Laminated coil component and method for manufacturing laminated coil component

Abstract

This laminated coil component (1) is provided with: a laminated body (10) which is formed by laminating a plurality of insulating layers (31) in the lamination direction and which has internal electrodes; and a first external electrode (21) and a second external electrode (22) provided on the outer surface of the laminated body (10), the internal electrode having a first lead-out conductor (41) extending in the lamination direction and connected to the first external electrode (21), and a second lead-out conductor (42) extending in the lamination direction and connected to the second external electrode (22). The first lead-out conductor (41) has a via hole conductor (33e) penetrating the insulating layer (10) and a pad (35e) provided on the insulating layer (10), and if one of both ends of the first lead-out conductor (41) in the stacking direction, which is in direct contact with the first external electrode (21), is defined as a first end (41a), the first external electrode (21) is provided with a second end (41b), which is in contact with the first external electrode (21), in addition to the first end (41a). The first lead-out conductor (41) is further in direct contact with at least one first pad (51) of the pads (35e) of the first lead-out conductor (41), said first pad being far away from the first end (41a).

Description

Technical Field

[0001] This invention relates to laminated coil components and a method for manufacturing laminated coil components. Background Technology

[0002] Patent Document 1 describes a stacked electronic component in which a coil conductor and an insulating layer made of a magnetic or non-magnetic material are stacked inside to form a coil. Terminal electrodes are provided at both ends in the stacking direction. The terminal electrode at least one end is connected to the end of the coil inside the stacked body via a conductor-filled through-hole provided in one or more insulating layers and a lead-out electrode provided to cover the end of the through-hole. The characteristic feature is that the area of ​​the lead-out electrode is set to be more than three times the cross-sectional area of ​​the through-hole and less than one-third of the inner area of ​​the coil when the stacked body is viewed in the stacking direction.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2002-15918.

[0004] In the stacked electronic component described in Patent Document 1, the coil conductor and the terminal electrode (external electrode) are connected via a lead conductor consisting of a conductor-filled through-hole and a lead electrode. However, as in the stacked electronic component described in Patent Document 1, when only the end face of the lead conductor is connected to the external electrode, the current concentrates at that end face, resulting in a high current density. As a result, the current concentration point may break due to the heat generated by the concentrated current, potentially leading to a break in the wire. Furthermore, even if a break in the wire does not occur, the resistance of the lead conductor may increase. Summary of the Invention

[0005] This invention was made to solve the aforementioned problems, and its object is to provide a laminated coil component capable of suppressing current concentration in the end face of the lead conductor. Furthermore, an object of this invention is to provide a method for manufacturing the aforementioned laminated coil component.

[0006] The multilayer coil component of the present invention comprises: a multilayer body formed by stacking multiple insulating layers in a stacking direction and having an internal electrode; and a first external electrode and a second external electrode disposed on the outer surface of the multilayer body. The internal electrode has: a first lead conductor extending in the stacking direction and connected to the first external electrode, and a second lead conductor extending in the stacking direction and connected to the second external electrode. The first lead conductor has a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer. If the end of the first lead conductor in the stacking direction that is in direct contact with the first external electrode is designated as the first end, then the first external electrode, in addition to the first end, is also in direct contact with at least one first pad of the first lead conductor that is away from the first end.

[0007] A first aspect of the manufacturing method of the stacked coil component of the present invention includes: a step of preparing a stacked body, the stacked body being formed by stacking multiple insulating layers in a stacking direction and having an internal electrode; a step of performing a tumbling process on the stacked body; and a step of forming an external electrode on the outer surface of the stacked body after tumbling, wherein the internal electrode has a first lead conductor and a second lead conductor extending respectively along the stacking direction, the first lead conductor having a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer, in the step of preparing the stacked body, a first end of one of the two ends of the first lead conductor in the stacking direction is exposed from the stacked body, and the pads of the first lead conductor that are away from the first end are not exposed from the stacked body, in the step of performing the tumbling process, the stacked body is ground so that at least one first pad away from the first end is exposed from the stacked body, and in the step of forming the external electrode, a first external electrode is formed to cover the first end exposed from the stacked body and at least one first pad.

[0008] A second embodiment of the manufacturing method of the laminated coil component of the present invention includes: a step of preparing a laminated block, the laminated block being formed by stacking multiple insulating layers in a stacking direction and having internal electrodes; a step of monolithically forming the laminated block to form a laminated body; and a step of forming external electrodes on the laminated body, wherein the internal electrodes have a first lead conductor and a second lead conductor extending respectively along the stacking direction, the first lead conductor having a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer, and the preparation of the laminated body... In the block forming process, the first end of one of the two ends of the first lead conductor in the stacking direction is exposed from the stack block, and the pads of the first lead conductor that are far from the first end are not exposed from the stack. In the process of monolithizing the stack block, the stack block is cut so that at least one first pad that is far from the first end is exposed from the stack. In the process of forming the external electrode, a first external electrode is formed to cover the first end exposed from the stack and at least one first pad.

[0009] According to the present invention, a laminated coil component capable of suppressing current concentration in the end face of the lead-out conductor can be provided. Furthermore, according to the present invention, a method for manufacturing the aforementioned laminated coil component can be provided. Attached Figure Description

[0010] Figure 1 This is a perspective view schematically illustrating an example of a stacked coil component of the present invention.

[0011] Figure 2 It is a schematic representation of the composition. Figure 1 An exploded perspective view of an example of a stack of coil components shown.

[0012] Figure 3 It is perspective composition Figure 1 An example of the internal structure of the stacked coil component is shown, along with a schematic side view.

[0013] Figure 4 It is a schematic representation along Figure 1 A cross-sectional view of an example of the cross-section of line segment A1-A1 of the stacked coil component shown.

[0014] Figure 5 yes Figure 3 The V-V line sectional view in the image.

[0015] Figure 6 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a first modified example of the laminated coil component of the present invention.

[0016] Figure 7 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a second modified example of the laminated coil component of the present invention.

[0017] Figure 8 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a third modified example of the laminated coil component of the present invention.

[0018] Figure 9 yes Figure 8 Sectional view along line IX-IX.

[0019] Figure 10 This is a perspective view schematically illustrating a fourth modified example of the stacked coil component of the present invention.

[0020] Figure 11 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes the fourth modified example of the laminated coil component of the present invention.

[0021] Figure 12 This is a perspective view schematically illustrating a fifth modified example of the stacked coil component of the present invention.

[0022] Figure 13 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes the fifth modified example of the laminated coil component of the present invention.

[0023] Figure 14 This is an exploded perspective view schematically illustrating an example of a laminate produced in the step of preparing the laminate in a first aspect of the manufacturing method of the coil component of the present invention.

[0024] Figure 15 This is a schematic side view showing an example of the internal structure of a laminate produced in the process of preparing the laminate in the first aspect of the manufacturing method of the coil component of the present invention.

[0025] Figure 16 This is a schematic side view illustrating an example of the internal structure of the laminate after the tumbling process has been performed in the first aspect of the manufacturing method of the coil component of the present invention.

[0026] Figure 17 This is a schematic side view illustrating an example of the internal structure of the laminate after the step of forming the external electrode is performed in the first aspect of the manufacturing method of the coil component of the present invention.

[0027] Figure 18 This is a schematic diagram illustrating an example of a laminated block produced in the step of preparing a laminated block in a second aspect of the manufacturing method of the laminated coil component of the present invention, viewed from the lamination direction. Detailed Implementation

[0028] The laminated coil component of the present invention will now be described. However, the present invention is not limited to the structure described below, and appropriate modifications can be made without departing from the spirit of the invention. Furthermore, structures formed by combining multiple preferred structures described below are also part of the present invention.

[0029] The accompanying drawings are schematic diagrams, and their dimensions, aspect ratios, and scales may sometimes differ from the actual product. In the drawings, the same or equivalent parts use the same reference numerals. Furthermore, in each drawing, the same reference numerals for the same elements omit redundant descriptions.

[0030] In this specification, terms indicating the relationship between elements (e.g., "parallel", "orthogonal", etc.) and terms indicating the shape of elements not only mean the strict literal meaning, but also imply a range of substantially equivalents, such as a range containing a difference of about a few percent.

[0031] The embodiments shown below are illustrative, and of course, parts of the structures shown in different embodiments can be replaced or combined. From the second embodiment onwards, descriptions of matters common to the first embodiment are omitted, and only the differences are explained. In particular, the same effects of the same structure are not mentioned sequentially in each embodiment.

[0032] Figure 1 This is a perspective view schematically illustrating an example of a stacked coil component of the present invention.

[0033] Figure 1 The stacked coil component 1 shown includes a stacked body (blank) 10, a first external electrode 21, and a second external electrode 22 disposed on the outer surface of the stacked body 10. The stacked body 10 is a generally cuboid shape with six faces. Although the structure of the stacked body 10 will be described later, it is formed by stacking multiple insulating layers in the stacking direction and has an internal electrode. The internal electrode includes a coil conductor. In the stacked body 10, multiple insulating layers and multiple coil conductors are stacked in the stacking direction, and a coil is disposed inside. In addition, the internal electrode has a first lead conductor connected to the first external electrode 21 and a second lead conductor connected to the second external electrode 22. The first external electrode and the second external electrode are electrically connected to the coil through the first lead conductor and the second lead conductor, respectively.

[0034] In the stacked coil components and stacked bodies described in this specification, the length direction, height direction, and width direction are defined as... Figure 1 The length direction (L), height direction (T), and width direction (W) are defined in the diagram. Here, the length direction (L), height direction (T), and width direction (W) are orthogonal to each other.

[0035] Here, the length direction L is parallel to the stacking direction.

[0036] like Figure 1 As shown, the laminate 10 has: a first end face 11 and a second end face 12 opposite to each other in the length direction L, a first main face 13 and a second main face 14 opposite to 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 opposite to each other in the width direction W orthogonal to the length direction L and the height direction T.

[0037] The laminate 10 preferably has rounded corners and edges. A corner is the intersection of three faces of the laminate, and an edge is the intersection of two faces. In this specification, a generally rectangular parallelepiped shape includes a shape in which at least one corner or edge of the parallelepiped is rounded.

[0038] For example, such as Figure 1 As 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 portion of the first main face 13, a portion of the second main face 14, a portion of the first side face 15, and a portion of the second side face 16.

[0039] For example, such as Figure 1 As 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 portion of the first main face 13, a portion of the second main face 14, a portion of the first side face 15, and a portion of the second side face 16.

[0040] As described above, when the stacked coil component 1, which is equipped with the first external electrode 21 and the second external electrode 22, is mounted on the substrate, any one of the first main surface 13, the second main surface 14, the first side surface 15, and the second side surface 16 of the stacked body 10 becomes the mounting surface.

[0041] However, the first external electrode 21 may extend from at least a portion of the first end face 11 of the laminate 10 to the mounting surface of the laminate 10.

[0042] Similarly, the second external electrode 22 may extend from at least a portion of the second end face 12 of the laminate 10 to the mounting surface of the laminate 10.

[0043] The first external electrode 21 and the second external electrode 22 can be either single-layer or multi-layer structures.

[0044] When the first external electrode 21 and the second external electrode 22 are both single-layer structures, the constituent materials of each external electrode include, for example, Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0045] When the first external electrode 21 and the second external electrode 22 are both multilayer structures, each external electrode may also have, for example, a substrate electrode layer containing Ag, a Ni-plated electrode, and a Sn-plated electrode sequentially from the surface side of the laminate 10.

[0046] The dimensions of the stacked coil component of the present invention are not particularly limited, and can also be 0603, 0402, 1005, or 1608.

[0047] Figure 2 It is a schematic representation of the composition. Figure 1 An exploded perspective view of an example of a stack of coil components shown.

[0048] like Figure 2 As shown, the laminate 10 is constructed by stacking multiple insulating layers 31a, 31b, 31c, 31d, 31e, and 31f from the first end face 11 side toward the second end face 12 side along the stacking direction (here, the length direction L). Hereinafter, insulating layers 31a, 31b, 31c, 31d, 31e, and 31f will also be collectively referred to as insulating layer 31.

[0049] Furthermore, in this specification, the direction in which the multiple insulating layers constituting the laminate are stacked is referred to as the stacking direction.

[0050] exist Figure 2In the laminate, insulating layer 31e is disposed on the lower side in the lamination direction (on the side of the first end face 11 of the laminate 10), and insulating layer 31f is disposed on the upper side in the lamination direction (on the side of the second end face 12 of the laminate 10).

[0051] As constituent materials of each insulating layer 31, magnetic materials such as ferrite materials are listed as examples.

[0052] Insulating layers 31a, 31b, 31c, and 31d are respectively provided with coil conductors 32a, 32b, 32c, and 32d, and via conductors 33a, 33b, 33c, and 33d. Insulating layer 31e is provided with via conductor 33e and pad 35e. Insulating layer 31f is provided with via conductor 33f and pad 35f. Insulating layer 31e can be one layer or two or more layers. Similarly, insulating layer 31f can be 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.

[0053] Coil conductors 32a, 32b, 32c, and 32d are respectively disposed on the main surfaces of insulating layers 31a, 31b, 31c, and 31d, and are stacked together with insulating layers 31a, 31b, 31c, 31d, 31e, and 31f. Figure 2 In the process, 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 repeatedly stacked as a unit (3 turns).

[0054] In addition, coil conductors 32a, 32b, 32c, and 32d each include annular winding portions 34a, 34b, 34c, and 34d with a gap due to a missing portion, and pads 35a, 35b, 35c, and 35d. Pads 35a, 35b, 35c, and 35d are provided at both ends of each winding portion 34a, 34b, 34c, and 34d. Hereinafter, winding portions 34a, 34b, 34c, and 34d will also be collectively referred to as winding portion 34.

[0055] The via conductors 33a, 33b, 33c, 33d, 33e, and 33f are respectively configured to penetrate the insulating layers 31a, 31b, 31c, 31d, 31e, and 31f in the stacking direction. Hereinafter, the via conductors 33a, 33b, 33c, 33d, 33e, and 33f will also be collectively referred to as via conductor 33.

[0056] Pads 35e and 35f are respectively provided directly above the via conductors 33e and 33f. Pads 35a, 35b, 35c, 35d, 35e, and 35f are preferably slightly larger than the linewidth of the winding portions 34a, 34b, 34c, and 34d. Hereinafter, pads 35a, 35b, 35c, 35d, 35e, and 35f will also be collectively referred to as pad 35. Pad 35 is larger than the adjacent via conductor 33, and when viewed from the stacking direction (length direction L), the via conductor 33 adjacent to pad 35 converges within the area of ​​pad 35.

[0057] Materials used to construct each coil conductor 32 and each via conductor 33, which includes the winding portion 34 and the pad 35, include, for example, Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0058] Multiple insulating layers 31a, 31b, 31c, 31d, 31e, and 31f, as described above, are stacked along the stacking direction. This forms a laminate 10, in which multiple coil conductors 32a, 32b, 32c, and 32d are electrically connected via through-hole conductors 33a, 33b, 33c, and 33d. As a result, a solenoid-shaped coil with a coil axis parallel to the stacking direction is formed within the laminate 10.

[0059] Additionally, the via conductor 33e and the pad 35e become the first lead conductor. The first lead conductor is exposed at the first end face 11 of the laminate 10. That is, the first lead conductor includes the via conductor 33e and the pad 35e. Furthermore, as Figure 2 As shown, a through-hole conductor 33e is present in the portion of the first lead conductor exposed at the first end face 11 of the laminate 10. As will be described later, the first lead conductor connects the first external electrode 21 and the coil conductor 32a opposite to it within the laminate 10.

[0060] The via conductor 33f and the pad 35f become the second lead conductor. The second lead conductor is exposed at the second end face 12 of the laminate 10. That is, the second lead conductor includes the via conductor 33f and the pad 35f. Wherein, as... Figure 2 As shown, a pad 35f is present in the portion of the second lead conductor exposed at the second end face 12 of the laminate 10. As described later, the second lead conductor connects the second external electrode 22 and the coil conductor 32d opposite it within the laminate 10.

[0061] When viewed from the stacking direction (length direction L), the coil conductors 32 preferably overlap each other. Alternatively, when viewed from the stacking direction, the coil can be... Figure 2The shape shown can be composed of straight lines (e.g., a rectangle or other polygon), or it can be composed of curved lines (e.g., a circle), or it can be composed of both straight lines and curved lines.

[0062] Figure 3 It is perspective composition Figure 1 An example of the internal structure of the stacked coil component is shown, along with a schematic side view.

[0063] like Figure 3 As shown, in the stacked coil component 1, multiple insulating layers 31 are stacked in the length direction L, so the length direction L is the stacking direction. In addition, the stacking direction of the stacked body 10 and the coil axis A of the coil 30 are parallel to the first main surface 13, the second main surface 14, the first side surface 15, or the second side surface 16, which serve as mounting surfaces.

[0064] In addition, such as Figure 3 As shown, the boundaries are not actually visible between adjacent insulating layers 31.

[0065] In addition, Figure 2 as well as Figure 3 In the example shown, the number of layers of the coil conductor 32 with 3 turns used to form the coil 30 is 4, that is, the repeating shape is 3 / 4 turn shape, but the number of layers of the coil conductor 32 with 1 turn used to form the coil 30 is not particularly limited.

[0066] For example, the number of layers of the coil conductor 32 used to form one turn of the coil 30 can also be 2, that is, the repeating shape can also be a 1 / 2 turn shape.

[0067] Furthermore, there is no particular limitation on the number of layers of coil conductor 32, that is, the total number of layers of coil conductor 32 contained in the laminate 10.

[0068] Figure 4 It is a schematic representation along Figure 1 A cross-sectional view of an example of the cross-section of line segment A1-A1 of the stacked coil component shown.

[0069] like Figure 4 As shown, when observing the cross-section perpendicular to the direction in which the coil conductor 32 extends, the cross-sectional shape of the coil conductor 32 is flat, and its long side is orthogonal to the stacking direction (length direction L). Figure 4 In the example shown, the cross-sectional shape of the coil conductor 32 is an ellipse with its 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 a pair of opposite sides of the same length in the stacking direction, or a trapezoid with a pair of opposite sides of different lengths in the stacking direction.

[0070] The following is for reference Figure 2 as well as Figure 3 The first lead conductor 41 will be described.

[0071] The first lead conductor 41 extends along the stacking direction within the laminate 10, connecting the first external electrode 21 disposed on the first end face 11 and the coil conductor 32a opposite thereto in a straight line. The first lead conductor 41 has a through-hole conductor 33e penetrating the insulating layer 31e and a pad 35e disposed on the insulating layer 31e.

[0072] Furthermore, it is preferable that the via conductors 33e constituting the first lead conductor 41 overlap each other when viewed from the stacking direction (length direction L), but the via conductors 33e constituting the first lead conductor 41 may also be arranged in a non-strict straight line.

[0073] The first end 41a of the first lead conductor 41 in the stacking direction is in direct contact with the first external electrode 21. A through-hole conductor 33e of the first lead conductor 41 is present at the first end 41a.

[0074] The first external electrode 21, in addition to the first end 41a, is in direct contact with at least one first pad 51 of the pad 35e of the first lead conductor 41, which is furthest from the first end 41a. In the stacked coil assembly 1, the pad 35e of the first lead conductor 41, located on the side closest to the first end face 11, protrudes from the stack 10 and becomes the first pad 51. The first external electrode 21 covers the portion of the first pad 51 that protrudes from the stack 10, thereby the first pad 51 and the first external electrode 21 are in direct contact. In the stacked coil assembly 1, the first lead conductor 41 has a first pad 51. At least one via conductor 33e exists between the first pad 51 and the first end 41a.

[0075] In the laminated coil component of the present invention, the first external electrode 21, in addition to the first end 41a, is in direct contact with at least one first pad 51 located away from the first end 41a. Therefore, compared to the case where the first lead conductor 41 is only connected to the first external electrode 21 at the first end 41a, the contact area between the first external electrode 21 and the first lead conductor 41 is increased to the portion where the first pad 51 is in direct contact with the first external electrode 21. In the laminated coil component of the present invention, the current is also distributed to the first pad 51, thus suppressing current concentration at the first end 41a.

[0076] By suppressing the current concentration at the first end 41a of the first lead conductor 41, it is possible to prevent the current concentration section from breaking due to the heat generated by the current concentration. In addition, it is also possible to prevent the resistance of the first lead conductor 41 from increasing even if the wire does not break.

[0077] Figure 5 yes Figure 3 The V-V line sectional view in the image.

[0078] Figure 5 This indicates the cross section containing the first pad 51.

[0079] like Figure 5 As shown, the outer periphery of the first pad 51 is in direct contact with the first external electrode 21. More specifically, only a portion of the outer periphery of the first pad 51 is in direct contact with the first external electrode 21, while the remaining portion of the outer periphery and the inner portion of the first pad 51 (the central portion surrounded by the outer periphery) are not exposed from the laminate 10 and do not contact the first external electrode 21.

[0080] The first pad 51 is in direct contact with the first external electrode 21 at the edge of the laminate 10. For example... Figure 5 As shown, the first pad 51 is in direct contact with the first external electrode 21 at the ridge portion formed by the second main surface 14 and the first side surface 15 of the laminate 10.

[0081] When the first pad 51 is in direct contact with the first external electrode 21 at the edge portion of the laminate 10, the laminate 10 is approximately hexahedral. It is sufficient that the first pad 51 and the first external electrode 21 are in direct contact at the edge portion of the approximately hexahedral laminate 10. For example, an approximately cuboid can be used. An approximately cuboid includes cases where at least one corner or edge portion of a cuboid is rounded.

[0082] The edge portion of the laminate 10 may be curved, and the first pad 51 may directly contact the first external electrode 21 at the rounded edge portion of the laminate 10. For example, by adjusting the rounding of the edge portion of the laminate 10, the first pad 51 can be exposed from the laminate 10 and directly contact the first external electrode 21.

[0083] If the first pad 51 directly contacts the first external electrode 21 at the edge of the laminate 10, the contact area between the first pad 51 and the first external electrode 21 can be increased. Therefore, current concentration at the first end 41a can be further suppressed. In addition, the structure in which the first pad 51 directly contacts the first external electrode 21 at the edge of the laminate 10 is easy to manufacture, and the contact area between the first pad 51 and the first external electrode 21 is easy to control.

[0084] The first pad 51 may also be exposed from the laminate 10 not at the edge of the laminate 10, but on the first main surface 13, the second main surface 14, the first side surface 15 or the second side surface 16, and directly contact the first external electrode 21.

[0085] The shape of the first pad 51 is not particularly limited. For example, when viewed from the stacking direction (length direction L), the first pad 51 may have a circular shape, or it may have a polygonal shape such as an oval, elliptical, or rectangular shape. In addition, the part that contacts the first external electrode 21 may have the aforementioned shape defects or interruptions. When viewed from the stacking direction (length direction L), the pads of the first lead conductor 41 that do not contact the first external electrode 21 may have the same shape as the first pad 51, or they may be different.

[0086] Next, refer to Figure 2 as well as Figure 3 The second lead conductor 42 will be described.

[0087] The second lead conductor 42 extends along the lamination direction within the laminate 10, connecting the second external electrode 22 disposed on the second end face 12 and the coil conductor 32d opposite to it in a straight line. The second lead conductor 42 has a through-hole conductor 33f penetrating the insulating layer 31f and a pad 35f disposed on the insulating layer 31f.

[0088] Furthermore, it is preferable that the via conductors 33f constituting the second lead conductor 42 overlap each other when viewed from the stacking direction (length direction L), but the via conductors 33f constituting the second lead conductor 42 may also be arranged in a non-strict straight line.

[0089] The second end 42a of the second lead conductor 42 in the stacking direction is in direct contact with the second external electrode 22. A pad 35f for the second lead conductor 42 is located at the second end 42a. The pad 35f located at the second end 42a can also be partially missing due to the curvature formed at the corner of the stack 10.

[0090] In addition to the second end 42a, the second external electrode 22 is in direct contact with at least one second pad 52 of the pad 35f of the second lead conductor 42 that is furthest from the second end 42a. In the stacked coil component 1, the pad 35f furthest from the second end 42a is the pad 52 located closest to the second end face 12. Figure 3 The second pad 35f from the right in the stacked coil assembly 1 becomes the second pad 52. In the stacked coil assembly 1, the second lead conductor 42 has a second pad 52. At least one via conductor 33f exists between the second pad 52 and the second end 42a. The second pad 52 may have the same structure as the first pad 51, except that it is different from the external electrode it directly contacts.

[0091] If the second lead conductor 42 has a second pad 52, the current is distributed to the second pad 52, thus suppressing current concentration at the second terminal 42a. By suppressing current concentration at the second terminal 42a, the possibility of the current concentration section breaking due to heat generated by the current concentration can be suppressed. In addition, the possibility of the resistance of the second lead conductor 42 increasing even if the wire does not break can also be suppressed.

[0092] In addition, Figure 2 as well as Figure 3 The diagram illustrates a structure with a via conductor 33e at the first end 41a and a pad 35f at the second end 42a. However, it is also possible for the pad to be present at the first end 41a and the via conductor at the second end 42a. Furthermore, in this specification, the structure may be described as having the first lead conductor 41 as a second lead conductor 42, or the structure may be described as having the second lead conductor 42 as a first lead conductor 41.

[0093] The positional relationship between the first lead conductor 41 and the second lead conductor 42 is not particularly limited. When viewed from the stacking direction, the first lead conductor 41 and the second lead conductor 42 may or may not overlap. The entire first lead conductor 41 and the entire second lead conductor 42 may overlap, or a part of the first lead conductor 41 and a part of the second lead conductor 42 may overlap.

[0094] Next, a first modified example of the stacked coil component of the present invention will be described.

[0095] Figure 6 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a first modified example of the laminated coil component of the present invention.

[0096] exist Figure 6 In the stacked coil component 1A shown, the first external electrode 21, in addition to the first end 41a, is in direct contact with two or more first pads 51.

[0097] If the first external electrode 21 is in direct contact with two or more first pads 51, the current is distributed to the two or more first pads 51, thus further suppressing the concentration of current at the first end 41a.

[0098] In the laminated coil component 1A, the first lead conductor 41 has three first pads 51. The number of first pads 51 on the first lead conductor 41 is not particularly limited; it can be two or more.

[0099] In the stacked coil component 1A, the three pads 35e present on the first end face 11 side are called first pads 51. There are no pads between the first end 41a and each of the first pads 51 that are not in contact with the first external electrode 21.

[0100] When the first external electrode 21 is in direct contact with two or more first pads 51, the size of the two or more first pads 51 can be the same or different when viewed from the stacking direction.

[0101] In the stacked coil component 1A, the second external electrode 22, in addition to the second end 42a, is in direct contact with two or more second pads 52.

[0102] If the second external electrode 22 is in direct contact with two or more second pads 52, the current is distributed to the two or more second pads 52, thus further suppressing the concentration of current at the second end 42a.

[0103] In the laminated coil component 1A, the second lead conductor 42 has two second pads 52. The number of second pads 52 on the second lead conductor 42 is not particularly limited; it can be two or more.

[0104] In the stacked coil component 1A, the two pads 35f located on the second end face 12 become the second pads 52. There are no pads between the second end 42a and each of the second pads 52 that are not in contact with the second external electrode 22.

[0105] Next, a second variation of the stacked coil component of the present invention will be described.

[0106] Figure 7 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a second modified example of the laminated coil component of the present invention.

[0107] exist Figure 7 In the stacked coil component 1B shown, in the first lead conductor 41, there is a pad 35e2 between the first end 41a and the first pad 51 that does not protrude from the stack 10 and does not contact the first external electrode 21. In the stacked coil component 1B, the second ( Figure 7 The second pad from the left is 35e, which exists between the first end 41a and the first pad 51, and becomes a pad 35e2 that does not contact the first external electrode 21.

[0108] That is, in the stacked coil component 1B, the first lead conductor 41 has two or more pads 35e, and the two or more pads 35e of the first lead conductor 41 include a pad 35e2 that does not contact the first external electrode 21 between the first end 41a and the first pad 51.

[0109] If there is a pad 35e2 between the first end 41a and the first pad 51 that does not contact the first external electrode 21, the distance between the first end 41a and the first pad 51 becomes greater. Therefore, when the first end 41a and the first pad 51 generate heat due to the concentration of electricity, the distance between the heat-generating parts is greater, thus further suppressing the conductor from becoming too hot and breaking.

[0110] In the case where the first lead conductor 41 has two or more first pads 51, there may also be pads 35e2 between adjacent first pads 51 that do not protrude from the laminate 10 and do not contact the first external electrode 21.

[0111] In the laminated coil component 1B, in the second lead conductor 42, there is a pad 35f2 between the second end 42a and the second pad 52 that does not protrude from the laminate 10 and does not contact the second external electrode 22. In the laminated coil component 1B, the second ( Figure 7 The second pad from the right (35f) exists between the second end 42a and the second pad 52, becoming a pad 35f2 that does not contact the second external electrode 22.

[0112] That is, in the stacked coil component 1B, the second lead conductor 42 has two or more pads 35f, and the two or more pads 35f of the second lead conductor 42 include a pad 35f2 that does not contact the second external electrode 22 between the second end 42a and the second pad 52.

[0113] If there is a pad 35f2 between the second end 42a and the second pad 52 that does not contact the second external electrode 22, the distance between the second end 42a and the second pad 52 becomes greater. Therefore, when heat is generated at the second end 42a and the second pad 52 due to the concentration of electricity, the increased distance between the heat-generating parts further suppresses the conductor from becoming too hot and breaking.

[0114] In the case where the second lead conductor 42 has two or more second pads 52, there may also be pads 35f2 between adjacent second pads 52 that do not protrude from the laminate 10 and do not contact the second external electrode 22.

[0115] Next, a third variation of the stacked coil component of the present invention will be described.

[0116] Figure 8 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes a third modified example of the laminated coil component of the present invention.

[0117] exist Figure 8In the stacked coil component 1C shown, in addition to the first lead conductor 41, the internal electrode also has a third lead conductor 43 connected to the first external electrode 21.

[0118] The third lead conductor 43 has a through-hole conductor 33 that penetrates the insulating layer 31 and a pad 35 disposed on the insulating layer 31.

[0119] The third lead conductor 43 extends along the stacking direction. The third end 43a of the third lead conductor 43 in the stacking direction is in direct contact with the first external electrode 21. A via conductor 33 is provided at the third end 43a, but a pad 35 may also be provided at the third end 43a.

[0120] In addition to the third end 43a, the first external electrode 21 is in direct contact with at least one third pad 53 of the pad 35 of the third lead conductor 43, which is away from the third end 43a. In the stacked coil component 1C, one third pad 53 is in direct contact with the first external electrode 21, but two or more third pads 53 may also be in direct contact with the first external electrode 21.

[0121] If a third lead conductor 43 is present, the current flowing through the first lead conductor 41 is also distributed to the third lead conductor 43, thus further suppressing the current concentration at the first terminal 41a. In addition, in the third lead conductor 43, the current is distributed to the third pad 53, thus also suppressing the current concentration at the third terminal 43a.

[0122] The third lead conductor 43 may have the same structure as the first lead conductor 41, except that its contact position with the coil conductor 32 and the first external electrode 21 is different.

[0123] In the stacked coil component 1C, the internal electrode may have a fourth lead conductor 44 connected to the second external electrode 22, in addition to the second lead conductor 42.

[0124] The fourth lead conductor 44 may have the same structure as the second lead conductor 42, except that its contact position with the coil conductor 32 and the second external electrode 22 differs. The fourth end 44a of the fourth lead conductor 44 in the stacking direction is in direct contact with the second external electrode 22. The fourth lead conductor 44 has at least one fourth pad 54 located away from the fourth end 44a and in contact with the second external electrode 22.

[0125] Figure 9 yes Figure 8 Sectional view along line IX-IX.

[0126] In the laminated coil component 1C, in addition to the first lead conductor 41 and the third lead conductor 43, the internal electrodes also have a fifth lead conductor 45 and a seventh lead conductor 47 connected to the first external electrode 21. The fifth end of the fifth lead conductor 45 in the lamination direction is in direct contact with the first external electrode 21. The fifth lead conductor 45 has at least one fifth pad 55 located away from the fifth end and in direct contact with the first external electrode 21. The seventh end of the seventh lead conductor 47 in the lamination direction is in direct contact with the first external electrode 21. The seventh lead conductor 47 has at least one seventh pad 57 located away from the seventh end and in contact with the first external electrode 21.

[0127] The fifth lead conductor 45 and the seventh lead conductor 47 may have the same structure as the first lead conductor 41 and the third lead conductor 43, except that their contact positions with the coil conductor 32 and the first external electrode 21 are different.

[0128] The first lead conductor 41, the third lead conductor 43, the fifth lead conductor 45, and the seventh lead conductor 47 are connected in parallel between the coil and the first external electrode 21. For example, the first lead conductor 41, the third lead conductor 43, the fifth lead conductor 45, and the seventh lead conductor 47 may also extend from the corners of the rectangular coil when viewed from the stacking direction. In addition, the first pad 51, the third pad 53, the fifth pad 55, and the seventh pad 57 may also be in direct contact with the first external electrode 21 at the edges of the laminate 10 when viewed from the stacking direction.

[0129] In the stacked coil component 1C, in addition to the second lead conductor 42 and the fourth lead conductor 44, the internal electrode may also have a sixth lead conductor and an eighth lead conductor connected to the second external electrode 22, similar to the fifth lead conductor 45 and the seventh lead conductor 47.

[0130] The sixth and eighth leads, except for their different contact positions with the coil conductor 32 and the second external electrode 22, may have the same structure as the second lead 42 and the fourth lead 44. That is, the sixth lead may also have a sixth end away from the second external electrode 22 and at least one sixth pad in direct contact with the second external electrode 22. The eighth lead may also have an eighth end away from the second external electrode 22 and at least one eighth pad in direct contact with the second external electrode 22. The second lead 42, the fourth lead 44, the sixth lead, and the eighth lead may also be connected in parallel between the coil and the second external electrode 22.

[0131] Next, a fourth variation of the laminated coil component of the present invention will be described.

[0132] Figure 10 This is a perspective view schematically illustrating a fourth modified example of the stacked coil component of the present invention.

[0133] Figure 11 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes the fourth modified example of the laminated coil component of the present invention.

[0134] exist Figure 10 as well as Figure 11 In the stacked coil component 1D shown, the first external electrode 21 covers a portion of the first end face 11 and a portion of the first main face 13 of the stacked body 10. Additionally, the second external electrode 22 covers a portion of the second end face 12 and a portion of the first main face 13 of the stacked body 10.

[0135] In the stacked coil component 1D, the first main surface 13 becomes the mounting surface.

[0136] In the multilayer coil component 1D, the first end 41a of the first lead conductor 41 is in direct contact with a portion of the first end face 11 of the cover laminate 10 in the first external electrode 21. The first pad 51 of the first lead conductor 41 is in direct contact with a portion of the first main surface 13 of the cover laminate 10 in the first external electrode 21.

[0137] The second end 42a of the second lead conductor 42 is in direct contact with a portion of the second end face 12 of the cover laminate 10 in the second external electrode 22. The second pad 52 of the second lead conductor 42 is in direct contact with a portion of the first main surface 13 of the cover laminate 10 in the second external electrode 22.

[0138] Next, a fifth variation of the laminated coil component of the present invention will be described.

[0139] Figure 12 This is a perspective view schematically illustrating a fifth modified example of the stacked coil component of the present invention.

[0140] Figure 13 This is a schematic side view illustrating an example of the internal structure of the laminate that constitutes the fifth modified example of the laminated coil component of the present invention.

[0141] Figure 12 as well as Figure 13 The stacked coil component 1E shown is an example of a stacked coil component in which the stacking direction is orthogonal to the mounting surface.

[0142] In the laminated coil component 1E, the first external electrode 21 covers a portion of the first end face 11 and a portion of the first main face 13 of the laminate 10. Additionally, the second external electrode 22 covers a portion of the second end face 12 and a portion of the first main face 13 of the laminate 10.

[0143] In the stacked coil component 1E, the first main surface 13 becomes the mounting surface.

[0144] In the stacked coil component 1E, the height direction T is the stacking direction. The stacking direction of the stacked body 10 and the coil axis A of the coil 30 are orthogonal to the first main surface 13, which serves as the mounting surface. The stacked coil component 1E has a so-called longitudinal winding structure.

[0145] The first lead conductor 41 and the second lead conductor 42 extend along the stacking direction. In the stacked coil component 1E, the first lead conductor 41 and the second lead conductor 42 extend along the height direction T.

[0146] The first end 41a of the first lead conductor 41 is in direct contact with a portion of the first main surface 13 of the cover laminate 10 in the first external electrode 21. The first pad 51 of the first lead conductor 41 is in direct contact with a portion of the first end surface 11 of the cover laminate 10 in the first external electrode 21.

[0147] The second end 42a of the second lead conductor 42 is in direct contact with a portion of the first main surface 13 of the cover laminate 10 in the second external electrode 22. The second pad 52 of the second lead conductor 42 is in direct contact with a portion of the second end surface 12 of the cover laminate 10 in the second external electrode 22.

[0148] [First method for manufacturing laminated coil components]

[0149] Next, a method for manufacturing the laminated coil component of the present invention, which is capable of manufacturing the laminated coil component of the present invention described herein, will be described.

[0150] A first embodiment of the manufacturing method of the stacked coil component of the present invention is characterized by comprising: a step of preparing a stacked body, the stacked body being formed by stacking multiple insulating layers in a stacking direction and having an internal electrode; a step of performing a tumbling process on the stacked body; and a step of forming an external electrode on the outer surface of the stacked body after tumbling, wherein the internal electrode has a first lead conductor and a second lead conductor extending respectively along the stacking direction, the first lead conductor having a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer, in the step of preparing the stacked body, a first end of one of the two ends of the first lead conductor in the stacking direction is exposed from the stacked body, and the pads of the first lead conductor that are away from the first end are not exposed from the stacked body, in the step of performing the tumbling process, the stacked body is ground so that at least one first pad away from the first end is exposed from the stacked body, and in the step of forming the external electrode, a first external electrode is formed so as to cover the first end exposed from the stacked body and at least one first pad.

[0151] The following is about manufacturing Figure 1 Taking the method of the stacked coil component 1 shown as an example, a first aspect of the manufacturing method of the stacked coil component of the present invention will be described.

[0152] <Manufacturing Process of Magnetic Materials>

[0153] First, weigh Fe2O3, ZnO, CuO, and NiO to achieve the specified ratio.

[0154] Next, after mixing these weighed materials, pure water, and PSZ (partially stabilized zirconia) media in a ball mill, the mixture is pulverized. The mixing and pulverizing time is set, for example, to be between 4 and 8 hours.

[0155] Then, after drying the resulting pulverized material, it is calcined. The calcination temperature is, for example, set to 700°C or higher and 800°C or lower. The calcination time is, for example, set to 2 hours or higher and 5 hours or lower.

[0156] In this way, magnetic materials in powder form, or more specifically, magnetic ferrite materials in powder form, are produced.

[0157] The preferred ferrite material is a Ni-Cu-Zn based ferrite material.

[0158] Regarding Ni-Cu-Zn ferrite materials, when the total amount is set to 100 mol%, it is preferable that Fe is converted to Fe2O3 and contains 40 mol% or more and 49.5 mol% or less, Zn is converted to ZnO and contains 2 mol% or more and 35 mol% or less, Cu is converted to CuO and contains 6 mol% or more and 13 mol% or less, and Ni is converted to NiO and contains 10 mol% or more and 45 mol% or less.

[0159] Ni-Cu-Zn ferrite materials can also further include additives such as Co, Bi, Sn, and Mn.

[0160] Ni-Cu-Zn ferrite materials may also contain unavoidable impurities.

[0161] <Processes for making raw slices>

[0162] First, magnetic materials, organic binders such as polyvinyl butyral resin, organic solvents such as ethanol and toluene, and plasticizers are mixed with PSZ media in a ball mill and then pulverized to produce a slurry.

[0163] Next, after the slurry is formed into a sheet of a specified thickness using a scraper or similar method, it is punched into a specified shape to produce a green sheet. The thickness of the green sheet is, for example, set to be 20 μm or more and 30 μm or less. The shape of the green sheet is, for example, set to be rectangular.

[0164] As a material for raw sheets, instead of magnetic materials, non-magnetic materials such as borosilicate glass can be used, or a mixture of magnetic and non-magnetic materials can be used.

[0165] <Conductor Pattern Formation Process>

[0166] First, through holes are formed by laser irradiation of designated areas on the raw film.

[0167] Next, a conductive paste such as Ag paste is filled into the through-holes and coated onto the surface of the green sheet using a screen printing method. Thus, for the green sheet, a conductor pattern for the through-hole conductor is formed in the through-hole, and a conductor pattern for the coil conductor connected to the conductor pattern for the through-hole conductor is formed on the surface. In this way, a coil sheet with both the coil conductor pattern and the through-hole conductor pattern formed on the green sheet is produced. The coil sheet has a structure equivalent to... Figure 2 The coil conductor 32 shown uses a conductor pattern and is equivalent to Figure 2 The conductive pattern for the through-hole conductor 33 (excluding through-hole conductors 33e and 33f) is shown. Additionally, the through-hole sheet is manufactured separately from the coil sheet, and a corresponding... Figure 2 The conductor patterns for the via conductors 33e and 33f shown are equivalent to... Figure 2 The conductor patterns for pads 35e and 35f are shown.

[0168] <Fabrication process of stacked blocks>

[0169] The coil pieces and the through-hole pieces are then connected with... Figure 2 After being stacked in a corresponding order in the stacking direction (length direction L), they are heat-pressed to form a laminated block.

[0170] <Process of forming a laminate by individually separating laminated blocks>

[0171] First, the stacked blocks are cut into specified sizes using a cutting machine or similar equipment to create monolithic chips (stacks).

[0172] Next, the monolithic chip is burned. The burning temperature is set, for example, above 900°C and below 920°C. The burning time is set, for example, above 2 hours and below 4 hours.

[0173] If a monolithic chip is fabricated, the green sheets of the coil sheet and the via sheet become the insulating layer.

[0174] Furthermore, if a monolithic chip is fabricated, the conductor pattern for the coil conductor, the conductor pattern for the via conductor, and the conductor pattern for the pad become the coil conductor, the via conductor, and the pad, respectively. As a result, a coil is formed by electrically connecting multiple coil conductors stacked together with the insulating layer via the via conductor.

[0175] Based on the above, a laminate containing internal electrodes is prepared by stacking multiple insulating layers in a stacking direction. The internal electrodes have a first lead conductor and a second lead conductor extending in the stacking direction, respectively. The first lead conductor and the second lead conductor have through-hole conductors penetrating the insulating layer and pads disposed on the insulating layer.

[0176] The process of preparing the laminate in the first method of manufacturing coil components may also include the above-mentioned <magnetic material manufacturing process>, <green sheet manufacturing process>, <conductor pattern formation process>, <laminate block manufacturing process>, and <process of forming a laminate by monolithizing the laminate block>.

[0177] Figure 14 This is an exploded perspective view schematically illustrating an example of a laminate produced in the step of preparing the laminate in a first aspect of the manufacturing method of the coil component of the present invention.

[0178] Figure 15 This is a schematic side view showing an example of the internal structure of a laminate produced in the process of preparing the laminate in the first aspect of the manufacturing method of the coil component of the present invention.

[0179] Figure 14 as well as Figure 15 The stacked body 10 shown and Figure 2 as well as Figure 3 Compared to the stacked body 10 shown, the corners and edges are not curved.

[0180] In the process of preparing the laminate, the first end 41a of one of the two ends of the first lead conductor 41 in the lamination direction is exposed from the laminate, and the pads 35e of the first lead conductor 41 that are far from the first end 41a are not exposed from the laminate 10. The same applies to the second lead conductor 42, the second end 42a is exposed from the laminate, and the pads 35f that are far from the second end 42a are not exposed from the laminate 10.

[0181] <Process of tumbling the laminate>

[0182] In the process of tumbling the laminate, the laminate is tumbled to give the corners and edges a rounded shape.

[0183] Figure 16 This is a schematic side view illustrating an example of the internal structure of the laminate after the tumbling process has been performed in the first aspect of the manufacturing method of the coil component of the present invention.

[0184] In the tumbling process, the laminate 10 is ground to expose at least one first pad 51 away from the first end 41a from the laminate 10. Figure 16 In the middle, a first pad 51 is exposed from the stack 10.

[0185] In a first embodiment of the manufacturing method for the coil component of the present invention, the edges and corners of the laminate 10 are rounded by a tumbling process, thereby exposing the first pad 51 from the rounded edges of the laminate 10. Alternatively, the first pad 51 can be exposed from the laminate 10 by extending the tumbling process time beyond normal. Furthermore, the position and size of the first pad 51 itself can be adjusted to expose the first pad 51 from the laminate 10 during the tumbling process.

[0186] At least one second pad 52, away from the second end 42a of the second lead conductor 42, can also be exposed from the laminate 10 in the same way.

[0187] <Process for forming external electrodes>

[0188] In the process of forming the external electrode, the external electrode is formed on the outer surface of the laminate after tumbling. In the process of forming the external electrode, a first external electrode is formed to cover a first end exposed from the laminate and at least one first pad. Additionally, a second external electrode is formed to cover a second end exposed from the laminate and at least one second pad.

[0189] Figure 17 This is a schematic side view illustrating an example of the internal structure of the laminate after the step of forming the external electrode is performed in the first aspect of the manufacturing method of the coil component of the present invention.

[0190] Figure 17 Is with Figure 3 Same as the attached diagram.

[0191] The following is for reference Figure 17 The process of forming the external electrode is described.

[0192] First, a conductive paste containing Ag and glass powder is applied to the first end face 11 and the second end face 12 of the lead-out coil on the outer surface of the laminate 10 to form a conductive paste layer.

[0193] Next, the base electrode of the external electrode is formed by sintering the conductive paste layer. The sintering temperature is, for example, set to 800°C or higher and 820°C or lower. The thickness of the base electrode is, for example, set to 5 μm.

[0194] Then, a Ni-plated electrode and a Sn-plated electrode are sequentially formed on the surface of the base electrode using electroplating or the like. Thus, a first external electrode 21 and a second external electrode 22 are formed, which sequentially have a base electrode, a Ni-plated electrode, and a Sn-plated electrode.

[0195] Through the above-described processes, a first external electrode 21 is formed to cover the first end 41a and the first pad 51 exposed from the laminate 10, and the first external electrode 21 is directly connected to the first end 41a and the first pad 51. Additionally, a second external electrode 22 is formed to cover the second end 42a and the second pad 52 exposed from the laminate 10, and the second external electrode 22 is directly connected to the second end 42a and the second pad 52.

[0196] Based on the above, manufacture the laminated coil component 1.

[0197] [Second method for manufacturing laminated coil components]

[0198] Next, a second aspect of the manufacturing method of the laminated coil component of the present invention will be described.

[0199] A second aspect of the manufacturing method for the laminated coil component of the present invention is characterized by comprising: a step of preparing a laminated block, the laminated block being formed by stacking multiple insulating layers in a stacking direction and having internal electrodes; a step of monolithically forming the laminated block into a laminated body; and a step of forming external electrodes on the laminated body, wherein the internal electrodes have a first lead conductor and a second lead conductor extending respectively along the stacking direction, the first lead conductor having a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer, wherein the preparation of the laminated block into the laminated body comprises: a step of preparing a laminated block; a step of monolithically forming the laminated body; and a step of forming external electrodes on the laminated body, wherein the internal electrodes have a first lead conductor and a second lead conductor extending respectively along the stacking direction, the first lead conductor having a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer; and a step of forming external electrodes on the laminated body. In the process of forming the stacked block, the first end of one of the two ends of the first lead conductor in the stacking direction is exposed from the stacked block, and the pads of the first lead conductor that are far from the first end are not exposed from the stacked block. In the process of monolithizing the stacked block, the stacked block is cut so that at least one first pad that is far from the first end is exposed from the stacked block. In the process of forming the external electrode, a first external electrode is formed so as to cover the first end exposed from the stacked block and at least one first pad.

[0200] Hereinafter, an example of a second aspect of the manufacturing method of the laminated coil component of the present invention will be described.

[0201] In addition to setting the structure of the stacked blocks as described later. Figure 18In addition to the structure shown, the laminated block can also be prepared by performing the same steps as those described up to the <Laminated Block Fabrication Step> in the first embodiment of the method for manufacturing the laminated coil component of the present invention. This allows for the preparation of a laminated block having internal electrodes formed by stacking multiple insulating layers in the stacking direction. The internal electrodes have a first lead conductor and a second lead conductor extending respectively along the stacking direction. The first lead conductor has a through-hole conductor penetrating the insulating layer and a pad disposed on the insulating layer.

[0202] Figure 18 This is a schematic diagram illustrating an example of a laminated block produced in the step of preparing a laminated block in a second aspect of the manufacturing method of the laminated coil component of the present invention, viewed from the lamination direction.

[0203] Figure 18 The stacked block 110 shown becomes four stacked blocks after being monolithized. Figure 18 The diagram shows the cutting lines X and Y when the laminated block 110 is monolithically formed into a laminate. Figure 18 In the above, the number of stacked bodies contained in the stacked body block 110 is 4, but there is no particular limitation on the number of stacked bodies contained in the stacked body block 110, as long as it is 2 or more.

[0204] A coil 30, to be fired, is disposed inside the laminated block 110. In addition, the first end 41a of one of the two ends of the first lead conductor 41 in the lamination direction is exposed from the laminated block 110.

[0205] exist Figure 18 In the stacked block 110 shown, a first pad pattern 151, corresponding to the first pad, is provided to cross the cut line X and the cut line Y. The first pad pattern 151, corresponding to the first pad, exists inside the stacked block 110 and does not protrude from the stacked block 110. In the stacked block 110, the pads of the first lead conductor 41 that are far from the first end 41a are not exposed from the stack.

[0206] <Process of forming a laminate by individually separating laminated blocks>

[0207] Cut along cutting line X and cutting line Y using a cutting machine or similar equipment. Figure 18 The stacked blocks are formed into a stack. As a result, the first pad pattern 151, corresponding to the first pad, is exposed from the cut surface of the stack. That is, in the process of monolithizing the stacked block 110, the stacked block 110 is cut so that at least one first pad away from the first end 41a is exposed from the stack.

[0208] Next, the monolithic chip is burned. The burning temperature is set, for example, above 900°C and below 920°C. The burning time is set, for example, above 2 hours and below 4 hours.

[0209] If a monolithic chip is fabricated, the green sheets of the coil sheet and the via sheet become the insulating layer.

[0210] Furthermore, if a monolithic chip is fabricated, the conductor pattern for the coil conductor, the conductor pattern for the via conductor, and the conductor pattern for the pad become the coil conductor, the via conductor, and the pad, respectively. As a result, a coil is formed by electrically connecting multiple coil conductors stacked together with the insulating layer via the via conductor.

[0211] Based on the above, a laminate containing internal electrodes is prepared by stacking multiple insulating layers in a stacking direction. The internal electrodes have a first lead conductor and a second lead conductor extending along the stacking direction, respectively. The first and second lead conductors have through-hole conductors penetrating the insulating layers and pads disposed on the insulating layers. At this stage, the first end of the first lead conductor and the first pad away from the first end are exposed from the laminate, and the second end of the second lead conductor and the second pad away from the second end are exposed from the laminate.

[0212] <Process of tumbling the laminate>

[0213] In a second embodiment of the manufacturing method for the laminated coil component of the present invention, the laminated body may or may not undergo tumbling. By tumbling the laminated body, the corners and edges are given a rounded shape.

[0214] <Process for forming external electrodes>

[0215] In the process of forming the external electrode, the external electrode is formed on the outer surface of the laminate after tumbling. In the process of forming the external electrode, a first external electrode is formed to cover a first end exposed from the laminate and at least one first pad. Additionally, a second external electrode is formed to cover a second end exposed from the laminate and at least one second pad.

[0216] First, a conductive paste containing Ag and glass powder is applied to the first and second end faces of the lead-out coils on the outer surface of the laminate to form a conductive paste layer.

[0217] Next, the base electrode of the external electrode is formed by sintering the conductive paste layer. The sintering temperature is, for example, set to 800°C or higher and 820°C or lower. The thickness of the base electrode is, for example, set to 5 μm.

[0218] Then, a Ni-plated electrode and a Sn-plated electrode are sequentially formed on the surface of the base electrode using electroplating or the like. This forms a first external electrode and a second external electrode having a base electrode, a Ni-plated electrode, and a Sn-plated electrode sequentially.

[0219] Through the above-described processes, a first external electrode is formed to cover the first end exposed from the laminate and the first pad, and the first external electrode 21 is directly connected to the first end and the first pad. Additionally, a second external electrode is formed to cover the second end exposed from the laminate and the second pad, and the second external electrode is directly connected to the second end and the second pad.

[0220] Based on the above, the laminated coil component of the present invention is manufactured.

[0221] The following information is disclosed in this specification.

[0222] <1> A laminated coil component, comprising:

[0223] A laminate, consisting of multiple insulating layers stacked in the stacking direction, and having internal electrodes; and

[0224] The first external electrode and the second external electrode are disposed on the outer surface of the aforementioned laminate.

[0225] The internal electrode has: a first lead conductor extending along the stacking direction and connected to the first external electrode, and a second lead conductor extending along the stacking direction and connected to the second external electrode.

[0226] The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer.

[0227] If the end of the first lead conductor that is in direct contact with the first external electrode in the stacking direction is designated as the first end, then

[0228] In addition to the first end, the first external electrode is in direct contact with at least one first pad of the first lead conductor that is far from the first end.

[0229] <2> According to the laminated coil component described in <1>, wherein,

[0230] In addition to the first end, the first external electrode is in direct contact with two or more of the first pads.

[0231] <3> According to the laminated coil components described in <1> or <2>, wherein,

[0232] The first lead conductor described above has two or more of the aforementioned pads.

[0233] The first lead conductor has two or more pads that do not contact the first external electrode between the first end and the first pad.

[0234] <4> According to any one of <1> to <3>, the laminated coil component, wherein,

[0235] The second lead conductor described above has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer.

[0236] If the end of the second lead conductor that is in direct contact with the second external electrode in the stacking direction is designated as the second end, then

[0237] In addition to the second end, the second external electrode is in direct contact with at least one second pad of the second lead conductor that is far from the second end.

[0238] <5> According to the laminated coil component described in <4>, wherein,

[0239] The aforementioned through-hole conductor has the aforementioned first lead-out conductor at the aforementioned first end.

[0240] The second terminal has the pad of the second lead conductor.

[0241] <6> According to any one of <1> to <5>, the laminated coil component, wherein,

[0242] The aforementioned internal electrode has a third lead conductor extending along the aforementioned stacking direction and connected to the aforementioned first external electrode.

[0243] The aforementioned third lead conductor has a through-hole conductor that penetrates the aforementioned insulating layer and a pad disposed on the aforementioned insulating layer.

[0244] If the end of the third lead conductor that is in direct contact with the first external electrode in the stacking direction is designated as the third end, then

[0245] In addition to the aforementioned third end, the aforementioned first external electrode is in direct contact with at least one third pad of the aforementioned third lead conductor that is far from the aforementioned third end.

[0246] <7> According to any one of <1> to <6>, the laminated coil component, wherein,

[0247] The aforementioned stacked body is approximately hexahedral.

[0248] All of the aforementioned first pads are in direct contact with the aforementioned first external electrode at the ridge portion of the aforementioned laminate.

[0249] <8> According to any one of <1> to <7>, the laminated coil component, wherein,

[0250] The aforementioned stacking direction is parallel to the mounting surface.

[0251] <9> According to any one of <1> to <7>, the laminated coil component, wherein,

[0252] The aforementioned stacking direction is orthogonal to the mounting surface.

[0253] <10> A method for manufacturing a laminated coil component, comprising:

[0254] The process of preparing a laminate, wherein the laminate is formed by stacking multiple insulating layers in the stacking direction and has internal electrodes;

[0255] The process of tumbling the above-mentioned laminated body; and

[0256] The process of forming external electrodes on the outer surface of the above-mentioned laminate after tumbling.

[0257] The aforementioned internal electrodes have a first lead conductor and a second lead conductor extending along the aforementioned stacking direction, respectively.

[0258] The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer.

[0259] In the process of preparing the aforementioned laminate, the first end of one of the two ends of the first lead conductor in the aforementioned lamination direction is exposed from the laminate, and the pads of the first lead conductor that are far from the first end are not exposed from the laminate.

[0260] In the above-described tumbling process, the laminate is ground so that at least one first pad, away from the first end, is exposed from the laminate.

[0261] In the process of forming the external electrode, a first external electrode is formed to cover the first end exposed from the laminate and at least one of the first pads.

[0262] <11> A method for manufacturing a laminated coil component, comprising:

[0263] The process of preparing a laminated block, wherein the laminated block is formed by stacking multiple insulating layers in the stacking direction and has internal electrodes;

[0264] The process of forming a laminate by individually separating the above-mentioned laminated blocks; and

[0265] In the process of forming the external electrode in the above-mentioned laminate,

[0266] The aforementioned internal electrodes have a first lead conductor and a second lead conductor extending along the aforementioned stacking direction, respectively.

[0267] The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer.

[0268] In the process of preparing the aforementioned laminated block, the first end of one of the two ends of the first lead conductor in the aforementioned lamination direction is exposed from the aforementioned laminated block, and the pads of the first lead conductor that are far from the first end are not exposed from the aforementioned laminated block.

[0269] In the process of monolithizing the above-mentioned stacked block, the stacked block is cut so that at least one first pad away from the first end is exposed from the stacked block.

[0270] In the process of forming the external electrode, a first external electrode is formed to cover the first end exposed from the laminate and at least one of the first pads.

[0271] Explanation of reference numerals in the attached figures

[0272] 1, 1A, 1B, 1C, 1D, 1E…Laminated coil components; 10…Laminated body; 11…First end face; 12…Second end face; 13…First main face; 14…Second main face; 15…First side face; 16…Second side face; 21…First external electrode; 22…Second external electrode; 30…Coil; 31, 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…Roll Winding section; 35, 35a, 35b, 35c, 35d, 35e, 35e2, 35f, 35f2… pads; 41… first lead conductor; 41a… first end; 42… second lead conductor; 42a… second end; 43… third lead conductor; 43a… third end; 44… fourth lead conductor; 44a… fourth end; 45… fifth lead conductor; 47… seventh lead conductor; 51… first pad; 52… second pad; 53… third pad; 54… fourth pad; 55… fifth pad; 57… seventh pad; 110… stacked block; 151… first pad pattern; A… coil shaft of the coil.

Claims

1. A laminated coil component, comprising: A laminate, which is composed of multiple insulating layers stacked in a stacking direction and has internal electrodes; and The first external electrode and the second external electrode are disposed on the outer surface of the laminate. The internal electrode has: a first lead-out conductor extending along the stacking direction and connected to the first external electrode, and a second lead-out conductor extending along the stacking direction and connected to the second external electrode. The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer. If the end of the first lead conductor that is in direct contact with the first external electrode in the stacking direction is designated as the first end, then In addition to the first end, the first external electrode is in direct contact with at least one first pad of the first lead conductor that is away from the first end.

2. The laminated coil component according to claim 1, wherein, In addition to the first end, the first external electrode is in direct contact with two or more of the first pads.

3. The laminated coil component according to claim 1 or 2, wherein, The first lead conductor has two or more of the aforementioned pads. The first lead conductor has two or more pads that do not contact the first external electrode between the first end and the first pad.

4. The laminated coil component according to any one of claims 1 to 3, wherein, The second lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer. If the end of the second lead conductor in the stacking direction that is in direct contact with the second external electrode is designated as the second end, then In addition to the second end, the second external electrode is in direct contact with at least one second pad of the second lead conductor that is away from the second end.

5. The laminated coil component according to claim 4, wherein, The through-hole conductor of the first lead-out conductor exists at the first end. The second lead conductor has a pad at the second end.

6. The laminated coil component according to any one of claims 1 to 5, wherein, The internal electrode has a third lead-out conductor extending along the stacking direction and connected to the first external electrode. The third lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer. If the end of the third lead conductor in the stacking direction that is in direct contact with the first external electrode is designated as the third end, then In addition to the third end, the first external electrode is in direct contact with at least one third pad of the third lead conductor that is away from the third end.

7. The laminated coil component according to any one of claims 1 to 6, wherein, The laminate is approximately hexahedral. All of the first pads are in direct contact with the first external electrode at the edge of the laminate.

8. The laminated coil component according to any one of claims 1 to 7, wherein, The stacking direction is parallel to the mounting surface.

9. The laminated coil component according to any one of claims 1 to 7, wherein, The stacking direction is orthogonal to the mounting surface.

10. A method for manufacturing a laminated coil component, comprising: The process of preparing a laminate, wherein the laminate is formed by stacking multiple insulating layers in a stacking direction and has internal electrodes; The process of performing a tumbling process on the laminated body; and The process of forming external electrodes on the outer surface of the laminate after tumbling. The internal electrode has a first lead-out conductor and a second lead-out conductor extending along the stacking direction, respectively. The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer. In the process of preparing the laminate, one end of one of the two ends of the first lead conductor in the lamination direction is exposed from the laminate, and none of the pads of the first lead conductor that are far from the first end are exposed from the laminate. In the rolling process, the laminate is ground so that at least one first pad away from the first end is exposed from the laminate. In the process of forming the external electrode, a first external electrode is formed to cover the first end exposed from the laminate and at least one of the first pads.

11. A method for manufacturing a laminated coil component, comprising: The process of preparing a laminated block, wherein the laminated block is formed by stacking multiple insulating layers in the stacking direction and has internal electrodes; The process of forming a laminate by individually separating the laminated blocks; and In the process of forming the external electrode in the laminated body The internal electrode has a first lead-out conductor and a second lead-out conductor extending along the stacking direction, respectively. The first lead conductor has a through-hole conductor that penetrates the insulating layer and a pad disposed on the insulating layer. In the process of preparing the laminated block, the first end of one of the two ends of the first lead conductor in the lamination direction is exposed from the laminated block, and the pads of the first lead conductor that are far from the first end are not exposed from the laminated block. In the process of monolithizing the laminated block, the laminated block is cut so that at least one first pad away from the first end is exposed from the laminated block. In the process of forming the external electrode, a first external electrode is formed to cover the first end exposed from the laminate and at least one of the first pads.

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