Magnetic coupling type coil components

Abstract

The coil component of the present invention comprises: an insulator main body in which a plurality of first insulator layers and a second insulator layer are stacked in a stacking direction; a plurality of first conductor patterns and a second conductor patterns respectively formed on the plurality of first insulator layers and the second insulator layers, the insulator main body having: a first end region and a second end region respectively arranged at the upper end and the lower end in the stacking direction; an intermediate region between the first end region and the second end region, wherein only the first insulator layer is arranged in the first end region and only the second insulator layer is arranged in the second end region, and in the intermediate region, the first insulator layer and the second insulator layer are alternately arranged in the stacking direction, the insulator main body comprising: a first portion covering the upper surface and the lower surface of at least one of one or more intermediate first conductor patterns in the intermediate region among the plurality of first conductor patterns; and a second portion other than the first portion, the resistivity of the first portion being higher than that of the second portion.

Description

Technical Field

[0001] The present invention relates to a coil component, and more particularly, to a magnetic coupling type coil component having a group of coil conductors magnetically coupled to each other. Further particularly, the present invention relates to a magnetic coupling type coil component manufactured by a lamination process. Background Art

[0002] A magnetically coupled coil component has a group of coil conductors that are magnetically coupled to each other. Examples of magnetically coupled coil components that have a group of coil conductors that are magnetically coupled to each other include a common mode choke coil, a transformer, and a coupled inductor. In such magnetically coupled coil components, in many cases, it is desired that the coupling coefficient between the group of coil conductors is high.

[0003] A magnetic coupling type coil component produced by a lamination process is described in Japanese Patent Application Publication No. 2016-131208 and International Publication No. 2014 / 136342.

[0004] The coupled coil component described in Japanese Patent Application Publication No. 2016-131208 has a plurality of coil units embedded in an insulator. The plurality of coil units are configured such that the winding axes of the coil conductors of each unit are substantially aligned, and the coil units are closely connected to each other, thereby improving the coupling degree between the coil conductors.

[0005] In Japanese Patent Application Laid-Open No. 2016-131208, since there is leakage magnetic flux passing between two coil conductors in the magnetic coupling type coil component, the leakage magnetic flux causes leakage inductance to occur. The leakage inductance deteriorates the coupling coefficient of the magnetic coupling type coil component.

[0006] In the coupled coil component described in International Publication No. 2014 / 136342, the coil conductor of the first system is formed across a plurality of insulating layers, and the coil conductor of the second system is formed across a plurality of insulating layers different from the insulating layers formed with the coil conductor of the first system. In the coupled coil component, the layers of the coil conductor of the first system and the layers of the coil conductor of the second system are alternately arranged along the stacking direction, thereby improving the coupling degree between the two systems.

[0007] [Prior technical literature]

[0008] [Patent Literature]

[0009] [Patent Document 1] Japanese Patent Application Publication No. 2016-131208

[0010] [Patent Document 2] International Publication No. 2014 / 136342

[0011] In the coupled coil component described in International Publication No. 2014 / 136342, the coil conductors of different systems are separated by only one insulating layer. In particular, depending on the direction of the current flowing to the coil conductors of each system, the potential difference between the coil conductors arranged in adjacent insulating layers becomes large. Therefore, it is difficult to ensure the insulation between the coil conductors of different systems. Summary of the invention

[0012] One of the objects of the present invention is to provide an improvement in magnetic coupling type coil components.

[0013] One of the more specific objects of the present invention is to provide a magnetic coupling type coil component having a high coupling coefficient between coils of different systems and high insulation reliability between the coils.

[0014] Other objects of the present invention will be clarified through the entire description of the specification.

[0015] A coil component according to an embodiment of the present invention comprises: an insulator body having a plurality of first insulator layers and a plurality of second insulator layers stacked in a stacking direction; a plurality of first conductor patterns formed on the plurality of first insulator layers; and a plurality of second conductor patterns formed on the plurality of second insulator layers. In the coil component according to this embodiment, the insulator body comprises: a first end region arranged at the upper end of the stacking direction, a second end region arranged at the lower end of the stacking direction, and an intermediate region arranged between the first end region and the second end region, wherein only the first insulator layer is arranged in the first end region, and only the second insulator layer is arranged in the second end region. In the intermediate region, the first insulator layer and the second insulator layer are alternately arranged in the stacking direction. In addition, the insulator body of the coil component comprises a first part and a second part other than the first part, wherein the first part refers to a part covering the upper surface and the lower surface of at least one of the one or more intermediate first conductor patterns in the intermediate region among the plurality of first conductor patterns, and the resistivity of the first part is higher than the resistivity of the second part.

[0016] The so-called "only" configuring the first insulator layer in the first end region means that in the first end region, the insulator layers included in the multiple first insulator layers and the multiple second insulator layers are configured, but the insulator layers included in the multiple second insulator layers are not configured. That is, in the first end region, the insulator layers included in the multiple second insulator layers are not configured. As a result, the multiple second conductor patterns formed in the second insulator layer are also not included in the first end region. On the other hand, in the first end region, if it is other than the insulator layer, it can also contain components other than the first insulator layer. For example, the first conductor pattern formed in the first insulator layer and the through-hole electrode connecting the first conductor patterns to each other can also be included in the first end region.

[0017] The so-called "only" second insulator layer is arranged in the second end region, which is the same as the description about the first end region, but the description focuses on the insulator layer. In short, the so-called "only" second insulator layer is arranged in the second end region, which means that the insulator layer included in the plurality of second insulator layers is arranged in the second end region, but the insulator layer included in the plurality of first insulator layers is not arranged.

[0018] According to the above embodiment, the first conductor pattern is arranged in the first end region, but the second conductor pattern is not arranged, and the second conductor pattern is arranged in the second end region, but the first conductor pattern is not arranged. The potential difference between the conductor patterns of the same system provided in the adjacent insulating layer (that is, the potential difference between the first conductor patterns and the second conductor pattern) is usually not greater than the potential difference that causes insulation breakdown, so insulation breakdown is unlikely to occur in the first end region and the second end region.

[0019] In the middle region, the adjacent insulator layer is provided with a conductor pattern of another system. Therefore, it is desired to improve the insulation between the adjacent insulator layers. For example, by increasing the thickness of the insulator layer included in the middle region, the insulation between the adjacent conductor patterns arranged in the middle region can be improved. According to the above embodiment, when improving the insulation by thickening the insulating layer, only the insulator layer arranged in the middle region is formed thick, so it is easy to achieve low profile compared to the case where the entire insulator layer is formed very thick.

[0020] In the above embodiment, in the middle region, the first insulator layer and the second insulator layer are alternately arranged in the stacking direction. Therefore, in the middle region, the first conductor pattern and the second conductor pattern are arranged in adjacent insulator layers. Therefore, the coupling coefficient between the coil including the first conductor pattern and the coil including the second conductor pattern can be improved.

[0021] According to the above embodiment, the upper surface and the lower surface of at least one of the one or more middle first conductor patterns in the middle region among the plurality of first conductor patterns are covered by the first portion having high resistivity, thereby further improving insulation reliability.

[0022] In the coil component of one embodiment, the first portion is configured to also cover the upper surface and the lower surface of at least one of the one or more middle second conductor patterns in the middle region among the plurality of second conductor patterns.

[0023] According to the above embodiment, it is possible to suppress insulation breakdown caused by the potential of the intermediate second conductor pattern, and thus it is possible to further improve insulation reliability.

[0024] In one embodiment, the coil component further comprises: a first external electrode electrically connected to the first end of a first coil unit including the plurality of first conductor patterns; a second external electrode electrically connected to the second end of the first coil unit, the plurality of first conductor patterns including: a first edge conductor pattern disposed closest to the first external electrode; a second edge conductor pattern disposed closest to the second external electrode, the first edge conductor pattern being included in the one or more intermediate first conductor patterns, and the first portion being disposed in a manner covering the upper surface and the lower surface of the first edge conductor pattern.

[0025] According to the above embodiment, since the first edge conductor pattern generating a high potential is provided near the first external electrode, it is possible to further improve the insulation reliability because the first edge conductor pattern generating a high potential is covered with the first portion having a high resistivity.

[0026] A coil component of one embodiment further comprises: a third external electrode electrically connected to the first end of a second coil unit including the plurality of second conductor patterns; a fourth external electrode electrically connected to the second end of the second coil unit, the plurality of second conductor patterns including: a third edge conductor pattern disposed closest to the third external electrode; a fourth edge conductor pattern disposed closest to the fourth external electrode, the fourth edge conductor pattern being included in the one or more intermediate first conductor patterns, the first portion being arranged in a manner covering the upper surface and the lower surface of the fourth edge conductor pattern.

[0027] According to the above embodiment, since the fourth edge conductor pattern generating a high potential is provided near the fourth external electrode, it is possible to further improve the insulation reliability because the fourth edge conductor pattern generating a high potential is covered by the first portion having a high resistivity.

[0028] In a coil component of one embodiment, the first external electrode, the second external electrode, the third external electrode and the fourth external electrode are all arranged on the lower surface of the insulator body, the first external electrode and the first edge conductor pattern are connected by a first lead-out through-hole conductor, the second external electrode and the second edge conductor pattern are connected by a second lead-out through-hole conductor, the third external electrode and the first edge conductor pattern are connected by a third lead-out through-hole conductor, the fourth external electrode and the first edge conductor pattern are connected by a fourth lead-out through-hole conductor, and the first part is set to be between the first lead-out through-hole conductor and the multiple second conductor patterns, between the second lead-out through-hole conductor and the multiple second conductor patterns, and between the fourth lead-out through-hole conductor and the multiple first conductor patterns.

[0029] According to the above embodiment, since all four external electrodes are provided on the lower surface of the insulator body, the coil component can be miniaturized in the length direction. In addition, since the first portion is provided between the first lead-out through-hole conductor and the plurality of second conductor patterns, between the second lead-out through-hole conductor and the plurality of second conductor patterns, and between the fourth lead-out through-hole conductor and the plurality of first conductor patterns, insulation breakdown caused by each lead-out through-hole conductor can be suppressed.

[0030] The coil component according to one embodiment further includes: one or more first connection via-hole conductors connecting the plurality of first conductor patterns to each other; and one or more second connection via-hole conductors connecting the plurality of second conductor patterns to each other.

[0031] According to various embodiments of the invention disclosed in this specification, it is possible to provide a magnetic coupling type coil component having a high coupling coefficient between coils of different systems and high insulation reliability between the coils. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a perspective view of a coil component according to one embodiment of the present invention.

[0033] Figure 2 From the front perspective Figure 1 A schematic perspective view of the interior of a coil component.

[0034] Figure 3a It is schematically indicated Figure 1 A three-dimensional view of an insulator layer included in a coil component.

[0035] Figure 3b It is schematically indicated Figure 1 A three-dimensional view of an insulator layer included in a coil component.

[0036] Figure 4This is a schematic perspective view showing a coil component according to another embodiment of the present invention from the front.

[0037] Figure 5 It is a perspective view of a coil component according to another embodiment of the present invention.

[0038] Figure 6 From the front perspective Figure 5 A schematic perspective view of the interior of a coil component.

[0039] Figure 7 From the front perspective Figure 5 A schematic perspective view of the interior of a coil component.

[0040] Explanation of symbols

[0041] 1, 51, 101 Coil components

[0042] 10 Insulator body

[0043] 19, 20a~20l Insulator layer

[0044] 21, 22, 23, 24, 121, 122, 123, 124 External electrodes

[0045] 25 Upper area

[0046] 26 Lower area

[0047] 27 Middle Area

[0048] 31a~31l Conductor pattern

[0049] 32a to 32e, 33a to 33e Connecting through-hole conductors

[0050] 35~38 Lead-out through-hole conductor

[0051] 41a, 41b, 42a, 42b, 43a to 43c, 44a, 44b Annular portion DETAILED DESCRIPTION

[0052] The following will describe various embodiments of the present invention with reference to the accompanying drawings as appropriate. In addition, common components in multiple drawings are marked with the same reference symbols in the multiple drawings. For the convenience of explanation, the drawings may not be described in exact scale, so please note this.

[0053] Reference Figures 1 to 3b , a coil component 1 according to an embodiment of the present invention will be described. Figure 1 is a perspective view of a coil component 1 according to an embodiment of the present invention. Figure 2 From the front perspective Figure 1A schematic perspective view of the interior of a coil component, Figure 3a and Figure 3b It is a perspective view schematically showing an insulating layer included in the coil component 1 .

[0054] The coil component 1 shown in these figures is a laminated magnetic coupling coil component manufactured by a lamination process, a thin film process or other processes. The coil component 1 can be used as a transformer, a coupled inductor and other various coil components in addition to a common mode choke coil.

[0055] The coil component 1 includes: an insulator body 10 formed of a magnetic material having excellent insulation properties; a first coil unit embedded in the insulator body 10; a second coil unit embedded in the insulator body 10; an external electrode 21 electrically connected to one end of the first coil unit; an external electrode 22 electrically connected to the other end of the first coil unit; an external electrode 23 electrically connected to one end of the second coil unit; and an external electrode 24 electrically connected to the other end of the second coil unit. The first coil unit and the second coil unit will be described later. The external electrode 21 is an example of a first external electrode, the external electrode 22 is an example of a second external electrode, the external electrode 23 is an example of a third external electrode, and the external electrode 24 is an example of a fourth external electrode.

[0056] The insulator body 10 is generally in the shape of a rectangular parallelepiped. The insulator body 10 has a first main surface 10a, a second main surface 10b, a first end surface 10c, a second end surface 10d, a first side surface 10e, and a second side surface 10f. The insulator body 10 has an outer surface formed by these six surfaces. The first main surface 10a and the second main surface 10b are opposite to each other, the first end surface 10c and the second end surface 10d are opposite to each other, and the first side surface 10e and the second side surface 10f are opposite to each other.

[0057] exist Figure 1 In the figure, since the first main surface 10a is located on the upper side of the insulator body 10, the first main surface 10a is called the "upper surface". Similarly, the second main surface 10b is called the "lower surface". Since the coil component 1 is arranged so that the second main surface 10b is opposite to the circuit substrate (not shown), the second main surface 10b is also called the "mounting surface". In addition, when referring to the up and down direction of the coil component 1, Figure 1 The up and down direction is used as the reference.

[0058] For convenience of description, the first side surface 10 e is taken as the front surface of the coil component 1 . Figure 2 The interior of the coil component 1 as viewed from the first side surface 10 e of the coil component 1 is schematically shown.

[0059] In this specification, unless otherwise explained in the text, the "length" direction, "width" direction, and "thickness" direction of the coil component 1 are respectively Figure 1 "L" direction, "W" direction, and "T" direction.

[0060] The external electrodes 21 and 23 are provided on the first end surface 10c of the insulator body 10. The external electrodes 22 and 24 are provided on the second end surface 10d of the insulator body 10. As shown in the figure, each external electrode extends to the upper surface 10a and the lower surface 10b of the insulator body 10.

[0061] like Figure 2 As shown, the insulator body 10 includes: an insulator portion 20 ; an upper cover layer 17 provided on the upper surface of the insulator portion 20 ; and a lower cover layer 18 provided on the lower surface of the insulator portion 20 .

[0062] The insulator portion 20 includes insulator layers 20a to 20l. In the insulator portion 20, the insulator layer 20a, the insulator layer 20b, the insulator layer 20c, the insulator layer 20d, the insulator layer 20e, the insulator layer 20f, the insulator layer 20g, the insulator layer 20h, the insulator layer 20i, the insulator layer 20j, the insulator layer 20k, and the insulator layer 20l are stacked in order from the positive direction side to the reverse direction side in the T-axis direction.

[0063] In one embodiment of the present invention, the insulating layer 19 and the insulating layers 20a to 201 contain a resin and a large amount of filler particles. The filler particles are dispersed in the resin. The insulating layers 20a to 201 may not contain filler particles.

[0064] The upper cover layer 17 is a laminated body formed by laminating a plurality of insulating layers. Similarly, the lower cover layer 18 is a laminated body formed by laminating a plurality of insulating layers. Each insulating layer constituting the upper cover layer 17 and the lower cover layer 18 is formed of a resin in which a large amount of filler particles are dispersed. These insulating layers may not contain filler particles.

[0065] The insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18 are formed of a magnetic material having excellent insulating properties. The insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18 may be formed of the same insulating material or different insulating materials. As the magnetic material for the insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18, a ferrite material, a particle group of a soft magnetic metal or a soft magnetic alloy, a composite material in which a large number of filler particles formed of a magnetic material are dispersed in a resin, or any other known magnetic material can be used. An insulating film formed of an insulating material having excellent insulating properties is formed on each particle included in the particle group of the soft magnetic metal or the soft magnetic alloy.

[0066] The ferrite used as the material for the insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper covering layer 17, and the insulator layers constituting the lower covering layer 18 may include Ni-Zn ferrite, Ni-Zn-Cu ferrite, Mn-Zn ferrite, or any ferrite other than these.

[0067] The soft magnetic metal used as the material of the insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18 may include one or more of Fe, Ni, Co, and any soft magnetic metal other than these.

[0068] The soft magnetic alloy used as the material for the insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper covering layer 17, and the insulator layers constituting the lower covering layer 18 may include Fe-Si alloys, Fe-Ni alloys, Fe-Co alloys, Fe-Cr-Si alloys, Fe-Si-Al alloys, Fe-Si-B-Cr alloys, or any soft magnetic alloy other than these.

[0069] When the insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper covering layer 17, and the insulator layers constituting the lower covering layer 18 are formed of a composite material in which a large number of filler particles are dispersed in a resin, as the resin, a thermosetting resin with excellent insulation properties can be used, such as epoxy resin, polyimide resin, polystyrene (PS) resin, high-density polyethylene (HDPE) resin, polyoxymethylene (POM) resin, polycarbonate (PC) resin, polyvinylidene fluoride (PVDF) resin, phenolic resin, polytetrafluoroethylene (PTFE) resin, or polyparaphenylene benzobisoxazole (PBO) resin. As the filler particles, particles of ferrite material, metal magnetic particles, or any known filler particles other than these can be used. Particles of ferrite material that can be applied to the present invention include, for example, particles of Ni-Zn ferrite or particles of Ni-Zn-Cu ferrite. The metal magnetic particles applicable to the present invention include, for example, (1) metal Fe or Ni, (2) alloy Fe-Si-Cr, Fe-Si-Al, or Fe-Ni, (3) amorphous Fe-Si-Cr-B-C, or Fe-Si-B-Cr, (4) or particles of mixed materials thereof.

[0070] The insulator layer 19, the insulator layers 20a to 201, the insulator layers constituting the upper covering layer 17, and the insulator layers constituting the lower covering layer 18 may all be formed of ferrite materials, may all be formed of soft magnetic metal materials or soft magnetic alloy materials, or may all be formed of composite materials in which a large number of filler particles are dispersed in a resin.

[0071] As described later, the insulator body 10 has a first portion having a higher resistivity than other portions. A portion or the entirety of the first portion is formed of a magnetic material or a non-magnetic material. As the magnetic material for the first portion, in order to improve the insulation, a mixed magnetic material can be used in which glass powder formed of various glasses such as quartz glass, alumina powder, zirconium oxide powder, and powders of oxides with excellent insulation properties other than these are added to the above-mentioned magnetic material. As the non-magnetic material for the first portion, a mixed material can be used in which glass powder formed of various glasses such as quartz glass, alumina powder, zirconium oxide powder, and powders of oxides with excellent insulation properties other than these are added to the above-mentioned magnetic material.

[0072] Conductor patterns 31a to 31l are formed on the upper surfaces of the insulating layers 20a to 20l, respectively. The conductor patterns 31a to 31l are formed by, for example, printing a conductive paste made of a metal or alloy having excellent conductivity by screen printing. As the material of the conductive paste, Ag, Pd, Cu, Al, or an alloy thereof can be used. The conductor patterns 31a to 31l can also be formed by other materials and methods.

[0073] The conductor patterns 31a to 31l are formed so as to extend circumferentially around the coil axis CL. Each of the conductor patterns 31a to 31l has a shape in which a portion is cut away. Therefore, each of the conductor patterns 31a to 31l has a set of ends. Each of the conductor patterns 31a to 31l is formed so as to have a C-shape or a U-shape in a plan view, for example.

[0074] The conductor pattern 31a includes a surrounding portion 31a1 extending in the circumferential direction, and a lead portion 31a2 extending in the radial direction from one end of the surrounding portion 31a1 to the second end face 10d of the insulator body 10. The conductor pattern 31a is electrically connected to the external electrode 22 via the lead portion 31a2. The conductor pattern 31i includes a surrounding portion 31i1 extending in the circumferential direction, and a lead portion 31i2 extending in the radial direction from one end of the surrounding portion 31i1 to the first end face 10c of the insulator body 10. The conductor pattern 31i is electrically connected to the external electrode 21 via the lead portion 31i2.

[0075] The conductor pattern 31d has a surrounding portion 31d1 extending in the circumferential direction, and a lead portion 31d2 extending in the radial direction from one end of the surrounding portion 31d1 to the second end face 10d of the insulator body 10. The conductor pattern 31d is electrically connected to the external electrode 24 via the lead portion 31d2. The conductor pattern 31l has a surrounding portion 31l1 extending in the circumferential direction, and a lead portion 31l2 extending in the radial direction from one end of the surrounding portion 31l1 to the first end face 10c of the insulator body 10. The conductor pattern 31l is electrically connected to the external electrode 23 via the lead portion 31l2.

[0076] The connecting via conductors 32a to 32e are formed at predetermined positions of the insulating layers 20a to 20h. The connecting via conductors 32a to 32e are formed by forming through holes extending in the T-axis direction at predetermined positions of the insulating layers 20a to 20h and embedding conductive paste in the through holes.

[0077] As described above, one end of the conductor pattern 31a is connected to the external electrode 22. The connecting via conductor 32a electrically connects the end of the conductor pattern 31a opposite to the end connected to the external electrode 22 to one end of the conductor pattern 31b.

[0078] The through-hole conductor 32b is connected to electrically connect the other end of the conductor pattern 31b and one end of the conductor pattern 31c. The through-hole conductor 32c is connected to electrically connect the other end of the conductor pattern 31c and one end of the conductor pattern 31e. The through-hole conductor 32d is connected to electrically connect the other end of the conductor pattern 31e and one end of the conductor pattern 31g.

[0079] As described above, one end of the conductor pattern 31i is connected to the external electrode 21. The connecting via conductor 32e electrically connects the other end of the conductor pattern 31g to the end of the conductor pattern 31i on the opposite side of the end connected to the external electrode 21.

[0080] The connecting via conductors 33a to 33e are formed at predetermined positions of the insulating layers 20d to 20k. The connecting via conductors 33a to 33e are formed by forming through holes extending in the T-axis direction at predetermined positions of the insulating layers 20d to 20k and embedding conductive paste in the through holes.

[0081] As described above, one end of the conductor pattern 31d is connected to the external electrode 24. The connecting via conductor 33a electrically connects the end of the conductor pattern 31d opposite to the end connected to the external electrode 24 to one end of the conductor pattern 31f.

[0082] The connecting via-hole conductor 33b electrically connects the other end of the conductor pattern 31f and one end of the conductor pattern 31h. The connecting via-hole conductor 33c electrically connects the other end of the conductor pattern 31h and one end of the conductor pattern 31j. The connecting via-hole conductor 33d electrically connects the other end of the conductor pattern 31j and one end of the conductor pattern 31k.

[0083] As described above, one end of the conductor pattern 311 is connected to the external electrode 23. The other end of the conductor pattern 31k and the end of the conductor pattern 311 opposite to the end connected to the external electrode 23 are electrically connected by the connecting via conductor 33e.

[0084] As described above, a first coil unit is provided between the external electrode 22 and the external electrode 21, which is formed by a conductor pattern 31a, a connecting through-hole conductor 32a, a conductor pattern 31b, a connecting through-hole conductor 32b, a conductor pattern 31c, a connecting through-hole conductor 32c, a conductor pattern 31e, a connecting through-hole conductor 32d, a conductor pattern 31g, a connecting through-hole conductor 32e, and a conductor pattern 31i.

[0085] In this specification, the insulator layer constituting the first coil unit is referred to as the first insulator layer. Figure 2 In the illustrated embodiment, the insulating layers 20a, 20b, 20c, 20e, 20g, 20i serve as first insulating layers.

[0086] In this specification, the conductor pattern constituting the first coil unit is referred to as the first conductor pattern. Figure 2In the embodiment shown, the conductor patterns 31a, 31b, 31c, 31e, 31g, and 31i are first conductor patterns. In this specification, the conductor pattern 31i disposed closest to the external electrode 21 among the plurality of first conductor patterns is referred to as a first edge conductor pattern, and the conductor pattern 31a disposed closest to the external electrode 22 is referred to as a second edge conductor pattern. In short, in the electrical path connecting the external electrode 21 and the external electrode 22, among the plurality of first conductor patterns constituting the first coil unit, the conductor pattern 31i is disposed closest to the external electrode 21, and the conductor pattern 31a is disposed closest to the external electrode 22.

[0087] A second coil unit is provided between the external electrode 24 and the external electrode 23 and is formed by a conductor pattern 31d, a connecting through-hole conductor 33a, a conductor pattern 31f, a connecting through-hole conductor 33b, a conductor pattern 31h, a connecting through-hole conductor 33c, a conductor pattern 31j, a connecting through-hole conductor 33d, a conductor pattern 31k, a connecting through-hole conductor 33e, and a conductor pattern 31l.

[0088] In this specification, the insulator layer constituting the second coil unit is referred to as the second insulator layer. Figure 2 In the illustrated embodiment, the insulating layers 20d, 20f, 20h, 20j, 20k, 201 serve as second insulating layers.

[0089] In this specification, the conductor pattern constituting the second coil unit is referred to as a second conductor pattern. Figure 2 In the embodiment shown, the conductor patterns 31d, 31f, 31h, 31j, 31k, and 31l are second conductor patterns. In this specification, the conductor pattern 31l disposed closest to the external electrode 23 among the plurality of third conductor patterns is referred to as a third edge conductor pattern, and the conductor pattern 31d disposed closest to the external electrode 24 is referred to as a fourth edge conductor pattern.

[0090] In one embodiment of the present invention, each of the insulating layers 20a to 201 is composed of: Figure 3a and Figure 3b The insulating layer 20a may be formed into a plate shape as shown. The insulating layer 20a may also be configured to have uniform insulation at any position on the WL plane. In other words, the insulating layer 20a may also be configured to have a substantially uniform resistivity. For example, the resistivity of 5 different points in the insulating layer 20a is measured, and the arithmetic average ρ of the measured values ​​at the 5 points is obtained. avg The difference ρΔ between the maximum and minimum values ​​of the 5-point measurement is relative to the arithmetic mean ρ avg The ratio (100·ρΔ / ρ avg ) is sufficiently small, it can be said that the resistivity of the insulating layer 20a is substantially uniform. For example, 100·ρΔ / ρ avgWhen the resistivity of the insulating layer 20a is within 20%, within 15%, within 10%, or within 5%, it can be considered that the resistivity of the insulating layer 20a is substantially uniform. In the illustrated embodiment, the insulating layers 20b, 20e, 20f, 20g, 20j, 20k, and 20l can also be configured in the same manner as the insulating layer 20a. That is, the insulating layers 20b, 20e, 20f, 20g, 20j, 20k, and 20l can also be configured so that the resistivity of each is substantially uniform.

[0091] like Figure 3b As shown, in one embodiment, the insulator layer 20c has: an insulator layer main body 20c1; an annular portion 41a that is embedded in the insulator layer main body 20c1 and is in the shape of a circular ring when viewed from above. The annular portion 41a may also be configured so that its upper surface and lower surface are flush with the upper surface and lower surface of the insulator layer main body 20c1, respectively. In one embodiment, the annular portion 41a may also be configured to have a shape that is consistent with the surrounding portion 31d1 of the conductor pattern 31d provided on the lower surface of the insulator layer 20c when viewed from above. The annular portion 41a may also be configured to have a shape that covers the surrounding portion 31d1 of the conductor pattern 31d provided on the lower surface of the insulator layer 20c when viewed from above. In this case, the annular portion 41a may also be configured so that its outer edge 41a1 is located radially outside the coil axis compared to the outer edge of the conductor pattern 31d. The annular portion 41a may also be configured to cover both the surrounding portion 31d1 and the lead portion 31d2 of the conductor pattern 31d provided on the lower surface of the insulating layer 20c in a plan view. The annular portion 41a also penetrates in the thickness direction via the lead-out via conductors 35 to 38 and the connecting via conductors 32a to 32e and 33a to 33e described later.

[0092] The annular portion 41a is formed in a manner having a higher resistivity than the insulator layer body 20c1. For example, when the insulator layer body 20c1 is formed of a composite material in which filler particles composed of a Fe-Si alloy are mixed in a resin, the annular portion 41a may be formed of a highly insulating material in which a powder of an oxide having high insulating properties is added to the composite material for the insulator layer body 20c1. In this way, by forming the annular portion 41a from a mixed magnetic material containing a highly insulating additive (for example, the above-mentioned glass powder, alumina powder, and / or zirconium oxide powder), the resistivity of the annular portion 41a can be made higher than that of the insulator layer body 20c1. In other embodiments, by making the interior of the annular portion 41a contain more voids than the insulator layer body 20c1, the insulation resistivity of the annular portion 41a can be made higher than that of the insulator layer body 20c1. The method of increasing the resistivity of the annular portion 41a compared to the insulator layer body 20c1 is not limited to the method specifically disclosed in this specification. The annular portion 41 a having an insulation resistivity higher than that of the insulating layer main body 20 c 1 can be produced by any known method.

[0093] Similar to the insulating layer 20c, the insulating layer 20d has the annular portion 41b, the insulating layer 20h has the annular portion 42a, and the insulating layer 20i has the annular portion 42b. The annular portions 41b, 42a, and 42b may be configured in a shape that matches the annular portion 41a in a plan view.

[0094] The annular portion 41b may also be configured to have a shape that is consistent with at least one of the conductor pattern 31d provided on the upper surface of the insulating layer 20d and the conductor pattern 31e provided on the lower surface of the insulating layer 20d in a plan view. The annular portion 41b may also be configured to have a plan view shape that is one circle larger than the outer edge of the plan view shape of at least one of the conductor pattern 31d and the conductor pattern 31e.

[0095] The annular portion 42a may be configured to have a shape that is consistent with at least one of the conductor pattern 31h provided on the upper surface of the insulating layer 20h and the conductor pattern 31i provided on the lower surface of the insulating layer 20h in a plan view. The annular portion 42a may be configured to have a plan view shape that is one circle larger than the outer edge of the plan view shape of at least one of the conductor pattern 31h and the conductor pattern 31i.

[0096] The annular portion 42b may be configured to have a shape that matches the shape of the conductor pattern 31j provided on the lower surface of the insulating layer 20i (or provided on the upper surface of the insulating layer 20j) in a plan view. The annular portion 42b may be configured to have a plan view shape that is slightly larger than the outer edge of the plan view shape of the conductor pattern 31j.

[0097] The annular portion 41b of the insulating layer 20d may also be configured to have a higher resistivity than the insulating layer main body that is the portion other than the annular portion 41b in the insulating layer 20d. Similarly, the annular portion 42a of the insulating layer 20h may be configured to have a higher resistivity than the insulating layer main body that is the portion other than the annular portion 42a in the insulating layer 20h, and the annular portion 42b of the insulating layer 20i may be configured to have a higher resistivity than the insulating layer main body that is the portion other than the annular portion 42b in the insulating layer 20i. The annular portions 41b, 42a, 42b can be manufactured using the same method as the annular portion 41a.

[0098] As described above, in the insulator layer 20c, the annular portion 41a has a higher resistivity than the insulator layer body 20c1 located around it. Similarly, in the insulator layers 20d, 20h, and 20i, the annular portions 41b, 42a, and 42b have a higher resistivity in each insulating layer than the insulator layer body located around the annular portion. In the insulator body 10 of one embodiment, the annular portions 41a, 41b, 42a, and 42b have a higher resistivity than any of the insulator layers 20a, 20b, 20e, 20f, 20g, 20j, 20k, and 20l other than the insulator layers 20c, 20d, 20h, and 20i, the insulator layer 19, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18.

[0099] In this way, the insulator body 10 is configured to have a first portion having a higher insulation resistivity than the surrounding portion and a second portion other than the first portion. Figure 2 In the illustrated embodiment, the annular portions 41a, 41b, 42a, 42b correspond to the first portion, and the portions of the insulator body 10 other than these (including the insulator layer body of the insulator layers 20c, 20d, 20h, 20i, the insulator layers 20a, 20b, 20e, 20f, 20g, 20j, 20k, 20l other than the insulator layers 20c, 20d, 20h, 20i, the insulator layer 19, the insulator layers constituting the upper covering layer 17, and the insulator layers constituting the lower covering layer 18) correspond to the second portion.

[0100] Figure 2 The annular portions 41a, 41b, 42a, and 42b shown are examples of the first portion of the insulator body 10. The shape and configuration of the first portion are not limited to Figure 2 For example, in other embodiments, a high-insulation portion corresponding to the annular portion 41a may be provided in a part or all of the insulating layer 20a among the insulating layers 20a, 20b, 20e, 20f, 20g, 20j, 20k, and 20l. Figure 4 , a schematic perspective view of a coil component 51 according to another embodiment is shown from the front. Figure 4 In the coil component 51 shown, in addition to the annular portions 41a, 41b, 42a, 42b provided on the insulating layers 20c, 20d, 20h, 20i, annular portions 43a, 43b, 43c are also provided on the insulating layers 20e, 20f, 20g, respectively. The annular portions 43a, 43b, 43c can be formed into the same shape from the same material as the annular portion 41a. Therefore, in the coil component 51, in addition to the annular portions 41a, 41b, 42a, 42b, the annular portions 43a, 43b, 43c also constitute the first part. Figure 4In the illustrated embodiment, the annular portions 41a, 41b, 42a, 42b, 43a, 43b, 43c have shapes that are identical to each other when viewed from above. Figure 4 In addition to the illustrated embodiments, the shape and arrangement of the first portion may be modified as appropriate without departing from the spirit of the present invention.

[0101] The resistivity of each insulator layer can be measured by a known method. For example, when measuring the resistivity of the insulator layer 20a, the surface resistance of the insulator layer 20a is measured using a surface resistance meter, and the thickness of the insulator layer 20a is measured using a microprobe, and the resistivity is calculated based on the measured surface resistance and thickness of the insulator layer 20a. The resistivity of each annular portion can also be calculated based on the measured values ​​of the surface resistance and thickness of each annular portion.

[0102] The insulator portion 20 is divided into an upper end region 25 , a lower end region 26 , and an intermediate region 27 disposed between the upper end region 25 and the lower end region 26 .

[0103] The upper region 25 includes the insulating layers 20 a , 20 b , and 20 c and the conductor patterns 31 a , 31 b , and 31 c . The upper end of the upper region 25 is in contact with the lower surface of the insulating layer 19 .

[0104] The lower end region 26 includes the insulating layers 20j, 20k, and 20l and the conductor patterns 31j, 31k, and 31l. The lower end of the lower end region 26 is in contact with the upper surface of the lower cover layer 18.

[0105] The middle region 27 includes insulating layers 20d, 20e, 20f, 20g, 20h, 20i and conductor patterns 31d, 31e, 31f, 31g, 31h, 31i. The middle region 27 has its upper end connected to the lower end of the upper region 25 and its lower end connected to the upper end of the lower region 26.

[0106] The upper end region 25 includes only the conductor patterns 31a to 311 embedded in the insulator body 10, which belong to the first coil unit (specifically, the conductor patterns 31a, 31b, and 31c). The upper end region 25 includes only the insulator layers 20a to 201 constituting the insulator portion 20, which have the conductor patterns belonging to the first coil unit (specifically, the insulator layers 20a, 20b, and 20c).

[0107] The conductor patterns 31a, 31b, 31c belonging to the first coil unit are arranged in the upper end region 25, but the second conductor pattern belonging to the second coil unit is not arranged. The potential difference between the conductor patterns of the first coil unit is usually not greater than that causing insulation breakdown, so insulation breakdown is unlikely to occur in the upper end region 25.

[0108] The lower end region 26 includes only the conductor patterns 31a to 31l embedded in the insulator body 10, which belong to the second coil unit (specifically, the conductor patterns 31j, 31k, and 31l). The lower end region 26 includes only the insulator layers 20a to 20l constituting the insulator portion 20, which include the conductor patterns 20j, 20k, and 20l.

[0109] The conductor patterns 31j, 31k, and 31l belonging to the second coil unit are arranged in the lower end region 26, but the first conductor pattern belonging to the first coil unit is not arranged. The potential difference between the conductor patterns of the second coil unit is usually not greater than that causing insulation breakdown, so insulation breakdown is unlikely to occur in the lower end region 26.

[0110] In the middle region 27, among the conductor patterns 31a to 31l embedded in the insulator body 10, the insulator layers having the conductor patterns belonging to the first coil unit and the insulator layers having the conductor patterns belonging to the second coil unit are alternately arranged in the stacking direction (the direction parallel to the coil axis CL). Figure 2 In the illustrated embodiment, from the upper part to the lower part of the stacking direction of the middle region 27, an insulating layer 20d having a conductor pattern 31d, an insulating layer 20e having a conductor pattern 31e, an insulating layer 20f having a conductor pattern 31f, an insulating layer 20g having a conductor pattern 31g, an insulating layer 20h having a conductor pattern 31h, and an insulating layer 20i having a conductor pattern 31i are stacked in this order. Among them, the conductor patterns 31d, 31f, and 31h all belong to the second coil unit, and the conductor patterns 31e, 31g, and 31i all belong to the first coil unit. In this specification, the first conductor pattern provided in the middle region 27 is referred to as the middle first conductor pattern. Figure 2 In the example shown, among the conductor patterns 31a, 31b, 31c, 31e, 31g, and 31i included in the first conductor pattern, the conductor patterns 31e, 31g, and 31i are provided in the middle region 27. Therefore, the conductor patterns 31e, 31g, and 31i are examples of the middle first conductor pattern. Similarly, among the second conductor patterns, the one provided in the middle region 27 is referred to as the middle first conductor pattern. Among the conductor patterns 31d, 31f, 31h, 31j, 31k, and 31l included in the second conductor pattern, the conductor patterns 31d, 31f, and 31h are provided in the middle region 27. Therefore, the conductor patterns 31d, 31f, and 31h are examples of the middle second conductor pattern.

[0111] As described above, in the middle region 27, the insulating layers 20d, 20f, 20h on which the conductor patterns 31d, 31f, 31h belonging to the first coil unit are formed, and the insulating layers 20e, 20g, 20i on which the conductor patterns 31e, 31g, 31i belonging to the first coil unit are formed are alternately arranged in the stacking direction. In this way, in the middle region 27, since the first conductor pattern and the second conductor pattern are arranged in adjacent insulating layers, the coupling coefficient between the first coil unit and the second coil unit can be improved.

[0112] The first coil unit has one end (the end of the conductor pattern 31a) connected to the external electrode 22, and the other end (the end of the conductor pattern 31i) connected to the external electrode 21. Thus, in the illustrated embodiment, the first coil unit has one end disposed in the upper end region 25, and the other end disposed in the middle region 27.

[0113] The second coil unit has one end (the end of the conductor pattern 31d) connected to the external electrode 24, and the other end (the end of the conductor pattern 31l) connected to the external electrode 23. Thus, in the illustrated embodiment, the second coil unit has one end disposed in the middle region 27, and the other end disposed in the lower end region 26.

[0114] In one embodiment of the present invention, the coil component 1 is mounted on an electronic circuit (not shown) in such a manner that a current flows from the external electrode 22 to the external electrode 21 through the first coil unit, and a current flows from the external electrode 23 to the external electrode 24 through the second coil unit. In this case, the potential of the voltage supplied from the external electrode 22 to the end portion (end portion of the conductor pattern 31a) disposed in the upper end region 25 of the first coil unit is equal to the potential of the voltage supplied from the external electrode 23 to the end portion (end portion of the conductor pattern 31l) disposed in the lower end region 26 of the second coil unit. Thus, in one embodiment of the present invention, the potential of the voltage supplied from the external electrode 22 to one end portion of the first coil unit is equal to the potential of the voltage supplied from the external electrode 23 to one end portion of the second coil unit, and the first coil unit and the second coil unit are configured and arranged.

[0115] The potential of the middle region 27 of the first coil unit is lower than the potential of the voltage supplied from the external electrode 22 due to the voltage drop in the conductor pattern (conductor pattern 31a, 31b, 31c) configured in the upper end region 25 of the first coil unit. Similarly, the potential of the middle region 27 of the second coil unit is lower than the potential of the voltage supplied from the external electrode 23 due to the voltage drop in the conductor pattern (conductor pattern 31j, 31k, 31l) configured in the lower end region 26 of the second coil unit. Therefore, according to the above-mentioned embodiment, the potential difference between the first coil unit and the second coil unit can be reduced in the middle region 27. As a result, it is easy to ensure the insulation between the first coil unit and the second coil unit in the middle region 27.

[0116] As described above, the insulator body 10 has: a first portion having a high resistivity; and a second portion having a lower resistivity than the first portion. In one embodiment, the first portion is provided in the insulator body 10 in a manner that covers the upper and lower surfaces of at least one of the one or more intermediate first conductor patterns. In one embodiment, the first portion is provided in the insulator body 10 in a manner that also covers the upper and lower surfaces of at least one of the one or more intermediate second conductor patterns. For example, in Figure 2 In the embodiment shown, the annular portions 41a, 41b, 42a, and 42b correspond to the first portion. The annular portion 42a covers the upper surface of the conductor pattern 31i, which is one of the middle first conductor patterns, and the annular portion 42b covers the lower surface of the conductor pattern 31i. In addition, the annular portion 41a covers the upper surface of the conductor pattern 31d, which is one of the middle second conductor patterns, and the annular portion 41b covers the lower surface of the conductor pattern 31d. In this way, Figure 4 In the embodiment shown, the annular portion 42a and the annular portion 42b included in the first portion cover the upper surface and the lower surface of the conductor pattern 31i, which is one of the middle first conductor patterns, and the annular portion 41a and the annular portion 41b included in the first portion cover the upper surface and the lower surface of the conductor pattern 31d, which is one of the middle second conductor patterns. In the middle region 27, since the conductor patterns included in the first coil unit and the conductor patterns included in the second coil unit are alternately stacked, the potential difference between the adjacent conductor patterns in the middle region 27 is greater than the potential difference between the adjacent conductor patterns in the upper end region 25 and the lower end region 26. In the above embodiment, since the upper surface and the lower surface of at least one of the conductor patterns (the middle first conductor pattern and / or the middle second conductor pattern) provided in the middle region 27 are covered by the first portion having a high resistivity, the insulation reliability of the middle region 27 can be improved.

[0117] Since the conductor pattern 31i is the first edge conductor pattern closest to the external electrode 21 among the first conductor patterns, the first portion is provided so as to cover the upper and lower surfaces of the first edge conductor pattern. According to the above embodiment, in the first coil unit, since it is arranged closest to the external electrode 21, the upper and lower surfaces of the first edge conductor pattern whose potential becomes high are covered by the first portion, so that the insulation reliability around the first edge conductor pattern can be improved in the insulator body 10. Since the conductor pattern 31a as the second edge conductor pattern is provided in the upper end region 25, the conductor pattern 31b of the same system (i.e., the first coil unit) is adjacent to the conductor pattern 31a. Since insulation breakdown is less likely to occur between conductor patterns of the same system, the first portion may not be provided so as to cover the upper and lower surfaces of the second edge conductor pattern. The first portion contributes to the improvement of insulation reliability, but on the other hand, there is a possibility of reducing the magnetic permeability, so it is desirable to reduce the proportion of the first portion in the insulator body 10. By providing the first portion so as to cover the upper and lower surfaces of the first edge conductor pattern but not cover the upper and lower surfaces of the second edge conductor pattern, it is possible to improve insulation reliability and suppress degradation of the Q value.

[0118] Since the conductor pattern 31d is the fourth edge conductor pattern provided closest to the external electrode 24 among the second conductor patterns, the first portion is provided to cover the upper and lower surfaces of the fourth edge conductor pattern. According to the above embodiment, in the second coil unit, since it is arranged closest to the external electrode 24, the upper and lower surfaces of the fourth edge conductor pattern whose potential becomes high are covered by the first portion, so that the insulation reliability around the fourth edge conductor pattern can be improved in the insulator body 10. Since the conductor pattern 31l as the third edge conductor pattern is provided in the lower end region 26, the conductor pattern 31l is adjacent to the conductor pattern 31k of the same system (that is, the second coil unit). Since insulation breakdown is difficult to occur between conductor patterns of the same system, the first portion may not be provided to cover the upper and lower surfaces of the third edge conductor pattern. By providing the first portion to cover the upper and lower surfaces of the fourth edge conductor pattern but not to cover the upper and lower surfaces of the third edge conductor pattern, the insulation reliability can be improved while suppressing the reduction of magnetic permeability.

[0119] The shape and configuration of the first portion can be changed as appropriate. Figure 4 In the embodiment shown, the insulating layers 20e, 20f, 20g are provided with annular portions 43a, 43b, 43c, respectively. The annular portions 43a, 43b, 43c are configured similarly to the annular portion 41a and are therefore part of the first portion. Figure 4In the embodiment, the upper and lower surfaces of the intermediate first conductor patterns 31e, 31g, 31i and the intermediate second conductor patterns 31d, 31f, 31h included in the intermediate region 27 are covered by the first portion. Thus, the insulation reliability of the insulator body 10 can be further improved.

[0120] In the coil component 1, the coupling coefficient can be further improved by increasing the number of stacked conductor patterns and insulator layers included in the middle region 27. According to the above-mentioned embodiment, the insulation between the conductor patterns of different systems is improved, so even if the interval between the conductor patterns of the different systems is narrow, it is difficult for insulation breakdown to occur. Therefore, in the above-mentioned embodiment, it becomes easy to increase the number of stacked conductor patterns that contribute to coupling.

[0121] Next, an example of a method for manufacturing the coil component 1 is described. The coil component 1 can be manufactured, for example, by a lamination process. Specifically, first, an insulator layer 19, an insulator layer 20a to an insulator layer 20l, each insulator layer constituting the upper covering layer 17, and each insulator layer covering the lower covering layer 18 are manufactured.

[0122] Specifically, in order to prepare each of these insulator layers, a solvent is added to a thermosetting resin (e.g., epoxy resin) in which filler particles are dispersed to prepare a slurry. The slurry is applied to the surface of a plastic base film and dried, and the dried slurry is cut into a predetermined size to obtain magnetic sheets as the insulator layer 19, the insulator layers 20a, 20b, 20e, 20f, 20g, 20j, 20k, 20l, the insulator layers constituting the upper cover layer 17, and the insulator layers constituting the lower cover layer 18.

[0123] Next, annular sheets are formed as annular parts 41a, 41b, 42a, 42b. The annular sheets as annular parts 41a, 41b, 42a, 42b are obtained by adding an oxide (glass powder, aluminum oxide powder, zirconium oxide powder, or a mixture thereof) with excellent insulation to the slurry for the above-mentioned magnet sheet, applying the slurry with the oxide added to the surface of the plastic base film and drying it, and cutting the dried slurry into annular shapes. A resin containing filler particles is printed around the annular sheets, thereby obtaining magnet sheets as insulating layers 20c, 20d, 20h, 20i.

[0124] Next, through holes penetrating through the magnet pieces in the T-axis direction are formed at predetermined positions of the magnet pieces serving as the insulator layers 20 a to 20 k .

[0125] Next, a conductive paste made of a metal material (e.g., Ag) is printed on the upper surface of each magnetic piece serving as the insulating layer 20a to the insulating layer 20l by screen printing to form conductor patterns 31a to 31l, and the metal paste is buried in the through holes formed in the magnetic pieces to form connecting through-hole conductors 32a to 32e and connecting through-hole conductors 33a to 33e.

[0126] Next, the magnetic sheets serving as the insulating layers 20a to 201 are stacked to obtain a coil stack serving as the insulating portion 20. Next, the magnetic sheets for the upper covering layer 17 are stacked to form an upper covering layer stack corresponding to the upper covering layer 17, and the magnetic sheets for the lower covering layer 18 are stacked to obtain a lower covering layer stack corresponding to the lower covering layer 18.

[0127] Next, a lower covering layer laminate as the lower covering layer 18, a coil laminate as the insulator portion 20, a magnetic sheet as the insulator layer 19, and an upper covering layer laminate as the upper covering layer 17 are stacked and thermally pressed using a press to obtain a main body laminate.

[0128] Next, the main body laminate is cut into pieces of a desired size using a dicing machine such as a slicer or a laser processing machine to obtain a chip laminate corresponding to the insulator main body 10. Next, the chip laminate is degreased and the degreased chip laminate is subjected to a heat treatment.

[0129] Next, conductive paste is applied to both end portions of the heat-treated chip laminate to form the external electrodes 21, 22, 23, and 24. As described above, the coil component 1 can be obtained.

[0130] Next, refer to Figure 5 to Figure 7 , a coil component 101 according to another embodiment of the present invention will be described. Figure 7 The coil component 101 shown has external electrodes 121 to 124 instead of the external electrodes 21 to 24 of the coil component 1. In addition, along with the change in the arrangement of the external electrodes, the shapes of the conductor patterns 31a, 31d, 31j, and 31l of the coil component 101 are slightly changed from the conductor patterns 31a, 31d, 31j, and 31l of the coil component 1. Among the components of the coil component 101, those that are the same as or similar to the components of the coil component 1 are appropriately omitted.

[0131] Figure 5 is a perspective view of a coil component 101 according to an embodiment of the present invention. Figure 6 and Figure 7 From the front perspective Figure 5 A schematic perspective view of the interior of the coil component 101 is shown. Figure 6 In FIG. 1 , lead-out via conductors connected to the external electrodes 121 and 122 are shown. Figure 7 In FIG. 1 , lead-out via conductors respectively connected to the external electrode 123 and the external electrode 124 are shown.

[0132] As shown in the figure, the external electrodes 121 to 124 are respectively provided on the lower surface 10b of the insulating body 10. The external electrodes 121 to 124 may also be formed in such a manner that a portion of each of them extends along at least one of the first end surface 110c, the second end surface 110d, the first side surface 110e, and the second side surface 110f. The shapes and configurations of the external electrodes 121 to 124 clearly described in this specification are examples. Therefore, the shapes and configurations of the external electrodes that can be applied to the present invention are not limited to those clearly described in this specification.

[0133] like Figure 6 As shown in FIG. 1 , the conductor pattern 31 a has: a surrounding portion 31 a 1 extending in the circumferential direction; and a lead portion 31 a 2 extending in the radial direction from one end of the surrounding portion 31 a 1 . Figure 6 In the embodiment of the present invention, the lead portion 31a2 is not exposed from the second end surface 10d of the insulator body 10. The conductor pattern 31i has: a surrounding portion 31i1 extending in the circumferential direction; and a lead portion 31i2 extending in the radial direction from one end of the surrounding portion 31i1. The lead portion 31i2 is not exposed from the first end surface 10c of the insulator body 10.

[0134] A first through hole penetrating through each layer in the T-axis direction is formed at a predetermined position of the insulating layers 20i to 201 and the lower cover layer 18. In the first through hole, a lead-out via conductor 35 is provided to electrically connect the lead-out portion 31i2 of the conductor pattern 31i and the external electrode 121. The lead-out via conductor 35 is an example of a first lead-out via conductor.

[0135] Second through holes penetrating through the layers in the T-axis direction are formed at predetermined positions of the insulating layers 20a to 201 and the lower cover layer 18. In the second through holes, lead-out via conductors 36 are provided to electrically connect the lead-out portion 31a2 of the conductor pattern 31a to the external electrode 122. The lead-out via conductors 36 are examples of second lead-out via conductors.

[0136] In this way, the conductor pattern 31 i is connected to the external electrode 121 through the lead-out via-hole conductor 35 , and the conductor pattern 31 a is connected to the external electrode 122 through the lead-out via-hole conductor 36 .

[0137] like Figure 7 As shown, the conductor pattern 31d has: a surrounding portion 31d1 extending in the circumferential direction; and a lead portion 31d2 extending in the radial direction from one end of the surrounding portion 31d1. Figure 7 In the embodiment, the lead portion 31d2 is not exposed from the second end surface 10d of the insulator body 10. The conductor pattern 31l has: a surrounding portion 31l1 extending in the circumferential direction; and a lead portion 31l2 extending in the radial direction from one end of the surrounding portion 31l1. The lead portion 31l2 is not exposed from the first end surface 10c of the insulator body 10.

[0138] A third through hole penetrating through each layer in the T-axis direction is formed at a predetermined position of the insulating layer 201 and the lower cover layer 18. In the third through hole, a lead-out via conductor 37 is provided to electrically connect the lead-out portion 3112 of the conductor pattern 311 and the external electrode 123. The lead-out via conductor 37 is an example of a third lead-out via conductor.

[0139] A fourth through hole penetrating through each layer in the T-axis direction is formed at a predetermined position of the insulating layer 20d to 201 and the lower cover layer 18. In the fourth through hole, a lead-out via conductor 38 is provided so as to electrically connect the lead-out portion 31d2 of the conductor pattern 31d and the external electrode 124. The lead-out via conductor 38 is an example of a fourth lead-out via conductor.

[0140] In this way, the conductor pattern 31 d is connected to the external electrode 124 through the lead-out via-hole conductor 38 , and the conductor pattern 31 l is connected to the external electrode 123 through the lead-out via-hole conductor 37 .

[0141] like Figure 6 and Figure 7 As shown in FIG. 1 , each of the insulating layers 20c to 20k is provided with a ring-shaped portion having a high resistivity. Figure 4 The corresponding annular portion of the coil component 51 shown is similarly configured. In addition, the insulating layer 20j has an annular portion 44a, and the insulating layer 20k has an annular portion 44b. The annular portions 44a and 44b may also be configured to form a plan view shape that is consistent with the plan view shape of each of the annular portions 41a, 41b, 42a, 42b, and 43a to 43c.

[0142] The annular portion 44a of the insulating layer 20j is configured to have a higher resistivity than the insulating layer main body which is a portion other than the annular portion 44a in the insulating layer 20j. Similarly, the annular portion 44b of the insulating layer 20k is configured to have a higher resistivity than the insulating layer main body which is a portion other than the annular portion 44b in the insulating layer 20k. The annular portions 44a and 44b can be manufactured using the same method as the annular portion 41a.

[0143] In the coil component 101, the annular portions 41a, 41b, 42a, 42b, 43a to 43c, 44a, 44b constitute a first portion. The first portion is not only between the conductor patterns, but also between the lead-out via-hole conductor 35 and the second conductor pattern (specifically, the conductor patterns 31j, 31k, 31l), between the lead-out via-hole conductor 36 and the second conductor pattern (specifically, the conductor patterns 31d, 31f, 31h, 31j, 31k, 31l), and between the lead-out via-hole conductor 38 and a plurality of first conductor patterns (specifically, the conductor patterns 31e, 31g, 31i).

[0144] The effect of the above-mentioned embodiment will be described. The potential of the intermediate region 27 between the first coil unit and the second coil unit decreases from the potential of the external electrode 22 and the external electrode 23 to the intermediate region 27. Therefore, according to the above-mentioned embodiment, the potential difference between the first coil unit and the second coil unit can be reduced in the intermediate region 27. Thus, the insulation reliability of the insulator body 10 can be improved.

[0145] In one embodiment, the upper surface and lower surface of at least one of the conductor patterns (the intermediate first conductor pattern and / or the intermediate second conductor pattern) provided in the intermediate region 27 are covered by a first portion having a high resistivity, thereby improving the insulation reliability of the intermediate region 27.

[0146] According to one embodiment, by setting the first part in a manner that covers the upper and lower surfaces of the first edge conductor pattern (conductor pattern 31i) in the middle area 27 but does not cover the upper and lower surfaces of the second edge conductor pattern (conductor pattern 31a) in the upper end area 25, the insulation reliability can be improved while the reduction in magnetic permeability can be suppressed.

[0147] According to one embodiment, by setting the first part in a manner that covers the upper surface and the lower surface of the fourth edge conductor pattern (conductor pattern 31d) in the middle area 27 but does not cover the upper surface and the lower surface of the third edge conductor pattern (conductor pattern 31l) in the lower end area 26, the insulation reliability can be improved while the reduction in magnetic permeability can be suppressed.

[0148] According to one embodiment, since the upper and lower surfaces of the intermediate first conductor patterns 31e, 31g, 31i and the intermediate second conductor patterns 31d, 31f, 31h included in the intermediate region 27 are covered by the first portion, the insulation reliability of the insulator body 10 can be further improved.

[0149] According to one embodiment, even when the lead-through hole conductors 35 to 38 are provided for connecting the external electrodes 121 to 124 and the conductor patterns, the insulation reliability between the lead-through hole conductors 35 to 38 and the conductor patterns can be improved.

[0150] The size, material and configuration of each component described in this specification are not limited to the contents clearly described in the embodiment, and each component can be deformed in a manner having any size, material and configuration that can be included in the scope of the present invention. In addition, the components not clearly described in this specification can be added to the described embodiment, and a part of the components described in each embodiment can also be omitted.

Claims

1. A coil component, comprising: An insulator body having a plurality of first insulator layers and a plurality of second insulator layers stacked in a stacking direction; a plurality of first conductor patterns formed on the plurality of first insulator layers; a plurality of second conductor patterns formed on the plurality of second insulator layers; a first external electrode electrically connected to a first end portion of a first coil unit including the plurality of first conductor patterns; a second external electrode electrically connected to the second end of the first coil unit, The insulator body comprises: a first end region arranged at the upper end in the stacking direction; a second end region arranged at the lower end in the stacking direction; and an intermediate region arranged between the first end region and the second end region. In the first end region, only the first insulating layer is arranged so as to include only a plurality of conductor patterns included in the plurality of first conductor patterns. In the second end region, only the second insulating layer is arranged so as to include only a plurality of conductor patterns included in the plurality of second conductor patterns. In the middle region, the first insulating layers and the second insulating layers are alternately arranged in the stacking direction. The insulator body includes a first portion and a second portion other than the first portion, wherein the first portion is a portion covering the upper surface and the lower surface of at least one of the one or more middle first conductor patterns in the middle region among the plurality of first conductor patterns, The resistivity of the first portion is higher than the resistivity of the second portion, The plurality of second conductor patterns in the middle region include an upper edge conductor pattern, wherein the upper edge conductor pattern is arranged between an uppermost conductor pattern among the plurality of first conductor patterns in the middle region and a lowermost conductor pattern among the plurality of first conductor patterns in the first end region, The plurality of first conductor patterns in the middle region include a lower edge conductor pattern, the lower edge conductor pattern being arranged between a lowermost conductor pattern among the plurality of second conductor patterns in the middle region and an uppermost conductor pattern among the plurality of second conductor patterns in the second end region, The first portion is arranged to cover the upper surface and the lower surface of the upper edge conductor pattern and the upper surface and the lower surface of the lower edge conductor pattern, The first part is arranged in a manner not to cover the upper surface and the lower surface of one or more conductor patterns other than the upper edge conductor pattern among the multiple second conductor patterns in the middle area, and not to cover the upper surface and the lower surface of one or more conductor patterns other than the lower edge conductor pattern among the multiple first conductor patterns in the middle area.

2. The coil component according to claim 1, wherein Also available: a third external electrode electrically connected to a first end portion of a second coil unit including the plurality of second conductor patterns; a fourth external electrode electrically connected to the second end of the second coil unit, The plurality of first conductor patterns include: a first edge conductor pattern disposed closest to the first external electrode; and a second edge conductor pattern disposed closest to the second external electrode. The plurality of second conductor patterns include: a third edge conductor pattern disposed closest to the third external electrode; and a fourth edge conductor pattern disposed closest to the fourth external electrode. The fourth edge conductor pattern is included in the one or more middle second conductor patterns, The first portion is provided in such a manner as to cover the upper surface and the lower surface of the fourth edge conductor pattern.

3. The coil component according to claim 2, wherein: The first external electrode, the second external electrode, the third external electrode and the fourth external electrode are all disposed on the lower surface of the insulator body. The first external electrode and the first edge conductor pattern are connected by a first lead-out via conductor, The second external electrode and the second edge conductor pattern are connected by a second lead-out via conductor, The third external electrode and the third edge conductor pattern are connected by a third lead-out via conductor, The fourth external electrode and the fourth edge conductor pattern are connected by a fourth lead-out via conductor, The first portion is provided between the first lead via conductor and the plurality of second conductor patterns, between the second lead via conductor and the plurality of second conductor patterns, and between the fourth lead via conductor and the plurality of first conductor patterns.

4. The coil component according to any one of claims 1 to 3, wherein: Also available: one or more first connecting via conductors connecting the plurality of first conductor patterns to each other; One or more second connecting via conductors connecting the plurality of second conductor patterns to each other.

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