomes sufficient. As a result, the decrease in the inductance of the remodeled inductor can be suppressed.

[0021] In addition, in this remodeled inductor, the distance from one end surface of the magnetic layer to the end wiring is 7 mm or less, so the remodeled inductor can be miniaturized.

[0022] Therefore, this redesigned inductor enables miniaturization while suppressing the decrease in inductance.

[0023] The present invention (5) includes a reorganized inductor described in (4), wherein the end surface of the wiring in the longitudinal direction has an exposed portion exposed from the magnetic layer.

[0024] The present invention (6) includes a reorganized inductor described in (4) or (5), wherein the end surface of the wiring in the longitudinal direction has a covering portion covered by the magnetic layer.

[0025] The present invention (7) includes a reorganized inductor described in any one of claims (4) to (6), having a rectangular shape including a curved corner portion when viewed from a planar view.

[0026] The present invention (8) is a modified inductor described in (7), wherein the curve is a curve with a radius of curvature of 0.1 mm or more and 5 mm or less.

[0027] If the radius of curvature of the curve is 0.1 mm or more as mentioned above, the shock resistance of the inductor can be improved.

[0028] If the radius of curvature of the curve is 5 mm or less as mentioned above, the area near the corner can be widened, allowing a mark to be installed in the empty space. Effects of the invention

[0029] The method for manufacturing a modified inductor of the present invention using the inductor of the present invention can manufacture a modified inductor that suppresses the reduction of inductance and promotes miniaturization.

[0030] The redesigned inductor of the present invention promotes the suppression of inductance reduction and miniaturization. Brief explanation of the drawing

[0031] FIG. 1 (A) and FIG. 1 (B) are plan views of the inductor and the reconfigured inductor of the present invention, respectively. FIG. 1 (A) is an inductor. FIG. 1 (B) is a plurality of reconfigured inductors. FIG. 2 (A) and FIG. 2 (B) are cross-sectional views corresponding to FIG. 1 (A) and FIG. 1 (B), respectively. FIG. 2 (A) is an inductor. FIG. 2 (B) is a plurality of reconfigured inductors. FIG. 3 (A) and FIG. 3 (B) are cross-sectional views of variations of the inductor and the reconfigured inductor, respectively. FIG. 3 (A) is an inductor. FIG. 3 (B) is a plurality of reconfigured inductors. FIG. 4 (A) and FIG. 4 (B) are cross-sectional views of variations of the inductor and the reconfigured inductor, respectively. FIG. 4 (A) is an inductor. FIG. 4 (B) is a plurality of reconfigured inductors. FIG. 5 (A) and FIG. 5 (B) are plan views of variations of an inductor and a reconfigured inductor, respectively. FIG. 5 (A) is an inductor. FIG. 5 (B) is a second reconfigured inductor. FIG. 6 is a front view of the end surface of the reconfigured inductor in the longitudinal direction in the variation. Specific details for implementing the invention

[0032] One embodiment of the inductor and reorganized inductor of the present invention will be described with reference to (A) of FIG. 1 to (B) of FIG. 2.

[0033] <Inductor (1)>

[0034] As illustrated in FIG. 1 (A) and FIG. 2 (A), the inductor (1) extends in a plane direction orthogonal to the thickness direction. The thickness direction is the plane depth direction in FIG. 1 (A). The thickness direction is the up-down direction in FIG. 2 (A). The plane direction includes a first direction and a second direction orthogonal to the first direction. The first direction is the up-down direction in FIG. 1 (A). The first direction is the plane depth direction in FIG. 2 (A). The second direction is the left-right direction in FIG. 1 (A) and FIG. 2 (A), respectively. The inductor (1) is a roughly rectangular sheet when viewed from a plane. The inductor (1) has a magnetic layer (2) and a plurality of wires (3).

[0035] <Magnetic layer (2)>

[0036] The magnetic layer (2) has the same external shape as the inductor (1). The magnetic layer (2) has two main surfaces (4) facing in the thickness direction, two first side end surfaces (20A, 20B) facing in the first direction (see (A) in FIG. 1), and two second side end surfaces (6) facing in the second direction in succession. The first side end surfaces (20A, 20B) (see (A) in FIG. 1) follow the second direction. The second side end surfaces (6) follow the first direction. The two second side end surfaces (6) include a second side end surface (61) positioned on one side of the second direction and a second other side end surface (62) positioned on the other side of the second direction. As a material for the magnetic layer (2), for example, a magnetic composition containing magnetic particles as a magnetic component may be used. A magnetic composition is described, for example, in Japanese Patent Publication No. 2020-150057. The thickness of the magnetic layer (2) is, for example, 1 μm or more and, for example, 5000 μm or less. The thickness of the magnetic layer (2) is the distance between two main surfaces (4). This magnetic layer (2) includes a wiring arrangement portion (7) described later, a margin portion (8) described later, and a second margin portion (9) described later.

[0037] <Wiring (3)>

[0038] The wiring (3) extends along the first direction. The first direction corresponds to the longitudinal direction of the wiring (3). The wiring (3) is arranged in multiple parallels at predetermined intervals in a cross-section along the thickness direction and the second direction. The cross-section along the thickness direction and the second direction is the cross-section depicted in (A) of FIG. 2. Therefore, the second direction corresponds to the parallel direction in which the wiring (3) is parallel. The wiring (3) is embedded in the magnetic layer (2). The configuration and dimensions of each of the multiple wirings (3) are described, for example, in Japanese Patent Publication No. 2020-150057. The radius (R) of the wiring (3) is, for example, 25 μm or more and, for example, 2000 μm or less. Next, the wiring arrangement portion (7) and the margin portion (8) will be described.

[0039] <Wiring layout section (7)>

[0040] A plurality of wiring arrangement portions (7) are included in the magnetic layer (2) (in this embodiment, three). The plurality of wiring arrangement portions (7) are spaced apart in a second direction. Each of the plurality of wiring arrangement portions (7) is arranged across the first direction in the inductor (1). In the wiring arrangement portions (7), wiring (3) is regularly arranged in parallel. Specifically, in the wiring arrangement portions (7), a plurality of wiring (3) (in this embodiment, three) are arranged in parallel at equal intervals (P0). The dimensions of the wiring (3) and the spacing (P0) between two adjacent wirings (3) are not limited. They are described, for example, in Japanese Patent Publication No. 2020-150057.

[0041] In the wiring arrangement section (7), a plurality of wirings (3) are arranged. The plurality of wirings (3) include a first end wiring (31), a second end wiring (32), and an intermediate wiring (33). The first end wiring (31) is arranged at one end of the second direction of the wiring arrangement section (7). The second end wiring (32) is arranged at the other end of the second direction of the wiring arrangement section (7). The intermediate wiring (33) is arranged between the first end wiring (31) and the second end wiring (32). Accordingly, in the wiring arrangement section (7), the first end wiring (31), the intermediate wiring (33), and the second end wiring (32) are arranged in order toward the other side of the second direction.

[0042] <Margin part (8)>

[0043] A margin portion (8) is positioned between adjacent wiring arrangement portions (7). Specifically, the margin portion (8) connects two adjacent wiring arrangement portions (7) in a second direction. Multiple margin portions (8) are included in the magnetic layer (2) (in this embodiment, two). The number of wiring arrangement portions (7) is one greater than the number of margin portions (8). Each of the multiple margin portions (8) is positioned across the first direction in the inductor (1).

[0044] In the margin portion (8), the wiring (3) is omitted. Specifically, in an inductor (1) in which all wiring (3) are arranged in parallel at equal intervals (P0) in the second direction, one wiring (3) is omitted for every predetermined number (4 in this embodiment) of wiring (3), and the area (and its vicinity) in the magnetic layer (2) where the wiring (3) is omitted becomes the margin portion (8), and the area in the magnetic layer (2) other than the margin portion (8) becomes the wiring arrangement portion (7).

[0045] In the margin portion (8), wiring (3) is not placed, and only the magnetic layer (2) is placed. Additionally, the margin portion (8) has a length in a second direction in which the distance (L0) described later is secured.

[0046] <Second Margin Part (9)>

[0047] The second margin portion (9) is positioned outside the wiring arrangement portion (7) located at the outermost side in the second direction. That is, the second margin portion (9) is positioned at both ends of the inductor (1) in the second direction. Specifically, the second margin portion (9) is positioned on one side of the wiring arrangement portion (7) located at the farthest side in the second direction and on the other side of the wiring arrangement portion (7) located at the farthest side in the second direction. In this embodiment, the number of second margin portions (9) is two. No wiring (3) is positioned in the second margin portion (9), and only the magnetic layer (2) is positioned.

[0048] <Method for manufacturing a modified inductor (10)>

[0049] Next, a method for manufacturing a modified inductor (10) using an inductor (1) is described. This manufacturing method comprises a first process and a second process.

[0050] Process 1

[0051] In the first process, an inductor (1) as shown in (A) of FIG. 1 and (A) of FIG. 2 is prepared. The method of preparing the inductor (1) is not limited. A method of preparing the inductor (1) is described, for example, in Japanese Patent Publication No. 2020-150057.

[0052] Process 2

[0053] In the second process, the margin portion (8) is cut. Specifically, the second direction approximately central portion (81) of the margin portion (8) is cut along the first direction. More specifically, in the magnetic layer (2), the second direction approximately central portion (81) between the second end wiring (32) and the first end wiring (31) facing the second direction is cut. More specifically, the magnetic layer (2) is cut so as to pass through a point that extends to the other side of the second direction by a length equal to the spacing (P0) of the wiring (3) and the total length (P0 + R) of the wiring (3) and the radius (R). In addition, the magnetic layer (2) is cut so as to pass through a point that extends toward one side of the second direction by a length equal to the spacing (P0) of the wiring (3) and the total length (P0+R) of the radius (R) of the wiring (3) from the first end wiring (31).

[0054] For cutting the margin portion (8), non-contact cutting such as a laser can be used, for example. Also, for cutting the margin portion (8), contact cutting such as stamping using a mold and dicing using a rotary cutter can be used, for example. In terms of shortening the time of the second process, contact cutting can be used, preferably, and in terms of improving product quality, stamping can be used, more preferably.

[0055] By cutting the margin portion (8) described above, one margin portion (8) is divided into two. In this embodiment, three reorganized inductors (10) are manufactured by cutting each of the two margin portions (8).

[0056] <Reorganized Inductor (10)>

[0057] The three reorganization inductors (10) include a first reorganization inductor (21), a second reorganization inductor (22), and a third reorganization inductor (23). The first reorganization inductor (21) includes a wiring arrangement portion (7) positioned on the outermost side of the second direction of the inductor (1). The third reorganization inductor (23) includes a wiring arrangement portion (7) positioned on the other side of the second direction of the inductor (1). The second reorganization inductor (22) includes a wiring arrangement portion (7) positioned in the middle of the second direction. The second reorganization inductor (22), the first reorganization inductor (21), and the third reorganization inductor (23) will be described in order.

[0058] First, the second reorganization inductor (22) will be explained in detail, and then the first reorganization inductor (21) and the third reorganization inductor (23) will be briefly explained. In the explanation of the first reorganization inductor (21) and the third reorganization inductor (23), the explanation of components common to the second reorganization inductor (22) will be omitted. Also, regarding components other than those specifically mentioned, they are the same as the components in the inductor (1) described above.

[0059] <Second reorganized inductor (22)>

[0060] The second reorganized inductor (22) is a sheet that is approximately rectangular when viewed from a flat surface. The second reorganized inductor (22) has a second direction length shorter than that of the inductor (1). The second reorganized inductor (22) is provided with a magnetic layer (2) and wiring (3). The wiring (3) is embedded in the magnetic layer (2).

[0061] <Magnetic layer (2) in the second reorganized inductor (22)>

[0062] The magnetic layer (2) in the second reorganized inductor (22) has the same external shape as the second reorganized inductor (22). The magnetic layer (2) has two main surfaces (4), two first side end surfaces (20A, 20B) (see (A) in FIG. 1), and two second side end surfaces (6). The main surfaces (4) and the first side end surfaces (20A, 20B) (see (A) in FIG. 1) are identical to those of the inductor (1). Both of the two second side end surfaces (6) are cut surfaces (cut end surfaces) formed by cutting the margin portion (8). The two second side end surfaces (6) include a second one-sided end surface (61) and a second other-sided end surface (62). The magnetic layer (2) includes a wiring arrangement portion (7).

[0063] <Wiring arrangement portion (7) in the second reorganized inductor (22)>

[0064] A wiring arrangement section (7) is provided in one second reorganized inductor (22). In the wiring arrangement section (7), a first end wiring (31), a second end wiring (32), and an intermediate wiring (33) are arranged.

[0065] <Distance (L0) between the second one-sided end surface (61) and the first end wiring (31)>

[0066] In the second direction, the distance (L0) from the second one-sided end surface (61) of the magnetic layer (2) to the first end wiring (31) is 0.2 mm or more and 7 mm or less. If the distance (L0) is less than 0.2 mm, the amount of magnetic particles existing between the second one-sided end surface (61) and the first end wiring (31) in the magnetic layer (2) becomes excessively small, so the decrease in the inductance of the second reorganized inductor (22) cannot be suppressed. If the distance (L0) is greater than 7 mm, the second reorganized inductor (22) cannot be miniaturized. The distance (L0) is preferably 0.4 mm or more, and also preferably 5 mm or less.

[0067] <Distance (L0) between the second other end surface (62) and the second end wiring (32)>

[0068] In the second direction, the distance (L0) from the second other end surface (62) of the magnetic layer (2) to the second end wiring (32) is 0.2 mm or more and 7 mm or less. If the distance (L0) is less than 0.2 mm, the amount of magnetic particles existing between the second other end surface (62) and the second end wiring (32) in the magnetic layer (2) becomes excessively small, so the decrease in the inductance of the second reorganized inductor (22) cannot be suppressed. If the distance (L0) is greater than 7 mm, the second reorganized inductor (22) cannot be miniaturized. The distance (L0) is preferably 0.4 mm or more, and also preferably 5 mm or less.

[0069] In addition, among the distances (L1, L2, L3) from each of the first point (P1), second point (P2), and third point (P3) that are spaced apart from each other in the first direction with respect to the second other end surface (62) of the magnetic layer (2) to each of the fourth point (P4), fifth point (P5), and sixth point (P6) (all not shown) that are adjacent in the second direction to each of the first point (P1), second point (P2), and third point (P3) in the second end wiring (32), the difference between the maximum value and the minimum value is, for example, 2 mm or less, preferably 1 mm or less. If the above difference is less than or equal to the above upper limit, the deviation of the inductance in the first direction of the second reorganized inductor (22) can be reduced.

[0070] <First reorganized inductor (21)>

[0071] The first modified inductor (21) has a magnetic layer (2) and wiring (3). The magnetic layer (2) has two main surfaces (4), two first side end surfaces (20A, 20B) (see (A) in FIG. 1), and two second side end surfaces (6). The main surfaces (4), the first side end surfaces (20A, 20B) (see (A) in FIG. 1), and the second side end surface (61) are identical to those of the inductor (1). The second other side end surface (62) is a cut surface (cut side end surface) formed by cutting the margin portion (8). The magnetic layer (2) includes a wiring arrangement portion (7). The distance (L0) from the second other side end surface (62) to the second end wiring (32) is the same as above. The distance (L4) from the second one-sided end surface (61) to the first end wiring (31) is the same as the distance (L0) described above. The distance (L4) in the second reorganized inductor (22) shown in (B) of FIG. 1 and (B) of FIG. 2 is the same as the distance (L4) in the inductor (1) shown in (A) of FIG. 1 and (A) of FIG. 2. The distance (L4) is also the width of the second margin portion (9).

[0072] <3rd reorganized inductor (23)>

[0073] The third modified inductor (23) is provided with a magnetic layer (2) and wiring (3). The magnetic layer (2) has two main surfaces (4), two first side end surfaces (20A, 20B) (see (A) in FIG. 1), and two second side end surfaces (6). The main surfaces (4), the first side end surfaces (20A, 20B) (see (A) in FIG. 1), and the second other side end surfaces (62) are identical to those of the inductor (1). The second side end surface (61) is a cut surface (cut side end surface) formed by cutting the margin portion (8). The magnetic layer (2) includes a wiring arrangement portion (7). The distance (L0) from the second side end surface (61) to the first end wiring (31) is the same as above. The distance (L5) from the second other end surface (62) to the second end wiring (32) is the same as the distance (L0) described above. The distance (L5) in the third divided inductor (23) shown in (B) of FIG. 1 and (B) of FIG. 2 is the same as the distance (L5) in the inductor (1) shown in (A) of FIG. 1 and (A) of FIG. 2. The distance (L5) is also the width of the second margin portion (9).

[0074] <Effect of operation of one embodiment>

[0075] In this inductor (1), the wiring (3) is omitted in the margin portion (8) of the magnetic layer (2). Therefore, if the margin portion (8) is cut along the first direction, the distance (L0) between the second one-sided end surface (61) of the magnetic layer (2) in the second reorganized inductor (22) and the first end wiring (31) can be sufficiently secured. Therefore, the amount of magnetic particles existing between the second one-sided end surface (61) and the first end wiring (31) in the magnetic layer (2) becomes sufficient. Additionally, the distance (L0) between the second other-sided end surface (62) of the magnetic layer (2) in the second reorganized inductor (22) and the first reorganized inductor (21) and the second end wiring (32) can be sufficiently secured. Therefore, the amount of magnetic particles present between the second end surface (62) and the second end wiring (32) in the magnetic layer (2) becomes sufficient. As a result, the decrease in inductance of the reorganized inductor (10) (first reorganized inductor (21), second reorganized inductor (22), third reorganized inductor (23)) after cutting can be suppressed.

[0076] Meanwhile, in the wiring arrangement section (7), the wiring (3) is arranged in a regular parallel manner. Therefore, in the wiring arrangement section (7), the wiring (3) can be arranged compactly. As a result, the reorganized inductor (10) after cutting can be made smaller.

[0077] Therefore, in this inductor (1), the decrease in inductance of the reorganized inductor (10) after cutting can be suppressed, and at the same time, the reorganized inductor (10) can be miniaturized.

[0078] In addition, in the manufacturing method of the remodeled inductor (10), the margin portion (8) is cut. Therefore, the distance (L0) between the second one-sided end surface (61) of the magnetic layer (2) in the second remodeled inductor (22) and the third remodeled inductor (23) and the first end wiring (31) can be sufficiently secured. The distance (L0) between the second other-sided end surface (62) of the magnetic layer (2) in the second remodeled inductor (22) and the first remodeled inductor (21) and the second end wiring (32) can be sufficiently secured. Therefore, the decrease in the inductance of the remodeled inductor (10) after the second process can be suppressed.

[0079] Meanwhile, in the wiring arrangement section (7), the wiring (3) is arranged in regular parallel. Therefore, the wiring (3) can be arranged compactly in the reorganized inductor (10). As a result, the reorganized inductor (10) after the second process can be made smaller.

[0080] Accordingly, in the method of manufacturing this reorganized inductor (10), it is possible to manufacture a reorganized inductor (10) in which the reduction of inductance is suppressed and miniaturization is achieved.

[0081] In addition, in this second reorganized inductor (22), since the distance (L0) from the second one-sided end surface (61) to the first end wiring (31) and the distance (L0) from the second other-sided end surface (62) to the second end wiring (32) are 0.2 mm or more, the amount of magnetic particles existing between the second one-sided end surface (61) and the first end wiring (31), and between the second other-sided end surface (62) and the second end wiring (32) becomes sufficient. Therefore, the decrease in the inductance of the second reorganized inductor (22) can be suppressed.

[0082] In addition, in the second reorganized inductor (22), the distance (L0) mentioned above is 7 mm or less, so miniaturization is achieved.

[0083] Therefore, this second reorganized inductor (22) is miniaturized while suppressing the decrease in inductance.

[0084] The first reorganization inductor (21) and the third reorganization inductor (23) also produce the same operating effect as the second reorganization inductor (22).

[0085] <Variation Example>

[0086] In each of the following variations, the same reference numerals are assigned to components and processes identical to those in the above-described embodiment, and their detailed descriptions are omitted. Furthermore, each variation may exhibit the same functional effects as the embodiment, except as not specified otherwise. Additionally, the embodiment and its variations may be appropriately combined.

[0087] In one embodiment, the intermediate wiring (33) is single. In a modified example, the intermediate wiring (33) is multiple. In one wiring arrangement section (7), multiple intermediate wirings (33) are arranged in parallel at equal intervals (P0) in the second direction.

[0088] As illustrated in FIG. 3 (A), in the wiring arrangement portion (7) of the inductor (1) of the modified example, a plurality of wires (3) are spaced apart by a first interval (P1) and a second interval (P2) that is longer than the first interval (P1), rather than by equal intervals (P0). That is, one wiring arrangement portion (7) has a plurality of wires (3) arranged with different intervals (P1 and P2). The first interval (P1) and the second interval (P2) are arranged alternately in the second direction. Meanwhile, the second interval (P2) is, for example, shorter than the second direction length of the margin portion (8).

[0089] One embodiment is preferred over a modified example. In the wiring arrangement portion (7) of the inductor (1) of one embodiment, a plurality of wires (3) are arranged in parallel at equal intervals (P0). Therefore, the wires (3) can be arranged more compactly by the wiring arrangement portion (7). In addition, the inductance of each wire (3) can be made equal. As a result, the reorganized inductor (10) can be made even more compact while the inductance of each wire (3) can be made equal.

[0090] Although not shown in the diagram, the number of margin portions (8) in the inductor (1) may be one.

[0091] Although not shown, a plurality of second reorganized inductors (22) may be manufactured by cutting one inductor (1). In this case, the inductor (1) has four or more wiring arrangement sections (7) and three or more margin sections (8). Two or more second reorganized inductors (22) are manufactured by cutting three or more margin sections (8).

[0092] In the modified example shown in (B) of FIG. 4, the spacing of the wires (P1, P2, P3) in the plurality of reorganized inductors (10) is different. Specifically, the first spacing (P1) of the adjacent wires (3) in the first reorganized inductor (21), the second spacing (P2) of the adjacent wires (3) in the second reorganized inductor (22), and the third spacing (P3) of the adjacent wires (3) in the third reorganized inductor (23) are different.

[0093] In the first reorganized inductor (21), a plurality of wires (3) are arranged in parallel at equal intervals (P1). In the first reorganized inductor (21), the distance (L1) between the second other end surface (62) and the second end wire (32) is 0.2 mm or more and 7 mm or less, and is also, for example, the same as the first interval (P1) mentioned above. In addition, the distance (L1) between the second other end surface (62) and the second end wire (32) is the same as the distance (L4) from the second one end surface (61) to the first end wire (31).

[0094] In the second reorganized inductor (22), a plurality of wires (3) are arranged in parallel at equal intervals (P2). In the second reorganized inductor (22), the distance (L2) between the second other end surface (62) and the second end wire (32) is 0.2 mm or more and 7 mm or less, and is also, for example, the same as the second interval (P2) mentioned above. In addition, the distance (L2) between the second other end surface (62) and the second end wire (32) is the same as the distance (L2) from the second one end surface (61) to the first end wire (31).

[0095] In the third sectionalizing inductor (23), a plurality of wires (3) are arranged in parallel at equal intervals (P3). In the third sectionalizing inductor (23), the distance (L3) from the second one-sided end surface (61) to the first end wire (31) is 0.2 mm or more and 7 mm or less, and is also, for example, the same as the third interval (P3) mentioned above. In addition, the distance (L3) between the second one-sided end surface (61) and the first end wire (31) is the same as the distance (L5) between the second other-sided end surface (62) and the second end wire (32).

[0096] As shown in (A) of FIG. 4, the inductor (1) prepared in the first process is provided with a wiring arrangement portion (7) corresponding to the first reorganized inductor (21), a wiring arrangement portion (7) corresponding to the second reorganized inductor (22), and a wiring arrangement portion (7) corresponding to the third reorganized inductor (23), with a margin portion (8).

[0097] In the second process, the magnetic layer (2) is cut in the middle section between the second end wiring (32) and the first end wiring (31) facing the second direction. More specifically, the magnetic layer (2) is cut so as to pass through a point extending from the second end wiring (32) to the other side of the second direction by a length equal to the first gap (P1) or the second gap (P2) and the total length of the radius (R) of the wiring (3). Alternatively, the magnetic layer (2) is cut so as to pass through a point extending from the first end wiring (31) to one side of the second direction by a length equal to the second gap (P2) or the third gap (P3) and the total length of the radius (R) of the wiring (3).

[0098] In the second process, the magnetic layer (2) and a plurality of wires (3) are cut along the second direction (parallel direction) along with the cutting of the margin portion (8). For example, the inductor (1) is cut into a rectangular shape when viewed from a plane. By doing so, a reorganized inductor (10) in a rectangular shape when viewed from a plane can be obtained.

[0099] In this variant, as illustrated in FIG. 6, for example, the end surface of the wiring (3) in the longitudinal direction (first side end surface and / or second side end surface) has an exposed portion (35) and a covered portion (36). The exposed portion (35) is the portion exposed from the magnetic layer (2) at the end surface of the wiring (3). The covered portion (36) is the portion covered by the magnetic layer (2) (attachment at the time of cutting) at the end surface of the wiring (3).

[0100] When obtaining the modified inductor (10) of this modified example, the inductor (1) shown in (A) of FIG. 5 is cut along the first direction and the second direction, respectively. In the cutting, preferably, stamping and dicing are used. For stamping, a die having four corner sections that are curved (curved) is used.

[0101] The magnetic layer (2) and wiring (3) in the inductor (1) are cut so that one end and the other end of the first direction remain.

[0102] In the second direction, the magnetic layer (2) is cut so that the central part (81) of the margin part (8) remains.

[0103] Along with cutting the margin portion (8), the second margin portion (9) is cut. The second margin portion (9) is cut along the first direction. By doing so, the outer end of the second margin portion (9) in the second direction remains.

[0104] The reorganized inductor (10) obtained by the above is, for example, approximately a rectangle when viewed from a plane in which each of the four corner portions (11) has a curve (a curved line). The radius of curvature of the corner portions (11) is, for example, 0.1 mm or more, preferably 0.2 mm or more. The radius of curvature of the corner portions (11) is, for example, 5 mm or less, preferably 4 mm or less.

[0105] The reorganized inductor (10) obtained by the above is, for example, approximately rectangular when viewed from a plane in which each of the four corner portions (11) has a curve (a curved line). The radius of curvature of the corner portions (11) is, for example, 0.1 mm or more, preferably 0.2 mm or more. The radius of curvature of the corner portions (11) is, for example, 5 mm or less, preferably 4 mm or less.

[0106] If the radius of curvature of the corner portion (11) is greater than or equal to the lower limit mentioned above, the impact resistance of the inductor (1) can be improved.

[0107] If the radius of curvature of the corner portion (11) is less than or equal to the upper limit mentioned above, the area near the corner portion (11) can be widened so that a mark (including an alignment mark (111)) can be installed in the empty space.

[0108] Furthermore, although the above invention has been provided as an exemplary embodiment of the present invention, it is merely an example and should not be interpreted restrictively. Variations of the present invention that are evident to those skilled in the art are included in the latter claims.

[0109] Inductors are used as electronic components in electric circuits. Explanation of the symbols

[0110] 1: Inductor 2: Magnetic layer 3: Wiring 7: Wiring layout section 8: Margin section 10: Reorganized inductor 11: Corner section 21: 1st reorganized inductor 22: Second reorganized inductor 23: Third reorganized inductor 35: Exposed area 36: Covered area L0: Distance L1: Distance L2: Street L3: Street P0: Equal intervals

Claims

Claim 1 An inductor comprising a magnetic layer and a plurality of wires embedded in the magnetic layer and extending in the longitudinal direction, wherein the plurality of wires are arranged in parallel at a predetermined interval in a direction perpendicular to the longitudinal direction, the magnetic layer comprises a plurality of wire arrangement portions in which the plurality of wires are arranged in parallel at equal intervals, and a margin portion in which the wires are omitted, which is arranged between the adjacent wire arrangement portions in the parallel direction of the wires, wherein the plurality of wires include a first end wire, an intermediate wire, and a second end wire in order toward the other side of the second direction, and the interval between the adjacent second end wire and the first end wire is wider than the equal interval of the adjacent plurality of wires. Claim 2 A method for manufacturing a singulated inductor comprising a first process for preparing an inductor described in claim 1 and a second process for cutting off the margin portion. Claim 3 delete Claim 4 delete Claim 5 delete Claim 6 delete Claim 7 delete Claim 8 delete

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