inductor component

Abstract

This invention provides an inductor component capable of suppressing Q-characteristic degradation and the generation of cracks, etc. The inductor component includes a blank, a coil, a first external electrode, a second external electrode, a first lead wire, and a second lead wire. The blank includes an insulator, and its surface includes a mounting surface and a top surface opposite the mounting surface in a height direction orthogonal to the coil axis. The first and second external electrodes are exposed at least on the mounting surface of the blank for separation from each other. The coil includes a plurality of coil wires electrically connected respectively. The plurality of coil wires are formed by electrically connecting a plurality of coil wires extending in a direction orthogonal to the coil axis and arranged at different positions in the coil axis. When viewed from the coil axis, the plurality of coil wires have straight portions and curved portions. At least one curved portion has a cut-out portion in a portion in the coil axis, and the wire thickness in the coil axis at the cut-out portion is smaller than the wire thickness in the coil axis at the straight portion.

Description

Technical Field

[0001] This invention relates to inductor components. Background Technology

[0002] Patent Document 1 discloses a method for manufacturing an inductor component, comprising: a step of preparing a photosensitive insulating paste and a conductive paste, wherein the insulating paste comprises a filler made of quartz, a glass material, and a resin material; a step of coating the insulating paste to form a first insulating layer; a step of exposing the first insulating layer to light while a first portion of the first insulating layer is shielded using a mask; a step of removing the first portion of the first insulating layer and forming a groove with a groove depth greater than its width at a position corresponding to the first portion; a step of coating the conductive paste in the groove and forming a coil conductor layer in the groove; and a step of coating the insulating paste on the first insulating layer and the coil conductor layer to form a second insulating layer.

[0003] Patent Document 1: Japanese Patent No. 6787286

[0004] According to the manufacturing method of the inductor component described in Patent Document 1, the coil characteristics can be improved because the aspect ratio and cross-sectional area of ​​the coil conductor layer can be increased.

[0005] Multilayer inductors are mostly manufactured by sintering a laminate containing metal paste and insulating paste. However, the linear expansion rates of wiring materials, which are mainly composed of metal, and insulating materials, which are composed of ceramics or magnetic materials, are different. As with inductor components manufactured by the method described in Patent Document 1, if the wiring thickness in the lamination direction increases, the wiring volume occupying the insulating layer in any space increases. Therefore, the residual stress generated during the cooling process after sintering increases, and the external impact resistance decreases. Moreover, due to the decrease in external impact resistance, there is a problem that the product may develop cracks / defects / fissures (hereinafter also referred to as cracks, etc.).

[0006] In addition, reducing integral stress is effective in suppressing the decrease in external shock resistance. Integral stress can be reduced by reducing the volume of a part of the coil wiring, but there is a problem that the Q characteristic (Q value) decreases due to the reduction of the cross-sectional area of ​​the coil wiring. Summary of the Invention

[0007] The present invention was made to solve the above-mentioned problems, and its object is to provide an inductor component that can suppress the reduction of Q characteristics and suppress the generation of cracks, etc.

[0008] The inductor component of the present invention is characterized by comprising: a blank; a coil disposed inside the blank and wound into a spiral shape along the coil axis; a first external electrode and a second external electrode exposed on the surface of the blank; a first lead wire disposed inside the blank and electrically connecting one end of the coil to the first external electrode; and a second lead wire disposed inside the blank and electrically connecting the other end of the coil to the second external electrode. The blank includes an insulator, and the surface of the blank includes a mounting surface and a top surface, wherein the mounting surface is parallel to the coil axis, and the top surface is perpendicular to the coil axis in a height direction orthogonal to the coil axis. With mounting surfaces facing each other, the first external electrode and the second external electrode are exposed at least on the mounting surfaces of the blank to separate them from each other. The coil includes a plurality of coil wires, which are electrically connected. The plurality of coil wires are formed by electrically connecting a plurality of coil wires that extend in a direction orthogonal to the coil axis and are arranged at different positions in the coil axis. When viewed from the coil axis, the plurality of coil wires have straight portions and curved portions. At least one of the curved portions has a cut portion in a portion in the coil axis. The wire thickness in the coil axis at the cut portion is smaller than the wire thickness in the coil axis at the straight portion.

[0009] According to the present invention, an inductor component capable of suppressing the reduction of Q characteristics and suppressing the generation of cracks, etc., can be provided. Attached Figure Description

[0010] Figure 1 This is a perspective view schematically illustrating an example of an inductor component according to Embodiment 1 of the present invention.

[0011] Figure 2 It is a schematic representation Figure 1 An exploded perspective view of an example of an inductor component shown.

[0012] Figure 3 This is a schematic representation taken from the axial direction of the coil. Figure 1 A top view of an example of an inductor component shown.

[0013] Figure 4 This is a diagram showing the distribution of residual stress after the firing of a typical inductor component.

[0014] Figure 5 It is a diagram showing the density distribution of the current flowing in the coil of a typical inductor component.

[0015] Figure 6 It is a schematic representation Figure 1A cross-sectional view of an example of an inductor component shown, along line segment a1-a2.

[0016] Figure 7 It is a schematic representation Figure 1 A perspective view of another example (Modified Example 1) of the inductor component shown.

[0017] Figure 8 It is a schematic representation Figure 7 A cross-sectional view of an example of an inductor component shown, along line segment b1-b2.

[0018] Figure 9 It is a schematic representation Figure 1 A perspective view of another example (Modified Example 2) of the inductor component shown.

[0019] Figure 10 It is a schematic representation Figure 9 A cross-sectional view of an example of an inductor component shown, along line segment c1-c2.

[0020] Figure 11 It is a diagram showing the surface density distribution of high-frequency current flowing in the coil of a typical inductor component.

[0021] Figure 12 It is a schematic representation Figure 1 A perspective view of another example of the inductor component shown (Modification 3).

[0022] Figure 13 This is a perspective view schematically illustrating an example of an inductor component according to Embodiment 2 of the present invention.

[0023] Figure 14 This is a schematic representation taken from the axial direction of the coil. Figure 13 A top view of an example of an inductor component shown.

[0024] Figure 15 This is a schematic representation taken from the axial direction of the coil. Figure 13 A top view of another example (Modified Example 1) of the inductor component shown.

[0025] Figure 16 This is a top view schematically illustrating an example of an inductor component according to Embodiment 3 of the present invention.

[0026] Figure 17 It is a schematic representation Figure 16 A top view of another example (Modified Example 1) of the inductor component shown.

[0027] Figure 18 It is a schematic representation Figure 1A perspective view of yet another example of an inductor component.

[0028] Figure 19 It is a schematic representation Figure 7 A perspective view of yet another example of an inductor component.

[0029] Figure 20 It is a schematic representation Figure 7 A perspective view of yet another example of an inductor component.

[0030] Explanation of reference numerals in the attached figures

[0031] 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K…Inductor components; 10…Blank; 11a, 11b…End faces of the blank; 12a…Top surface of the blank; 12b…Bottom surface of the blank; 13a, 13b…Side surfaces of the blank; 15a, 15b, 15c, 15d, 15e, 15f, 15g, 15h, 15i…Insulating layers; 20…Coil; 21, 21… a, 21b…coil wiring; 22a…first lead wiring; 22b…second lead wiring; 23…straight section; 23a…first straight section; 23b…second straight section; 23c…third straight section; 24…bending section; 24a…first bending section; 24b…second bending section; 25…arc section; 29a…conductor; 30a…first external electrode; 30b…second external electrode; 51…cutout section; 12 1aa, 121ab, 121ac, 121ba, 121bb, 121bc…coil conductor layer; 122aa, 122ab, 122ac…first lead conductor layer; 122ba, 122bb, 122bc…second lead conductor layer; 129aa…conducting conductor layer; 130aa, 130ab, 130ac, 130ad, 130ae, 130af, 130ag…first outer conductor layer; 130ba, 130bb, 130bc, 130bd, 130be, 130bf, 130bg…second outer conductor layer; CA…coil axis; L…length direction; T…height direction; W…width direction; t1…thickness of each part of the bend cut off by the cut; t2…thickness of the coil wiring in the coil axis of the straight part; w1…width direction in the coil wiring. Detailed Implementation

[0032] The inductor component of the present invention will now be described. Furthermore, the present invention is not limited to the following structure, and appropriate modifications may be made without departing from the spirit of the invention. Additionally, a structure combining multiple preferred structures described below is also part of the present invention.

[0033] The embodiments shown below are illustrative, and of course, parts of the structures shown in different embodiments can be replaced or combined. From Embodiment 2 onwards, descriptions of matters common to Embodiment 1 are omitted, and the differences are mainly explained. In particular, the same effects resulting from the same structure are not mentioned sequentially in each embodiment.

[0034] In the following description, unless otherwise specified, each embodiment will be referred to simply as "the inductor component of the present invention".

[0035] The attached diagrams are schematic diagrams, and their dimensions, aspect ratios, and scales may differ from the actual product.

[0036] In this specification, terms indicating the relationship between elements (e.g., "parallel", "perpendicular", "orthogonal", etc.) and terms indicating the shape of elements do not mean only a strict literal form, but also a range of substantially equivalents, such as a range that includes a difference of about a few percent.

[0037] The inductor component of the present invention is characterized by comprising: a blank; a coil disposed inside the blank and wound into a spiral shape along the coil axis; a first external electrode and a second external electrode exposed on the surface of the blank; a first lead wire disposed inside the blank and electrically connecting one end of the coil to the first external electrode; and a second lead wire disposed inside the blank and electrically connecting the other end of the coil to the second external electrode. The blank includes an insulator, and the surface of the blank includes a mounting surface and a top surface, wherein the mounting surface is parallel to the coil axis, and the top surface is perpendicular to the coil axis in a height direction orthogonal to the coil axis. With mounting surfaces facing each other, the first external electrode and the second external electrode are exposed at least on the mounting surfaces of the blank to separate them from each other. The coil includes a plurality of coil wires, which are electrically connected. The plurality of coil wires are formed by electrically connecting a plurality of coil wires that extend in a direction orthogonal to the coil axis and are arranged at different positions in the coil axis. When viewed from the coil axis, the plurality of coil wires have straight portions and curved portions. At least one of the curved portions has a cut portion in a portion in the coil axis. The wire thickness in the coil axis at the cut portion is smaller than the wire thickness in the coil axis at the straight portion.

[0038] [Implementation Method 1]

[0039] Figure 1 This is a perspective view schematically illustrating an example of an inductor component according to Embodiment 1 of the present invention.

[0040] Figure 1The inductor component 1A shown includes a blank 10, a coil 20, a first external electrode 30a, a second external electrode 30b, a first lead wire 22a, and a second lead wire 22b.

[0041] In this instruction manual, such as Figure 1 As shown, the length, height, and width directions are defined by L, T, and W, respectively. Here, the length direction L, height direction T, and width direction W are orthogonal to each other.

[0042] like Figure 1 As shown, in inductor component 1A, the surface of blank 10 includes: end faces 11a and 11b opposite each other in the length direction L, a top surface 12a and a bottom surface 12b opposite each other in the height direction T, and side surfaces 13a and 13b opposite each other in the width direction W. In inductor component 1A, the width direction W is parallel to the coil axis of coil 20. That is, in inductor component 1A, the surface of blank 10 includes a bottom surface 12b parallel to the coil axis and a top surface 12a opposite to the bottom surface 12b in the height direction T orthogonal to the coil axis.

[0043] In this embodiment, unless otherwise specified, the coil axis is set to be parallel to the width direction W.

[0044] In the inductor component 1A, the bottom surface 12b of the blank 10 is a mounting surface. More specifically, the bottom surface 12b of the blank 10 is the mounting surface that faces the mounting object (e.g., a substrate) when the inductor component 1A is mounted. Therefore, in the inductor component 1A, the mounting surface of the blank 10, i.e., the bottom surface 12b of the blank 10, is parallel to the coil axis.

[0045] Markings for easy identification of each surface may also be applied to at least one of the surfaces of the blank 10, namely end face 11a, end face 11b, top face 12a, bottom face 12b, side face 13a, and side face 13b.

[0046] The end faces 11a and 11b of the billet 10 do not need to be strictly orthogonal to the length direction L. Furthermore, the top face 12a and bottom face 12b of the billet 10 do not need to be strictly orthogonal to the height direction T. Also, the side faces 13a and 13b of the billet 10 do not need to be strictly orthogonal to the width direction W.

[0047] like Figure 1 As shown, the blank 10 is, for example, a cuboid shape.

[0048] In this specification, "cubic parallelogram" refers to any shape that can be substantially described as cuboid, such as, as described later, a generally cuboid shape with rounded corners and edges.

[0049] The blank 10 preferably has rounded corners and edges. The corners of the blank 10 are the parts where three faces of the blank 10 intersect. The edges of the blank 10 are the parts where two faces of the blank 10 intersect.

[0050] Figure 2 It is a schematic representation Figure 1 An exploded perspective view of an example of an inductor component shown.

[0051] The blank 10 includes an insulator. Figure 2 In the example shown, the insulator is formed by stacking multiple insulating layers along the axial direction of the coil.

[0052] exist Figure 2 In the example shown, multiple insulating layers include insulating layer 15a, insulating layer 15b, insulating layer 15c, insulating layer 15d, insulating layer 15e, insulating layer 15f, insulating layer 15g, insulating layer 15h, and insulating layer 15i. Insulating layers 15a, 15b, 15c, 15d, 15e, 15f, 15g, 15h, and 15i are sequentially stacked in the coil axial direction from side 13b of the blank 10 toward side 13a.

[0053] Furthermore, when multiple insulating layers are integrated, their boundaries are not clearly defined.

[0054] In addition to the aforementioned insulating layers, the plurality of insulating layers may further include at least one other insulating layer. For example, at least one insulating layer may exist between insulating layers 15a and 15b along the coil axial direction. Alternatively, at least one insulating layer may exist between insulating layers 15h and 15i along the coil axial direction.

[0055] Examples of insulating materials constituting an insulator (insulating layer) include glass materials with borosilicate glass as the main component, ceramic materials, organic materials such as epoxy resin, fluororesin, and polymer resin, and composite materials such as glass epoxy resin. Materials with low dielectric constant and low dielectric loss are particularly preferred as insulating materials.

[0056] The insulating materials that make up multiple insulating layers can be the same as each other, different from each other, or partially different.

[0057] The thickness of multiple insulating layers along the coil axis can be the same, different, or partially different.

[0058] like Figure 1 As shown, the coil 20 is disposed inside the blank 10 and wound into a spiral shape along the coil axis.

[0059] The coil axis of coil 20 is the direction in which the coil axis CA of coil 20 extends, as described above, and is parallel to the bottom surface 12b of the blank 10, which serves as the mounting surface. Furthermore, the coil axis of coil 20 is parallel to the lamination direction.

[0060] like Figure 1 and Figure 2 As shown, the coil 20 includes a plurality of coil wirings 21, which are electrically connected to each other. The plurality of coil wirings 21 are formed by electrically connecting a plurality of coil wirings 21 that extend in a direction orthogonal to the coil axis and are arranged at different positions in the coil axis.

[0061] In inductor component 1A, coil wiring 21a and coil wiring 21b are arranged at different positions along the coil axis.

[0062] exist Figure 2 In the example shown, coil wiring 21a is formed by stacking coil conductor layers 121aa, 121ab, and 121ac in the coil axial direction. Similarly, coil wiring 21b is formed by stacking coil conductor layers 121ba, 121bb, and 121bc in the coil axial direction.

[0063] In coil wiring 21a, in addition to the coil conductor layer described above, at least one other coil conductor layer may be further stacked along the coil axis. Similarly, in coil wiring 21b, in addition to the coil conductor layer described above, at least one other coil conductor layer may be further stacked along the coil axis.

[0064] Alternatively, at least one other coil wiring may exist between coil wiring 21a and coil wiring 21b along the coil axis.

[0065] Examples of conductive materials constituting the coil wiring 21 include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0066] The conductive materials constituting the multiple coil wirings 21 can be the same as each other, different from each other, or partially different.

[0067] The thickness of multiple coil wirings 21 along the coil axis can be the same, different, or partially different.

[0068] Regarding the multiple coil wirings 21, the thickness in the direction orthogonal to the coil axis and the direction in which the coil wirings 21 extend, that is, the width direction w1 of the coil wirings 21 (refer to...). Figure 1 The thicknesses on each surface can be the same, different, or partially different.

[0069] The coil wirings 21 that are adjacent in the coil axis can be electrically connected via a conductive conductor that passes through the insulation layer between the adjacent coil wirings 21 in the coil axis, or they can be directly connected without a conductive conductor. That is, the coil 20 can be formed by electrically connecting multiple coil wirings 21 that are arranged at different positions in the coil axis via a conductive conductor, or it can be directly connected without a conductive conductor.

[0070] exist Figure 2 In the example shown, coil wiring 21a and coil wiring 21b are electrically connected via a conductive conductor 29a that passes through the insulation layer 15e in the axial direction of the coil.

[0071] exist Figure 2 In the example shown, the conductive conductor 29a is composed of a conductive conductor layer 129aa.

[0072] In the conducting conductor 29a, in the axial direction of the coil, at least one other conducting conductor layer may be stacked in addition to the conducting conductor layer 129aa.

[0073] The conducting conductor 29a can have a single-layer structure or a multi-layer structure.

[0074] Examples of conductive materials constituting the conductive conductor 29a include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0075] Figure 3 This is a schematic representation taken from the axial direction of the coil. Figure 1 A top view of an example of an inductor component shown.

[0076] like Figure 3 As shown, when viewed from the coil axis, the multiple coil wirings 21 have straight portions 23 and curved portions 24.

[0077] When viewed from the axial direction of the coil, the multiple coil wirings 21 arranged at different positions have straight portions 23 and curved portions 24, and the coil 20 only needs to be shaped to include both straight and curved portions; for example, it could be... Figure 3 The polygonal shape shown can also be the runway shape or heart shape described later.

[0078] like Figure 1 As shown, one end of the coil 20 is electrically connected to the first external electrode 30a via the first lead wire 22a.

[0079] exist Figure 2 In the example shown, the first lead wire 22a is composed of the first lead conductor layer 122aa, the first lead conductor layer 122ab, and the first lead conductor layer 122ac.

[0080] In the first lead wire 22a, in addition to the first lead conductor layer described above, at least one other lead conductor layer may be stacked in the axial direction of the coil.

[0081] The first lead-out wiring 22a can have a single-layer structure or a multi-layer structure.

[0082] like Figure 1 As shown, the other end of the coil 20 is electrically connected to the second external electrode 30b via the second lead wire 22b.

[0083] exist Figure 2 In the example shown, the second lead wire 22b is composed of the second lead conductor layer 122ba, the second lead conductor layer 122bb, and the second lead conductor layer 122bc.

[0084] In the second lead wire 22b, in addition to the second lead conductor layer described above, at least one other lead conductor layer may be stacked in the axial direction of the coil.

[0085] The second lead-out wiring 22b can have a single-layer structure or a multi-layer structure.

[0086] Examples of conductive materials used to form lead-out wiring include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0087] The conductive materials constituting the first lead wire 22a and the second lead wire 22b can be the same or different from each other.

[0088] In this specification, the wiring that does not overlap with the coil winding portion when viewed from the coil axially (extending from the coil winding portion) is referred to as the lead wiring.

[0089] like Figure 1 As shown, the first external electrode 30a is exposed on the surface of the blank 10.

[0090] like Figure 1 As shown, preferably, the first external electrode 30a is exposed at least on the bottom surface 12b of the blank 10.

[0091] exist Figure 1 In the example shown, the first external electrode 30a extends from a portion of the bottom surface 12b of the blank 10 to a portion of the end surface 11a. That is, in Figure 1 In the example shown, the first external electrode 30a is exposed in part of the end face 11a of the blank 10, in addition to part of the bottom surface 12b of the blank 10.

[0092] In addition, the first external electrode 30a may also be exposed only on the bottom surface 12b of the blank 10.

[0093] exist Figure 2 In the example shown, the first external electrode 30a is formed by stacking the first external conductor layer 130aa, the first external conductor layer 130ab, the first external conductor layer 130ac, the first external conductor layer 130ad, the first external conductor layer 130ae, the first external conductor layer 130af, and the first external conductor layer 130ag in the axial direction of the coil.

[0094] In the first external electrode 30a, in the axial direction of the coil, at least one other external conductor layer may be further stacked in addition to the first external conductor layer described above.

[0095] The first external electrode 30a can have a single-layer structure or a multi-layer structure.

[0096] like Figure 1 As shown, the second external electrode 30b is exposed on the surface of the blank 10.

[0097] like Figure 1 As shown, the second external electrode 30b is preferably exposed at least on the bottom surface 12b of the blank 10.

[0098] exist Figure 1 In the example shown, the second external electrode 30b extends from a portion of the bottom surface 12b of the blank 10 to a portion of the end surface 11b. That is, in Figure 1 In the example shown, the second external electrode 30b is exposed in part of the end face 11b of the blank 10, in addition to a part of the bottom surface 12b of the blank 10.

[0099] In addition, the second external electrode 30b may also be exposed only on the bottom surface 12b of the blank 10.

[0100] exist Figure 2 In the example shown, the second external electrode 30b is formed by stacking second external conductor layers 130ba, 130bb, 130bc, 130bd, 130be, 130bf, and 130bg in the axial direction of the coil.

[0101] In the second external electrode 30b, in the axial direction of the coil, at least one other external conductor layer may be further stacked in addition to the second external conductor layer described above.

[0102] The second external electrode 30b can have a single-layer structure or a multi-layer structure.

[0103] As described above, the first external electrode 30a and the second external electrode 30b are preferably exposed at least on the bottom surface 12b of the blank 10 so as to be separated from each other. Figure 1 In the example shown, the first external electrode 30a and the second external electrode 30b are configured to be separated from each other in a direction orthogonal to the coil axis (here, the length direction L).

[0104] Furthermore, if the first external electrode 30a and the second external electrode 30b are exposed on the bottom surface 12b of the blank 10, which serves as the mounting surface, the mounting performance of the inductor component 1A can be easily improved.

[0105] exist Figure 1 In the example shown, the axial dimension of the first external electrode 30a is smaller than the axial dimension of the blank 10.

[0106] Furthermore, the axial dimension of the first external electrode 30a in the coil direction can also be the same as the axial dimension of the blank 10 in the coil direction.

[0107] exist Figure 1 In the example shown, the dimension of the second external electrode 30b in the coil axial direction is smaller than the dimension of the blank 10 in the coil axial direction.

[0108] Furthermore, the axial dimension of the second external electrode 30b in the coil direction can also be the same as the axial dimension of the blank 10 in the coil direction.

[0109] Examples of conductive materials constituting the first external electrode 30a and the second external electrode 30b include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0110] The first external electrode 30a may sequentially include a base electrode containing the aforementioned conductive material (e.g., Ag), a Ni-plated electrode, and a Sn-plated electrode, starting from the coil 20 side. In this case, the base electrode may also be attached to the surface of the blank 10 (in... Figure 1 In the middle, the end face 11a and bottom face 12b of the blank 10 are formed as one surface, and the Ni-plated electrode and the Sn-plated electrode are formed from the surface of the blank 10 (in the middle). Figure 1 In the middle, the end face 11a and bottom face 12b of the blank 10 are raised to cover the base electrode.

[0111] The second external electrode 30b may sequentially include a base electrode containing the aforementioned conductive material (e.g., Ag), a Ni-plated electrode, and a Sn-plated electrode, starting from the coil 20 side. In this case, the base electrode in the second external electrode 30b may also be adjacent to the surface of the blank 10 (in... Figure 1In the middle, the end face 11b and bottom face 12b of the blank 10 are formed as one surface, and the Ni-plated electrode and the Sn-plated electrode are formed from the surface of the blank 10 (in the middle). Figure 1 In the middle, the end face 11b and bottom face 12b of the blank 10 are raised to cover the base electrode.

[0112] The conductive materials constituting the first external electrode 30a and the second external electrode 30b can be the same or different from each other.

[0113] like Figure 1 As shown, at least one curved portion 24 has a cutout portion 51 on a portion along the coil axial direction. Furthermore, the wiring thickness along the coil axial direction at the cutout portion 51 is smaller than the wiring thickness along the coil axial direction at the straight portion 23.

[0114] Figure 4 This is a diagram showing the distribution of residual stress after the firing of a typical inductor component.

[0115] like Figure 4 As shown, after the inductor component is fired, generally near the bend in the coil wiring (e.g., in...). Figure 4 The portion indicated by the arrow (in the middle) retains particularly high stress. In the inductor component 1A, by providing a cutout 51 in a portion along the coil axial direction of at least one bent portion 24, the wiring thickness along the coil axial direction at the cutout 51 is smaller than the wiring thickness along the coil axial direction at the straight portion 23. In particular, the volume of the coil wiring 21 can be reduced in the bent portion 24 where the residual stress is high after firing, thereby alleviating the integral stress applied in any region. As a result, in the inductor component 1A, the reduction in external impact resistance and the generation of cracks, etc., can be suppressed.

[0116] Figure 5 It is a diagram showing the density distribution of direct current flowing in the coil of a typical inductor component.

[0117] like Figure 5 As shown, typically, in bends, the current concentrates on the inner circumferential side where the current path is shortest (e.g., in...). Figure 5 In the part enclosed by the dotted line, only a portion of the cross-sectional area of ​​the coil wiring is effectively utilized. In the inductor component 1A, by providing the cutout 51 in the bend 24, compared to providing the cutout 51 in the straight section 23 that effectively utilizes the entire cross-sectional area of ​​the coil wiring 21, it is possible to suppress the decrease in Q characteristics caused by the reduced cross-sectional area of ​​the coil wiring 21, and to suppress the decrease in external shock resistance.

[0118] As described above, according to the inductor component 1A, an inductor component capable of suppressing the reduction of Q characteristics and suppressing the generation of cracks, etc., can be realized.

[0119] In this specification, the term "wire thickness along the coil axis at the cutout" refers to the thickness of the coil wire along the coil axis where the cutout is provided, and specifically includes the area of ​​the cutout, i.e., the thickness of the coil wire at the bend where the cutout is provided. Furthermore, as... Figure 1 As shown, the "thickness of the coil wiring at the bend where the cut is provided" can be the thickness t1 of any part that is cut off by the cut 51, or it can be the sum of the thicknesses t1 of all parts that are cut off by the cut 51.

[0120] Furthermore, in this specification, the term "wire thickness in the coil axial direction at the straight portion" refers to the thickness of the coil wire with the cut portion for which the thickness is compared in the coil axial direction, and specifically the thickness of the coil wire at the straight portion of that coil wire (see reference). Figure 1 The thickness t2).

[0121] exist Figure 1 In this case, the thickness t1 of any part cut by the cut portion 51 is smaller than the thickness t2 of the coil wiring in the straight portion, and the sum of the thicknesses t1 of each part cut by the cut portion 51 is also smaller than the thickness t2 of the coil wiring in the straight portion.

[0122] Furthermore, in the inductor component of the present invention, no cutouts are provided in the first lead wire and the second lead wire.

[0123] like Figure 3 As shown, when viewed from the coil axis, the coil 20 is polygonal in shape. The straight section 23 has one first straight section 23a and one or more second straight sections 23b. The center line of the first straight section 23a relative to the height direction T of the blank 10 is located on the top surface side, and the center line of the second straight sections 23b relative to the height direction T of the blank 10 is located on the mounting surface side. The straight section 23 also has a third straight section 23c connecting the first straight section 23a and the second straight section 23b. The first straight section 23a and the second straight section 23b are parallel to the bottom surface 12b, which serves as the mounting surface. The curved section 24 has a first curved section 24a and a second curved section 24b. The first curved section 24a connects the first straight section 23a and the third straight section 23c, and the second curved section 24b connects any one of the second straight sections 23b and the third straight section 23c, or connects the second straight sections 23b to each other. As a result, the coil wiring 21 can be drawn to the maximum extent inside the blank, the cross-sectional area of ​​the coil 20 is increased, and the efficiency of obtaining the L value is improved.

[0124] Furthermore, in the inductor component 1A having such a coil 20, such as Figure 1As shown, preferably, at least one of the first curved portion 24a and the second curved portion 24b has a cutout 51 in a portion along the coil axial direction, and the wiring thickness in the coil axial direction at the cutout 51 is smaller than the wiring thickness in the coil axial direction at the straight portion 23. Figure 3 In the coil 20 of the shape shown, large residual stress is generated in the first bend 24a and the second bend 24b connecting adjacent straight sections 23. However, as described above, by providing a cutout 51 in this area to reduce the wiring volume, the integral stress can be reduced, the reduction in impact resistance can be suppressed, and the generation of cracks in the product caused by this can be suppressed.

[0125] More specifically, such as Figure 3 As shown, the multiple coil wirings 21 in the inductor component 1A, for each roll of coil 20, have as straight sections 23 a first straight section 23a whose center line in the height direction T relative to the blank 10 is located on the top surface side, three second straight sections 23b whose center line in the height direction T relative to the blank 10 is located on the mounting surface side, and two third straight sections 23c connecting the first straight sections 23a and the second straight sections 23b. As curved sections 24, they have two first curved sections 24a connecting the first straight sections 23a and the third straight sections 23c, and four second curved sections 24b connecting any one of the second straight sections 23b and the third straight section 23c or connecting the second straight sections 23b to each other. In addition, the first straight sections 23a and the second straight sections 23b are parallel to the bottom surface 12b, which is the mounting surface. Moreover, the first curved section 24a of each coil wiring 21 has a cutout 51 in the axial direction of the coil (see reference). Figure 1 ).

[0126] Figure 6 It is a schematic representation Figure 1 A cross-sectional view of an example of an inductor component shown, along line segment a1-a2.

[0127] like Figure 1 and Figure 6 As shown, in the inductor component 1A, a cutout 51 is provided in the middle of the coil axial direction of the bent portion 24. By providing the cutout 51 in the middle of the coil axial direction of the bent portion 24, the thickness of the coil wiring 21 in the coil axial direction is interrupted via the cutout 51. Therefore, the total cross-sectional area of ​​the bent portion 24 can be ensured and the high integral stress area can be dispersed, thereby suppressing the reduction of Q characteristics and the reduction of external shock resistance.

[0128] In addition, such as Figure 2As shown, the coil wiring 21a is formed by stacking coil conductor layers 121aa and 121ac without cutouts 51 via coil conductor layers 121ab having cutouts 51 in the bend 24. In this way, multiple coil conductor layers without cutouts 51 are connected via coil conductor layers with cutouts 51 in the bend 24, the cutouts 51 being located at the middle of the coil axis in the bend 24.

[0129] Figure 7 It is a schematic representation Figure 1 A perspective view of another example (Modified Example 1) of the inductor component shown.

[0130] Figure 8 It is a schematic representation Figure 7 A cross-sectional view of an example of an inductor component shown, along line segment b1-b2.

[0131] like Figure 7 and Figure 8 As shown, in the inductor component 1B, the cutout portion 51 is provided at the outer end of the blank in the coil axial direction of the bent portion 24.

[0132] In inductor component 1B, by providing the cutout 51 at the outer end of the blank in the coil axial direction of the bent portion 24, the integrated stress in the region near the surface of the blank 10, which is prone to transmitting external impacts, is reduced. Therefore, compared to inductor component 1A, the reduction in external impact resistance can be further suppressed. In this case, it is preferable that the cutout 51 is provided in the outermost coil wire in the coil axial direction among the plurality of coil wires 21.

[0133] The term "outer end of the blank along the coil axis" refers to the end closest to the blank surface along the coil axis. For example, in Figure 8 In the middle, the cut portion 51 is provided at the end of the side closest to the side surface 13a in the W direction.

[0134] Figure 9 It is a schematic representation Figure 1 A perspective view of another example (Modified Example 2) of the inductor component shown.

[0135] Figure 10 It is a schematic representation Figure 9 A cross-sectional view of an example of an inductor component shown, along line segment c1-c2.

[0136] like Figure 9 and Figure 10 As shown, in the inductor component 1C, the cutout portion 51 is provided at the inner end of the blank body in the axial direction of the bent portion 24.

[0137] Figure 11 This is a graph showing the surface density distribution of the high-frequency current flowing in the coil of a typical inductor component. Furthermore, Figure 11 The results of a simulation at a frequency of 3 GHz are shown.

[0138] like Figure 11 As shown, generally speaking, high-frequency current flows more along the side of coil 20 closer to the blank body side in the coil axial direction. In inductor component 1C, by providing a cutout 51 at the inner end of the curved portion 24 inside the blank body in the coil axial direction, the high current density portion (e.g., in...) Figure 11 The portion indicated by the arrow (in the middle) can reduce current reflection losses and reduce the volume of the coil wiring 21. Therefore, compared with the inductor component 1A, it can further suppress the reduction of Q characteristics and suppress the reduction of external shock resistance. In this case, it is preferable that the cutout portion 51 is provided in the outermost coil wiring in the coil axis among the plurality of coil wirings 21.

[0139] The term "the inner end of the billet along the coil axis" refers to the end closest to the center of the billet along the coil axis. For example, in Figure 10 In the middle, the cut portion 51 is set at the end of the side closest to the center of the blank in the W direction.

[0140] Figure 12 It is a schematic representation Figure 1 A perspective view of another example (Modified Example 3) of the inductor component shown.

[0141] like Figure 12 As shown, in the inductor component 1D, a cutout 51 is provided in the second curved portion 24b located on the mounting surface side. Furthermore, in Figure 12 In the middle, the cut-out portion 51 is provided in the second curved portion 24b connecting the second straight portions 23b to each other, but it can also be provided in the second curved portion 24b connected to the third straight portion 23c.

[0142] like Figure 1 As shown, in the inductor component 1A, a cutout 51 is provided in the first curved portion 24a located on the top surface side. By providing the cutout 51 in the curved portion 24a located on the top surface side, the integrated stress in the area of ​​the surface not protected by the first external electrode 30a and the second external electrode 30b can be reduced, thereby suppressing the reduction of external impact resistance in that area.

[0143] Inductor components are typically subjected to external impact by being pushed against the measuring terminals from the mounting surface side during the sorting process. In inductor component 1D, by providing a cutout 51 in the bend 24 located on the mounting surface side, the integrated stress near the area where the external impact is applied during the sorting process can be reduced, thereby suppressing the reduction of external impact resistance in that area.

[0144] In addition, in having Figure 3 In the inductor component of the coil 20 shown in the diagram, it can also be combined as follows: Figure 1 The inductor component 1A shown has a structure in which a cutout 51 is provided in the first bent portion 24a located on the top surface side, and as shown in the figure. Figure 12 The inductor component 1D shown has a structure in which a cutout 51 is provided in the second bent portion 24b located on the mounting surface side. That is, at least one cutout 51 may also be provided in the first bent portion 24a and the second bent portion 24b respectively.

[0145] Inductor component 1A is manufactured, for example, by the following method.

[0146] <Processes for fabricating the master laminate>

[0147] First, for example, by repeatedly applying insulating paste using screen printing or other methods, an insulating paste layer that later becomes insulating layer 15a is formed, wherein the insulating paste contains glass materials, such as borosilicate glass as the main component.

[0148] Next, for example, a photosensitive conductive paste layer is formed on an insulating paste layer by applying a photosensitive conductive paste with Ag or the like using screen printing. Then, after irradiating the photosensitive conductive paste layer with ultraviolet light or the like through a photomask, it is developed using an alkaline solution or the like, thereby forming, at multiple locations on the insulating paste layer, a coil conductor layer that later becomes the coil conductor layer 121ba, an outer conductor layer that later becomes the first outer conductor layer 130aa and the second outer conductor layer 130ba, and a lead conductor layer that, after being connected to the coil conductor layer and the outer conductor layer, becomes the second lead conductor layer 122ba.

[0149] In addition, when forming the coil conductor layer, lead conductor layer and outer conductor layer, DI exposure (also known as direct imaging exposure or direct drawing) without using a photomask can be performed instead of photomask exposure.

[0150] Next, for example, by applying a photosensitive insulating paste using screen printing or the like, an insulating paste layer that will later become insulating layer 15b and insulating layer 15c is formed on the insulating paste layer that will later become insulating layer 15a. Then, after irradiating the insulating paste layer that will later become insulating layer 15c with ultraviolet light or the like via a photomask, it is developed using an alkaline solution or the like, thereby forming an opening for a coil conductor layer, an opening for an outer conductor layer, and an opening for a lead-out conductor layer connected to the openings for the coil conductor layer and the outer conductor layer in the insulating paste layer that will later become insulating layer 15c. The opening for the coil conductor layer formed here overlaps with the coil conductor layer that will later become coil conductor layer 121ba, except for the area where the cut portion is provided, and has the same shape as the coil conductor layer that will later become coil conductor layer 121bb. The opening for the lead-out conductor layer formed here overlaps with the lead-out conductor layer that will later become the second lead-out conductor layer 122ba. The opening for the outer conductor layer formed here overlaps with the outer conductor layers that will later become the first outer conductor layer 130aa and the second outer conductor layer 130ba.

[0151] In addition, when forming an insulating paste layer with openings, DI exposure without a photomask can be performed instead of exposure using a photomask.

[0152] Next, for example, by applying a photosensitive conductive paste with Ag or the like as the main metal component using screen printing, a new photosensitive conductive paste layer is formed inside the opening, and a new photosensitive conductive paste layer is formed on the insulating paste layer that will later become the insulating layer 15c. Furthermore, after irradiating the photosensitive conductive paste layer with ultraviolet light or the like through a photomask, it is developed using an alkaline solution or the like, thereby forming a coil conductor layer that will later become the coil conductor layer 121bb inside the opening for the coil conductor layer, and forming a coil conductor layer that will later become the coil conductor layer 121bc connected to this coil conductor layer. Further, a lead-out conductor layer that will later become the second lead-out conductor layer 122bb is formed inside the opening for the lead-out conductor layer, and forming a lead-out conductor layer that will later become the second lead-out conductor layer 122bc connected to this lead-out conductor layer. Furthermore, an outer conductor layer, which subsequently becomes the first outer conductor layer 130ab, is formed inside the opening for the outer conductor layer and is connected to the outer conductor layer that subsequently becomes the first outer conductor layer 130aa. An outer conductor layer that subsequently becomes the first outer conductor layer 130ac is also formed on this outer conductor layer. Furthermore, an outer conductor layer, which subsequently becomes the second outer conductor layer 130bb, is formed inside the opening for the outer conductor layer and is connected to the outer conductor layer that subsequently becomes the second outer conductor layer 130ba. An outer conductor layer that subsequently becomes the second outer conductor layer 130bc is also formed on this outer conductor layer.

[0153] Next, for example, by applying a photosensitive insulating paste using screen printing or the like, an insulating paste layer that will later become insulating layer 15d and insulating layer 15e is formed on the insulating paste layer that will later become insulating layer 15c. Then, after irradiating the insulating paste layer that will later become insulating layer 15e with ultraviolet light or the like via a photomask, it is developed using an alkaline solution or the like, thereby forming vias and openings for the outer conductor layer in the insulating paste layer that will later become insulating layer 15e. The vias formed here overlap with the ends of the coil conductor layer that will later become coil conductor layer 121bc, and have the same shape as the conductive conductor layer that will later become conductive conductor layer 129aa. The openings for the outer conductor layer formed here overlap with the outer conductor layers that will later become the first outer conductor layer 130ac and the second outer conductor layer 130bc.

[0154] Next, for example, by applying a photosensitive conductive paste with Ag or the like as the main metal component using screen printing, a new photosensitive conductive paste layer is formed inside the via and the opening, and a new photosensitive conductive paste layer is formed on the insulating paste layer that will later become the insulating layer 15e. Further, after irradiating the photosensitive conductive paste layer with ultraviolet light or the like through a photomask, it is developed using an alkaline solution or the like, thereby forming a conductive conductor layer that will later become the conductive conductor layer 129aa inside the via, and forming a coil conductor layer that will later become the coil conductor layer 121aa connected to this conductive conductor layer. Further, an outer conductor layer that will later become the first outer conductor layer 130ad connected to the outer conductor layer that will later become the first outer conductor layer 130ac is formed inside the opening, and an outer conductor layer that will later become the first outer conductor layer 130ae is formed on this outer conductor layer. Furthermore, an outer conductor layer, which subsequently becomes the second outer conductor layer 130bd and is connected to the outer conductor layer that later becomes the second outer conductor layer 130bc, is formed inside the opening, and an outer conductor layer that later becomes the second outer conductor layer 130be is formed on this outer conductor layer. Furthermore, a lead conductor layer, which subsequently becomes the first lead conductor layer 122aa and is connected to the coil conductor layer that later becomes the coil conductor layer 121aa and the outer conductor layer that later becomes the first outer conductor layer 130ae, is formed on the insulating paste layer that later becomes the insulating layer 15e.

[0155] Furthermore, when forming the conductive layer and the outer conductor layer, DI exposure without a photomask can be performed instead of exposure using a photomask.

[0156] Similar to the manufacturing method described above, while forming the remaining coil conductor layer, lead conductor layer and outer conductor layer, an insulating slurry layer that will later become insulating layer 15f, insulating layer 15g and insulating layer 15h is formed.

[0157] Finally, for example, by repeatedly applying insulating paste using screen printing or other methods, an insulating paste layer that later becomes insulating layer 15i is formed, wherein the insulating paste contains glass materials, such as borosilicate glass as the main component.

[0158] As described above, a master laminate is fabricated.

[0159] The method for forming conductor patterns in the coil conductor layer, lead conductor layer, conductive conductor layer, and outer conductor layer is not limited to the photolithography method described above. For example, it can be a method of printing laminated conductive paste using a screen printing plate with openings set in the shape of conductor patterns. It can also be a method of etching the conductor film to form the shape of conductor patterns after forming the conductor film by sputtering, vapor deposition, or foil lamination. Alternatively, it can be a method of forming a negative image pattern using a semi-additive method, forming a coating, and then removing unwanted parts of the coating by etching to form the shape of conductor patterns.

[0160] When forming conductor patterns for the coil conductor layer, lead conductor layer, conduction conductor layer, and outer conductor layer, a high aspect ratio is achieved by forming conductor patterns in multiple stages, thereby reducing losses caused by resistance at high frequencies. There are no particular limitations on the method for forming conductor patterns in multiple stages. For example, it can be a method of repeatedly overlapping conductor patterns by repeatedly using photolithography processes as described above; it can be a method of repeatedly overlapping conductor patterns formed by a semi-additive process; it can be a method of overlapping conductor patterns formed by a semi-additive process and conductor patterns formed by etching additional deposited films in different sequences; or it can be a method of further depositing and growing films formed by a semi-additive process.

[0161] The conductive material constituting the conductor pattern of the coil conductor layer, lead conductor layer, conductive conductor layer and outer conductor layer is not limited to photosensitive conductive paste with Ag or other metals as the main component. For example, it can also be a conductor containing metals such as Ag, Au, Cu formed by sputtering, vapor deposition, foil pressing, plating and other methods.

[0162] The method of forming the insulating paste layer is not limited to the photolithography method mentioned above. For example, it can also be a method of pressing a sheet made of insulating material, a method of spin coating insulating material, or a method of spray coating insulating material.

[0163] The method for forming an insulating paste layer with vias and openings is not limited to the photolithography method described above. For example, it can also be a method of forming vias and openings by laser processing, drilling, etc., after forming an insulating film by pressing a sheet made of insulating material, spin-coating insulating material, spraying insulating material, etc.

[0164] The insulating material constituting the insulating paste layer is not limited to the glass material with borosilicate glass as the main component mentioned above. For example, it can also be organic materials such as ceramic materials, epoxy resins, fluororesins, and polymer resins, or composite materials such as glass epoxy resins. As an insulating material, materials with low dielectric constant and dielectric loss are particularly preferred.

[0165] <Processes for forming the blank, coil, and external electrodes>

[0166] First, the parent laminate is cut into pieces, such as by cutting, so that it is monolithically divided into multiple unfired laminates.

[0167] The unfired laminate has: an insulating paste laminate formed by laminating insulating paste layers, a coil conductor laminate formed by laminating coil conductor layers to electrically connect adjacent coil conductor layers via conductive conductor layers, and an outer conductor laminate formed by laminating outer conductor layers.

[0168] When monolithically forming an unburned laminate, for example, the outer conductor laminate is exposed in two places on the bottom surface of at least the insulating paste laminate included in the cut surface of the unburned laminate.

[0169] Next, the unfired laminate is fired to create the laminate.

[0170] If the unfired laminate is fired, the insulating slurry layer becomes an insulating layer, and the insulating slurry laminate becomes a blank 10. Furthermore, if the unfired laminate is fired, the coil conductor layer becomes coil wiring 21, and the coil conductor laminate becomes a coil 20. Further, if the unfired laminate is fired, one of the two outer conductor laminates becomes part of the first outer electrode 30a, and the other becomes part of the second outer electrode 30b.

[0171] Next, the resulting laminate can be subjected to, for example, tumbling, to give the corners and edges of the blank 10 a rounded shape.

[0172] Finally, using the two fired outer conductor stacks as base electrodes, Ni-plated electrodes and Sn-plated electrodes are sequentially formed on the surface of each base electrode through a plating process. The thicknesses of the Ni-plated electrodes and Sn-plated electrodes are set, for example, to be 2 μm or more and 10 μm or less.

[0173] Thus, a first external electrode 30a and a second external electrode 30b are formed, sequentially having a base electrode, a Ni-plated electrode, and a Sn-plated electrode, starting from the surface side of the blank 10. In this case, the base electrode may also be attached to the surface of the blank 10 (in...) in the first external electrode 30a. Figure 1In the middle, the end face 11a and bottom face 12b of the blank 10 are formed as one surface, and the Ni-plated electrode and the Sn-plated electrode are formed from the surface of the blank 10 (in the middle). Figure 1 In the middle, the end face 11a and bottom face 12b of the blank 10 are raised to cover the base electrode. Additionally, in the second external electrode 30b, the base electrode may also be flush with the surface of the blank 10 (in... Figure 1 In the middle, the end face 11b and bottom face 12b of the blank 10 are formed as one surface, and the Ni-plated electrode and the Sn-plated electrode are formed from the surface of the blank 10 (in the middle). Figure 1 In the middle, the end face 11b and bottom face 12b of the blank 10 are raised to cover the base electrode.

[0174] The method of forming the external electrode is not limited to the method described above, which involves plating the exposed portion of the external conductor stack on the cut surface of the unburned laminate (e.g., at least the bottom surface of the insulating paste stack). For example, it may also be a method described above, in which the exposed portion of the external conductor stack is immersed (soaked) in conductive paste after the cut surface of the unburned laminate (e.g., at least the bottom surface of the insulating paste stack) is exposed, or in which conductive paste is formed on the exposed portion of the external conductor stack by sputtering and then plating is performed.

[0175] As described above, inductor component 1A is manufactured.

[0176] Inductor component 1A is manufactured, for example, with dimensions of 0402 (0.4mm × 0.2mm × 0.2mm). The dimensions of inductor component 1A are not limited to 0402 (0.4mm × 0.2mm × 0.2mm).

[0177] [Implementation Method 2]

[0178] Figure 13 This is a perspective view schematically illustrating an example of an inductor component according to Embodiment 2 of the present invention.

[0179] like Figure 13 As shown, the coil 20 in the inductor component 1E is composed of two layers of coil wiring, coil wiring 21a and coil wiring 21b.

[0180] Figure 14 This is a schematic representation taken from the axial direction of the coil. Figure 13 A top view of an example of an inductor component shown.

[0181] like Figure 14As shown, the straight section 23 has a first straight section 23a whose center line in the height direction T relative to the blank 10 is located on the top surface side, and one or more second straight sections 23b whose center line in the height direction T relative to the blank 10 is located on the mounting surface side. The first straight section 23a and the second straight section 23b are parallel to the mounting surface. The curved section 24 has a first curved section 24a that connects the first straight section 23a and the second straight section 23b. Thus, the first straight section 23a and the second straight section 23b can be connected by the arc-shaped first curved section 24a, thereby reducing reflection loss at the connection point and increasing the Q value. In this way, when viewed from the coil axial direction, the coil 20 can form a racetrack shape (elliptical shape).

[0182] Furthermore, in the inductor component 1E equipped with such a coil 20, such as Figure 13 As shown, preferably at least one of the first curved portions 24a has a cutout 51 in the axial direction of the coil, and the wiring thickness in the axial direction of the cutout 51 is smaller than the wiring thickness in the axial direction of the coil at the straight portion 23. Figure 14 In the coil 20 of the shape shown, a large residual stress is generated in the first bend 24a connecting the first straight section 23a and the second straight section 23b. However, by providing a cutout 51 in this area as described above to reduce the wiring volume, the integral stress can be reduced, the reduction in impact resistance can be suppressed, and the generation of cracks and other defects in the product caused by this can be suppressed.

[0183] More specifically, such as Figure 14 As shown, the multiple coil wirings 21 in the inductor component 1E, for each roll of coil 20, have, as straight sections 23, a first straight section 23a located on the top surface side with the center line of the coil in the height direction T relative to the blank 10, and a second straight section 23b located on the mounting surface side with the center line of the coil in the height direction T relative to the blank 10; and as curved sections 24, two first curved sections 24a connecting the first straight section 23a and the second straight section 23b. Furthermore, the first straight sections 23a and 23b are parallel to the bottom surface 12b, which serves as the mounting surface. Moreover, each coil wiring 21's first curved section 24a has a cutout 51 in the coil axial direction (see reference). Figure 13 ).

[0184] Figure 15 This is a schematic representation taken from the axial direction of the coil. Figure 13 A top view of another example of the inductor component shown (Modification 1).

[0185] like Figure 15As shown in the inductor component 1F, it may also have three second straight sections 23b, and the bent section 24 may also have two second bent sections 24b connecting the second straight sections 23b to each other. That is, the coil 20 may also have a portion on the mounting surface side that is similar to... Figure 3 The coil 20 in the inductor component 1A shown has a common shape. Therefore, in this part, similar to inductor component 1A, the coil wiring 21 can be drawn larger inside the blank, the cross-sectional area of ​​the coil 20 is increased, and the efficiency of obtaining the L value is improved.

[0186] Furthermore, in the inductor component 1F with such a coil 20, similarly to the inductor component 1D, the cutout portion 51 may also be provided in a portion of at least one second bend 24b located on the mounting surface side along the coil axial direction. Thus, similarly to the inductor component 1D, it is possible to reduce the integral stress near the area where external impacts are applied during the sorting process, and suppress the reduction of external impact resistance in that area.

[0187] [Implementation Method 3]

[0188] Figure 16 This is a top view schematically illustrating an example of an inductor component according to Embodiment 3 of the present invention.

[0189] like Figure 16 As shown, when viewed from the coil axial direction, the multiple coil wirings 21 have an arc portion 25 on the mounting surface side relative to the center line in the height direction T of the blank 10. The arc portion 25 protrudes towards the mounting surface side. The straight portion 23 has a first straight portion 23a located on the top surface side relative to the center line in the height direction T of the blank 10. The first straight portion 23a is parallel to the mounting surface. The curved portion 24 has a first curved portion 24a, which is directly connected to the first straight portion 23a and electrically connected to both the first straight portion 23a and the arc portion 25. This increases the distance between the portion of the coil wiring 21 on the mounting surface side and the first external electrode 30a and the second external electrode 30b formed on the mounting surface side, reducing the high-frequency characteristics of the Q value caused by stray capacitance, thus increasing the Q value. Since the multiple coil wirings 21 have an arc portion 25 protruding towards the mounting surface side when viewed from the coil axial direction, the coil 20 can also be heart-shaped.

[0190] Furthermore, in the inductor component 1G having such a coil 20, it is preferable that at least one of the first bent portions 24a has a cutout 51 in the axial direction of the coil, and the wiring thickness in the axial direction of the coil at the cutout 51 is smaller than the wiring thickness in the axial direction of the coil at the straight portion 23. By providing the cutout 51 as described above, the wiring volume is reduced, especially in the bent portion 24 where the residual stress after firing is large, thereby reducing the integral stress applied in any area, suppressing the reduction of impact resistance, and suppressing the generation of cracks and the like in the product caused by it.

[0191] like Figure 16 As shown in the inductor component 1G, the straight portion 23 may also have a third straight portion 23c connecting the first straight portion 23a and the arc portion 25, the first curved portion 24a connecting the first straight portion 23a and the third straight portion 23c, and the curved portion 24 may also have a second curved portion 24b connecting the arc portion 25 and the third straight portion 23c. That is, the portion of the coil 20 other than the portion having an arc portion 25 protruding towards the mounting surface may also have the same... Figure 3 The coil 20 in the inductor component 1A shown has a common shape. As a result, in this other part, similar to the inductor component 1A, the coil wiring 21 can be drawn larger inside the blank, the cross-sectional area of ​​the coil 20 is increased, and the efficiency of obtaining the L value is improved.

[0192] More specifically, such as Figure 16 As shown, in the inductor component 1G, each of the multiple coil wirings 21 has an arc portion 25 on the mounting surface side relative to the center line in the height direction T of the blank 10 for each roll of the coil 20. As a straight portion 23, it has a first straight portion 23a located on the top surface side relative to the center line in the height direction T of the blank 10, and two third straight portions 23c connecting the first straight portion 23a and the arc portion 25. As a curved portion 24, it has two first curved portions 24a connecting the first straight portion 23a and the third straight portion 23c, and two second curved portions 24b connecting the third straight portion 23c and the arc portion 25. Furthermore, the first straight portion 23a is parallel to the bottom surface 12b, which serves as the mounting surface, and the arc portion 25 protrudes towards the mounting surface side. Moreover, each coil wiring 21's first curved portion 24a has a cutout portion 51 on a portion along the coil axial direction.

[0193] Furthermore, in the inductor component 1G having such a coil 20, similarly to the inductor component 1D, the cutout portion 51 may also be provided in a portion of at least one second bend 24b located on the mounting surface side along the coil axial direction. Thus, similarly to the inductor component 1D, it is possible to reduce the integral stress near the area where external impacts are applied during the sorting process, and suppress the reduction of external impact resistance in that area.

[0194] Figure 17 It is a schematic representation Figure 16 A top view of another example of the inductor component shown (Modification 1).

[0195] like Figure 17 As shown in the inductor component 1H, the first bent portion 24a can also directly connect the first straight portion 23a and the arc portion 25. That is, the portion of the coil 20 other than the portion having an arc portion 25 protruding towards the mounting surface can also have the same... Figure 14 The coils 20 in the inductor component 1E shown have a common shape. As a result, the distance between the portion of the coil wiring 21 on the mounting surface side and the first external electrode 30a and the second external electrode 30b formed on the mounting surface side can be further increased, further reducing the high-frequency characteristics of the Q value caused by stray capacitance, and thus further increasing the Q value.

[0196] More specifically, such as Figure 17 As shown, in the inductor component 1H, each of the multiple coil wirings 21 has an arc portion 25 on the mounting surface side relative to the center line in the height direction T of the blank 10, as a straight portion 23, having a first straight portion 23a located on the top surface side relative to the center line in the height direction T of the blank 10, and as a curved portion 24, having two first curved portions 24a connecting the first straight portion 23a and the arc portion 25. Furthermore, the first straight portion 23a is parallel to the bottom surface 12b, which serves as the mounting surface, and the arc portion 25 protrudes towards the mounting surface side. Moreover, each coil wiring 21's first curved portion 24a has a cutout portion 51 on a portion along the coil axial direction.

[0197] In addition, Figure 16 and Figure 17 The diagram shows a case where the arc portion 25 has an imaginary arc center inside the product, but it can also have an imaginary arc center outside the product.

[0198] The arc portion 25 only needs to contain an arc shape, such as Figure 16 and Figure 17 As shown, it may also include straight lines extending from both ends of the arc shape along the tangent direction.

[0199] [Common aspects of implementation methods 1-3]

[0200] Figure 18 It is a schematic representation Figure 1 A perspective view of yet another example of an inductor component.

[0201] like Figure 18 As shown, the coil 20 in the inductor component 1I is composed of three layers of coil wiring 21a, 21b and 21c.

[0202] In any of embodiments 1 to 3, an example is shown where the coil 20 is composed of 1.5T (turns), i.e., two layers of coil wiring 21, but it is not limited to 1.5T, such as... Figure 18 As shown, it can also be composed of coil wiring 21 with a thickness of 2.5T or more, that is, three or more layers. In addition, the notch 51 provided for cases where the thickness of the coil wiring 21 along the coil axis is large has a greater effect on suppressing the reduction of external impact resistance.

[0203] The notch 51 can be provided on the entire layer of the coil 20 or only on a portion of the layer. If the notch 51 is provided on the entire layer of the coil 20, the effect of suppressing the reduction of external impact resistance is increased, but at the same time the effect of suppressing the reduction of Q characteristics is reduced. Therefore, it is not preferred to provide the notch 51 on the entire layer of the coil 20.

[0204] In an inductor component where the coil 20 is composed of three or more layers of coil wiring 21, when the cutout 51 is provided at the center of the coil wiring 21 located in the coil axial direction of the blank 10, it is provided at the middle of the bend 24 in the coil axial direction. However, in order to reduce integral stress, it is not necessary to provide the cutout 51 at the middle of the bend 24 in the coil axial direction; it can be provided near any side of the bend 24 in the coil axial direction.

[0205] Additionally, when the cutout 51 is provided in multiple bends 24, it is also possible to... Figure 1 The inductor component 1A shown is Figure 7 The inductor component 1B shown and Figure 9 The inductor component 1C shown has at least two of the structures in the cutout portion. That is, the cutout portion can be provided in two or more of the following locations in the inductor components 1A to 1C: the middle, the outer end of the blank, and the inner end of the blank.

[0206] In addition, in any one of the embodiments 1 to 3, an example is shown in which a cutout 51 is provided in the coil axial direction of the bend 24 in the coil wiring 21, but multiple cutouts 51 may also be provided in the coil axial direction of the bend 24 in the coil wiring 21.

[0207] The thickness of the cut portion 51 in the coil axial direction can be more than 1 / 10 and less than 1 / 2 of the thickness t2 in the coil axial direction of the straight portion 23. Furthermore, when multiple cut portions 51 are provided in the coil axial direction of the curved portion 24, the thickness of the cut portion 51 in the coil axial direction is the sum of the thicknesses of each cut portion 51 in the coil axial direction.

[0208] Figure 19It is a schematic representation Figure 7 A perspective view of yet another example of an inductor component. Figure 20 It is a schematic representation Figure 7 A perspective view of yet another example of an inductor component.

[0209] In the inductor components shown in embodiments 1 to 3, the cutout portion 51 extends through the bend portion 24 in the width direction w1. As a result, compared to the case where the cutout portion 51 does not extend through the bend portion 24 in the width direction w1, the volume of the coil wiring 21 in the bend portion 24 can be further reduced, and the integral stress can be further reduced.

[0210] On the other hand, such as Figure 19 and Figure 20 As shown, in inductor components 1J and 1K, the cutout 51 may not penetrate the bend 24 in the width direction w1. Therefore, compared to the case where the cutout 51 penetrates the bend 24 in the width direction w1, the cross-sectional area of ​​the coil wiring 21 in the bend 24 will not become too small, and the reduction in Q characteristics can be further suppressed.

[0211] like Figure 19 As shown in the inductor component 1J, the bend 24 may not be continuous in the width direction w1, and the cutout 51 may be left on the inner circumference side of the bend 24. Therefore, in general, the cross-sectional area of ​​the coil wiring 21 will not decrease on the inner circumference side of the bend 24 where the current is concentrated, and the reduction of Q characteristics can be further suppressed.

[0212] like Figure 20 As shown in the inductor component 1K, the bend 24 may not be extended through in the width direction w1, and the cutout 51 may be left on the outer periphery of the bend 24.

[0213] Furthermore, in inductor components where the cutout 51 does not penetrate the bend 24 in the width direction w1, such as Figure 19 and Figure 20 As shown, the cutout 51 can also be provided at the outer end of the blank in the coil axial direction of the bent portion 24. Thus, similar to the inductor component 1B, the integrated stress in the region near the surface of the blank 10, which is prone to transmitting external impacts, can be reduced, thus suppressing the decrease in external impact resistance and preventing the generation of cracks or other defects in the product.

[0214] like Figure 19 and Figure 20 Thus, the wiring thickness of the cut portion 51 in the coil axial direction when the cut portion 51 does not penetrate in the width direction w1 is obtained by subtracting the thickness of the cut portion 51 in the coil axial direction from the wiring thickness of the bent portion 24 in the coil axial direction. Therefore, in Figure 19 and Figure 20 In the middle, the wiring thickness in the axial direction of the coil at the cut portion 51 is also smaller than the wiring thickness in the axial direction of the coil at the straight portion.

[0215] In any of embodiments 1 to 3, an example is shown where the cutout 51 is provided only in the curved portion 24, but the cutout 51 may also be provided in the straight portion 23. Furthermore, the cutout 51 may be provided only in the straight portion 23, or it may be provided in both the straight portion 23 and the curved portion 24.

[0216] In any of the embodiments 1 to 3, an example is shown where the mounting surface is parallel to the coil axis, but the mounting surface of the inductor component of the present invention may also be perpendicular to the coil axis.

Claims

1. An inductor component, characterized in that, have: blank; A coil is disposed inside the aforementioned blank and wound into a spiral shape along the coil axis; The first and second external electrodes are exposed on the surface of the aforementioned blank. A first lead wire is disposed inside the blank, and one end of the coil is electrically connected to the first external electrode; and The second lead wire is disposed inside the blank, and the other end of the coil is electrically connected to the second external electrode. The aforementioned blank contains an insulator. The surface of the aforementioned blank includes a mounting surface and a top surface, wherein the mounting surface is parallel to the axial direction of the coil, and the top surface is opposite to the mounting surface in a height direction orthogonal to the axial direction of the coil. The first external electrode and the second external electrode are exposed at least on the mounting surface of the blank so that they can be separated from each other. The aforementioned coil comprises multiple coil wirings, which are electrically connected respectively. The aforementioned multiple coil wirings are formed by electrically connecting multiple coil wirings that extend in a direction orthogonal to the axial direction of the coil and are arranged at different positions along the axial direction of the coil. When viewed from the axial direction of the aforementioned coils, the aforementioned plurality of coil wirings have straight portions and curved portions. At least one of the aforementioned bent portions has a cutout in a portion along the axial direction of the coil. The wiring thickness along the coil axis at the cut portion is smaller than the wiring thickness along the coil axis at the straight portion.

2. The inductor component according to claim 1, wherein, The aforementioned cut is located at the middle of the aforementioned curved portion along the axial direction of the aforementioned coil.

3. The inductor component according to claim 1, wherein, The aforementioned cut is located at the outer end of the blank in the axial direction of the aforementioned bend.

4. The inductor component according to claim 1, wherein, The aforementioned cut is located at the inner end of the blank in the axial direction of the aforementioned bend.

5. The inductor component according to any one of claims 1 to 4, wherein, When viewed from the axial direction of the coil, the coil is polygonal in shape. The aforementioned straight section has one first straight section and one or more second straight sections, wherein the center line of the first straight section relative to the height direction of the blank is located on the top surface side, and the center line of the second straight section relative to the height direction of the blank is located on the mounting surface side. The straight section also has a third straight section connecting the first straight section and the second straight section. The first straight section and the second straight section are parallel to the mounting surface. The aforementioned curved portion has a first curved portion and a second curved portion, wherein the first curved portion connects the first straight portion and the third straight portion, and the second curved portion connects either the second straight portion and the third straight portion or connects the second straight portions to each other. At least one of the aforementioned first and second curved portions has the aforementioned cut portion provided in a portion along the axial direction of the coil. The wiring thickness along the coil axis at the cut portion is smaller than the wiring thickness along the coil axis at the straight portion.

6. The inductor component according to claim 5, wherein, The aforementioned cut portion is provided at least one of the aforementioned first curved portions.

7. The inductor component according to claim 5 or 6, wherein, The aforementioned cut portion is provided at least one of the aforementioned second curved portions.

8. The inductor component according to any one of claims 1 to 4, wherein, The aforementioned straight section has one first straight section and one or more second straight sections, wherein the center line of the first straight section relative to the height direction of the blank is located on the top surface side, and the center line of the second straight section relative to the height direction of the blank is located on the mounting surface side. The first straight section and the second straight section are parallel to the mounting surface. The aforementioned curved portion has a first curved portion, which connects the aforementioned first straight portion and the aforementioned second straight portion. At least one of the aforementioned first curved portions has the aforementioned cut portion provided on a portion of the coil axial direction. The wiring thickness along the coil axis at the cut portion is smaller than the wiring thickness along the coil axis at the straight portion.

9. The inductor component according to any one of claims 1 to 4, wherein, When viewed from the axial direction of the coil, the plurality of coil wirings have an arc portion on the mounting surface side relative to the center line of the center line in the height direction of the blank. The aforementioned arc-shaped portion protrudes towards the aforementioned mounting surface. The aforementioned straight section has a first straight section, and the center line of the first straight section relative to the height direction of the aforementioned blank is located on the top surface side. The first straight section is parallel to the mounting surface. The aforementioned curved portion has a first curved portion, which is directly connected to the aforementioned first straight portion and electrically connected to both the aforementioned first straight portion and the aforementioned arc portion. At least one of the aforementioned first curved portions has the aforementioned cut portion provided on a portion of the coil axial direction. The wiring thickness along the coil axis at the cut portion is smaller than the wiring thickness along the coil axis at the straight portion.

10. The inductor component according to claim 9, wherein, The aforementioned straight section also includes a third straight section, which connects the aforementioned first straight section and the aforementioned arc section. The aforementioned first curved portion connects the aforementioned first straight portion and the aforementioned third straight portion. The aforementioned curved portion also has a second curved portion, which connects the aforementioned arc portion and the aforementioned third straight portion.

11. The inductor component according to claim 9, wherein, The first curved portion directly connects the first straight portion and the arc portion.

12. The inductor component according to any one of claims 1 to 11, wherein, In the above coil wiring, the direction orthogonal to the coil axis and the direction in which the coil wiring extends is taken as the width direction. The cut extends through the curved portion in the width direction.

13. The inductor component according to any one of claims 1 to 11, wherein, In the above coil wiring, the direction orthogonal to the coil axis and the direction in which the coil wiring extends is taken as the width direction. The cut portion does not penetrate the curved portion in the aforementioned width direction.

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