Inductor component

Abstract

The inductor component includes a body including an insulator, a coil provided inside the body, and a first external electrode electrically connected to the coil, a first end surface and a first main surface of the body intersect at a first ridge portion, a second end surface and the first main surface intersect at a second ridge portion, and a second end surface and a second main surface of the body intersect at a third ridge portion. The first external electrode has a first electrode layer embedded in the body and at least partially exposed from the body, and the first electrode layer extends from the first ridge line portion toward the second ridge line portion at a position away from the second ridge line portion and is exposed on the first main surface but not on the second main surface. In a cross section including the first electrode layer in a cross section along the longitudinal direction and the height direction, a first point corresponding to the first ridge line portion, a second point corresponding to the second ridge line portion, and a third point corresponding to a tip of the first electrode layer located on the second ridge line portion side of the first main surface are defined. The third point is located closer to the second main surface than an imaginary straight line connecting the first point and the second point.

Description

Technical Field

[0001] The present invention relates to inductor components. Background Art

[0002] Patent document 1 discloses a stacked inductor, characterized in that it includes a stacked body in a substantially rectangular shape, the stacked body including a plurality of stacked insulating layers and a plurality of internal conductive layers stacked via the insulating layers, wherein in the stacked inductor having a coil structure connected in a spiral shape, the internal conductive layers are configured such that the coil axis of the coil structure is parallel to the bottom surface of the stacked body and is perpendicular to the opposing direction of a pair of external electrodes formed on opposing end surfaces of the stacked body, and the edge portion of the cross section of the internal conductive layer has rounded corners.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2013-98356

[0004] In the method for manufacturing a laminated inductor described in Patent Document 1, a green laminated inductor is obtained by laminating insulating sheets on which a conductor paste for a coil structure and a conductor paste for an external electrode are printed, and then cutting the sheets into individual sheets. Then, in the method for manufacturing a laminated inductor described in Patent Document 1, the green laminated inductor is fired to obtain a laminated inductor.

[0005] In the manufacturing method of the stacked inductor described in Patent Document 1, when firing the green laminated inductor, it is necessary to simultaneously fire the conductor paste for the external electrode and the insulator paste for the insulator sheet, which are made of different materials. Therefore, in the manufacturing method of the stacked inductor described in Patent Document 1, due to the difference in expansion coefficient, elastic modulus and other characteristics between the conductor paste for the external electrode and the insulator paste for the insulator sheet, in the laminated inductor obtained by firing the green laminated inductor, residual stress may be generated at the interface between the external electrode obtained by the conductor paste for the external electrode and the insulating layer obtained by the insulator sheet. In the laminated inductor, if residual stress is generated at the interface between the external electrode and the insulating layer, for example, when the laminated inductor is mounted, a load (impact) is applied to the laminated inductor, and cracks may be generated inside the laminated inductor starting from the above-mentioned interface. Summary of the invention

[0006] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide an inductor component capable of suppressing the occurrence of cracks due to stress remaining at the interface between an external electrode and a base body.

[0007] The inductor component of the present invention is characterized in that it comprises: a body including an insulator; a coil provided inside the body; a first external electrode electrically connected to the coil, the body having: a first end face and a second end face opposite to each other in a length direction; a first main face and a second main face opposite to each other in a height direction perpendicular to the length direction; and a first side face and a second side face opposite to each other in a width direction perpendicular to the length direction and the height direction, the first end face and the first main face intersecting at a first ridgeline portion, the second end face and the first main face intersecting at a second ridgeline portion, the first external electrode having a first electrode layer, the first electrode layer being buried The first electrode layer is inserted into the above-mentioned blank and at least a portion is exposed from the above-mentioned blank, the first electrode layer extends from the above-mentioned first ridge portion toward the above-mentioned second ridge portion at a position away from the above-mentioned second ridge portion, and is exposed on the above-mentioned first principal surface but not on the above-mentioned second principal surface, and in a cross-section including the above-mentioned first electrode layer in the cross-section along the above-mentioned length direction and the above-mentioned height direction, a first point corresponding to the above-mentioned first ridge portion, a second point corresponding to the above-mentioned second ridge portion, and a third point corresponding to the front end of the above-mentioned first electrode layer on the side of the above-mentioned second ridge portion located on the above-mentioned first principal surface are defined, and the above-mentioned third point is located on the side of the above-mentioned second principal surface than a virtual straight line connecting the above-mentioned first point and the above-mentioned second point.

[0008] According to the present invention, it is possible to provide an inductor component capable of suppressing the occurrence of cracks due to stress remaining at the interface between the external electrode and the base body. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a schematic perspective view showing an example of the inductor component of the present invention.

[0010] Figure 2 Yes means Figure 1 A schematic cross-sectional view of an example of a cross section of the inductor component along line segment a1 - a2 is shown.

[0011] Figure 3 It is a schematic cross-sectional view showing another example of the inductor component of the present invention. DETAILED DESCRIPTION

[0012] The inductor component of the present invention is described below. The present invention is not limited to the following configurations, and can be appropriately modified without departing from the gist of the present invention. In addition, a configuration obtained by combining a plurality of the preferred configurations described below is also the present invention.

[0013] The drawings shown below are schematic diagrams and may differ from actual products in size, aspect ratio, etc.

[0014] In this specification, unless otherwise specified, terms indicating the relationship between elements (for example, "parallel", "perpendicular", etc.) and terms indicating the shape of an element refer not only to the strict manner described in the text, but also to a substantially equivalent range, for example, a range containing a difference of about several percent.

[0015] The inductor component of the present invention is characterized in that it comprises: a body including an insulator; a coil arranged inside the body; and a first external electrode electrically connected to the coil, the body having: a first end face and a second end face opposite to each other in a length direction; a first main face and a second main face opposite to each other in a height direction perpendicular to the length direction; and a first side face and a second side face opposite to each other in a width direction perpendicular to the length direction and the height direction, the first end face and the first main face intersect at a first ridgeline portion, the second end face and the first main face intersect at a second ridgeline portion, the first external electrode having a first electrode layer, the first electrode layer being The first electrode layer is embedded in the above-mentioned blank and at least a portion is exposed from the above-mentioned blank, the first electrode layer extends from the above-mentioned first ridge portion toward the above-mentioned second ridge portion at a position away from the above-mentioned second ridge portion, and is exposed on the above-mentioned first principal surface and not exposed on the above-mentioned second principal surface, and in a cross-section including the above-mentioned first electrode layer in the cross-section along the above-mentioned length direction and the above-mentioned height direction, a first point corresponding to the above-mentioned first ridge portion, a second point corresponding to the above-mentioned second ridge portion, and a third point corresponding to the front end of the above-mentioned first electrode layer on the second ridge portion side located on the above-mentioned first principal surface are defined, and the above-mentioned third point is located on the side of the above-mentioned second principal surface closer to the virtual straight line connecting the above-mentioned first point and the above-mentioned second point.

[0016] Figure 1 It is a schematic perspective view showing an example of the inductor component of the present invention.

[0017] Figure 1 The inductor component 1A shown has a green body 10 , a coil 20 , and a first external electrode 30 a .

[0018] In this manual, if Figure 1 As shown in FIG. 1 and FIG. 2 , the length direction, the height direction, and the width direction are respectively defined by L, T, and W. Here, the length direction L, the height direction T, and the width direction W are in a mutually perpendicular relationship.

[0019] exist Figure 1 In the example shown, the width direction W is parallel to the coil axial direction of the coil 20 .

[0020] The coil axial direction of the coil 20 is the direction in which the coil axis C of the coil 20 extends.

[0021] The blank 10 has a first end face 11 a and a second end face 11 b facing each other in the longitudinal direction L, a first main face 12 a and a second main face 12 b facing each other in the height direction T, and a first side face 13 a and a second side face 13 b facing each other in the width direction W.

[0022] exist Figure 1 In the example shown, the first main surface 12a is arranged along the coil axial direction (in Figure 1 , extending in the width direction W).

[0023] exist Figure 1 In the example shown, the first main surface 12a is a mounting surface. Specifically, the first main surface 12a is a mounting surface that faces a mounting object (e.g., a substrate) when the inductor component 1A is mounted. Therefore, in the inductor component 1A, the mounting surface corresponding to the first main surface 12a extends in the coil axial direction.

[0024] A mark for easily identifying each surface may be applied to at least one of the surfaces of the blank 10, i.e., at least one of the first end surface 11a, the second end surface 11b, the first main surface 12a, the second main surface 12b, the first side surface 13a, and the second side surface 13b.

[0025] The first end face 11a and the second end face 11b do not need to be strictly perpendicular to the longitudinal direction L. In addition, the first main face 12a and the second main face 12b do not need to be strictly perpendicular to the height direction T. Furthermore, the first side face 13a and the second side face 13b do not need to be strictly perpendicular to the width direction W.

[0026] The blank 10 is, for example, in the shape of a rectangular parallelepiped.

[0027] In this specification, the rectangular parallelepiped shape may be a shape that can be basically called a rectangular parallelepiped shape, and includes, for example, a substantially rectangular parallelepiped shape with rounded corners and ridges as described later.

[0028] It is preferable that at least one of the corners and ridges of the body 10 be rounded.

[0029] The corner of the blank 10 is a portion where three surfaces of the blank 10 intersect.

[0030] The ridgeline portion of the blank 10 is a portion where two surfaces of the blank 10 intersect.

[0031] exist Figure 1 In the example shown, the first end surface 11a and the first main surface 12a intersect at the first ridge line portion 14a. Figure 1 In the example shown, the second end surface 11b and the first main surface 12a intersect at the second ridgeline portion 14b. Figure 1 In the example shown, the first end surface 11a and the second main surface 12b intersect at the third ridgeline portion 14c. Figure 1In the illustrated example, the second end surface 11 b and the second main surface 12 b intersect at the fourth ridgeline portion 14 d .

[0032] The green body 10 includes an insulator.

[0033] exist Figure 1 In the example shown, the insulator is provided with a plurality of insulating layers along the axial direction of the coil (in Figure 1 In the middle, the width direction W) is stacked.

[0034] exist Figure 1 In the example shown, the plurality of insulating layers include an insulating layer 15 a , an insulating layer 15 b , an insulating layer 15 c , and an insulating layer 15 d .

[0035] In addition, although Figure 1 Although not shown in the figure, in fact, there is at least one insulating layer between the insulating layer 15b and the insulating layer 15c in the axial direction of the coil.

[0036] In addition, Figure 1 In the figure, for convenience of explanation, the boundaries between the plurality of insulating layers are shown, but in reality, the plurality of insulating layers are integrated and the boundaries between the insulating layers are often not clearly shown.

[0037] The insulating material constituting the insulator refers to the insulating material constituting the insulating layer, and examples thereof include glass materials mainly composed of borosilicate glass, ceramic materials, organic materials such as epoxy resins, fluororesins, and polymer resins, and composite materials such as glass epoxy resins. As the insulating material, materials with small dielectric constants and dielectric losses are particularly preferred.

[0038] The insulating materials constituting the plurality of insulating layers may be the same as or different from each other, or may be partially different from each other.

[0039] The dimensions of the plurality of insulating layers in the coil axial direction may be the same as or different from each other, or may be partially different from each other.

[0040] The coil 20 is disposed inside the blank 10 .

[0041] exist Figure 1 In the example shown, the coil 20 is wound in a spiral shape along the coil axial direction.

[0042] exist Figure 1 In the illustrated example, the coil 20 is formed by laminating a plurality of coil wires in the coil axial direction and electrically connecting them.

[0043] exist Figure 1 In the illustrated example, the plurality of coil wirings include a first coil wiring 21 a and a second coil wiring 21 b .

[0044] The first coil wiring 21 a exists at the outermost position on the first side surface 13 a side in the coil axial direction among the plurality of coil wirings.

[0045] The first coil wiring 21 a may have a single-layer structure or a multi-layer structure.

[0046] The second coil wiring 21 b exists at the outermost position on the second side surface 13 b side in the coil axial direction among the plurality of coil wirings.

[0047] The second coil wiring 21 b may have a single-layer structure or a multi-layer structure.

[0048] In addition, although Figure 1 Although not shown in the figure, actually, there is at least one coil wiring between the first coil wiring 21a and the second coil wiring 21b in the coil axial direction.

[0049] Examples of the conductive material constituting the coil wiring include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0050] The conductive materials constituting the plurality of coil wirings may be the same as or different from each other, or may be partially different from each other.

[0051] The dimensions of the plurality of coil wirings in the coil axial direction may be the same as or different from each other, or may be partially different from each other.

[0052] For a plurality of coil wirings, the dimension in the direction perpendicular to the direction in which the coil wirings extend when viewed from the coil axial direction, in other words, the width when viewed from the coil axial direction, may be the same as, different from, or partially different from each other.

[0053] The coil wirings adjacent to each other in the coil axial direction among the plurality of coil wirings may be electrically connected via a connection conductor penetrating through an insulating layer between the adjacent coil wirings in the coil axial direction.

[0054] The connecting conductor may have a single-layer structure or a multi-layer structure.

[0055] Examples of the conductive material constituting the connection conductor include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0056] When the coil axial direction is observed, the coil 20 may be, for example, a shape consisting of only straight portions, a shape consisting of only curved portions, or a shape consisting of both straight portions and curved portions. For example, when the coil axial direction is observed, the coil 20 may be a polygonal shape consisting of only straight portions, a circular shape or an elliptical shape consisting of only curved portions, or an elliptical shape (orbital shape) consisting of both straight portions and curved portions.

[0057] In addition, as mentioned above, Figure 1 In the example shown, the coil 20 is formed by three or more coil wirings in which at least one coil wiring is added to the first coil wiring 21a and the second coil wiring 21b. However, the coil 20 can also be formed by only two coil wirings by adjusting the position of the connecting conductor.

[0058] The first external electrode 30 a is electrically connected to the coil 20 .

[0059] exist Figure 1 In the example shown, the first external electrode 30a is electrically connected to one end of the coil 20. Specifically, the first external electrode 30a is electrically connected to the first coil wiring 21a constituting the coil 20 via the first lead wiring 22a. In other words, the first lead wiring 22a connects the first coil wiring 21a and the first external electrode 30a.

[0060] The first lead wiring 22a may have a single-layer structure or a multi-layer structure.

[0061] Examples of the conductive material constituting the lead wiring include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0062] In this specification, when viewed from the coil axial direction, in the route where the coil wiring is electrically connected to the external electrode, the wiring that is inclined relative to the straight portion of the coil wiring and extends toward the external electrode is referred to as the lead wiring (for example, Figure 1 In this case, when viewed from the axial direction of the coil, the coil wiring and the lead wiring do not exist on the same straight line with the connection portion of the two as the boundary. In addition, when the wiring corresponding to the lead wiring specified as described above is not visible when viewed from the axial direction of the coil, the wiring that does not overlap with the winding portion of the coil (protrudes from the winding portion of the coil) when viewed from the axial direction of the coil is used as the lead wiring (for example, Figure 1 different examples).

[0063] The first external electrode 30 a includes a first electrode layer 31 a which is buried in the body 10 and at least a portion of which is exposed from the body 10 .

[0064] The first electrode layer 31a extends from the first ridgeline portion 14a toward the second ridgeline portion 14b at a position away from the second ridgeline portion 14b and is exposed on the first major surface 12a. In other words, the first electrode layer 31a is exposed on a portion of the first major surface 12a.

[0065] exist Figure 1 In the example shown, the first electrode layer 31a is exposed in a portion of the first main surface 12a on the first ridgeline 14a side. Specifically, the first electrode layer 31a is exposed in a region closer to the first ridgeline 14a side than the center in the longitudinal direction L of the first main surface 12a.

[0066] like Figure 1 As shown in FIG. 1 , the first electrode layer 31 a preferably extends from the first main surface 12 a to the first end surface 11 a via the first ridge line portion 14 a and is exposed on the first end surface 11 a .

[0067] exist Figure 1 In the illustrated example, the first electrode layer 31 a is exposed from a portion of the first major surface 12 a on the first ridge line 14 a side over a portion of the first end surface 11 a on the first ridge line 14 a side.

[0068] Alternatively, the first electrode layer 31 a may be exposed only on a portion of the first major surface 12 a .

[0069] On the other hand, the first electrode layer 31 a is not exposed on the second major surface 12 b .

[0070] The size of the first electrode layer 31a in the coil axial direction may be smaller than the size of the first ridgeline portion 14a in the coil axial direction (the size of the coil axial direction of the blank 10), or may be the same as the size of the first ridgeline portion 14a in the coil axial direction (the size of the coil axial direction of the blank 10). In other words, the first electrode layer 31a may be in contact with a portion of the first ridgeline portion 14a, or may be in contact with the entire first ridgeline portion 14a.

[0071] like Figure 1 As shown, the first external electrode 30a preferably further includes a second electrode layer 31b, which is provided outside the body 10 to cover the first electrode layer 31a. In other words, the first external electrode 30a preferably includes the first electrode layer 31a and the second electrode layer 31b in order from the coil 20 side.

[0072] It is preferable that the second electrode layer 31 b is in contact with the first electrode layer 31 a .

[0073] The second electrode layer 31b is preferably provided outside the body 10, specifically, on the first main surface 12a, extending from the first ridgeline 14a toward the second ridgeline 14b at a position away from the second ridgeline 14b. In other words, the second electrode layer 31b is preferably provided on a portion of the first main surface 12a.

[0074] exist Figure 1 In the example shown, the second electrode layer 31b is provided on a portion of the first main surface 12a on the first ridgeline 14a side. Specifically, the second electrode layer 31b is provided on a region on the first main surface 12a closer to the first ridgeline 14a side than the center in the longitudinal direction L.

[0075] like Figure 1 As shown in FIG. 1 , the second electrode layer 31 b preferably extends from the first main surface 12 a to the first end surface 11 a via the first ridge line portion 14 a .

[0076] exist Figure 1 In the illustrated example, the second electrode layer 31 b extends from a portion of the first major surface 12 a on the first ridge line 14 a side to a portion of the first end surface 11 a on the first ridge line 14 a side.

[0077] In addition, the second electrode layer 31 b may be provided only on a portion of the first major surface 12 a .

[0078] On the other hand, the second electrode layer 31 b is preferably provided on the second major surface 12 b .

[0079] The size of the second electrode layer 31b in the coil axial direction may be smaller than the size of the first ridgeline portion 14a in the coil axial direction (the size of the coil axial direction of the blank 10), or may be the same as the size of the first ridgeline portion 14a in the coil axial direction (the size of the coil axial direction of the blank 10). In other words, the second electrode layer 31b may be in contact with a portion of the first ridgeline portion 14a, or may be in contact with the entire first ridgeline portion 14a.

[0080] Examples of the conductive material constituting the electrode layer include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0081] In the case where the first external electrode 30a has the first electrode layer 31a and the second electrode layer 31b, it is preferred that the first electrode layer 31a is a base electrode layer containing the above-mentioned conductive material, and the second electrode layer 31b is a plated electrode layer containing the above-mentioned conductive material. In this case, it is preferred that the first external electrode 30a has, in order from the coil 20 side, an Ag base electrode layer as the first electrode layer 31a and a Ni-plated electrode layer as the second electrode layer 31b. Furthermore, it is further preferred that the first external electrode 30a has, in order from the coil 20 side, an Ag base electrode layer as the first electrode layer 31a, a Ni-plated electrode layer as the second electrode layer 31b, and a Sn-plated electrode layer as another electrode layer covering the second electrode layer 31b.

[0082] Figure 2 Yes means Figure 1 The cross-sectional schematic diagram of an example of a cross section of the inductor component shown along the line segment a1-a2. Specifically, Figure 2 Show Figure 1 The cross section of the inductor component 1A shown in the figure, taken along the longitudinal direction L and the height direction T, is a cross section including the first coil wiring 21 a and the first electrode layer 31 a .

[0083] like Figure 2 As shown in FIG. 1 , in the cross section including the first electrode layer 31a in the cross section along the length direction L and the height direction T, a first point E1 corresponding to the first ridge portion 14a, a second point E2 corresponding to the second ridge portion 14b, and a third point E3 corresponding to the front end of the first electrode layer 31a on the second ridge portion 14b side located on the first principal surface 12a are defined. The third point E3 can also be said to correspond to the intersection of the interface between the first electrode layer 31a and the body 10 (insulator) and the first principal surface 12a.

[0084] like Figure 2 As shown, when the first point E1, the second point E2, and the third point E3 are defined, the third point E3 is located closer to the second main surface 12b than the virtual straight line F connecting the first point E1 and the second point E2.

[0085] In conventional inductor components (e.g., the laminated inductor described in Patent Document 1), when the external electrode and the green body (insulator) are formed by a simultaneous firing method (also referred to as a co-firing method), residual stress may be generated at the interface between the external electrode and the green body (insulator) due to differences in expansion coefficient, elastic modulus, and other properties between the constituent materials of the external electrode and the green body (insulator). In conventional inductor components, if residual stress is generated at the interface between the external electrode and the green body (insulator), a load (impact) is applied to the inductor component when, for example, the inductor component is installed or the inductor component is flown in a selected machine or other equipment, and cracks may be generated inside the inductor component starting from the above interface. In conventional inductor components, cracks are easily generated starting from the tip of the external electrode located on the main surface (mounting surface) of the green body in the interface between the external electrode and the green body (insulator) where residual stress may be generated as described above.

[0086] In contrast, in the inductor component 1A, the third point E3 is located on the second main surface 12b side relative to the virtual straight line F connecting the first point E1 and the second point E2, and the third point E3 corresponds to the interface between the external electrode and the base body 10 (insulator), which is the front end of the second ridgeline 14b side of the first electrode layer 31a on the first main surface 12a in the interface between the first electrode layer 31a and the base body 10 (insulator). In other words, in the inductor component 1A, the height position of the third point E3 on the first main surface 12a is closer to the second main surface 12b side than the height positions of the first point E1 and the second point E2. Therefore, when the inductor component 1A is mounted, when the inductor component 1A is flown in a selected machine or the like, even if the inductor component 1A is placed from the first main surface 12a side, the load applied to the inductor component 1A is not easily concentrated on the third point E3. Therefore, in the inductor component 1A, even if stress remains at the interface between the first electrode layer 31a and the base body 10 (insulator), cracks due to the stress are unlikely to occur starting from the third point E3 when the inductor component 1A is mounted.

[0087] As described above, the inductor component 1A can realize an inductor component capable of suppressing the occurrence of cracks due to stress remaining at the interface between the external electrode and the base body 10 (insulator), here, the interface between the first electrode layer 31 a and the base body 10 (insulator).

[0088] In the inductor component 1A, in any cross section including the first electrode layer 31a in the cross section along the length direction L and the height direction T, the third point E3 may be located on the second main surface 12b side relative to the virtual straight line F. In the inductor component 1A, the third point E3 may be located on the second main surface 12b side relative to the virtual straight line F in any cross section including the first electrode layer 31a in the cross section along the length direction L and the height direction T (see Figure 2 ) may be established in a cross section including the second coil wiring 21b and the first electrode layer 31a, or in both cross sections, but it is particularly preferred that it be established in all cross sections including the first electrode layer 31a.

[0089] In the inductor component 1A, in any cross section including the first electrode layer 31a among the cross sections along the length direction L and the height direction T, as shown in FIG. Figure 2 As shown in FIG. 1 , it is preferable that the entire contour line connecting the first point E1 and the third point E3 on the first main surface 12a is located on the second main surface 12b side relative to the virtual straight line F. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a in the cross section along the length direction L and the height direction T, as shown in FIG. Figure 2 As shown in FIG. 1 , it is preferable that the entire contour line connecting the first point E1 and the third point E3 on the first main surface 12 a does not protrude from the virtual straight line F to the side opposite to the second main surface 12 b .

[0090] Furthermore, in the inductor component 1A, as long as the third point E3 is located closer to the second main surface 12b than the virtual straight line F in any cross section including the first electrode layer 31a among the cross sections along the length direction L and the height direction T, a portion of the contour line connecting the first point E1 and the third point E3 on the first main surface 12a may be located on the side opposite to the second main surface 12b with respect to the virtual straight line F. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a among the cross sections along the length direction L and the height direction T, a portion of the contour line connecting the first point E1 and the third point E3 on the first main surface 12a may protrude from the virtual straight line F to the side opposite to the second main surface 12b.

[0091] It is preferable that a distance G1 between the third point E3 and the virtual straight line F in the height direction T is greater than or equal to 2 μm and less than or equal to 12 μm.

[0092] exist Figure 2 In the example shown, the distance G1 between the third point E3 and the virtual straight line F in the height direction T corresponds to the dimension of a perpendicular line drawn from the third point E3 to the virtual straight line F.

[0093] If the distance G1 between the third point E3 and the virtual straight line F in the height direction T is greater than or equal to 2 μm and less than or equal to 12 μm, the occurrence of the above-mentioned cracks is sufficiently suppressed, and reductions in the L value (inductance) and the Q value (quality factor) are also sufficiently suppressed.

[0094] When the distance G1 between the third point E3 and the virtual straight line F in the height direction T is less than 2 μm, it is difficult to obtain the effect that the load applied to the inductor component 1A is not easily concentrated on the third point E3 when the inductor component 1A is mounted. Therefore, when the distance G1 between the third point E3 and the virtual straight line F in the height direction T is less than 2 μm, it is difficult to obtain the effect that the above-mentioned crack is not easily generated starting from the third point E3.

[0095] When the distance G1 in the height direction T between the third point E3 and the virtual straight line F is greater than 12 μm, the area in which the coil 20 is provided in the blank 10 (for example, the distance J1 in the height direction T between the third point E3 and the second main surface 12b) becomes too small, thereby the inner diameter of the coil 20 becomes too small, so that the L value and the Q value are easily reduced.

[0096] It is preferable that a distance G1 between the third point E3 and the virtual straight line F in the height direction T is not less than 1% and not more than 7% of the maximum dimension H in the height direction T of the inductor component 1A.

[0097] If the distance G1 between the third point E3 and the virtual straight line F in the height direction T is greater than or equal to 1% and less than or equal to 7% of the maximum dimension H in the height direction T of the inductor component 1A, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the reduction in the L value and the Q value is also sufficiently suppressed.

[0098] When the distance G1 in the height direction T between the third point E3 and the virtual straight line F is less than 1% of the maximum dimension H in the height direction T of the inductor component 1A, it is difficult to obtain the effect that the load applied to the inductor component 1A is not easily concentrated on the third point E3 when the inductor component 1A is mounted. Therefore, when the distance G1 in the height direction T between the third point E3 and the virtual straight line F is less than 1% of the maximum dimension H in the height direction T of the inductor component 1A, it is difficult to obtain the effect that the above-mentioned crack is not easily generated starting from the third point E3.

[0099] When the distance G1 in the height direction T between the third point E3 and the virtual straight line F is greater than 7% of the maximum dimension H in the height direction T of the inductor component 1A, the area in which the coil 20 is provided in the blank 10 (for example, the distance J1 in the height direction T between the third point E3 and the second main surface 12b) becomes too small, thereby the inner diameter of the coil 20 becomes too small, so that the L value and the Q value are easily reduced.

[0100] It is preferable that a distance J1 between the third point E3 and the second main surface 12 b in the height direction T is smaller than a distance J2 between the first point E1 and the second main surface 12 b in the height direction T.

[0101] exist Figure 2 In the example shown, the difference between the distance J1 in the height direction T between the third point E3 and the second main surface 12b and the distance J2 in the height direction T between the first point E1 and the second main surface 12b corresponds to the distance G1 in the height direction T between the third point E3 and the virtual straight line F.

[0102] It is preferable that the shortest distance K1 between the third point E3 and the surface of the coil 20 is 25 μm or less.

[0103] In conventional inductor components, when the above-mentioned cracks occur, in order to prevent the cracks from reaching the coil and causing a negative impact on the coil characteristics, the first electrode layer and the coil are often sufficiently separated and arranged. Therefore, in conventional inductor components, there is a limit to how much the L value can be increased by bringing the first electrode layer and the coil closer together.

[0104] In contrast, in the inductor component 1A, the occurrence of the above-mentioned cracks is suppressed, so it is not necessary to sufficiently separate the first electrode layer 31a and the coil 20. Therefore, in the inductor component 1A, the L value can be increased by bringing the first electrode layer 31a and the coil 20 close to each other so that the shortest distance K1 between the third point E3 and the surface of the coil 20 is 25 μm or less.

[0105] like Figure 1 As shown in FIG. 1 , the inductor component 1A preferably further includes a second external electrode 30 b .

[0106] The second external electrode 30 b is disposed at a position away from the first external electrode 30 a .

[0107] exist Figure 1 In the example shown, the second external electrode 30b is arranged in a direction perpendicular to the axial direction of the coil. Figure 1 The center is a position in the length direction L away from the first external electrode 30a.

[0108] The second external electrode 30 b is electrically connected to the coil 20 .

[0109] exist Figure 1 In the example shown, the second external electrode 30b is electrically connected to the other end of the coil 20. Specifically, the second external electrode 30b is electrically connected to the second coil wiring 21b constituting the coil 20 via the second lead wiring 22b. In other words, the second lead wiring 22b connects the second coil wiring 21b and the second external electrode 30b.

[0110] The second lead wiring 22 b may have a single-layer structure or a multi-layer structure.

[0111] The conductive material constituting the second lead wiring 22 b may be the same as or different from the conductive material constituting the first lead wiring 22 a .

[0112] It is preferred that the second external electrode 30 b includes a third electrode layer 31 c which is buried in the body 10 and at least a portion of which is exposed from the body 10 .

[0113] The third electrode layer 31c preferably extends from the second ridgeline 14b toward the first ridgeline 14a at a position away from the first electrode layer 31a and is exposed on the first main surface 12a. In other words, the third electrode layer 31c preferably is exposed on a portion of the first main surface 12a at a position away from the first electrode layer 31a.

[0114] exist Figure 1 In the example shown, the third electrode layer 31c is exposed on a portion of the first main surface 12a on the second ridgeline 14b side. Specifically, the third electrode layer 31c is exposed on a region on the first main surface 12a closer to the second ridgeline 14b side than the center in the longitudinal direction L.

[0115] like Figure 1 As shown in the figure, the third electrode layer 31 preferably extends from the first main surface 12 a to the second end surface 11 b via the second ridge line portion 14 b and is exposed on the second end surface 11 b .

[0116] exist Figure 1 In the illustrated example, the third electrode layer 31 c is exposed from a portion of the first major surface 12 a on the second ridge line 14 b side over a portion of the second end surface 11 b on the second ridge line 14 b side.

[0117] Alternatively, the third electrode layer 31 c may be exposed only on a portion of the first major surface 12 a at a position away from the first electrode layer 31 a .

[0118] On the other hand, the third electrode layer 31 c is not exposed on the second major surface 12 b .

[0119] The dimension of the third electrode layer 31c in the coil axial direction may be smaller than the dimension of the second ridgeline portion 14b in the coil axial direction (the dimension of the coil axial direction of the blank 10), or may be the same as the dimension of the second ridgeline portion 14b in the coil axial direction (the dimension of the coil axial direction of the blank 10). In other words, the third electrode layer 31c may be in contact with a portion of the second ridgeline portion 14b or may be in contact with the entire second ridgeline portion 14b.

[0120] like Figure 1As shown, the second external electrode 30b preferably further includes a fourth electrode layer 31d, which is provided outside the body 10 to cover the third electrode layer 31c. In other words, the second external electrode 30b preferably includes the third electrode layer 31c and the fourth electrode layer 31d in order from the coil 20 side.

[0121] It is preferable that the fourth electrode layer 31d is in contact with the third electrode layer 31c.

[0122] The fourth electrode layer 31d is preferably provided outside the body 10, specifically, on the first main surface 12a, extending from the second ridgeline 14b toward the first ridgeline 14a at a position away from the first ridgeline 14a. In other words, the fourth electrode layer 31d is preferably provided on a portion of the first main surface 12a.

[0123] When the first external electrode 30a has the second electrode layer 31b, the fourth electrode layer 31d is preferably provided outside the body 10, specifically, on the first main surface 12a, extending from the second ridge portion 14b toward the first ridge portion 14a at a position away from the second electrode layer 31b. In other words, the fourth electrode layer 31d is preferably provided on a portion of the first main surface 12a at a position away from the second electrode layer 31b.

[0124] exist Figure 1 In the example shown, the fourth electrode layer 31d is provided on a portion of the first main surface 12a on the second ridgeline 14b side. Specifically, the fourth electrode layer 31d is provided on a region of the first main surface 12a closer to the second ridgeline 14b side than the center in the longitudinal direction L.

[0125] like Figure 1 As shown in FIG. 1 , the fourth electrode layer 31 d preferably extends from the first main surface 12 a to the second end surface 11 b via the second ridge line portion 14 b .

[0126] exist Figure 1 In the illustrated example, the fourth electrode layer 31 d extends from a portion of the first major surface 12 a on the second ridge line 14 b side to a portion of the second end surface 11 b on the second ridge line 14 b side.

[0127] Furthermore, the fourth electrode layer 31d may be provided only on a portion of the first major surface 12a. When the first external electrode 30a has the second electrode layer 31b, the fourth electrode layer 31d may be provided only on a portion of the first major surface 12a at a position away from the second electrode layer 31b.

[0128] On the other hand, it is preferable that the fourth electrode layer 31d is not provided on the second major surface 12b.

[0129] The size of the fourth electrode layer 31d in the coil axial direction may be smaller than the size of the second ridgeline portion 14b in the coil axial direction (the size of the coil axial direction of the blank 10), or may be the same as the size of the second ridgeline portion 14b in the coil axial direction (the size of the coil axial direction of the blank 10). In other words, the fourth electrode layer 31d may be in contact with a portion of the second ridgeline portion 14b or may be in contact with the entire second ridgeline portion 14b.

[0130] In the case where the second external electrode 30b has the third electrode layer 31c and the fourth electrode layer 31d, it is preferred that the third electrode layer 31c is a base electrode layer containing the above-mentioned conductive material, and the fourth electrode layer 31d is a plated electrode layer containing the above-mentioned conductive material. In this case, it is preferred that the second external electrode 30b has, in order from the coil 20 side, an Ag base electrode layer as the third electrode layer 31c and a Ni-plated electrode layer as the fourth electrode layer 31d. Furthermore, it is further preferred that the second external electrode 30b has, in order from the coil 20 side, an Ag base electrode layer as the third electrode layer 31c, a Ni-plated electrode layer as the fourth electrode layer 31d, and a Sn-plated electrode layer as another electrode layer covering the fourth electrode layer 31d.

[0131] exist Figure 2 In the cross section shown, in addition to the first point E1, the second point E2, and the third point E3, a fourth point E4 corresponding to the front end of the third electrode layer 31c on the first ridgeline portion 14a side of the first main surface 12a is defined. The fourth point E4 can also be said to correspond to the intersection of the interface between the third electrode layer 31c and the body 10 (insulator) and the first main surface 12a.

[0132] like Figure 2 As shown, when the first point E1, the second point E2, the third point E3, and the fourth point E4 are defined, the fourth point E4 is preferably located closer to the second main surface 12b than the virtual straight line F.

[0133] In the inductor component 1A, if the fourth point E4 is located on the second main surface 12b side relative to the virtual straight line F, when the inductor component 1A is mounted, even if the inductor component 1A is placed from the first main surface 12a side, the load applied to the inductor component 1A is the same as the third point E3, and is not easily concentrated on the fourth point E4, which corresponds to the interface between the external electrode and the base body 10 (insulator), and is the front end of the third electrode layer 31c located on the first ridgeline 14a side of the first main surface 12a in the interface between the third electrode layer 31c and the base body 10 (insulator). Therefore, in the inductor component 1A, even if stress remains at the interface between the third electrode layer 31c and the base body 10 (insulator), cracks caused by the stress are not easily generated starting from the fourth point E4 when the inductor component 1A is mounted.

[0134] In the inductor component 1A, it is preferred that the fourth point E4 is located on the second main surface 12b side of the virtual straight line F in any cross section including the first electrode layer 31a and the third electrode layer 31c in the cross section along the length direction L and the height direction T. In the inductor component 1A, the fourth point E4 may be located on the second main surface 12b side of the virtual straight line F in any cross section including the first electrode layer 31a and the third electrode layer 31c in the cross section along the length direction L and the height direction T (see Figure 2 ) may also be established in a cross section including the second coil wiring 21b, the first electrode layer 31a, and the third electrode layer 31c, or in these two cross sections, but it is particularly preferred that it be established in all cross sections including the first electrode layer 31a and the third electrode layer 31c.

[0135] In the inductor component 1A, it is preferable that in any cross section including the first electrode layer 31a and the third electrode layer 31c in the cross section along the length direction L and the height direction T, as shown in FIG. Figure 2 As shown in FIG. 1 , the contour line connecting the second point E2 and the fourth point E4 on the first main surface 12a is located on the second main surface 12b side relative to the virtual straight line F. In other words, in the inductor component 1A, it is preferred that in any cross section including the first electrode layer 31a and the third electrode layer 31c in the cross section along the length direction L and the height direction T, as shown in FIG. Figure 2 As shown, the contour line connecting the second point E2 and the fourth point E4 on the first main surface 12 a does not protrude from the virtual straight line F to the side opposite to the second main surface 12 b as a whole.

[0136] Furthermore, in the inductor component 1A, when the fourth point E4 is located on the second main surface 12b side of the virtual straight line F in any cross section including the first electrode layer 31a and the third electrode layer 31c among the cross sections along the length direction L and the height direction T, a portion of a contour line connecting the second point E2 on the first main surface 12a and the fourth point E4 may be located on the opposite side of the second main surface 12b with respect to the virtual straight line F. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a and the third electrode layer 31c among the cross sections along the length direction L and the height direction T, a portion of a contour line connecting the second point E2 on the first main surface 12a and the fourth point E4 may be directed from the virtual straight line F to the opposite side of the second main surface 12b.

[0137] exist Figure 2 In the example shown, in the first main surface 12a, the entire contour line connecting the first point E1 and the third point E3 and the entire contour line connecting the second point E2 and the fourth point E4 are located on the second main surface 12b side relative to the virtual straight line F, and the first main surface 12a becomes concave toward the second main surface 12b.

[0138] It is preferable that a distance G2 between the fourth point E4 and the virtual straight line F in the height direction T is greater than or equal to 2 μm and less than or equal to 12 μm.

[0139] exist Figure 2 In the example shown, the distance G2 between the fourth point E4 and the virtual straight line F in the height direction T corresponds to the dimension of a perpendicular line drawn from the fourth point E4 to the virtual straight line F.

[0140] When the distance G2 between the fourth point E4 and the virtual straight line F in the height direction T is 2 μm or more and 12 μm or less, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the decrease in the L value and the Q value is also sufficiently suppressed.

[0141] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 2 μm, it is difficult to obtain the effect that the load applied to the inductor component 1A is not easily concentrated on the fourth point E4 when the inductor component 1A is mounted. Therefore, when the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 2 μm, it is difficult to obtain the effect that the above-mentioned crack is not easily generated starting from the fourth point E4.

[0142] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is greater than 12 μm, the area in which the coil 20 is provided in the blank 10 (for example, the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b) becomes too small, and thus the inner diameter of the coil 20 becomes too small, so that the L value and the Q value are easily reduced.

[0143] It is preferable that a distance G2 between the fourth point E4 and the virtual straight line F in the height direction T is not less than 1% and not more than 7% of the maximum dimension H in the height direction T of the inductor component 1A.

[0144] If the distance G2 between the fourth point E4 and the virtual straight line F in the height direction T is 1% to 7% of the maximum dimension H in the height direction T of the inductor component 1A, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the reduction in L value and Q value is also sufficiently suppressed.

[0145] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 1% of the maximum dimension H in the height direction T of the inductor component 1A, it is difficult to obtain the effect that the load applied to the inductor component 1A is not easily concentrated on the fourth point E4 when the inductor component 1A is mounted. Therefore, when the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 1% of the maximum dimension H in the height direction T of the inductor component 1A, it is difficult to obtain the effect that the above-mentioned crack is not easily generated starting from the fourth point E4.

[0146] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is greater than 7% of the maximum dimension H in the height direction T of the inductor component 1A, the area in which the coil 20 is provided in the blank 10 (for example, the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b) becomes too small, and thus the inner diameter of the coil 20 becomes too small, so that the L value and the Q value are easily reduced.

[0147] It is preferable that a distance J3 between the fourth point E4 and the second main surface 12 b in the height direction T is smaller than a distance J4 between the second point E2 and the second main surface 12 b in the height direction T.

[0148] exist Figure 2 In the example shown, the difference between the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b and the distance J4 in the height direction T between the second point E2 and the second main surface 12b corresponds to the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F.

[0149] It is preferable that a distance J3 between the fourth point E4 and the second main surface 12 b in the height direction T is the same as a distance J1 between the third point E3 and the second main surface 12 b in the height direction T.

[0150] In addition, the distance J3 between the fourth point E4 and the second main surface 12b in the height direction T may be different from the distance J1 between the third point E3 and the second main surface 12b in the height direction T. In this case, the distance J3 between the fourth point E4 and the second main surface 12b in the height direction T may be greater than the distance J1 between the third point E3 and the second main surface 12b in the height direction T, or may be less than the distance J1 between the third point E3 and the second main surface 12b in the height direction T.

[0151] It is preferable that a distance J3 between the fourth point E4 and the second main surface 12 b in the height direction T is smaller than a distance J2 between the first point E1 and the second main surface 12 b in the height direction T.

[0152] It is preferred that the distance J4 in the height direction T between the second point E2 and the second main surface 12b is greater than the distance J1 in the height direction T between the third point E3 and the second main surface 12b. In other words, it is preferred that the distance J1 in the height direction T between the third point E3 and the second main surface 12b is smaller than the distance J4 in the height direction T between the second point E2 and the second main surface 12b.

[0153] It is preferable that a distance J4 between the second point E2 and the second main surface 12 b in the height direction T is the same as a distance J2 between the first point E1 and the second main surface 12 b in the height direction T.

[0154] In addition, the distance J4 between the second point E2 and the second main surface 12b in the height direction T may be different from the distance J2 between the first point E1 and the second main surface 12b in the height direction T. In this case, the distance J4 between the second point E2 and the second main surface 12b in the height direction T may be greater than the distance J2 between the first point E1 and the second main surface 12b in the height direction T, or may be less than the distance J2 between the first point E1 and the second main surface 12b in the height direction T.

[0155] It is preferable that the shortest distance K2 between the fourth point E4 and the surface of the coil 20 is 25 μm or less.

[0156] In the inductor component 1A, the generation of the above-mentioned cracks is suppressed, so it is not necessary to sufficiently separate the third electrode layer 31c and the coil 20. Therefore, in the inductor component 1A, the L value can be increased by bringing the third electrode layer 31c and the coil 20 close to each other so that the shortest distance K2 between the fourth point E4 and the surface of the coil 20 is 25 μm or less.

[0157] like Figure 1 as well as Figure 2 As shown in FIG. 1 , it is preferred that the first main surface 12a has a flat portion 12aa located between the first external electrode 30a and the second external electrode 30b. In other words, the first external electrode 30a and the second external electrode 30b are not provided on the flat portion 12aa of the first main surface 12a. Specifically, the first electrode layer 31a and the third electrode layer 31c are not exposed on the flat portion 12aa of the first main surface 12a, and the second electrode layer 31b and the fourth electrode layer 31d are not provided on the flat portion 12aa of the first main surface 12a.

[0158] like Figure 1 as well as Figure 2 As shown in FIG. 1 , the second main surface 12b is preferably parallel to the flat portion 12aa of the first main surface 12a. In other words, the second main surface 12b is preferably flat in the same manner as the flat portion 12aa of the first main surface 12a.

[0159] The second main surface 12b is parallel to the flat portion 12aa of the first main surface 12a. Figure 2 In the cross section along the length direction L and the height direction T shown, when the contour line of the second main surface 12b is moved along the height direction T and overlaps with the contour line (preferably a straight line) of the flat portion 12aa of the first main surface 12a, the contour line of the second main surface 12b as a whole is in a range of ±1μm in the height direction T relative to the contour line of the flat portion 12aa of the first main surface 12a.

[0160] In the inductor component 1A, if the second main surface 12b is parallel to the flat portion 12aa of the first main surface 12a, for example, when the inductor component 1A is mounted, even if the inductor component 1A is picked up (for example, sucked) from the second main surface 12b side by a mounter (chip mounter), the load applied to the inductor component 1A is not likely to be concentrated on a part of the second main surface 12b, for example, the third ridgeline portion 14c and the fourth ridgeline portion 14d. Therefore, when the inductor component 1A is mounted, the inductor component 1A is not likely to be damaged or broken on the second main surface 12b side by the load applied to the inductor component 1A by the mounter.

[0161] In the inductor component, the second main surface 12 b may not be parallel to the flat portion 12 aa of the first main surface 12 a .

[0162] Figure 3 It is a schematic cross-sectional view showing another example of the inductor component of the present invention.

[0163] exist Figure 3 In the inductor component 1B shown, the second main surface 12 b is not parallel to the flat portion 12 aa of the first main surface 12 a.

[0164] exist Figure 3 In the example shown, the second main surface 12 b has a concave shape that is recessed toward the first main surface 12 a side.

[0165] When the inductor component 1B is mounted, if the inductor component 1B is picked up from the second main surface 12b side by a mounting machine, the load applied to the inductor component 1B is likely to be concentrated on a part of the second main surface 12b, and here, is likely to be concentrated on the third ridgeline portion 14c and the fourth ridgeline portion 14d. Therefore, when the inductor component 1B is mounted, compared with when the inductor component 1A is mounted, the inductor component 1B is likely to be damaged or broken on the second main surface 12b side by the load applied to the inductor component 1B by the mounting machine.

[0166] As described above, in the inductor component 1A, the problem of chipping or cracking of the second main surface 12 b side due to the load applied during mounting is suppressed compared to the inductor component 1B.

[0167] In the above, an example in which the coil axial direction is parallel to the width direction W is shown, but the coil axial direction may be parallel to the longitudinal direction L or the height direction T.

[0168] When the coil axial direction is parallel to the longitudinal direction L or the width direction W, it is preferable that the flat portion 12 aa of the first main surface 12 a is parallel to the coil axial direction.

[0169] When the coil axial direction is parallel to the height direction T, it is preferable that the flat portion 12 aa of the first main surface 12 a is perpendicular to the coil axial direction.

[0170] The inductor component 1A is manufactured, for example, by the following method.

[0171] <Step of Producing a Mother Laminated Body>

[0172] First, for example, an insulating paste layer is formed by repeatedly applying an insulating paste containing a glass material mainly composed of borosilicate glass by screen printing, etc. The insulating paste layer formed here will later become the insulating layer 15a.

[0173] Next, for example, a photosensitive conductive paste layer is formed on the insulating paste layer by applying a photosensitive conductive paste mainly composed of Ag by screen printing or the like. Furthermore, after irradiating the photosensitive conductive paste layer with ultraviolet rays or the like through a photomask, the photosensitive conductive paste layer is developed by using an alkaline solution or the like, thereby forming a coil conductor layer, an external conductor layer, and a lead conductor layer connected to the coil conductor layer and the external conductor layer on the insulating paste layer. As described above, a coil conductor layer, a lead conductor layer, and an external conductor layer are formed in multiple locations by photolithography. The coil conductor layer formed here will subsequently become the first coil wiring 21a. The lead conductor layer formed here will subsequently become the first lead wiring 22a connecting the first coil wiring 21a and the first external electrode 30a (specifically, the first electrode layer 31a). The external conductor layer formed here will subsequently become a part of the first electrode layer 31a constituting the first external electrode 30a and a part of the third electrode layer 31c constituting the second external electrode 30b.

[0174] In forming the coil conductor layer, the lead conductor layer, and the external conductor layer, instead of exposure using a photomask, for example, DI exposure (also called direct image exposure or direct drawing) without using a photomask may be performed.

[0175] Next, for example, a new insulating paste layer is formed on the already formed insulating paste layer by applying a photosensitive insulating paste by screen printing or the like. And, after irradiating the newly formed insulating paste layer with ultraviolet rays or the like through a photomask, developing it with an alkaline solution or the like, through holes and openings are formed in the insulating paste layer. As described above, an insulating paste layer having through holes and openings provided at multiple locations is formed by photolithography. The insulating paste layer formed here includes an insulating paste layer that will later become the insulating layer 15b. The through hole formed here overlaps with a portion of the already formed coil conductor layer. The opening formed here overlaps with the already formed external conductor layer.

[0176] Furthermore, when forming an insulating paste layer provided with a through hole and an opening, for example, DI exposure without using a photomask may be performed instead of exposure using a photomask.

[0177] Next, for example, by applying a photosensitive conductive paste mainly composed of Ag using screen printing or the like, a new photosensitive conductive paste layer is formed inside the through hole and the opening, and on the already formed insulating paste layer. Furthermore, by irradiating the photosensitive conductive paste layer with ultraviolet rays or the like through a photomask, and then developing it using an alkaline solution or the like, a connecting conductor layer is formed inside the through hole, and a new coil conductor layer connected to the connecting conductor layer is formed on the insulating paste layer, and a new external conductor layer connected to the already formed external conductor layer is formed inside the opening, and a new external conductor layer is further formed on the external conductor layer. As described above, the coil conductor layer, the connecting conductor layer, and the external conductor layer are formed by photolithography. The connecting conductor layer formed here will later become a connecting conductor that connects adjacent coil wirings in the coil axial direction.

[0178] In addition, when forming the coil conductor layer, the connection conductor layer, and the external conductor layer, instead of the exposure using a photomask, for example, DI exposure without using a photomask may be performed.

[0179] Then, by repeating the above steps, the insulating paste layer, the coil conductor layer, the connection conductor layer, and the external conductor layer are formed into a predetermined laminated structure. For example, the coil conductor layer formed here includes a coil conductor layer that will later become the second coil wiring 21b.

[0180] Furthermore, when forming the coil conductor layer that will later become the second coil wiring 21b and the external conductor layer that is the same layer as the coil conductor layer, a lead conductor layer connected to the coil conductor layer and the external conductor layer is also formed. The lead conductor layer formed here later becomes the second lead wiring 22b that connects the second coil wiring 21b and the second external electrode 30b (specifically, the third electrode layer 31c).

[0181] Finally, a new insulating paste layer is formed by repeatedly applying an insulating paste containing a glass material mainly composed of borosilicate glass, for example, by screen printing, etc. The insulating paste layer formed here includes insulating paste layers that will later become insulating layer 15c and insulating layer 15d.

[0182] Through the above, a mother laminated body is produced.

[0183] The method for forming the conductor patterns of the coil conductor layer, the lead conductor layer, the connecting conductor layer, and the external conductor layer is not limited to the above-mentioned photolithography method. For example, it may be a method of printing and stacking a conductive paste using a screen printing plate with an opening set in the shape of the conductor pattern, or a method of forming a conductor film by sputtering, evaporation, foil crimping, etc., and then etching the conductor film to have the shape of the conductor pattern. It may also be a method of forming a negative pattern by a semi-additive method and then forming an electroplated film, and then removing unnecessary parts of the electroplated film by etching to have the shape of the conductor pattern.

[0184] When forming the conductor patterns of the coil conductor layer, the lead conductor layer, the connection conductor layer, and the external conductor layer, a higher aspect ratio is achieved by forming the conductor patterns in multiple stages, thereby reducing the loss caused by resistance at high frequencies. The method of forming the conductor patterns in multiple stages is not particularly limited, and for example, it may be a method of repeatedly overlapping the conductor patterns by repeatedly performing the above-mentioned process using the photolithography method, a method of repeatedly overlapping the conductor patterns formed by the semi-additive method, a method of overlapping the conductor patterns formed by the semi-additive method and the electroplated film grown by etching in any order, or a method of further electroplating the electroplated film formed by the semi-additive method.

[0185] The conductive material of the conductor patterns constituting the coil conductor layer, the lead conductor layer, the connecting conductor layer, and the external conductor layer is not limited to the photosensitive conductive paste with metal as the main component such as the above-mentioned photosensitive conductive paste with Ag as the main component, and may also be a conductor containing metals such as Ag, Au, Cu, etc. formed by sputtering, evaporation, foil crimping, electroplating, etc.

[0186] The method of forming the insulating paste layer is not limited to the above-mentioned photolithography method, and may be, for example, a method of crimping a sheet made of an insulating material, a method of spin coating the insulating material, or a method of spray coating the insulating material.

[0187] The method of forming an insulating paste layer having through holes and openings is not limited to the above-mentioned photolithography method. For example, it can also be a method of forming an insulating film by crimping a sheet made of insulating material, spin coating the insulating material, spraying the insulating material, etc., and then providing through holes and openings by laser processing, drilling, etc. on the insulating film.

[0188] The insulating material constituting the insulating paste layer is not limited to the glass material mainly composed of the above-mentioned borosilicate glass, and may be, for example, a ceramic material, an organic material such as epoxy resin, fluororesin, polymer resin, a composite material such as glass epoxy resin, etc. As the insulating material, a material having a small dielectric constant and dielectric loss is particularly preferred.

[0189] <Steps of forming a base body, a coil, and external electrodes>

[0190] First, the mother laminate is cut by dicing or the like to be cut into a plurality of unfired laminates.

[0191] The unfired laminated body includes an insulating paste laminated portion in which insulating paste layers are laminated, a coil conductor laminated portion in which coil conductor layers are laminated so that adjacent coil conductor layers are electrically connected via a connecting conductor layer, and an external conductor laminated portion in which external conductor layers are laminated.

[0192] When the unfired laminate is cut, the outer conductor laminate is exposed at two locations on at least the bottom surface of the insulating paste laminate included in the cut section of the unfired laminate. The bottom surface of the insulating paste laminate will later become the first main surface 12a of the green body 10.

[0193] Next, the unfired laminated body is fired to produce a laminated body.

[0194] When the unfired laminate is fired, the insulating paste layer becomes an insulating layer, and the insulating paste laminate portion becomes an insulator included in the green body 10. In addition, when the unfired laminate is fired, the coil conductor layer becomes a coil wiring, and the coil conductor laminate portion becomes the coil 20. Furthermore, when the unfired laminate is fired, one of the two external conductor laminate portions becomes the first electrode layer 31a of the first external electrode 30a, and the other becomes the third electrode layer 31c of the second external electrode 30b.

[0195] Next, the obtained laminated body may be subjected to, for example, barrel polishing to chamfer the corners and ridges of the blank 10 .

[0196] Finally, the first electrode layer 31a and the third electrode layer 31c are set as Ag base electrode layers, and Ni-plated electrode layers and Sn-plated electrode layers are formed on the surface of each Ag base electrode layer in sequence through electroplating. One of the two Ni-plated electrode layers formed here is the second electrode layer 31b of the first external electrode 30a, and the other is the fourth electrode layer 31d of the second external electrode 30b. One of the two Sn-plated electrode layers formed here is another electrode layer of the first external electrode 30a that is different from the first electrode layer 31a and the second electrode layer 31b, and the other is another electrode layer of the second external electrode 30b that is different from the third electrode layer 31c and the fourth electrode layer 31d. The thickness of the Ni-plated electrode layer and the Sn-plated electrode layer is, for example, not less than 2 μm and not more than 10 μm.

[0197] In this way, the Ag base electrode layer, the Ni plated electrode layer, and the Sn plated electrode layer are provided in order from the coil 20 side, thereby forming the first external electrode 30 a and the second external electrode 30 b .

[0198] The method for forming the external electrode is not limited to the method of performing electroplating treatment on the external conductor laminate portion exposed in the cross section of the unfired laminate (at least the bottom surface of the insulating paste laminate portion) as described above. For example, it can also be the following method, as described above, the external conductor laminate portion is exposed in the cross section of the unfired laminate (at least the bottom surface of the insulating paste laminate portion), and then the exposed portion of the external conductor laminate portion is immersed (immersed) in the conductive paste, or the conductive paste is formed into a film on the exposed portion of the external conductor laminate portion by sputtering, and then the electroplating treatment is performed.

[0199] Through the above, the inductor component 1A is manufactured.

[0200] In the inductor component 1A, as described above (see Figure 2 ), the first main surface 12a is concave toward the second main surface 12b, so that the third point E3 is located on the second main surface 12b side relative to the virtual straight line F, and the fourth point E4 is located on the second main surface 12b side relative to the virtual straight line F. The method for making the first main surface 12a concave in this way is not particularly limited, and for example, the following methods can be cited.

[0201] As a first method, in the <step of forming a mother laminate>, a portion of the outer edge of each of the plurality of insulating paste layers forming a laminated structure is formed into a concave shape, thereby making the bottom surface of the insulating paste laminated portion in the unfired laminate obtained in the <step of forming a green body, a coil, and an external electrode> into a concave shape. Then, when the unfired laminated body having the concave bottom surface of the insulating paste laminated portion is fired, the first main surface 12a of the obtained green body 10 is concave.

[0202] As a second method, in the step of forming a green body, a coil, and external electrodes, the first main surface 12 a of the green body 10 is concave by subjecting the fired laminated body to grinding, laser processing, or the like.

[0203] The inductor component 1A is manufactured in, for example, a 0402 (0.4 mm×0.2 mm×0.2 mm) size. In addition, the size of the inductor component 1A is not limited to the 0402 (0.4 mm×0.2 mm×0.2 mm) size.

[0204] This specification discloses the following contents.

[0205] <1>

[0206] An inductor component comprising:

[0207] a body including an insulator;

[0208] A coil is disposed inside the blank; and

[0209] A first external electrode is electrically connected to the coil.

[0210] The blank has: a first end face and a second end face opposite to each other in the length direction; a first main face and a second main face opposite to each other in the height direction perpendicular to the length direction; a first side face and a second side face opposite to each other in the width direction perpendicular to the length direction and the height direction,

[0211] The first end surface and the first main surface intersect at the first ridgeline portion,

[0212] The second end surface and the first main surface intersect at the second ridgeline portion,

[0213] The first external electrode has a first electrode layer, the first electrode layer is buried in the green body and at least a portion of the first electrode layer is exposed from the green body.

[0214] The first electrode layer extends from the first ridge portion toward the second ridge portion at a position away from the second ridge portion and is exposed on the first main surface but not on the second main surface.

[0215] In a cross section including the first electrode layer in the cross section along the length direction and the height direction, a first point corresponding to the first ridge portion, a second point corresponding to the second ridge portion, and a third point corresponding to the front end of the second ridge portion side of the first electrode layer located on the first main surface are defined, and the third point is located closer to the second main surface than a virtual straight line connecting the first point and the second point.

[0216] <2>

[0217] The inductor component according to <1>, wherein:

[0218] A distance between the third point and the virtual straight line in the height direction is greater than or equal to 2 μm and less than or equal to 12 μm.

[0219] <3>

[0220] The inductor component according to <1> or <2>, wherein:

[0221] A distance between the third point and the virtual straight line in the height direction is not less than 1% and not more than 7% of a maximum dimension of the inductor component in the height direction.

[0222] <4>

[0223] The inductor component according to any one of <1> to <3>, wherein:

[0224] A distance between the third point and the second main surface in the height direction is smaller than a distance between the first point and the second main surface in the height direction.

[0225] <5>

[0226] The inductor component according to any one of <1> to <4>, wherein:

[0227] The shortest distance between the third point and the surface of the coil is 25 μm or less.

[0228] <6>

[0229] The inductor component according to any one of <1> to <5>, wherein:

[0230] The first electrode layer further extends from the first main surface to the first end surface via the first ridge line portion and is exposed at the first end surface.

[0231] <7>

[0232] The inductor component according to any one of <1> to <6>, wherein:

[0233] The first external electrode further includes a second electrode layer, which is disposed outside the body to cover the first electrode layer.

[0234] <8>

[0235] The inductor component according to any one of <1> to <7>, wherein:

[0236] further comprising a second external electrode, the second external electrode being disposed at a position away from the first external electrode and being electrically connected to the coil,

[0237] The second external electrode has a third electrode layer, the third electrode layer is buried in the green body and at least a portion of the third electrode layer is exposed from the green body.

[0238] The third electrode layer extends from the second ridgeline portion toward the first ridgeline portion at a position away from the first electrode layer, and is exposed on the first main surface but not on the second main surface.

[0239] In a cross section along the length direction and the height direction including the first electrode layer and the third electrode layer, when a fourth point corresponding to the front end of the third electrode layer on the first ridge line side located on the first principal surface is defined, the fourth point is located closer to the second principal surface than the virtual straight line.

[0240] <9>

[0241] The inductor component according to <8>, wherein:

[0242] A distance between the fourth point and the virtual straight line in the height direction is greater than or equal to 2 μm and less than or equal to 12 μm.

[0243] <10>

[0244] The inductor component according to <8> or <9>, wherein:

[0245] A distance between the fourth point and the virtual straight line in the height direction is not less than 1% and not more than 7% of a maximum dimension of the inductor component in the height direction.

[0246] <11>

[0247] The inductor component according to any one of <8> to <10>, wherein:

[0248] A distance between the fourth point and the second main surface in the height direction is smaller than a distance between the second point and the second main surface in the height direction.

[0249] <12>

[0250] The inductor component according to any one of <8> to <11>, wherein:

[0251] The shortest distance between the fourth point and the surface of the coil is 25 μm or less.

[0252] <13>

[0253] The inductor component according to any one of <8> to <12>, wherein:

[0254] The third electrode layer further extends from the first main surface to the second end surface via the second ridge line portion and is exposed at the second end surface.

[0255] <14>

[0256] The inductor component according to any one of <8> to <13>, wherein:

[0257] The second external electrode further includes a fourth electrode layer, which is disposed outside the body to cover the third electrode layer.

[0258] <15>

[0259] The inductor component according to any one of <8> to <14>, wherein:

[0260] The first main surface has a flat portion located between the first external electrode and the second external electrode,

[0261] The second main surface is parallel to the flat portion of the first main surface.

[0262] Description of Reference Numerals

[0263] 1A, 1B inductor component; 10 green body; 11a first end face; 11b second end face; 12a first main face; 12aa flat portion of the first main face; 12b second main face; 13a first side face; 13b second side face; 14a first ridge portion; 14b second ridge portion; 14c third ridge portion; 14d fourth ridge portion; 15a, 15b, 15c, 15d insulating layer; 20 coil; 21a first coil wiring; 21b second coil wiring; 22a first lead wiring; 22b second lead wiring; 30a first external electrode; 30b second external electrode; 31a first electrode layer; 31b second electrode layer; 31c third electrode layer; 31d fourth electrode layer; C coil axis ; E1 the first point; E2 the second point; E3 the third point; E4 the fourth point; F the virtual straight line; G1 the distance in the height direction between the third point and the virtual straight line; G2 the distance in the height direction between the fourth point and the virtual straight line; H the maximum dimension of the inductor component in the height direction; J1 the distance in the height direction between the third point and the second main surface; J2 the distance in the height direction between the first point and the second main surface; J3 the distance in the height direction between the fourth point and the second main surface; J4 the distance in the height direction between the second point and the second main surface; K1 the shortest distance between the third point and the surface of the coil; K2 the shortest distance between the fourth point and the surface of the coil; L length direction; T height direction; W width direction.

Claims

1. An inductor component, comprising: a body including an insulator; A coil is disposed inside the blank; and A first external electrode is electrically connected to the coil. The blank has: a first end face and a second end face opposite to each other in the length direction; a first main face and a second main face opposite to each other in the height direction perpendicular to the length direction; and a first side face and a second side face opposite to each other in the width direction perpendicular to the length direction and the height direction. The first end surface and the first main surface intersect at the first ridgeline portion, The second end surface and the first main surface intersect at the second ridgeline portion, The first external electrode has a first electrode layer, the first electrode layer is buried in the green body and at least a portion of the first electrode layer is exposed from the green body. The first electrode layer extends from the first ridge portion toward the second ridge portion at a position away from the second ridge portion, and is exposed on the first main surface but not on the second main surface. In a cross section including the first electrode layer in the cross section along the length direction and the height direction, a first point corresponding to the first ridge portion, a second point corresponding to the second ridge portion, and a third point corresponding to the front end of the second ridge portion side of the first electrode layer located on the first main surface are defined, and the third point is located closer to the second main surface than a virtual straight line connecting the first point and the second point.

2. The inductor component according to claim 1, wherein A distance between the third point and the virtual straight line in the height direction is greater than or equal to 2 μm and less than or equal to 12 μm.

3. The inductor component according to claim 1 or 2, wherein: A distance between the third point and the virtual straight line in the height direction is not less than 1% and not more than 7% of a maximum dimension of the inductor component in the height direction.

4. The inductor component according to any one of claims 1 to 3, wherein: A distance between the third point and the second main surface in the height direction is smaller than a distance between the first point and the second main surface in the height direction.

5. The inductor component according to any one of claims 1 to 4, wherein: The shortest distance between the third point and the surface of the coil is 25 μm or less.

6. The inductor component according to any one of claims 1 to 5, wherein: The first electrode layer further extends from the first main surface to the first end surface via the first ridge line portion and is exposed at the first end surface.

7. The inductor component according to any one of claims 1 to 6, wherein: The first external electrode further includes a second electrode layer, which is disposed outside the body to cover the first electrode layer.

8. The inductor component according to any one of claims 1 to 7, wherein: further comprising a second external electrode, the second external electrode being disposed at a position away from the first external electrode and being electrically connected to the coil, The second external electrode has a third electrode layer, the third electrode layer is buried in the green body and at least a portion of the third electrode layer is exposed from the green body. The third electrode layer extends from the second ridge portion toward the first ridge portion at a position away from the first ridge portion, and is exposed on the first main surface but not on the second main surface. In a cross section along the length direction and the height direction including the first electrode layer and the third electrode layer, when a fourth point corresponding to the front end of the third electrode layer on the first ridge line side located on the first principal surface is defined, the fourth point is located closer to the second principal surface than the virtual straight line.

9. The inductor component according to claim 8, wherein A distance between the fourth point and the virtual straight line in the height direction is greater than or equal to 2 μm and less than or equal to 12 μm.

10. The inductor component according to claim 8 or 9, wherein: A distance between the fourth point and the virtual straight line in the height direction is not less than 1% and not more than 7% of a maximum dimension of the inductor component in the height direction.

11. The inductor component according to any one of claims 8 to 10, wherein: A distance between the fourth point and the second main surface in the height direction is smaller than a distance between the second point and the second main surface in the height direction.

12. The inductor component according to any one of claims 8 to 11, wherein: The shortest distance between the fourth point and the surface of the coil is 25 μm or less.

13. The inductor component according to any one of claims 8 to 12, wherein: The third electrode layer further extends from the first main surface to the second end surface via the second ridge line portion and is exposed at the second end surface.

14. The inductor component according to any one of claims 8 to 13, wherein: The second external electrode further includes a fourth electrode layer, which is disposed outside the body to cover the third electrode layer.

15. The inductor component according to any one of claims 8 to 14, wherein: The first main surface has a flat portion located between the first external electrode and the second external electrode, The second main surface is parallel to the flat portion of the first main surface.

Images