Laminated coil component and method for manufacturing laminated coil component

Abstract

The laminated coil component is provided with a laminated body which is formed by laminating a plurality of insulating layers and has a coil therein, and a first external electrode and a second external electrode which are electrically connected to the coil, and the coil is formed by electrically connecting a plurality of coil conductors laminated together with the insulating layers. The laminated body has a first end surface and a second end surface facing each other in a longitudinal direction, a first main surface and a second main surface facing each other in a height direction orthogonal to the longitudinal direction, and a first side surface and a second side surface facing each other in a width direction orthogonal to the longitudinal direction and the height direction. The coil axis of the coil is parallel to the first main surface, and the laminated body further has a plate-shaped member laminated together with the insulating layer, the plate-shaped member having a dimension in a direction perpendicular to the coil axis larger than a dimension in a direction parallel to the coil axis. The area of the plate-like member is smaller than the area of the first end surface of the laminate.

Description

Technical Field

[0001] The present invention relates to a laminated coil component and a method for manufacturing the laminated coil component. Background Art

[0002] Patent Document 1 discloses a method for manufacturing a laminated coil component by laminating a plurality of ceramic green sheets having a conductor pattern printed on the surface as a coil conductor to form an element with a built-in coil, and forming external electrodes on both end faces in the lamination direction of the element.

[0003] Patent Document 1: Japanese Patent Application Laid-Open No. 2001-196240

[0004] However, in the case of forming external electrodes on a laminate manufactured by the method described in Patent Document 1, there is a case where the formation of the external electrodes is defective under specific conditions.

[0005] In the case of manufacturing a laminated coil component by the method described in Patent Document 1, there is a case where a portion where the winding shapes of the coils overlap on the end faces in the lamination direction of the element protrudes, and relatively, the inner portion of the winding shape of the coil is recessed. Also, a portion that protrudes more than the surrounding portion where the winding shape of the coil overlaps in such a case is referred to as a "coil mark".

[0006] If a "coil mark" is generated on the end face where the external electrodes of the element are formed, it is considered that when a paste that becomes an external electrode is applied to the end face of the element, air bubbles enter the depression in the center of the coil mark, resulting in defective formation of the external electrodes.

[0007] However, in conventional laminated coil components, it has not been known that defective formation of external electrodes is caused by coil marks.

[0008] Although coil marks are formed on the end faces in the lamination direction of the element, in Patent Document 1, external electrodes are formed on end faces that are not the end faces in the lamination direction of the element.

[0009] Therefore, when the end face where the coil marks are generated is different from the end face where the external electrodes are formed, defective formation of the external electrodes does not occur.

[0010] In addition, depending on the size (depth) of the coil mark, defective formation of the external electrodes is not caused.

[0011] In conventional laminated coil components, the coil marks are small, and even when a paste that becomes an external electrode is applied to the end face of the element, air bubbles do not enter the depression in the center of the coil mark.

[0012] However, it is known that when the size of the component is increased or the number of layers of the coil conductor is increased in order to improve the performance of the multilayer coil component, the depth of the coil mark becomes larger (deeper). When the paste that becomes the external electrode is coated, there is a case where air bubbles enter the depression in the center of the coil mark, causing defective formation of the external electrode.

[0013] Based on the above, the defective formation of the external electrode caused by the coil mark is a problem that significantly occurs when the conditions such as the larger size of the multilayer coil component or the larger number of layers of the coil conductor resulting in a deeper depth of the coil mark overlap with the condition that the end face where the coil mark is generated coincides with the end face where the external electrode is formed. So far, it has not been generally recognized. Summary of the Invention

[0014] The present invention is completed to solve the above problems, and an object thereof is to provide a multilayer coil component capable of suppressing structural defects of the external electrode by reducing the coil mark on the end face of the green body.

[0015] The multilayer coil component of the present invention includes a laminate formed by laminating a plurality of insulating layers and having a coil inside, a first external electrode and a second external electrode electrically connected to the coil. The coil is formed by electrically connecting a plurality of coil conductors laminated together with the insulating layers. The laminate has a first end face and a second end face facing each other in the length direction, a first main face and a second main face facing each other in the height direction orthogonal to the length direction, and a first side face and a second side face facing each other in the width direction orthogonal to the length direction and the height direction. The coil axis of the coil is parallel to the first main face. The laminate further has a plate-like member laminated together with the insulating layers and having a size in a direction perpendicular to the coil axis larger than a size in a direction parallel to the coil axis. The area of the plate-like member is smaller than the area of the first end face of the laminate.

[0016] According to the present invention, it is possible to provide a multilayer coil component capable of suppressing structural defects of the external electrode by reducing the coil mark on the end face of the green body. Brief Description of the Drawings

[0017] Figure 1 It is a perspective view schematically showing an example of the multilayer coil component of the present invention.

[0018] Figure 2 It schematically shows Figure 1 An exploded perspective view of an example of the laminate constituting the shown multilayer coil component.

[0019] Figure 3 It is a side view schematically showing an example of the internal structure of the laminate constituting the Figure 1 Shown multilayer coil component.

[0020] Figure 4 is schematically showing Figure 1 A cross-sectional view of an example of a cross-section along line segment A1 - A1 of the stacked coil component shown.

[0021] Figure 5 is a cross-sectional view schematically showing an example of a stacked coil component without a plate-like component being arranged.

[0022] Figure 6 is viewed from the first end face side Figure 5 A side view of the stacked coil component shown.

[0023] Figure 7 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0024] Figure 8 is a perspective view Figure 7 A side view schematically showing an example of the internal structure of the stack shown.

[0025] Figure 9 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0026] Figure 10 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0027] Figure 11 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0028] Figure 12 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0029] Figure 13 is a developed view schematically showing another example of the stack that constitutes the stacked coil component of the present invention.

[0030] Figure 14 is a graph obtained by adding an approximate curve to a graph plotting the relationship between the ratio of the area of the plate-like component to the cross-sectional area of the coil and the depth of the depression for the stacked coil components of Examples 1 to 6.

[0031] Explanation of reference numerals

[0032] 1... Stacked coil component, 10, 100, 101, 102, 103, 104, 105... Stacked body, 11, 11’... First end face, 11a, 11a’... First recess, 11a1, 11a1’... Deepest part of the first recess, 11b, 11b’... First protrusion, 11b1, 11b1’... Vertex of the first protrusion, 12, 12’... Second end face, 12a, 21a’... Second recess, 12a1, 12a1’... Deepest part of the second recess, 12b, 12b’... Second protrusion, 12b1, 12b1’... Vertex of the second protrusion, 13, 13’... First main face, 14, 14’... Second main face, 15, 15’... First side face, 16, 16’... Second side face, 21, 21’... First external electrode, 22, 22’... Second external electrode, 23’... Gap, 24’... Crack, 30... Coil, 31a, 31b, 31c, 31d, 31e, 31f... Insulating layer, 32, 32a, 32b, 32c, 32d... Coil conductor, 33, 33a, 33b, 33c, 33d, 33e, 33f... Through-hole conductor, 34, 34a, 34b, 34c, 34d... Winding part, 35, 35a, 35b, 35c, 35d, 35e, 35f... Pad, 37a, 37b, 37c, 37d, 37e, 37f, 137e, 137f... Plate-like component, 41... First lead conductor, 42... Second lead conductor, 131a, 131b, 131c, 131d, 131e, 131f, 231e, 231f... Insulating layer (with plate-like component), A... Coil axis of the coil, d1, d1’... Depth of the first recess, d2, d2’... Depth of the second recess. Detailed implementation mode

[0033] Hereinafter, the stacked coil component of the present invention will be described. In addition, the present invention is not limited to the following structure, and can also be appropriately changed without departing from the gist of the present invention. In addition, a structure obtained by combining a plurality of the following described preferred structures is also the present invention.

[0034] The following drawings are schematic views, and there are cases where the dimensions, aspect ratio scales, etc. are different from those of actual products. In the figures, the same or corresponding parts are denoted by the same reference numerals. In addition, in each figure, the same elements are denoted by the same reference numerals and repeated descriptions are omitted.

[0035] In this specification, the statements indicating the relationality between elements (e.g., "parallel", "orthogonal", etc.) and the statements indicating the shape of elements do not only refer to the exact manner as literally described, but also refer to the actual equivalent range, for example, a range including a difference of about several percent.

[0036] Taking each of the following embodiments as an example, it is of course possible to perform replacement or combination of parts of the structures shown in different embodiments. In the second embodiment and subsequent embodiments, descriptions of matters the same as those in the first embodiment are omitted, and only differences are described. In particular, the same effects brought about by the same structures are not mentioned in sequence for each embodiment.

[0037] [Stacked Coil Component]

[0038] The stacked coil component of the present invention includes a stack formed by stacking a plurality of insulating layers and having a coil inside, and a first external electrode and a second external electrode electrically connected to the coil. The coil is formed by electrically connecting a plurality of coil conductors stacked together with the insulating layers. The stack has a first end face and a second end face facing each other in the length direction, a first main face and a second main face facing each other in the height direction orthogonal to the length direction, and a first side face and a second side face facing each other in the width direction orthogonal to the length direction and the height direction. The coil axis of the coil is parallel to the first main face. The stack further has a plate-like member stacked together with the insulating layers and having a size in a direction perpendicular to the coil axis larger than a size in a direction parallel to the coil axis. The area of the plate-like member is smaller than the area of the first end face of the stack.

[0039] Figure 1 It is a perspective view schematically showing an example of the stacked coil component of the present invention.

[0040] Figure 1 The stacked coil component 1 shown includes a stack (green body) 10, and a first external electrode 21 and a second external electrode 22 provided on the outer surface of the stack 10. The stack 10 has a rectangular parallelepiped shape with six faces. Although the structure of the stack 10 will be described later, a plurality of insulating layers and a plurality of coil conductors are stacked in the stacking direction, and a coil is provided inside. The first external electrode 21 and the second external electrode 22 are electrically connected to the coil respectively.

[0041] In the stacked coil component and the stack in this specification, the length direction, the height direction, and the width direction are respectively set as Figure 1 the L direction, the T direction, and the W direction in

[0042] Here, the length direction L is a direction parallel to the stacking direction.

[0043] As Figure 1As shown, the laminate 10 has a first end face 11 and a second end face 12 facing each other in the length direction L, a first main face 13 and a second main face 14 facing each other in the height direction T orthogonal to the length direction L, and a first side face 15 and a second side face 16 facing each other in the width direction W orthogonal to the length direction L and the height direction T.

[0044] Although not shown in Figure 1 , it is preferable that the corners and ridge lines of the laminate 10 are chamfered. A corner is a part where three faces of the laminate intersect, and a ridge line is a part where two faces of the laminate intersect.

[0045] For example, as Figure 1 shown, the first external electrode 21 covers the entire first end face 11 of the laminate 10, and extends from the first end face 11 to cover a part of the first main face 13, a part of the second main face 14, a part of the first side face 15, and a part of the second side face 16.

[0046] For example, as Figure 1 shown, the second external electrode 22 covers the entire second end face 12 of the laminate 10, and extends from the second end face 12 to cover a part of the first main face 13, a part of the second main face 14, a part of the first side face 15, and a part of the second side face 16.

[0047] When the laminated coil component 1 having the first external electrode 21 and the second external electrode 22 is mounted and arranged on the substrate as described above, any one of the first main face 13, the second main face 14, the first side face 15, and the second side face 16 of the laminate 10 becomes the mounting face.

[0048] However, the first external electrode 21 only needs to extend from at least a part of the first end face 11 of the laminate 10 to the mounting face of the laminate 10.

[0049] Similarly, the second external electrode 22 only needs to extend from at least a part of the second end face 12 of the laminate 10 to the mounting face of the laminate 10.

[0050] Each of the first external electrode 21 and the second external electrode 22 can be either a single-layer structure or a multi-layer structure.

[0051] In the case where the first external electrode 21 and the second external electrode 22 are respectively of a single-layer structure, examples of the constituent materials of each external electrode include Ag, Au, Cu, Pd, Ni, Al, alloys containing at least one of these metals, and the like.

[0052] In the case where the first external electrode 21 and the second external electrode 22 are each of a multilayer structure, each external electrode may sequentially include, for example, a base electrode layer containing Ag, a Ni coating, and a Sn coating from the surface side of the laminate 10.

[0053] The size of the laminated coil component of the present invention is not particularly limited, but it is preferably 1608 size or more in JIS C 5101-21(2021) (however, the symbol M indicating the size represented by the public manufacturing method is omitted).

[0054] Figure 2 is schematically showing the constitution of Figure 1 an exploded perspective view of an example of the laminate constituting the shown laminated coil component.

[0055] As Figure 2 shown, the laminate 10 is formed by laminating a plurality of insulating layers 31a, 31b, 31c, 31d, 31e, 31f, 131e, and 131f in the lamination direction (here, the length direction L) from the second end face 12 side of the laminate 10 toward the first end face 11 side. Hereinafter, the insulating layers 31a, 31b, 31c, 31d, 31e, and 31f are also collectively referred to as the insulating layer 31. In addition, the insulating layer 131e and the insulating layer 131f are also collectively referred to as the insulating layer 131.

[0056] In addition, in the present specification, the direction in which a plurality of insulating layers constituting the laminate are laminated is referred to as the lamination direction.

[0057] In Figure 2 it, the insulating layers 31e and 131e are arranged on the lower side in the lamination direction (the second end face 12 side of the laminate 10), and the insulating layers 31f and 131f are arranged on the upper side in the lamination direction (the first end face 11 side of the laminate 10).

[0058] As a constituent material of each insulating layer 31, for example, a magnetic material such as a ferrite material can be cited.

[0059] Coil conductors 32a, 32b, 32c, and 32d and via conductors 33a, 33b, 33c, and 33d are respectively provided in insulating layers 31a, 31b, 31c, and 31d. A via conductor 33e and a pad 35e are provided in insulating layer 31e. A via conductor 33f and a pad 35f are provided in insulating layer 31f. A via conductor 33e, a pad 35e, and a plate-like component 37e are provided in insulating layer 131e. A via conductor 33f, a pad 35f, and a plate-like component 37f are provided in insulating layer 131f. Insulating layer 131e and insulating layer 131f may be a total of one layer or two or more layers. Insulating layer 31e may be a total of zero layers, one layer, or two or more layers. Insulating layer 31e and insulating layer 131e may be a total of one layer or two or more layers. Similarly, insulating layer 31f may be a total of zero layers, one layer, or two or more layers. Insulating layer 31f and insulating layer 131f may be a total of one layer or two or more layers. Hereinafter, coil conductors 32a, 32b, 32c, and 32d will also be collectively referred to as coil conductor 32.

[0060] Coil conductors 32a, 32b, 32c, and 32d are respectively provided on the main surfaces of insulating layers 31a, 31b, 31c, and 31d and are laminated together with insulating layers 31a, 31b, 31c, 31d, 31e, 31f, 131e, and 131f. In Figure 2 each, each coil conductor 32 has a 3 / 4 turn shape, and four insulating layers 31 arranged in the order of insulating layers 31a, 31b, 31c, and 31d are taken as one unit (three turns) and laminated repeatedly.

[0061] In addition, coil conductors 32a, 32b, 32c, and 32d respectively include annular winding portions 34a, 34b, 34c, and 34d with one position missing and partially having gaps, and pads 35a, 35b, 35c, and 35d. Pads 35a, 35b, 35c, and 35d are respectively provided at both end portions of each of winding portions 34a, 34b, 34c, and 34d. Hereinafter, winding portions 34a, 34b, 34c, and 34d will also be collectively referred to as winding portion 34.

[0062] Via conductors 33a, 33b, 33c, 33d, 33e, and 33f are respectively provided so as to penetrate insulating layers 31a, 31b, 31c, 31d, 31e, 31f, 131e, and 131f in the lamination direction. Hereinafter, via conductors 33a, 33b, 33c, 33d, 33e, and 33f will also be collectively referred to as via conductor 33.

[0063] Above the through-hole conductors 33e and 33f, pads 35e and 35f are respectively provided. Preferably, the pads 35a, 35b, 35c, 35d, 35e, and 35f are slightly wider than the wire widths of the winding portions 34a, 34b, 34c, and 34d. Hereinafter, the pads 35a, 35b, 35c, 35d, 35e, and 35f are also collectively referred to as pad 35.

[0064] As the constituent materials of each coil conductor 32 including the winding portion 34 and the pad 35, and each through-hole conductor 33, for example, Ag, Au, Cu, Pd, Ni, Al, an alloy containing at least one of these metals, etc. can be cited.

[0065] A plurality of insulating layers 31a, 31b, 31c, 31d, 31e, 31f, 131e, and 131f configured as described above are laminated in the stacking direction. Thereby, the laminate 10 is formed, and the plurality of coil conductors 32a, 32b, 32c, and 32d are electrically connected via the through-hole conductors 33a, 33b, 33c, and 33d. As a result, a solenoid-shaped coil having a coil axis parallel to the stacking direction is formed within the laminate 10.

[0066] In addition, the through-hole conductor 33e and the pad 35e become the second lead conductor within the laminate 10 and are exposed at the second end face 12 of the laminate 10. That is, the second lead conductor includes the through-hole conductor 33e and the pad 35e. As will be described later, the second lead conductor connects the second external electrode 22 and the coil conductor 32a opposed thereto within the laminate 10.

[0067] The through-hole conductor 33f and the pad 35f become the first lead conductor within the laminate 10 and are exposed at the first end face 11 of the laminate 10. That is, the first lead conductor includes the through-hole conductor 33f and the pad 35f. As will be described later, the first lead conductor connects the first external electrode 21 and the coil conductor 32d opposed thereto within the laminate 10.

[0068] Preferably, when viewed from the stacking direction (length direction L), the coil conductors 32 overlap each other. In addition, when viewed from the stacking direction, the coil can be Figure 2 a shape composed of straight portions (e.g., a polygon such as a rectangle) as shown, a shape composed of curved portions (e.g., a circle), or a shape composed of straight portions and curved portions.

[0069] By laminating the insulating layers 131e and 131f together with the insulating layers 31a, 31b, 31c, 31d, 31e, and 31f, the laminate 10 has plate-like members 37e and 37f. Hereinafter, the plate-like members 37e and 37f are also collectively referred to as plate-like member 37.

[0070] Specifically, by laminating the insulating layer 131e together with the insulating layer 31e, a plate-like member 37e is provided between the second end face 12 of the laminate 10 and the coil conductor 32a closest to the second end face 12.

[0071] In addition, by laminating the insulating layer 131f together with the insulating layer 31f, a plate-like member 37f is provided between the first end face 11 of the laminate 10 and the coil conductor 32d closest to the first end face 11.

[0072] The dimension of the plate-like member 37 in the direction perpendicular to the coil axis is larger than the dimension in the direction parallel to the coil axis. Therefore, the shape of the plate-like member 37 can also be said to be plate-like extending in the same direction as the insulating layer 131.

[0073] In addition, the plate-like member 37 only covers a part of the insulating layer 131. Therefore, the area of the plate-like member 37 is smaller than the area of the insulating layer 131 corresponding to the area of the first end face 11 or the second end face 12 of the laminate 10.

[0074] When the cross-sectional area of the coil is set to 1, the area of the plate-like member is preferably 1.63 or less, more preferably 0.18 or more and 1.40 or less.

[0075] In addition, the area of the plate-like member refers to the area of the plate-like member when viewed from the coil axis direction. In addition, in the case where two or more plate-like members are provided, each plate-like member is measured and the average is regarded as the area of the plate-like member.

[0076] In addition, the cross-sectional area of the coil refers to the area obtained from the shape of the inner part (inner profile) of the winding shape of the coil.

[0077] Figure 2 The distance between the coil conductors in the width direction W of the laminate 10 in the exploded perspective view of the laminate shown is the length represented by R W The distance between the coil conductors in the height direction T of the laminate 10 is the length represented by R T The shapes of the plate-like members 37e and 37f observed from the lamination direction of the laminate 10 are such that the lengths in the height direction T and the width direction W of the laminate 10 are L W and L T , and L W = L T of a square. In addition, the inner profile shape of the winding shape of the coil is a square with a length of R T in the height direction T of the laminate 10 and a length of R W in the width direction.

[0078] Therefore, through L W 2 , LT 2 or L W ×L T represents the area of the plate-like member. Through R T ×R W represents the cross-sectional area of the coil.

[0079] The area of the plate-like member may be 1 or less when the cross-sectional area of the coil is set to 1. When the cross-sectional area of the coil is set to 1, if the cross-sectional area of the plate-like member exceeds 1, there is a case where a part of the coil conductor constituting the coil overlaps with the plate-like member in the stacking direction, and the size of the coil trace cannot be sufficiently reduced.

[0080] Preferably, when viewed through the laminate in the longitudinal direction, the outer contour shape of the plate-like member is similar to the inner contour shape of the winding shape of the coil.

[0081] Since the coil trace is likely to be formed in a shape similar to the inner contour of the winding shape of the coil on the inner side of the winding shape of the coil, if the outer contour shape of the plate-like member is similar to the inner contour shape of the winding shape of the coil, it is easy to reduce the coil trace.

[0082] In Figure 2 In the exploded perspective view of the laminate shown, the inner contour shape of the winding shape of the coil is substantially square, and the outer contour shape of the plate-like member is also substantially square, so it can be said that the outer contour shape of the plate-like member is similar to the inner contour shape of the winding shape of the coil.

[0083] In addition, regardless of the inner contour shape of the winding shape of the coil, the outer contour shape of the plate-like member may not be similar to the inner contour shape of the winding shape of the coil. For example, when the inner contour shape of the winding shape of the coil is substantially square, the outer contour shape of the plate-like member may also be substantially circular, pentagonal or rectangular, etc.

[0084] In this way, by arbitrarily changing the outer contour shape of the plate-like member with respect to the inner contour shape of the winding shape of the coil, the size of the coil trace can be adjusted.

[0085] Figure 3 is a side view schematically showing an example of the internal structure of the laminate constituting the Figure 1 laminated coil member shown in perspective.

[0086] As Figure 3 shown, in the laminated coil member 1, since a plurality of insulating layers 31 are laminated in the longitudinal direction L, the longitudinal direction L is the lamination direction. In addition, the lamination direction of the laminate 10 and the coil axis A of the coil 30 are parallel to any one of the first main surface 13, the second main surface 14, the first side surface 15, or the second side surface 16 as the mounting surface, for example, parallel to the first main surface 13.

[0087] In addition, as Figure 3 shown, no boundary can be visually confirmed between the actually adjacent insulating layers 31.

[0088] The first lead conductor 41 extends in the stacking direction within the laminate 10 and linearly connects the first external electrode 21 provided on the first end face 11 and the coil conductor 32a opposed thereto. Similarly, the second lead conductor 42 extends in the stacking direction within the laminate 10 and linearly connects the second external electrode 22 provided on the second end face 12 and the coil conductor 32d opposed thereto.

[0089] In addition, preferably, when viewed from the stacking direction (length direction L), the via conductors constituting the lead conductors overlap each other, but the via conductors constituting the lead conductors may not be strictly arranged in a straight line.

[0090] In addition, in Figure 2 and Figure 3 an example is shown in which the number of stacked layers of the coil conductors 32 for forming three turns of the coil 30 is 4, that is, the repeating shape is a 3 / 4 turn shape, but the number of stacked layers of the coil conductors 32 for forming one turn of the coil 30 is not particularly limited.

[0091] For example, the number of stacked layers of the coil conductors 32 for forming one turn of the coil 30 may also be 2, that is, the repeating shape is a 1 / 2 turn shape.

[0092] In addition, although the number of stacked layers of the coil conductors 32, that is, the total number of stacked layers of all the coil conductors 32 included in the laminate 10 is not particularly limited, it is preferably 30 or more and 120 or less.

[0093] Since coil marks are likely to occur on the first end face of the laminate in which the total number of stacked layers of all the coil conductors included in the laminate is 50 or more, it is suitable for the laminated coil conductor of the present invention.

[0094] Figure 4 is a schematic cross-sectional view showing an example of a cross-section along the line A1 - A1 of the laminated coil component shown in Figure 1 shown.

[0095] As Figure 4 shown, when observing a cross-section in a direction perpendicular to the extending direction of the coil conductor 32, the cross-sectional shape of the coil conductor 32 is a flat shape (elongated shape), and its long side direction is orthogonal to the stacking direction (length direction L). In Figure 4In the example shown, the cross-sectional shape of the coil conductor 32 is an ellipse with the major axis orthogonal to the stacking direction. However, the cross-sectional shape of the coil conductor 32 is not particularly limited. For example, it can also be a rectangle with the same length for a pair of opposite sides in the stacking direction, or a trapezoidal shape with different lengths for a pair of opposite sides in the stacking direction, etc.

[0096] Figure 4 The stacked body 10 shown has two plate-like members 37f between the first end face 11 of the stacked body 10 and the coil conductor 32d closest to the first end face 11. This is because, as Figure 2 shown, the insulating layer for forming the first lead conductor 41 includes, in addition to the through-hole conductor 33f and the pad 35f, the insulating layer 131f provided with the plate-like member 37f.

[0097] By having the plate-like member 37f, the stacked body 10 can adjust the shape of the first end face 11 of the stacked body 10. Specifically, by arranging the plate-like member 37f, the first depression 11a generated on the first end face 11 of the stacked body 10 can be reduced by the thickness of the plate-like member 37f. Therefore, compared with the case where the plate-like member 37f is not arranged, the depth d1 of the first depression 11a generated on the first end face 11 of the stacked body 10 can be reduced.

[0098] In addition, the depth d1 of the first depression 11a is the length in the stacking direction from the deepest part 11a1 of the first depression 11a on the first end face 11 to the vertex 11b1 of the first convex part 11b, which is the part protruding from the first end face 11.

[0099] Figure 4 The first depression 11a shown is a depression formed as a result of a coil mark being generated on the first end face 11 of the stacked body 10. Since the coil mark is formed at a position overlapping the winding shape of the coil when the stacked body 10 is viewed through in the length direction L, the shape of the first depression 11a can be said to be a shape in which the inner part of the part of the first end face 11 of the stacked body 10 overlapping the winding shape of the coil is recessed toward the second end face 12 side.

[0100] Figure 4 It is also a cross-sectional view obtained by cutting the center in the width direction W of the stacked body 10 in a plane parallel to the length direction L and the height direction T of the stacked body 10.

[0101] It is also possible that the outer contour shapes of the plate-like members 37e and 37f and the inner contour shape of the winding shape of the coil 30 are all squares with equal dimensions in the height direction T and the width direction W. Therefore, in this case, Figure 4 the cross-sectional area of the coil 30 shown is R T 2 , and the areas of the plate-like members 37e and 37f are LT 2 According to Figure 4 , since R T > L T , when the cross-sectional area R T 2 of the coil 30 is set to 1, it can be said that the area L T 2 of the plate-like members 37e and 37f is 1 or less.

[0102] Figure 4 The laminated body 10 shown has a plate-like member 37e between the second end face 12 of the laminated body 10 and the coil conductor 32a closest to the second end face 12. This is because as Figure 2 shown, the insulating layer for forming the second lead conductor 42 includes the insulating layer 131e provided with the plate-like member 37e in addition to the through-hole conductor 33e and the pad 35e.

[0103] By having the plate-like member 37e, the laminated body 10 can adjust the shape of the second end face 12 of the laminated body 10. Specifically, by arranging the plate-like member 37e, the second recess 12a generated on the second end face 12 of the laminated body 10 can be reduced by the amount of the thickness of the plate-like member 37e. Therefore, compared with the case where the plate-like member 37e is not arranged, the depth d2 of the second recess 12a generated on the second end face 12 of the laminated body 10 can be reduced.

[0104] In addition, the depth d2 of the second recess 12a is the length in the lamination direction from the deepest part 12a1 of the second recess 12a on the second end face 12 to the vertex 12b1 of the second convex part 12b, which is the part protruding from the second end face 12.

[0105] Figure 4 The second recess 12a shown is a recess formed as a result of a coil mark being generated on the second end face 12 of the laminated body 10. Since the coil mark is formed at a position overlapping the winding shape of the coil when the laminated body 10 is viewed through in the longitudinal direction L, the shape of the second recess 12a can be said to be a shape in which the inner part of the part of the second end face 12 of the laminated body 10 overlapping the winding shape of the coil is recessed toward the first end face 11.

[0106] Use Figure 5 to illustrate the shapes of the first end face and the second end face of the laminated body in the case where the plate-like member is arranged and in the case where it is not arranged.

[0107] Figure 5 is a cross-sectional view schematically showing an example of a laminated coil component without a plate-like member arranged.

[0108] Figure 5The stacked coil component 1' shown is also an example in which, in the exploded perspective view of the stacked coil component shown in Figure 2 the insulating layers 31e and 31f are used instead of the insulating layers 131e and 131f. That is, it is an example in which the laminate does not have the plate-like member 37.

[0109] As Figure 5 shown, a first recess 11a' with a depth d1' is formed in the first end face 11' of the laminate 10' that constitutes the stacked coil component 1'. In addition, a second recess 12a' with a depth d2' is formed in the second end face 12' of the laminate 10'.

[0110] The depth d1' of the first recess 11a' formed in the first end face 11' of the laminate 10' that constitutes the stacked coil component 1' is larger than Figure 4 the depth d1 of the first recess 11a formed in the first end face 11 of the laminate 10 that constitutes the stacked coil component 1, as shown.

[0111] In Figure 5 the stacked coil component 1' shown, since the first recess 11a' in the first end face 11' is large, a gap 23' is formed between the first external electrode 21' and the first recess 11a'.

[0112] Figure 6 It is a side view of the stacked coil component shown when viewed from the first end face side Figure 5 as shown.

[0113] As Figure 6 shown, cracks 24' due to the gap 23' shown are generated on the surface of the first external electrode 21' formed on the first end face 11'. Figure 5 as shown.

[0114] In contrast, as in the stacked coil component 1 shown in Figure 4 by providing the plate-like member 37 in the laminate 10, it is possible to reduce the recess (make it shallower) generated in the end face where the external electrode is formed, that is, the first end face 11, and suppress defective formation of the external electrode.

[0115] The depth of the recess on the first end face of the laminate and the depth of the recess on the second end face may be the same or different. However, it is preferable that the difference between the depth of the recess on the first end face and the depth of the recess on the second end face is 12 μm or less.

[0116] If the difference between the depth of the recess on the first end face and the depth of the recess on the second end face is 12 μm or less, it is possible to suppress the deviation between the shape on the first end face side and the shape on the second end face side of the stacked coil component.

[0117] It is preferable to Figures 2 - 4In the stacked coil component shown, the difference between the depth d1 of the first recess on the first end face 11 and the depth d2 of the second recess on the second end face is 12 μm or less.

[0118] In addition, by grinding the stacked body from the main surface (L T surface) of the stacked body to the center in the width direction W to expose the L T cross section, and in the cross-sectional image obtained from this cross section using a digital microscope or the like, the depth of the first recess on the first end face is measured by using a parallel dimension measurement tool or the like to measure the dimension difference between the lowest position (the most recessed position) and the highest position (the most protruding position, i.e., the vertex corresponding to the first convex portion) of the insulating layer in the length direction L. The depth of the second recess on the second end face can also be measured by the same procedure.

[0119] The plate-like component can also be disposed between the coil conductor closest to the first end face of the stacked body and the first end face in the length direction of the stacked body.

[0120] If the plate-like component is disposed between the coil conductor closest to the first end face of the stacked body and the first end face, the plate-like component can be prevented from falling off the stacked body, and the depth of the first recess can be effectively alleviated.

[0121] For example, in Figures 2 - 4 the stacked coil component 1 shown, the plate-like component 37f is disposed between the coil conductor 32d closest to the first end face 11 of the stacked body 10 and the first end face 11 of the stacked body 10.

[0122] The plate-like component can also be disposed between the coil conductor closest to the second end face of the stacked body and the second end face in the length direction of the stacked body.

[0123] For example, in Figures 2 - 4 the stacked coil component 1 shown, the plate-like component 37e is disposed between the coil conductor 32a closest to the second end face 12 of the stacked body 10 and the second end face 12 of the stacked body 10.

[0124] Preferably, the plate-like component is disposed at a position exposed from the first end face of the stacked body. In addition, "exposed from the first end face of the stacked body" means exposed from the stacked body, and does not necessarily mean that the plate-like component is exposed on the surface of the stacked coil component. That is, for example, a part or all of the plate-like component exposed at the first end portion of the stacked body may be covered by a first external electrode or the like outside the stacked body.

[0125] In this case, it is preferable that the first external electrode covers at least a part of the plate-like component.

[0126] The closer the plate-like member is disposed to the first end face of the laminate, the higher the effect of reducing coil marks. Therefore, if the plate-like member is provided at a position exposed at the first end face of the laminate, the effect of reducing coil marks brought by the plate-like member is particularly high. Moreover, if the first external electrode covers at least a part of the plate-like member, it is easy to suppress defective formation of the external electrode due to coil marks.

[0127] The plate-like member may also be disposed inside the coil.

[0128] In this case, it is preferable that when the cross-sectional area of the coil is set to 1, the area of the plate-like member in the height direction and the width direction is less than 1.

[0129] If when the cross-sectional area of the coil is set to 1, the area of the plate-like member in the height direction and the width direction is less than 1, then when the laminate is observed through from the length direction, the plate-like member can be arranged to be accommodated inside the winding shape of the coil, so that the depression of the first end face of the laminate can be efficiently suppressed.

[0130] Two or more plate-like members may also be provided.

[0131] By changing the number of plate-like members, the size of the coil marks can be adjusted.

[0132] For example, in the laminate 10 constituting Figures 2 - 4 the laminated coil member 1 shown, a total of three plate-like members are provided.

[0133] If two or more plate-like members are provided, compared with the case where there is one plate-like member, the coil marks can be further suppressed.

[0134] Preferably, in the case where two or more plate-like members are provided, at least one plate-like member is disposed between the coil conductor closest to the first end face in the length direction and the first end face, and at least one plate-like member is disposed between the coil conductor closest to the second end face in the length direction and the second end face.

[0135] If the plate-like member is disposed at the above positions, not only the coil marks generated at the first end face of the laminate can be suppressed, but also the coil marks generated at the second end face can be suppressed.

[0136] For example, in Figures 2 - 4 the laminated coil member 1 shown, one plate-like member 37e is disposed between the coil conductor 32a closest to the first end face 11 of the laminate 10 and the first end face 11 of the laminate 10, and two plate-like members 37f are disposed between the coil conductor 32d closest to the second end face 12 of the laminate 10 and the second end face 12 of the laminate 10.

[0137] Preferably, in the case where there are two or more plate-like members provided, when the laminate is bisected in the longitudinal direction into a region on the first end face side and a region on the second end face side, at least one plate-like member is provided on both the region on the first end face side and the region on the second end face side.

[0138] In addition, in this case, the number of plate-like members provided may be the same in the region on the first end face side and the region on the second end face side, but it is preferably different.

[0139] The plate-like member disposed in the region on the first end face side is likely to contribute to reducing the coil mark on the first end face, and the plate-like member disposed in the region on the second end face side is likely to contribute to reducing the coil mark on the second end face. Therefore, if two or more plate-like members are provided at the above positions, not only can the coil mark generated on the first end face of the laminate be suppressed, but also the coil mark generated on the second end face can be suppressed.

[0140] In addition, in the process of laminating the insulating layers, generally, a plurality of insulating layers are laminated on the substrate with the lamination direction being the same as the vertical direction. Either the first end face or the second end face on the substrate side is supported in a planar manner, and the other is not supported. Thus, in the case where no plate-like member is disposed, since only one side of the end face is pressed against the substrate, there is a case where the depths of the coil marks on the first end face and the second end face of the laminate are asymmetric. Therefore, if the number of plate-like members provided in the region on the first end face side and the region on the second end face side is different, the depth of the depression on the first end face and the depth of the depression on the second end face can be respectively reduced accordingly, so that the difference in the size of the depressions between the first end face and the second end face of the laminate can be reduced.

[0141] For example, in Figures 2 - 4 the laminated coil member 1 shown, it can be said that the fifth insulating layer 31d from the upper side among the eight insulating layers 31a, 31b, 31c, 31d laminated, and the insulating layer disposed above this insulating layer 31d belong to the region on the first end face 11 side of the laminate 10. Similarly, it can be said that the fifth insulating layer 31a from the upper side among the eight insulating layers 31a, 31b, 31c, 31d laminated, and the insulating layer disposed below this insulating layer 31a belong to the region on the second end face 12 side of the laminate 10.

[0142] Therefore, in Figures 2 - 4 the laminated coil member 1 shown, it can be said that one plate-like member 37e is provided in the region on the first end face 11 side, and two plate-like members 37f are provided in the region on the second end face 12 side, and it can be said that the number of plate-like members provided in the region on the first end face side is different from the number of plate-like members provided in the region on the second end face side.

[0143] Preferably, the thickness of each plate-like member is 15 μm or more and 40 μm or less.

[0144] Preferably, with the center in the stacking direction of the laminate as the boundary, the total thickness of the plate-like members in each of the regions on the first end face side and the second end face side is 20 μm or more and 150 μm or less. Further, preferably, in the stacking direction, the total thickness of the plate-like members in the region on the first end face side provided compared with the coil conductor closest to the first end face, and the total thickness of the plate-like members in the region on the second end face side provided compared with the coil conductor closest to the second end face are each 20 μm or more and 150 μm or less.

[0145] The material of the plate-like member is not particularly limited, but it is preferably made of an inorganic material.

[0146] When the plate-like member is included in the laminate, if a plate-like member made of an inorganic material is used, the volume change during firing is small, and the adjustment based on the depression of the plate-like member becomes easy. Further, when the plate-like member is exposed from the laminate, it is also considered to provide the plate-like member after firing the laminate, and an organic material can also be used. However, since inorganic materials generally have higher heat resistance and chemical resistance, it is preferably made of an inorganic material.

[0147] Examples of the inorganic material include ceramic materials and metal materials.

[0148] Examples of the ceramic material include crystalline materials such as ferrite, alumina, and zirconia materials, non-crystalline materials such as borosilicate glass materials, and glass ceramics.

[0149] Examples of the metal material include Ag, Au, Cu, Pd, Ni, Al, alloys containing at least one of these metals, etc. Further, for example, by using a material (such as alumina or Cu) cheaper than the metal material (such as Ag) constituting the internal electrode (coil conductor) as an inorganic material such as a ceramic material or a metal material, the cost for reducing the coil mark can be suppressed.

[0150] Preferably, the plate-like member contains the same metal element as the coil.

[0151] The plate-like member may also be made of metal and be electrically connected to the coil.

[0152] If the plate-like component is made of metal and is electrically connected to the coil, the capacitance of the laminated coil component can be adjusted through the plate-like component. Specifically, if the plate-like component is made of metal and is electrically connected to the coil, capacitance is generated between the plate-like component and the coil, and between the plate-like component and the external electrode. In addition, in the case where there are two or more plate-like components made of metal, capacitance is also generated between the plate-like components. Since they act as capacitors in series, the overall capacitance of the laminated coil component decreases. As a result, the impedance value above the self-resonant frequency increases.

[0153] In addition, the plate-like component can be directly connected to the coil or the pad, or can be connected to the coil via a via conductor.

[0154] For example, as will be described later Figure 7 and Figure 8 a part of the pad can be integrated with the plate-like component. Although not shown, the entire pad can also be integrated with the plate-like component.

[0155] In addition, in the case where the plate-like component is integrated with the pad provided on the same layer, the area of the pad is also included in the calculation of the area of the plate-like component.

[0156] Figure 7 is an exploded view schematically showing another example of the laminate constituting the laminated coil component of the present invention. Figure 7 The shown exploded view is a view after increasing the area of the plate-like component from the Figure 2 shown exploded view.

[0157] Specifically, in the Figure 2 shown laminate 10, the insulating layers 131e and 131f of the plate-like components 37e and 37f having a dimension of L in the height direction T T and a dimension of L in the width direction W W are respectively changed to the insulating layers 231e and 231f of the plate-like components 137e and 137f having a dimension of L in the height direction T Figure 7 and a dimension of L in the width direction W 1T in the shown laminate 100. 1W The dimension L in the height direction of the plate-like components 137e and 137f

[0158] is larger than the dimension R in the height direction T of the inner profile shape of the winding shape of the coil 1T and the dimension L in the width direction W of the plate-like components 137e and 137f T is larger than the dimension R in the width direction W of the inner profile shape of the winding shape of the coil 1W and W is larger.

[0159] Therefore, it can be said that a part of the pads 35e and 35f is integrated with the plate-like members 137e and 137f. In this case, the areas of the pads 35e and 35f are also included in the areas of the plate-like members 137e and 137f.

[0160] Figure 8 Is perspective Figure 7 A side view schematically showing an example of the internal structure of the laminated body shown.

[0161] As Figure 8 As shown, the laminated body 100 has the same structure as the laminated body 10 shown, except that the size of the plate-like member is increased and a part of the pad is integrated. Figure 3 shown.

[0162] The plate-like members 137e and 137f are made of metal. In this case, the plate-like members 137e and 137f are electrically connected to the pads 35e and 35f and the via conductors 33e and 33f, respectively. In addition, it can be said that the plate-like members 137e and 137f are electrically connected to the coil 30 via the pads 35e and 35f and the via conductors 33e and 33f.

[0163] In addition, when the size of the plate-like member is larger than Figure 7 and Figure 8 and the outer shape of the pad cannot be confirmed, it is regarded that the pad is completely integrated with the plate-like member.

[0164] In addition, the plate-like member made of conductive metal may not be electrically connected to the coil.

[0165] When the plate-like member made of conductive metal is not electrically connected to the coil, the plate-like member functions as an iron core. Therefore, by adjusting the magnetic permeability of the plate-like member, the inductance of the laminated coil member can be adjusted.

[0166] Preferably, the plate-like member contains the same ceramic material as the insulating layer.

[0167] The plate-like member may have the same composition as the coil or the same composition as the insulating layer.

[0168] As the material constituting the insulating layer, magnetic materials such as magnetic ferrite materials, non-magnetic materials such as borosilicate glass materials, etc. can be cited. In addition, magnetic materials and non-magnetic materials can also be used in combination.

[0169] Preferably, the ferrite material is a Ni-Cu-Zn-based ferrite material.

[0170] The material constituting the coil conductor only needs to be a conductive material. For example, Ag, Au, Cu, Pd, Ni, Al, an alloy containing at least one of these metals, etc. can be cited.

[0171] Hereinafter, another example of the structure of the stacked body of the stacked coil component of the present invention will be described using the same exploded perspective view. Figure 2 The same exploded perspective view is used to illustrate another example of the structure of the stacked body of the stacked coil component of the present invention.

[0172] Figure 9 FIG. is an exploded view schematically showing another example of the stacked body constituting the stacked coil component of the present invention.

[0173] Figure 9 The stacked body 101 shown is equivalent to the stacked body obtained by changing the first insulating layer from the second end face 12 side to the insulating layer 131e, the second insulating layer from the second end face 12 side to the insulating layer 31e, the first insulating layer 31f from the first end face 11 side to the insulating layer 131f, and the second and third insulating layers 131f from the first end face 11 side to the insulating layer 31f in the four insulating layers 31e and 131e that constitute the second lead conductor in the insulating layer of the stacked body 10 shown. Figure 2 The stacked body 101 shown is equivalent to the stacked body obtained by changing the first insulating layer from the second end face 12 side to the insulating layer 131e, the second insulating layer from the second end face 12 side to the insulating layer 31e, the first insulating layer 31f from the first end face 11 side to the insulating layer 131f, and the second and third insulating layers 131f from the first end face 11 side to the insulating layer 31f in the four insulating layers 31e and 131e that constitute the second lead conductor in the insulating layer of the stacked body 10 shown.

[0174] The plate-like member 37e is disposed between the coil conductor 32a closest to the second end face 12 and the second end face 12. The plate-like member 37f is exposed at the first end face 11 of the stacked body 10.

[0175] Figure 10 FIG. is an exploded view schematically showing another example of the stacked body constituting the stacked coil component of the present invention.

[0176] Figure 10 The stacked body 102 shown is equivalent to the stacked body obtained by changing the first, second, seventh, and eighth insulating layers 31a, 31b, 31c, and 31d from the second end face 12 side to the insulating layers 131a, 131b, 131c, and 131d in the insulating layer of the stacked body 10 shown, respectively. Figure 2 The stacked body 102 shown is equivalent to the stacked body obtained by changing the first, second, seventh, and eighth insulating layers 31a, 31b, 31c, and 31d from the second end face 12 side to the insulating layers 131a, 131b, 131c, and 131d in the insulating layer of the stacked body 10 shown, respectively.

[0177] The through-hole conductor 33a, the pad 35a, and the plate-like member 37a are provided in the insulating layer 131a. The through-hole conductor 33b, the pad 35b, and the plate-like member 37b are provided in the insulating layer 131b. The through-hole conductor 33c, the pad 35c, and the plate-like member 37c are provided in the insulating layer 131c. The through-hole conductor 33d, the pad 35d, and the plate-like member 37d are provided in the insulating layer 131d.

[0178] The four plate-like members 37a, 37b, 37c, and 37d are respectively disposed inside the spiral forming the coil, that is, inside the coil.

[0179] Figure 11 It is an exploded view schematically showing another example of the laminate constituting the laminated coil component of the present invention.

[0180] Figure 11 This is an example where plate-like components are provided on all the insulating layers corresponding to the coil sheets. Therefore, two plate-like components 37a, 37b, 37c, and 37d are respectively provided in each of the coil inner parts constituting the laminate 103.

[0181] Figure 12 It is an exploded view schematically showing another example of the laminate constituting the laminated coil component of the present invention.

[0182] Figure 12 This is an example where plate-like components are provided on all the insulating layers corresponding to the via-hole sheets. Therefore, four plate-like components 37e are provided between the coil conductor 32a closest to the second end face 12 of the laminate 104 and the second end face 12 of the laminate 104, and three plate-like components 37f are provided between the coil conductor 32d closest to the first end face 11 of the laminate 104 and the first end face 11 of the laminate 104.

[0183] One plate-like component 37f is exposed on the first end face 11 of the laminate 104.

[0184] Figure 13 It is an exploded view schematically showing another example of the laminate constituting the laminated coil component of the present invention.

[0185] Figure 13 This is an example where plate-like components are provided on all the insulating layers constituting the laminate. Therefore, four plate-like components 37e are provided between the coil conductor 32a closest to the second end face 12 of the laminate 105 and the second end face 12 of the laminate 105, three plate-like components 37f are provided between the coil conductor 32d closest to the first end face 11 of the laminate 105 and the first end face 11 of the laminate 105, one plate-like component 37f is exposed on the first end face 11 of the laminate 104, and two plate-like components 37a, 37b, 37c, and 37d are respectively provided in each of the coil inner parts.

[0186] [Manufacturing method of laminated coil component]

[0187] The manufacturing method of the stacked coil component of the present invention is characterized by including a process of preparing a ceramic green sheet containing a ceramic material, a printing process of printing a conductor paste that becomes a coil conductor layer and / or a via conductor on the ceramic green sheet, a process of laminating the ceramic green sheets on which the coil conductor layer is formed to form an unfired laminate with an unfired coil, and a process of firing the unfired laminate to form a laminate. Further, in the process of forming the unfired laminate or the printing process, a process of providing a layer containing an inorganic material with an area smaller than that of the ceramic green sheet is included.

[0188] Hereinafter, an example of the manufacturing method of the stacked coil component of the present invention will be described.

[0189] <Manufacture of magnetic material>

[0190] First, Fe2O3, ZnO, CuO, and NiO are weighed in a specified ratio.

[0191] Next, these weighed substances, pure water, etc. are put into a ball mill together with a PSZ (partially stabilized zirconia) medium and mixed and then pulverized. The mixing and pulverizing time is, for example, four hours or more and eight hours or less.

[0192] Then, after drying the obtained pulverized product, it is calcined. The calcination temperature is, for example, 700°C or more and 800°C or less. The calcination time is, for example, two hours or more and five hours or less.

[0193] In this way, a powdery magnetic material is produced. More specifically, a powdery magnetic ferrite material is produced.

[0194] Preferably, the ferrite material is a Ni-Cu-Zn series ferrite material.

[0195] Preferably, when the total amount of the Ni-Cu-Zn series ferrite material is set to 100 mol%, it contains 40 mol% or more and 49.5 mol% or less in terms of Fe converted to Fe2O3, 2 mol% or more and 35 mol% or less in terms of Zn converted to ZnO, 6 mol% or more and 13 mol% or less in terms of Cu converted to CuO, and 10 mol% or more and 45 mol% or less in terms of Ni converted to NiO.

[0196] The Ni-Cu-Zn series ferrite material may also contain additives such as Co, Bi, Sn, and Mn.

[0197] The Ni-Cu-Zn series ferrite material may also contain inevitable impurities.

[0198] <Process of preparing ceramic green sheet>

[0199] First, a ceramic material, an organic binder such as polyvinyl butyral resin, an organic solvent such as ethanol and toluene, a plasticizer, etc. are put together with the PSZ medium into a ball mill for mixing, and then pulverized to form a slurry.

[0200] As the ceramic material, the above-mentioned magnetic material can be used.

[0201] Next, the slurry is formed into a sheet of a specified thickness by using a doctor blade method or the like, and then blanked into a specified shape to form a green ceramic sheet. The thickness of the green ceramic sheet is, for example, 20 μm or more and 30 μm or less. The shape of the green ceramic sheet is, for example, a rectangular shape.

[0202] As the material of the green ceramic sheet, instead of the magnetic material, a non-magnetic material such as a borosilicate glass material can also be used, or a mixed material of a magnetic material and a non-magnetic material can also be used.

[0203] First, a through-hole is formed by laser irradiating a specified position of the green ceramic sheet.

[0204] <Printing process>

[0205] Next, by a screen printing method or the like, a conductive paste such as an Ag paste is filled into the through-hole and coated on the surface of the green ceramic sheet. Thereby, for the green ceramic sheet, a conductor pattern for a via-hole conductor is formed in the through-hole, and a conductor pattern for a coil conductor connected to the conductor pattern for the via-hole conductor is formed on the surface. In this way, a coil sheet in which a conductor pattern for a coil conductor and a conductor pattern for a via-hole conductor are formed on the green ceramic sheet is manufactured. A conductor pattern for a coil conductor corresponding to the Figure 2 shown coil conductor 32 and a conductor pattern for a via-hole conductor corresponding to the Figure 2 shown via-hole conductor 33 (except for the via-hole conductors 33e and 33f) are formed on the coil sheet. In addition, a via-hole sheet in which a conductor pattern for a via-hole conductor corresponding to the Figure 2 shown via-hole conductors 33e and 33f is formed is manufactured separately from the coil sheet.

[0206] <Process of manufacturing an unfired laminate>

[0207] By laminating the coil sheet and the via-hole sheet in the lamination direction (length direction L) in the order corresponding to the Figure 2 , and then performing thermocompression bonding, an unfired laminate block is manufactured.

[0208] <Process of providing a layer containing an inorganic material>

[0209] The process of providing a layer containing an inorganic material is performed in the process of manufacturing an unfired laminate or the printing process.

[0210] The step of forming a layer containing an inorganic material may also be a step of printing a paste containing an inorganic material on a part of the surface of a green ceramic sheet.

[0211] The paste containing an inorganic material printed on a part of the surface of the green ceramic sheet is disposed in the unfired laminate by laminating the green ceramic sheets, and is fired to form a plate-like component. That is, by the step of printing a paste containing an inorganic material on a part of the surface of the green ceramic sheet, a plate-like component can be provided in the laminate.

[0212] In addition, the timing of performing the step of printing a paste containing an inorganic material on a part of the surface of the green ceramic sheet is not particularly limited as long as it is in the printing process. It may be performed simultaneously with the printing of the conductor pattern for the coil conductor and the conductor pattern for the via conductor, may be performed before the printing of the conductor pattern for the coil conductor and the conductor pattern for the via conductor, or may be performed after the printing of the conductor pattern for the coil conductor and the conductor pattern for the via conductor.

[0213] In any case, it can be said that the step of printing a paste containing an inorganic material on a part of the surface of the green ceramic sheet is performed in the printing process.

[0214] At this time, the object of printing the paste containing an inorganic material may be either a coil sheet or a via sheet.

[0215] Preferably, the paste containing an inorganic material is printed in a region inside the winding shape of the coil.

[0216] In the step of forming a layer containing an inorganic material, the paste printed on a part of the surface of the green ceramic sheet may contain the same ceramic material as the green ceramic sheet, or may contain the same metal element as the conductor paste that becomes the coil conductor layer.

[0217] The step of forming a layer containing an inorganic material may also be a step of laminating a solid plate-like component together with the green ceramic sheet in the step of forming an unfired laminate.

[0218] In the step of forming an unfired laminate, by laminating a solid plate-like component together with the green ceramic sheet, a plate-like component can be provided in the fired laminate.

[0219] In the step of forming an unfired laminate, in the step of laminating a solid plate-like component together with the green ceramic sheet, the solid plate-like component may contain the same ceramic material as the green ceramic sheet, or may contain the same metal element as the conductor paste that becomes the coil conductor layer.

[0220] <Manufacturing Process of Laminate and Coil>

[0221] A chip is made by cutting a stacked body into a specified size using a dicing machine or the like to make it into a single-chip form.

[0222] Next, the single-chip chip is fired. The firing temperature is, for example, 900 °C or higher and 920 °C or lower. The firing time is, for example, two hours or longer and four hours or shorter.

[0223] When the single-chip chip is fired, the green sheets of the coil sheet and the via hole sheet become insulating layers.

[0224] In addition, when the single-chip chip is fired, the conductor pattern for the coil conductor and the conductor pattern for the via hole conductor become the coil conductor and the via hole conductor, respectively. As a result, a coil is formed in which a plurality of coil conductors laminated together with the insulating layer are electrically connected via the via hole conductor.

[0225] Through the above, a stacked body is formed in which a plurality of insulating layers are stacked in the stacking direction and a coil is built in inside.

[0226] It is also possible to chamfer the corners and edges by, for example, subjecting the stacked body to barrel polishing.

[0227] <External electrode forming process>

[0228] First, a conductive paste layer is formed by coating a conductive paste such as a paste containing Ag and glass powder on the first end face and the second end face from which the coil is led out on the outer surface of the stacked body.

[0229] Next, a base electrode of the external electrode is formed by sintering the conductive paste layer. The sintering temperature is, for example, 800 °C or higher and 820 °C or lower. The thickness of the base electrode is, for example, 5 μm.

[0230] Then, a Ni plating electrode and a Sn plating electrode are sequentially formed on the surface of the base electrode by electrolytic plating or the like. Thus, an external electrode having a base electrode, a Ni plating electrode, and a Sn plating electrode in sequence is formed.

[0231] Through the above, a stacked coil component is manufactured.

[0232] The following matters are described in this specification.

[0233] The present disclosure (1) is a stacked coil component including a stacked body formed by stacking a plurality of insulating layers and having a coil inside, and a first external electrode and a second external electrode electrically connected to the coil.

[0234] The above coil is formed by electrically connecting a plurality of coil conductors laminated together with the above insulating layer.

[0235] The above laminate has a first end face and a second end face facing each other in the length direction, a first main face and a second main face facing each other in the height direction orthogonal to the above length direction, and a first side face and a second side face facing each other in the width direction orthogonal to the above length direction and the above height direction.

[0236] The coil axis of the above coil is parallel to the above first main face.

[0237] The above laminate further has a plate-like member laminated together with the above insulating layer and having a dimension in a direction perpendicular to the above coil axis larger than a dimension in a direction parallel to the above coil axis.

[0238] The area of the above plate-like member is smaller than the area of the above first end face of the above laminate.

[0239] According to the laminated coil component described in the present disclosure (1), when the cross-sectional area of the above coil is set to 1, the area of the above plate-like member is 1.63 or less.

[0240] According to the laminated coil component described in the present disclosure (1) or (2), in the above length direction, the above plate-like member is provided between the above coil conductor closest to the above first end face and the above first end face.

[0241] According to the laminated coil component described in the present disclosure (1) or (2), the above plate-like member is provided at a position exposed from the above first end face of the above laminate.

[0242] The above first external electrode covers at least a part of the above plate-like member.

[0243] According to the laminated coil component described in the present disclosure (1) or (2), the above plate-like member is provided inside the above coil.

[0244] According to the laminated coil component according to any arbitrary combination of the present disclosure (1) to (5), the above plate-like member is made of an inorganic material.

[0245] According to the laminated coil component according to any arbitrary combination of the present disclosure (1) to (6), the above plate-like member contains the same metal element as the above coil.

[0246] According to the laminated coil component according to any arbitrary combination of the present disclosure (1) to (6), the above plate-like member is made of metal and is electrically connected to the above coil.

[0247] The present disclosure (9) is a laminated coil component according to any combination of any one of the present disclosures (1) to (6), and the plate-like component contains the same ceramic material as the insulating layer.

[0248] The present disclosure (10) is a laminated coil component according to any combination of any one of the present disclosures (1) to (9), and two or more of the plate-like components are provided.

[0249] The present disclosure (11) is a laminated coil component according to the laminated coil component described in the present disclosure (10), and at least one of the plate-like components is disposed between the coil conductor closest to the first end face and the first end face in the length direction.

[0250] At least one of the plate-like components is disposed between the coil conductor closest to the second end face and the second end face in the length direction.

[0251] The present disclosure (12) is a laminated coil component according to the laminated coil component described in the present disclosure (10). When the laminate is bisected in the length direction into a first end face side region and a second end face side region, at least one of the plate-like components is provided in both the first end face side region and the second end face side region, and the number of the plate-like components provided is different between the first end face side region and the second end face side region.

[0252] The present disclosure (13) is a laminated coil component according to any combination of any one of the present disclosures (1) to (12), and the difference in depth between the recess on the first end face of the laminate and the recess on the second end face of the laminate is 12 μm or less.

[0253] The present disclosure (14) is a laminated coil component according to any combination of any one of the present disclosures (1) to (13), and the area of the plate-like component is in the range of 0.18 or more and 1.40 or less when the cross-sectional area of the coil is set to 1.

[0254] The present disclosure (15) is a laminated coil component according to any combination of any one of the present disclosures (1) to (14). When observing the laminate through from the length direction,

[0255] The outer contour shape of the plate-like component is similar to the inner contour shape of the winding shape of the coil.

[0256] The present disclosure (16) is a method for manufacturing a laminated coil component, characterized by including: a step of preparing a ceramic green sheet containing a ceramic material;

[0257] a printing step of printing a conductor paste that becomes a coil conductor layer and / or a via conductor on the ceramic green sheet;

[0258] A process of forming a green laminate having an unfired coil by laminating the green ceramic sheets that form the above-described coil conductor layers; and

[0259] A process of firing the above-described unfired laminate to form a laminate,

[0260] And, in the process of forming the above-described unfired laminate or the above-described printing process, there is a process of providing a layer containing an inorganic material having an area smaller than that of the green ceramic sheet.

[0261] In the method of manufacturing a laminated coil component according to the present disclosure (17) based on the present disclosure (16), the process of providing the layer containing an inorganic material is a process of printing a paste containing an inorganic material on a part of the surface of the green ceramic sheet.

[0262] In the method of manufacturing a laminated coil component according to the present disclosure (18) based on the present disclosure (17), the printed paste contains the same ceramic material as the green ceramic sheet.

[0263] In the method of manufacturing a laminated coil component according to the present disclosure (19) based on the present disclosure (17), the printed paste contains the same metal element as the conductor paste that forms the above-described coil conductor layer.

[0264] In the method of manufacturing a laminated coil component according to the present disclosure (20) based on the present disclosure (16), the process of providing the layer containing an inorganic material is a process of laminating a solid plate-like component together with the green ceramic sheet in the process of forming the above-described unfired laminate.

[0265] In the method of manufacturing a laminated coil component according to the present disclosure (21) based on the present disclosure (20), the solid plate-like component contains the same ceramic material as the green ceramic sheet.

[0266] In the method of manufacturing a laminated coil component according to the present disclosure (22) based on the present disclosure (20), the solid plate-like component contains the same metal element as the conductor paste that forms the above-described coil conductor layer.

[0267]

Example

[0268] Hereinafter, embodiments of the present invention will be disclosed more specifically. In addition, the present invention is not limited to these embodiments.

[0269] (Example 1 and Comparative Example 1)

[0270] <Fabrication of Laminated Coil Component>

[0271] According to the manufacturing method of the laminated coil component described above, twenty laminated bodies of Example 1 provided with plate-like components and twenty laminated bodies of Comparative Example 1 not provided with plate-like components were each manufactured.

[0272] The size of the laminated body is all 3225 size (length × height × width = 3.2 mm × 2.5 mm × 2.5 mm).

[0273] As Figure 2 shown, the laminated bodies of Example 1 are each provided with four through-hole sheets on the first end face side and the second end face side, and only two plate-like components are provided on the first end face side.

[0274] In addition, the number of laminated coil sheets is 72. In addition, for the winding shape of the coil, the inner profile shape is a square with each side being approximately 480 μm.

[0275] By using the same Ag paste as the internal electrode, a square area is printed in the region on the surface of the through-hole sheet that is inside the winding shape of the coil to form the plate-like component. At this time, the Ag paste that becomes the plate-like component does not contact the conductor paste that becomes the through-hole conductor, and is arranged at a position where its center of gravity overlaps with the center of gravity of the inner profile shape of the winding shape of the coil, and the four sides of the square are respectively parallel to the inner profile shape of the winding shape of the coil.

[0276] When observing the cross-section of the laminated coil component of Example 1 ground to the center of the W size from the side (L T face) through a digital microscope and measuring the length from the most protruding part of the first end face in the length direction L of the laminated body to the most sunken part that overlaps with the inside of the winding shape of the coil as the depth of the depression (the depth of the first depression), it is 10.4 μm.

[0277] The thickness of each of the plate-like components on this cross-section is 22.0 μm, the interval between the two plate-like components is 28.0 μm, the distance from the first end face of the laminated body to the plate-like component in the length direction of the laminated body is 60.4 μm, and the distance from the outermost layer of the coil to the plate-like component in the length direction of the laminated body is 22.3 μm.

[0278] And, based on this cross-section, it was confirmed that the dimension in the height direction of the plate-like component is 435 μm. Thus, it was confirmed that the outer profile shape of the plate-like component is a square with one side being 435 μm, and its area is 189225 μm 2 .

[0279] Similarly, based on this cross-section, it was confirmed that the height of the inner profile shape of the winding shape of the coil is 526 μm. Thus, it was confirmed that the inner profile shape of the winding shape of the coil is a square with one side being 526 μm, and its area (the cross-sectional area of the coil) is 276676 μm 2 .

[0280] The laminate of Comparative Example 1 is the same as that of Example 1 except that the plate-like member is not provided.

[0281] When the depth of the depression of the laminated coil member of Comparative Example 1 was also measured in the same manner as in Example 1, it was 45 μm.

[0282] Based on the above results, it was confirmed that the coil mark of the laminate can be reduced by the plate-like member.

[0283] (Examples 2 to 6)

[0284] Except for changing the size of the Ag paste printed on the via-hole sheet (the length of one side of the square) and changing the lengths of the respective sides of the outer contour shape of the plate-like member to 115 μm, 285 μm, 520 μm, 605 μm, and 229 μm, respectively, a laminated coil member was produced in the same order as in Example 1, and the depth (size) of the depression was measured. The results are shown in Table 1.

[0285]

Table 1

[0286]

[0287] As shown in Table 1, it was confirmed that by changing the area of the plate-like member, the depth (size) of the coil mark can be controlled.

[0288] From the above, it can be seen that the laminated coil member of the present invention can reduce the coil mark on the end face of the laminate and can suppress structural defects of the external electrode.

[0289] Figure 14 It is a graph obtained by adding an approximate curve to a graph showing the relationship between the ratio of the area of the plate-like member to the cross-sectional area of the coil and the depth of the depression of the laminated coil members of Examples 1 to 6.

[0290] According to Figure 14 the approximate curve shown (R2 = 0.9985), it was confirmed that in order to make the depth of the depression (the size of the coil mark) 22.5 μm or less, it is sufficient to make the area of the plate-like member 0.18 or more and 1.40 or less of the cross-sectional area of the coil.

[0291] In addition, considering that even when a conductive paste that becomes an external electrode is applied to the end face of the laminate by the dipping method, if the depth of the coil mark is 22.5 μm or less, it is not likely to cause poor formation of the external electrode. Therefore, it can be said that the laminated coil members of Examples 1 and 3 to 6 are particularly suitable for laminated coil members manufactured by the dipping method.

Claims

1. A laminated coil component, characterized in that: A laminated body including a plurality of insulating layers and a coil therein, and a first external electrode and a second external electrode electrically connected to the coil. The coil is formed by electrically connecting a plurality of coil conductors stacked together with the insulating layer. The stacked body has a first end face and a second end face facing each other in the length direction, a first main face and a second main face facing each other in the height direction orthogonal to the length direction, and a first side face and a second side face facing each other in the width direction orthogonal to the length direction and the height direction. The coil axis of the coil is parallel to the first main surface. The laminate further comprises a plate-like member which is laminated together with the insulating layer and has a dimension in a direction perpendicular to the coil axis that is larger than a dimension in a direction parallel to the coil axis. The area of ​​the plate-shaped member is smaller than the area of ​​the first end surface of the stacked body.

2. The laminated coil component according to claim 1, wherein: When the cross-sectional area of ​​the coil is assumed to be 1, the area of ​​the plate-shaped member is equal to or less than 1.

63.

3. The laminated coil component according to claim 1, wherein: The plate-shaped member is provided between the coil conductor closest to the first end surface and the first end surface in the longitudinal direction.

4. The laminated coil component according to claim 1, wherein: The plate-like member is disposed at a position exposed from the first end surface of the stacked body. The first external electrode covers at least a portion of the plate-shaped member.

5. The laminated coil component according to claim 1, wherein: The plate-shaped member is disposed inside the coil.

6. The laminated coil component according to claim 1, wherein: The plate-shaped member is made of an inorganic material.

7. The laminated coil component according to claim 1, wherein: The plate-shaped member contains the same metal element as the coil.

8. The laminated coil component according to claim 1, wherein: The plate-shaped member is made of metal and is electrically connected to the coil.

9. The laminated coil component according to claim 1, wherein: The plate-shaped member contains the same ceramic material as the insulating layer.

10. The laminated coil component according to claim 1, wherein: Two or more of the above-mentioned plate-like members are provided.

11. The laminated coil component according to claim 10, wherein: At least one of the plate-shaped members is disposed between the coil conductor closest to the first end face and the first end face in the longitudinal direction. At least one of the plate-shaped members is provided between the coil conductor closest to the second end face and the second end face in the longitudinal direction.

12. The laminated coil component according to claim 10, wherein: When the stacked body is divided into two equal parts in the length direction, namely, an area on the first end face side and an area on the second end face side, at least one plate-like component is provided in both the area on the first end face side and the area on the second end face side, and the number of the plate-like components provided is different in the area on the first end face side and the area on the second end face side.

13. The laminated coil component according to claim 1, wherein: A difference between a depth of the depression on the first end surface of the stacked body and a depth of the depression on the second end surface of the stacked body is 12 μm or less.

14. The laminated coil component according to claim 1, wherein: When the cross-sectional area of ​​the coil is 1, the area of ​​the plate-shaped member is in a range of 0.18 to 1.

40.

15. The laminated coil component according to claim 1, wherein: When the laminate is observed through the longitudinal direction, The outer shape of the plate-like member is similar to the inner shape of the winding shape of the coil.

16. A method for manufacturing a laminated coil component, characterized in that: Include: A step of preparing a ceramic green sheet containing a ceramic material; A step of printing a conductor paste to be a coil conductor layer and / or a through-hole conductor on the ceramic green sheet; The step of stacking the ceramic green sheets having the coil conductor layers formed thereon to produce an unfired laminated body having an unfired coil built therein; and The step of firing the unfired laminate to obtain a laminate, Furthermore, in the step of producing the unfired laminate or the printing step, there is provided a step of providing a layer containing an inorganic material having a smaller area than the ceramic green sheet.

17. The method for manufacturing a laminated coil component according to claim 16, wherein: The step of providing the layer containing an inorganic material is a step of printing a paste containing an inorganic material on a part of the surface of the ceramic green sheet.

18. The method for manufacturing a laminated coil component according to claim 17, wherein: The printed paste contains the same ceramic material as the ceramic green sheet.

19. The method for manufacturing a laminated coil component according to claim 17, wherein: The printed paste contains the same metal element as the conductor paste that becomes the coil conductor layer.

20. The method for manufacturing a laminated coil component according to claim 16, wherein: The step of providing the layer containing an inorganic material is a step of laminating a solid plate-like member together with the ceramic green sheet in the step of forming the unfired laminated body.

21. The method for manufacturing a laminated coil component according to claim 20, wherein: The solid plate-shaped member contains the same ceramic material as the ceramic green sheet.

22. The method for manufacturing a laminated coil component according to claim 20, wherein: The solid plate-shaped member contains the same metal element as that of the conductor paste that becomes the coil conductor layer.

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