Inductor component

Abstract

To provide an inductor component capable of suppressing generation of a cracking caused by stress remained on a boundary surface between an external part electrode and an element body.SOLUTION: An inductor component 1A comprises: an element body 10; a coil 20; and a first external part electrode 30a. The element body 10 includes: first and second end surfaces 11a and 11b; first and second main surfaces 12a and 12b; and first and second side surfaces. The first external part electrode 30a includes a first electrode layer 31a that is embedded into the element body 10 so that at least one part is exposed from the element body 10. When a first point E1 corresponded to a first ridge part 14a, a second point E2 corresponded to a second ridge part 14b, and a third point E3 that is corresponded to a tip end on the second ridge part 14b side of the first electrode layer 31a positioned at the first main surface 12a are defined in a cross section containing the first electrode layer 31a from a cross rection along a longer direction L and a height direction T are defined, the third point E3 is positioned closer to the second main surface 12b relative to a virtual straight line F connecting the first point E1 with the second point E2.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an inductor component. [Background technology]

[0002] Patent Document 1 discloses a multilayer inductor comprising a laminate having a substantially rectangular parallelepiped shape composed of a plurality of stacked insulating layers and a plurality of internal conductor layers stacked via the insulating layers, the internal conductor layers being spirally connected to form a coil structure, the coil axis of the coil structure being configured to be parallel to the bottom surface of the laminate and perpendicular to the opposing direction of a pair of external electrodes formed on opposing end surfaces of the laminate, and the edges of the cross section of the internal conductor layers being rounded. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2013-98356 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the method for manufacturing a laminated inductor described in Patent Document 1, insulating sheets on which a conductor paste for a coil structure and a conductor paste for external electrodes are printed are laminated, and then cut into individual pieces to obtain a green laminated inductor. In the method for manufacturing a laminated inductor described in Patent Document 1, the green laminated inductor is fired to obtain a laminated inductor.

[0005] In the method for manufacturing a laminated inductor described in Patent Document 1, when firing a green laminated inductor, it is necessary to simultaneously fire the conductor paste for the external electrodes and the insulating paste for the insulating sheet, which are made of different materials. Therefore, in the method for manufacturing a laminated inductor described in Patent Document 1, since the conductor paste for the external electrodes and the insulating paste for the insulating sheet have different properties such as expansion coefficient and elastic modulus, there is a risk that stress will remain at the interface between the external electrodes obtained from the conductor paste for the external electrodes and the insulating layer obtained from the insulating sheet in the laminated inductor obtained by firing the green laminated inductor. If stress remains at the interface between the external electrodes and the insulating layer in the laminated inductor, for example, when a load (shock) is applied to the laminated inductor when mounting the laminated inductor, a crack may occur inside the laminated inductor starting from the interface.

[0006] The present invention has been made to solve the above problems, and aims to provide an inductor component that can suppress the occurrence of cracks caused by residual stress at the interface between the external electrode and the element body. [Means for solving the problem]

[0007] The inductor component of the present invention comprises an element body including an insulator, a coil provided inside the element body, and a first external electrode electrically connected to the coil, the element body having a first end face and a second end face opposing each other in a length direction, a first main face and a second main face opposing each other in a height direction perpendicular to the length direction, and a first side face and a second side face opposing each other in a width direction perpendicular to the length direction and the height direction, the first end face and the first main face intersecting at a first ridge portion, the second end face and the first main face intersecting at a second ridge portion, and the first external electrode is embedded in the element body such that at least a portion of the first external electrode is exposed from the element body. the first electrode layer extends from the first ridge line portion toward the second ridge line portion at a position away from the second ridge line portion, is exposed on the first main surface, and is not exposed on the second main surface, and when a first point corresponding to the first ridge line portion, a second point corresponding to the second ridge line portion, and a third point corresponding to a tip of the first electrode layer located on the first main surface on the second ridge line portion side are defined in a cross section including the first electrode layer among cross sections along the length direction and the height direction, the third point is located on the second main surface side of a virtual straight line connecting the first point and the second point. Effect of the Invention

[0008] According to the present invention, it is possible to provide an inductor component that can suppress the occurrence of cracks due to residual stress at the interfaces between external electrodes and the element body. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic perspective view showing an example of an inductor component of the present invention. [Diagram 2] FIG. 2 is a schematic cross-sectional view showing an example of a cross section of the inductor component shown in FIG. 1 taken along line segment a1-a2. [Diagram 3] FIG. 3 is a schematic cross-sectional view showing another example of an inductor component of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The inductor component of the present invention will be described below. Note that the present invention is not limited to the following configurations, and may be modified as appropriate without departing from the gist of the present invention. In addition, a combination of multiple individual preferred configurations described below also constitutes the present invention.

[0011] The drawings shown below are schematic diagrams, and the dimensions, aspect ratio, and scale may differ from those of the actual product.

[0012] In this specification, unless otherwise specified, terms indicating the relationship between elements (e.g., "parallel", "perpendicular", etc.) and terms indicating the shape of elements not only mean the literal strict form, but also mean a range that is substantially equivalent, for example, a range that includes a difference of about a few percent.

[0013] The inductor component of the present invention comprises an element body including an insulator, a coil provided inside the element body, and a first external electrode electrically connected to the coil, the element body having a first end face and a second end face opposing each other in a length direction, a first main face and a second main face opposing each other in a height direction perpendicular to the length direction, and a first side face and a second side face opposing each other in a width direction perpendicular to the length direction and the height direction, the first end face and the first main face intersecting at a first ridge portion, the second end face and the first main face intersecting at a second ridge portion, and the first external electrode is embedded in the element body such that at least a portion of the first external electrode is exposed from the element body. the first electrode layer extends from the first ridge line portion toward the second ridge line portion at a position away from the second ridge line portion, is exposed on the first main surface, and is not exposed on the second main surface, and when a first point corresponding to the first ridge line portion, a second point corresponding to the second ridge line portion, and a third point corresponding to a tip of the first electrode layer located on the first main surface on the second ridge line portion side are defined in a cross section including the first electrode layer among cross sections along the length direction and the height direction, the third point is located on the second main surface side of a virtual straight line connecting the first point and the second point.

[0014] FIG. 1 is a schematic perspective view showing an example of an inductor component of the present invention.

[0015] The inductor component 1A shown in FIG. 1 includes an element body 10, a coil 20, and a first external electrode 30a.

[0016] In this specification, the length direction, height direction, and width direction are defined as directions L, T, and W, respectively, as shown in Fig. 1 etc. Here, the length direction L, height direction T, and width direction W are perpendicular to each other.

[0017] In the example shown in FIG. 1, the width direction W is parallel to the coil axis direction of the coil 20.

[0018] The coil axis direction of the coil 20 is the direction in which the coil axis C of the coil 20 extends.

[0019] The element body 10 has a first end face 11a and a second end face 11b facing each other in the longitudinal direction L, a first main surface 12a and a second main surface 12b facing each other in the height direction T, and a first side surface 13a and a second side surface 13b facing each other in the width direction W.

[0020] In the example shown in FIG. 1, the first main surface 12a extends in the coil axis direction (width direction W in FIG. 1).

[0021] 1, the first main surface 12a is a mounting surface. Specifically, the first main surface 12a is a mounting surface that faces an object to be mounted (e.g., a substrate) when the inductor component 1A is mounted. Therefore, in the inductor component 1A, the mounting surface corresponding to the first main surface 12a extends in the coil axis direction.

[0022] At least one of the surfaces of the element body 10, i.e., at least one of the first end face 11a, the second end face 11b, the first main face 12a, the second main face 12b, the first side face 13a, and the second side face 13b, may be marked to make each face easier to identify.

[0023] The first end face 11a and the second end face 11b do not need to be strictly perpendicular to the length direction L. In addition, the first main surface 12a and the second main surface 12b do not need to be strictly perpendicular to the height direction T. Furthermore, the first side surface 13a and the second side surface 13b do not need to be strictly perpendicular to the width direction W.

[0024] The element body 10 has, for example, a rectangular parallelepiped shape.

[0025] In this specification, the rectangular parallelepiped shape may refer to any shape that can be said to be substantially rectangular parallelepiped, and includes, for example, a roughly rectangular parallelepiped shape with rounded corners and edges as described below.

[0026] It is preferable that at least one of the corners and ridges of the element 10 be rounded.

[0027] A corner of element body 10 is a portion where three faces of element body 10 intersect.

[0028] The ridge portion of element body 10 is the portion where two faces of element body 10 intersect.

[0029] In the example shown in Fig. 1, the first end face 11a and the first main surface 12a intersect at the first ridge portion 14a. In the example shown in Fig. 1, the second end face 11b and the first main surface 12a intersect at the second ridge portion 14b. In the example shown in Fig. 1, the first end face 11a and the second main surface 12b intersect at the third ridge portion 14c. In the example shown in Fig. 1, the second end face 11b and the second main surface 12b intersect at the fourth ridge portion 14d.

[0030] The element body 10 includes an insulator.

[0031] In the example shown in FIG. 1, the insulator is formed by stacking a plurality of insulating layers in the coil axial direction (width direction W in FIG. 1).

[0032] In the example shown in FIG. 1, the multiple insulating layers include insulating layer 15a, insulating layer 15b, insulating layer 15c, and insulating layer 15d.

[0033] Although not shown in FIG. 1, in reality, at least one insulating layer exists between insulating layer 15b and insulating layer 15c in the coil axis direction.

[0034] In FIG. 1, for the sake of convenience, the boundaries between a plurality of insulating layers are shown; however, in reality, the plurality of insulating layers are often integrated together, and the boundaries between these layers are often not clearly visible.

[0035] Examples of the insulating material constituting the insulator, that is, the insulating material constituting the insulating layer here, include glass materials mainly composed of borosilicate glass, ceramic materials, organic materials such as epoxy resins, fluororesins, and polymer resins, composite materials such as glass epoxy resins, etc. As the insulating material, a material having a small dielectric constant and dielectric loss is particularly preferable.

[0036] The insulating materials constituting the multiple insulating layers may be the same as each other, may be different from each other, or may be partially different from each other.

[0037] The dimensions of the multiple insulating layers in the coil axis direction may be the same as each other, may be different from each other, or may be partially different.

[0038] The coil 20 is provided inside the element body 10 .

[0039] In the example shown in FIG. 1, the coil 20 is wound in a spiral shape along the coil axial direction.

[0040] In the example shown in FIG. 1, the coil 20 is formed by stacking a plurality of coil wires in the coil axial direction and electrically connecting them.

[0041] In the example shown in FIG. 1, the multiple coil wirings include a first coil wiring 21a and a second coil wiring 21b.

[0042] The first coil wiring 21a is located at the outermost position on the first side surface 13a side in the coil axial direction among the multiple coil wirings.

[0043] The first coil wiring 21a may have a single-layer structure or a multi-layer structure.

[0044] The second coil wiring 21b is located at the outermost position of the multiple coil wirings on the second side surface 13b side in the coil axial direction.

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

[0046] Although not shown in FIG. 1, in reality, at least one coil wiring exists between the first coil wiring 21a and the second coil wiring 21b in the coil axial direction.

[0047] Examples of conductive materials constituting the coil wiring include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0048] The conductive materials constituting the multiple coil wirings may be the same as each other, may be different from each other, or may be partially different from each other.

[0049] The dimensions of the multiple coil wirings in the coil axis direction may be the same as each other, may be different from each other, or may be partially different.

[0050] For multiple coil wirings, the dimensions in the direction perpendicular to the direction in which the coil wiring extends when viewed from the coil axis direction, i.e., the widths when viewed from the coil axis direction, may be the same as each other, may be different from each other, or may be different in some areas.

[0051] Of the multiple coil wirings, adjacent coil wirings in the coil axis direction may be electrically connected via a connection conductor that passes through an insulating layer between the adjacent coil wirings in the coil axis direction.

[0052] The connecting conductor may have a single-layer structure or a multi-layer structure.

[0053] Examples of conductive materials constituting the connecting conductor include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0054] When viewed from the coil axial direction, the coil 20 may have, for example, a shape consisting of only straight lines, a shape consisting of only curved lines, or a shape consisting of straight lines and curved lines. For example, when viewed from the coil axial direction, the coil 20 may have a polygonal shape consisting of only straight lines, a circular or elliptical shape consisting of only curved lines, or an oval shape (track shape) consisting of straight lines and curved lines.

[0055] As described above, in the example shown in FIG. 1, the coil 20 is formed from three or more coil wirings, including the first coil wiring 21a and the second coil wiring 21b and at least one other coil wiring, but it is also possible to form the coil 20 from only two coil wirings by adjusting the position of the connecting conductors.

[0056] The first external electrode 30 a is electrically connected to the coil 20 .

[0057] 1, the first external electrode 30a is electrically connected to one end of the coil 20. Specifically, the first external electrode 30a is electrically connected to the first coil wiring 21a constituting the coil 20 via the first escape wiring 22a. In other words, the first escape wiring 22a connects the first coil wiring 21a and the first external electrode 30a.

[0058] The first escape routing 22a may have a single-layer structure or a multi-layer structure.

[0059] Examples of conductive materials constituting the lead-out wiring include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0060] In this specification, the wiring that extends toward the external electrode while being inclined with respect to the straight portion of the coil wiring in the path where the coil wiring is electrically connected to the external electrode when viewed from the coil axis direction is defined as the draw-out wiring (for example, the example shown in FIG. 1). In this case, when viewed from the coil axis direction, the coil wiring and the draw-out wiring are not on the same straight line with the connection part between the two as the boundary. Note that, when viewed from the coil axis direction, if no wiring that corresponds to the draw-out wiring defined as above is found, the wiring that does not overlap the winding part of the coil (protruding from the winding part of the coil) when viewed from the coil axis direction is defined as the draw-out wiring (for example, an example different from FIG. 1).

[0061] The first external electrode 30a has a first electrode layer 31a embedded in the element body 10 so that at least a portion of the first electrode layer 31a is exposed from the element body 10.

[0062] The first electrode layer 31a extends from the first ridge line 14a toward the second ridge line 14b at a position away from the second ridge line 14b and is exposed on the first main surface 12a. That is, the first electrode layer 31a is exposed on a portion of the first main surface 12a.

[0063] 1, the first electrode layer 31a is exposed in a part of the first main surface 12a on the first ridge line 14a side. Specifically, the first electrode layer 31a is exposed in a region of the first main surface 12a that is closer to the first ridge line 14a than the center in the length direction L.

[0064] As shown in FIG. 1, the first electrode layer 31a preferably extends from the first main surface 12a to the first end face 11a via a first ridge portion 14a and is exposed at the first end face 11a.

[0065] In the example shown in FIG. 1, the first electrode layer 31a is exposed from a part of the first main surface 12a on the first ridge line 14a side to a part of the first end surface 11a on the first ridge line 14a side.

[0066] The first electrode layer 31a may be exposed only in a portion of the first major surface 12a.

[0067] On the other hand, the first electrode layer 31a is not exposed to the second major surface 12b.

[0068] The dimension of the first electrode layer 31a in the coil axis direction may be smaller than the dimension of the first ridge portion 14a in the coil axis direction (the dimension of the element body 10 in the coil axis direction), or may be the same as the dimension of the first ridge portion 14a in the coil axis direction (the dimension of the element body 10 in the coil axis direction). In other words, the first electrode layer 31a may be in contact with a part of the first ridge portion 14a, or may be in contact with the entirety of the first ridge portion 14a.

[0069] 1, the first external electrode 30a preferably further includes a second electrode layer 31b provided outside the element body 10 so as to cover the first electrode layer 31a. That is, the first external electrode 30a preferably includes, in order from the coil 20 side, the first electrode layer 31a and the second electrode layer 31b.

[0070] The second electrode layer 31b is preferably in contact with the first electrode layer 31a.

[0071] Second electrode layer 31b preferably extends from first ridge portion 14a toward second ridge portion 14b at a position away from second ridge portion 14b on the outside of element body 10, specifically, on first main surface 12a. In other words, second electrode layer 31b is preferably provided on a portion of first main surface 12a.

[0072] 1, the second electrode layer 31b is provided on a part of the first main surface 12a on the first ridge portion 14a side. Specifically, the second electrode layer 31b is provided on a region of the first main surface 12a that is closer to the first ridge portion 14a than the center in the length direction L.

[0073] As shown in FIG. 1, the second electrode layer 31b preferably further extends from above the first main surface 12a to above the first end surface 11a via the first ridge portion 14a.

[0074] In the example shown in FIG. 1, the second electrode layer 31b extends from a portion of the first main surface 12a on the first ridge line 14a side to a portion of the first end surface 11a on the first ridge line 14a side.

[0075] The second electrode layer 31b may be provided only on a portion of the first major surface 12a.

[0076] On the other hand, the second electrode layer 31b is preferably not provided on the second major surface 12b.

[0077] The dimension of the second electrode layer 31b in the coil axis direction may be smaller than the dimension of the first ridge portion 14a in the coil axis direction (the dimension of the element body 10 in the coil axis direction), or may be the same as the dimension of the first ridge portion 14a in the coil axis direction (the dimension of the element body 10 in the coil axis direction). In other words, the second electrode layer 31b may be in contact with a part of the first ridge portion 14a, or may be in contact with the entirety of the first ridge portion 14a.

[0078] Examples of conductive materials constituting the electrode layer include Ag, Au, Cu, Pd, Ni, Al, and alloys containing at least one of these metals.

[0079] When the first external electrode 30a has the first electrode layer 31a and the second electrode layer 31b, it is preferable that the first electrode layer 31a is a base electrode layer containing the above-mentioned conductive material, and the second electrode layer 31b is a plated electrode layer containing the above-mentioned conductive material. In this case, it is preferable that the first external electrode 30a has, in order from the coil 20 side, an Ag base electrode layer as the first electrode layer 31a and a Ni plated electrode layer as the second electrode layer 31b. Furthermore, it is more preferable that the first external electrode 30a has, in order from the coil 20 side, an Ag base electrode layer as the first electrode layer 31a, a Ni plated electrode layer as the second electrode layer 31b, and a Sn plated electrode layer as another electrode layer covering the second electrode layer 31b.

[0080] Fig. 2 is a schematic cross-sectional view showing an example of a cross-section along line segment a1-a2 of the inductor component shown in Fig. 1. Specifically, Fig. 2 shows a cross-section including the first coil wiring 21a and the first electrode layer 31a, among cross-sections along the length direction L and height direction T of the inductor component 1A shown in Fig. 1.

[0081] 2, in a cross section including the first electrode layer 31a among cross sections along the length direction L and height direction T, a first point E1 corresponding to the first ridge portion 14a, a second point E2 corresponding to the second ridge portion 14b, and a third point E3 corresponding to the tip of the first electrode layer 31a located on the first main surface 12a on the side of the second ridge portion 14b are defined. It can also be said that the third point E3 corresponds to the intersection of the interface between the first electrode layer 31a and the element body 10 (insulator) and the first main surface 12a.

[0082] As shown in FIG. 2, when a first point E1, a second point E2, and a third point E3 are defined, the third point E3 is located on the second main surface 12b side of a virtual straight line F connecting the first point E1 and the second point E2.

[0083] In a conventional inductor component (for example, a laminated inductor described in Patent Document 1), when the external electrodes and the element body (insulator) are formed by a method in which they are simultaneously fired (also called a co-firing method), there is a risk of stress remaining at the interface between the external electrodes and the element body (insulator) due to differences in properties such as expansion coefficient and elastic modulus between the constituent materials of the external electrodes and the element body (insulator). In a conventional inductor component, if stress remains at the interface between the external electrodes and the element body (insulator), for example, when the inductor component is mounted and the inductor component is caused to flow in a special sorting machine or other equipment, a load (shock) is applied to the inductor component, which may cause cracks to occur inside the inductor component starting from the interface. In a conventional inductor component, cracks are likely to occur at the tip of the external electrode located on the main surface (mounting surface) of the element body among the interfaces between the external electrodes and the element body (insulator) where stress may remain as described above.

[0084] In contrast, in the inductor component 1A, a third point E3 corresponding to the tip of the first electrode layer 31a located on the first main surface 12a on the second ridge portion 14b side of the interface between the external electrode and the element body 10 (insulator), here, between the first electrode layer 31a and the element body 10 (insulator), is located closer to the second main surface 12b than the imaginary line F connecting the first point E1 and the second point E2. That is, in the inductor component 1A, the height position of the third point E3 on the first main surface 12a is closer to the second main surface 12b than the height positions of the first point E1 and the second point E2. Therefore, when mounting the inductor component 1A, even if the inductor component 1A is placed from the first main surface 12a side when the inductor component 1A is moved by a facility such as a special sorting machine, the load applied to the inductor component 1A is unlikely to concentrate on the third point E3. Therefore, in the inductor component 1A, even if stress remains at the interface between the first electrode layer 31a and the element body 10 (insulator), cracks caused by the stress are less likely to occur starting from the third point E3 when the inductor component 1A is mounted, etc.

[0085] As a result of the above, the inductor component 1A can realize an inductor component that can suppress the occurrence of cracks caused by residual stress at the interface between the external electrode and the element body 10 (insulator), in this case, the interface between the first electrode layer 31a and the element body 10 (insulator).

[0086] In the inductor component 1A, it is sufficient that the third point E3 is located on the second principal surface 12b side of the imaginary line F in any cross section including the first electrode layer 31a among cross sections along the length direction L and the height direction T. In the inductor component 1A, the aspect in which the third point E3 is located on the second principal surface 12b side of the imaginary line F may be realized in, for example, a cross section including the first coil wiring 21a and the first electrode layer 31a (see FIG. 2), or in a cross section including the second coil wiring 21b and the first electrode layer 31a, or in both of these cross sections, but it is particularly preferable that it is realized in any cross section including the first electrode layer 31a.

[0087] In the inductor component 1A, in any cross section including the first electrode layer 31a among cross sections along the length direction L and the height direction T, it is preferable that the entire contour line connecting the first point E1 and the third point E3 on the first main surface 12a is located on the second main surface 12b side with respect to the virtual straight line F as shown in Fig. 2. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a among cross sections along the length direction L and the height direction T, it is preferable that the entire contour line connecting the first point E1 and the third point E3 on the first main surface 12a does not protrude from the virtual straight line F to the side opposite the second main surface 12b as shown in Fig. 2.

[0088] In the inductor component 1A, in any cross section including the first electrode layer 31a among cross sections taken along the length direction L and the height direction T, as long as the third point E3 is located on the second principal surface 12b side of the imaginary line F, a part of the contour line connecting the first point E1 and the third point E3 on the first principal surface 12a may be located on the opposite side to the second principal surface 12b with respect to the imaginary line F. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a among cross sections taken along the length direction L and the height direction T, a part of the contour line connecting the first point E1 and the third point E3 on the first principal surface 12a may protrude from the imaginary line F to the opposite side to the second principal surface 12b.

[0089] A distance G1 in the height direction T between the third point E3 and the virtual straight line F is preferably 2 μm or more and 12 μm or less.

[0090] In the example shown in FIG. 2, a distance G1 in the height direction T between the third point E3 and the imaginary line F corresponds to the dimension of a perpendicular line drawn from the third point E3 to the imaginary line F.

[0091] When the distance G1 in the height direction T between the third point E3 and the virtual straight line F is 2 μm or more and 12 μm or less, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the decrease in the L value (inductance) and the Q value (quality factor) is also sufficiently suppressed.

[0092] If the distance G1 in the height direction T between the third point E3 and the virtual straight line F is less than 2 μm, it may be difficult to obtain the effect that the load applied to the inductor component 1A is less likely to concentrate on the third point E3 when mounting the inductor component 1A, etc. Therefore, if the distance G1 in the height direction T between the third point E3 and the virtual straight line F is less than 2 μm, it may be difficult to obtain the effect that the above-mentioned cracks are less likely to occur starting from the third point E3.

[0093] If the distance G1 in the height direction T between the third point E3 and the virtual straight line F is greater than 12 μm, the region in which the coil 20 is provided in the body 10 (for example, the distance J1 in the height direction T between the third point E3 and the second main surface 12b) becomes too small, causing the inner diameter of the coil 20 to become too small, which may result in a decrease in the L value and Q value.

[0094] A distance G1 in the height direction T between the third point E3 and the imaginary line F is preferably 1% or more and 7% or less of the maximum dimension H in the height direction T of the inductor component 1A.

[0095] When the distance G1 in the height direction T between the third point E3 and the virtual straight line F is 1% or more and 7% or less of the maximum dimension H in the height direction T of the inductor component 1A, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the decrease in the L value and the Q value is also sufficiently suppressed.

[0096] If the distance G1 in the height direction T between the third point E3 and the virtual straight line F is smaller than 1% of the maximum dimension H of the inductor component 1A in the height direction T, it may be difficult to obtain the effect that the load applied to the inductor component 1A is less likely to concentrate on the third point E3 when mounting the inductor component 1A, etc. Therefore, if the distance G1 in the height direction T between the third point E3 and the virtual straight line F is smaller than 1% of the maximum dimension H of the inductor component 1A in the height direction T, it may be difficult to obtain the effect that the above-mentioned cracks are less likely to occur starting from the third point E3.

[0097] If the distance G1 in the height direction T between the third point E3 and the virtual straight line F is greater than 7% of the maximum dimension H in the height direction T of the inductor component 1A, the area in the base body 10 in which the coil 20 is provided (for example, the distance J1 in the height direction T between the third point E3 and the second main surface 12b) will become too small, causing the inner diameter of the coil 20 to become too small, which may result in a decrease in the L value and Q value.

[0098] A distance J1 in the height direction T between the third point E3 and the second main surface 12b is preferably smaller than a distance J2 in the height direction T between the first point E1 and the second main surface 12b.

[0099] In the example shown in Figure 2, the difference between the distance J1 in the height direction T between the third point E3 and the second main surface 12b and the distance J2 in the height direction T between the first point E1 and the second main surface 12b corresponds to the distance G1 in the height direction T between the third point E3 and the virtual straight line F.

[0100] The shortest distance K1 between the third point E3 and the surface of the coil 20 is preferably 25 μm or less.

[0101] In conventional inductor components, in the event that the above-mentioned cracks occur, the first electrode layer and the coil are often arranged sufficiently apart to prevent the cracks from reaching the coil and adversely affecting the coil characteristics. Therefore, in conventional inductor components, there is a limit to how close the first electrode layer and the coil can be to increase the L value.

[0102] In contrast, in the inductor component 1A, the occurrence of the above-mentioned cracks is suppressed, so there is no need to place the first electrode layer 31a and the coil 20 sufficiently apart. Therefore, in the inductor component 1A, the L value can be increased by placing the first electrode layer 31a and the coil 20 close to each other so that the shortest distance K1 between the third point E3 and the surface of the coil 20 is 25 μm or less.

[0103] As shown in FIG. 1, the inductor component 1A preferably further includes a second external electrode 30b.

[0104] The second external electrode 30b is provided at a position spaced apart from the first external electrode 30a.

[0105] In the example shown in FIG. 1, the second external electrode 30b is provided at a position spaced apart from the first external electrode 30a in a direction perpendicular to the coil axis direction, that is, in the length direction L in FIG.

[0106] The second external electrode 30b is electrically connected to the coil 20.

[0107] 1, the second external electrode 30b is electrically connected to the other end of the coil 20. Specifically, the second external electrode 30b is electrically connected to the second coil wiring 21b that constitutes the coil 20 via the second escape wiring 22b. In other words, the second escape wiring 22b connects the second coil wiring 21b and the second external electrode 30b.

[0108] The second escape wiring 22b may have a single-layer structure or a multi-layer structure.

[0109] The conductive material constituting the second escape routing 22b may be the same as the conductive material constituting the first escape routing 22a, or may be different from the conductive material constituting the first escape routing 22a.

[0110] The second external electrode 30b preferably has a third electrode layer 31c embedded in the element body 10 so that at least a portion of the third electrode layer 31c is exposed from the element body 10.

[0111] The third electrode layer 31c is preferably exposed on the first main surface 12a while extending from the second ridge portion 14b toward the first ridge portion 14a at a position away from the first electrode layer 31a. In other words, the third electrode layer 31c is preferably exposed on a part of the first main surface 12a at a position away from the first electrode layer 31a.

[0112] 1, the third electrode layer 31c is exposed in a part of the first main surface 12a on the second ridge line portion 14b side. Specifically, the third electrode layer 31c is exposed in a region of the first main surface 12a that is closer to the second ridge line portion 14b than the center in the length direction L.

[0113] As shown in FIG. 1, the third electrode layer 31c preferably further extends from the first main surface 12a to the second end surface 11b via the second ridge portion 14b and is exposed at the second end surface 11b.

[0114] In the example shown in FIG. 1, the third electrode layer 31c is exposed from a part of the first main surface 12a on the second ridge line 14b side to a part of the second end surface 11b on the second ridge line 14b side.

[0115] The third electrode layer 31c may be exposed only on a part of the first major surface 12a at a position away from the first electrode layer 31a.

[0116] On the other hand, the third electrode layer 31c is not exposed to the second major surface 12b.

[0117] The dimension of the third electrode layer 31c in the coil axis direction may be smaller than the dimension of the second ridge portion 14b in the coil axis direction (the dimension of the element body 10 in the coil axis direction), or may be the same as the dimension of the second ridge portion 14b in the coil axis direction (the dimension of the element body 10 in the coil axis direction). In other words, the third electrode layer 31c may be in contact with a part of the second ridge portion 14b, or may be in contact with the entire second ridge portion 14b.

[0118] 1, the second external electrode 30b preferably further includes a fourth electrode layer 31d provided outside the element body 10 so as to cover the third electrode layer 31c. That is, the second external electrode 30b preferably includes, in order from the coil 20 side, the third electrode layer 31c and the fourth electrode layer 31d.

[0119] The fourth electrode layer 31d is preferably in contact with the third electrode layer 31c.

[0120] The fourth electrode layer 31d preferably extends from the second ridge line 14b toward the first ridge line 14a at a position away from the first ridge line 14a on the outside of the element body 10, specifically on the first main surface 12a. In other words, the fourth electrode layer 31d is preferably provided on a portion of the first main surface 12a.

[0121] When the first external electrode 30a has the second electrode layer 31b, the fourth electrode layer 31d preferably extends from the second ridge portion 14b toward the first ridge portion 14a at a position away from the second electrode layer 31b outside the element body 10, specifically on the first main surface 12a. In other words, the fourth electrode layer 31d is preferably provided on a part of the first main surface 12a at a position away from the second electrode layer 31b.

[0122] 1, the fourth electrode layer 31d is provided on a part of the first main surface 12a on the second ridge line portion 14b side. Specifically, the fourth electrode layer 31d is provided on a region of the first main surface 12a that is closer to the second ridge line portion 14b than the center in the length direction L.

[0123] As shown in FIG. 1, the fourth electrode layer 31d preferably further extends from above the first main surface 12a to above the second end surface 11b via the second ridge portion 14b.

[0124] In the example shown in FIG. 1, the fourth electrode layer 31d extends from a portion of the first main surface 12a on the second ridge line 14b side to a portion of the second end surface 11b on the second ridge line 14b side.

[0125] The fourth electrode layer 31d may be provided only on a portion of the first principal surface 12a. When the first external electrode 30a has the second electrode layer 31b, the fourth electrode layer 31d may be provided only on a portion of the first principal surface 12a at a position away from the second electrode layer 31b.

[0126] On the other hand, the fourth electrode layer 31d is preferably not provided on the second major surface 12b.

[0127] The dimension of the fourth electrode layer 31d in the coil axis direction may be smaller than the dimension of the second ridge portion 14b in the coil axis direction (the dimension of the element body 10 in the coil axis direction), or may be the same as the dimension of the second ridge portion 14b in the coil axis direction (the dimension of the element body 10 in the coil axis direction). In other words, the fourth electrode layer 31d may be in contact with a part of the second ridge portion 14b, or may be in contact with the entire second ridge portion 14b.

[0128] When the second external electrode 30b has the third electrode layer 31c and the fourth electrode layer 31d, it is preferable that the third electrode layer 31c is a base electrode layer containing the above-mentioned conductive material, and the fourth electrode layer 31d is a plated electrode layer containing the above-mentioned conductive material. In this case, it is preferable that the second external electrode 30b has, in order from the coil 20 side, an Ag base electrode layer as the third electrode layer 31c, and a Ni plated electrode layer as the fourth electrode layer 31d. Furthermore, it is more preferable that the second external electrode 30b has, in order from the coil 20 side, an Ag base electrode layer as the third electrode layer 31c, a Ni plated electrode layer as the fourth electrode layer 31d, and a Sn plated electrode layer as another electrode layer covering the fourth electrode layer 31d.

[0129] 2, in addition to the first point E1, the second point E2, and the third point E3, a fourth point E4 is defined, which corresponds to the tip of the third electrode layer 31c located on the first main surface 12a on the side of the first ridge portion 14a. It can also be said that the fourth point E4 corresponds to the intersection of the interface between the third electrode layer 31c and the element body 10 (insulator) and the first main surface 12a.

[0130] As shown in FIG. 2, when a first point E1, a second point E2, a third point E3, and a fourth point E4 are defined, it is preferable that the fourth point E4 is located closer to the second main surface 12b than the virtual straight line F.

[0131] In the inductor component 1A, if a fourth point E4 corresponding to the tip of the third electrode layer 31c located on the first main surface 12a on the first ridge portion 14a side of the interface between the external electrode and the element body 10 (insulator), here the interface between the third electrode layer 31c and the element body 10 (insulator), is located closer to the second main surface 12b than the virtual straight line F, the load applied to the inductor component 1A is less likely to concentrate on the fourth point E4, as is the case with the third point E3, even if the inductor component 1A is placed from the first main surface 12a side when mounting the inductor component 1A, etc. Therefore, even if stress remains at the interface between the third electrode layer 31c and the element body 10 (insulator), cracks caused by the stress are less likely to occur starting from the fourth point E4 when mounting the inductor component 1A, etc.

[0132] In the inductor component 1A, in any cross section along the length direction L and the height direction T that includes the first electrode layer 31a and the third electrode layer 31c, the fourth point E4 is preferably located on the second principal surface 12b side of the imaginary line F. In the inductor component 1A, the aspect in which the fourth point E4 is located on the second principal surface 12b side of the imaginary line F may be, for example, in a cross section along the length direction L and the height direction T that includes the first coil wiring 21a, the first electrode layer 31a, and the third electrode layer 31c (see FIG. 2), or in a cross section that includes the second coil wiring 21b, the first electrode layer 31a, and the third electrode layer 31c, or in both of these cross sections, but is particularly preferably in any cross section that includes the first electrode layer 31a and the third electrode layer 31c.

[0133] In the inductor component 1A, in any cross section including the first electrode layer 31a and the third electrode layer 31c among cross sections taken along the length direction L and the height direction T, it is preferable that the entire contour line connecting the second point E2 and the fourth point E4 on the first main surface 12a is located on the second main surface 12b side with respect to the virtual straight line F as shown in Fig. 2. In other words, in the inductor component 1A, in any cross section including the first electrode layer 31a and the third electrode layer 31c among cross sections taken along the length direction L and the height direction T, it is preferable that the entire contour line connecting the second point E2 and the fourth point E4 on the first main surface 12a does not protrude from the virtual straight line F to the side opposite the second main surface 12b as shown in Fig. 2.

[0134] In the inductor component 1A, when the fourth point E4 is located on the second principal surface 12b side of the virtual line F in any cross section including the first electrode layer 31a and the third electrode layer 31c among cross sections taken along the length direction L and the height direction T, a part of the contour line connecting the second point E2 and the fourth point E4 on the first principal surface 12a may be located on the opposite side to the second principal surface 12b with respect to the virtual line F. In other words, in the inductor component 1A, when the fourth point E4 is located on the second principal surface 12b side of the virtual line F in any cross section including the first electrode layer 31a and the third electrode layer 31c among cross sections taken along the length direction L and the height direction T, a part of the contour line connecting the second point E2 and the fourth point E4 on the first principal surface 12a may protrude from the virtual line F to the opposite side to the second principal surface 12b.

[0135] In the example shown in Figure 2, on the first principal surface 12a, the entire contour line connecting the first point E1 and the third point E3 and the entire contour line connecting the second point E2 and the fourth point E4 are located on the second principal surface 12b side with respect to the virtual straight line F, and the first principal surface 12a is concave toward the second principal surface 12b.

[0136] A distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is preferably 2 μm or more and 12 μm or less.

[0137] In the example shown in FIG. 2, a distance G2 in the height direction T between the fourth point E4 and the imaginary line F corresponds to the dimension of a perpendicular line drawn from the fourth point E4 to the imaginary line F.

[0138] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is 2 μm or more and 12 μm or less, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the decrease in the L value and the Q value is also sufficiently suppressed.

[0139] If the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 2 μm, it may be difficult to obtain the effect that the load applied to the inductor component 1A is less likely to concentrate on the fourth point E4 when mounting the inductor component 1A, etc. Therefore, if the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is less than 2 μm, it may be difficult to obtain the effect that the above-mentioned crack is less likely to occur starting from the fourth point E4.

[0140] If the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is greater than 12 μm, the region in the body 10 in which the coil 20 is provided (for example, the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b) becomes too small, causing the inner diameter of the coil 20 to become too small, which may result in a decrease in the L value and Q value.

[0141] A distance G2 in the height direction T between the fourth point E4 and the imaginary line F is preferably 1% or more and 7% or less of the maximum dimension H in the height direction T of the inductor component 1A.

[0142] When the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is 1% or more and 7% or less of the maximum dimension H in the height direction T of the inductor component 1A, the occurrence of the above-mentioned cracks is sufficiently suppressed, and the decrease in the L value and the Q value is also sufficiently suppressed.

[0143] If the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is smaller than 1% of the maximum dimension H of the inductor component 1A in the height direction T, it may be difficult to obtain the effect that the load applied to the inductor component 1A is less likely to concentrate on the fourth point E4 when mounting the inductor component 1A, etc. Therefore, if the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is smaller than 1% of the maximum dimension H of the inductor component 1A in the height direction T, it may be difficult to obtain the effect that the above-mentioned crack is less likely to occur starting from the fourth point E4.

[0144] If the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F is greater than 7% of the maximum dimension H in the height direction T of the inductor component 1A, the area in the base body 10 in which the coil 20 is provided (for example, the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b) becomes too small, and the inner diameter of the coil 20 becomes too small, which may make the L value and Q value more likely to decrease.

[0145] A distance J3 in the height direction T between the fourth point E4 and the second main surface 12b is preferably smaller than a distance J4 in the height direction T between the second point E2 and the second main surface 12b.

[0146] In the example shown in Figure 2, the difference between the distance J3 in the height direction T between the fourth point E4 and the second main surface 12b and the distance J4 in the height direction T between the second point E2 and the second main surface 12b corresponds to the distance G2 in the height direction T between the fourth point E4 and the virtual straight line F.

[0147] A distance J3 in the height direction T between the fourth point E4 and the second main surface 12b is preferably the same as a distance J1 in the height direction T between the third point E3 and the second main surface 12b.

[0148] The distance J3 between the fourth point E4 and the second main surface 12b in the height direction T may be different from the distance J1 between the third point E3 and the second main surface 12b in the height direction T. In this case, the distance J3 between the fourth point E4 and the second main surface 12b in the height direction T may be greater than the distance J1 between the third point E3 and the second main surface 12b in the height direction T, or may be smaller than the distance J1 between the third point E3 and the second main surface 12b in the height direction T.

[0149] A distance J3 in the height direction T between the fourth point E4 and the second main surface 12b is preferably smaller than a distance J2 in the height direction T between the first point E1 and the second main surface 12b.

[0150] The distance J4 between the second point E2 and the second main surface 12b in the height direction T is preferably greater than the distance J1 between the third point E3 and the second main surface 12b in the height direction T. In other words, the distance J1 between the third point E3 and the second main surface 12b in the height direction T is preferably smaller than the distance J4 between the second point E2 and the second main surface 12b in the height direction T.

[0151] A distance J4 in the height direction T between the second point E2 and the second main surface 12b is preferably the same as a distance J2 in the height direction T between the first point E1 and the second main surface 12b.

[0152] Note that the distance J4 between the second point E2 and the second main surface 12b in the height direction T may be different from the distance J2 between the first point E1 and the second main surface 12b in the height direction T. In this case, the distance J4 between the second point E2 and the second main surface 12b in the height direction T may be greater than the distance J2 between the first point E1 and the second main surface 12b in the height direction T, or may be smaller than the distance J2 between the first point E1 and the second main surface 12b in the height direction T.

[0153] The shortest distance K2 between the fourth point E4 and the surface of the coil 20 is preferably 25 μm or less.

[0154] In the inductor component 1A, the occurrence of the above-mentioned cracks is suppressed, so there is no need to place the third electrode layer 31c and the coil 20 sufficiently apart. Therefore, in the inductor component 1A, the L value can be increased by placing the third electrode layer 31c and the coil 20 close to each other so that the shortest distance K2 between the fourth point E4 and the surface of the coil 20 is 25 μm or less.

[0155] 1 and 2, the first main surface 12a preferably has a flat portion 12aa located between the first external electrode 30a and the second external electrode 30b. That is, the first external electrode 30a and the second external electrode 30b are not provided on the flat portion 12aa of the first main surface 12a. Specifically, the first electrode layer 31a and the third electrode layer 31c are not exposed on the flat portion 12aa of the first main surface 12a, and the second electrode layer 31b and the fourth electrode layer 31d are not provided on the flat portion 12aa of the first main surface 12a.

[0156] 1 and 2, the second main surface 12b is preferably parallel to the flat portion 12aa of the first main surface 12a. In other words, the second main surface 12b is preferably flat like the flat portion 12aa of the first main surface 12a.

[0157] The second main surface 12b being parallel to the flat portion 12aa of the first main surface 12a means that, in a cross section along the length direction L and height direction T as shown in FIG. 2, when the contour line of the second main surface 12b is moved in the height direction T and superimposed on the contour line (preferably a straight line) of the flat portion 12aa of the first main surface 12a, the entire contour line of the second main surface 12b is within a range of ±1 μm in the height direction T with respect to the contour line of the flat portion 12aa of the first main surface 12a.

[0158] In the inductor component 1A, if the second main surface 12b is parallel to the flat portion 12aa of the first main surface 12a, for example, when mounting the inductor component 1A, even if the inductor component 1A is picked up (e.g., sucked) from the second main surface 12b side by a mounting machine (mounter), the load applied to the inductor component 1A is unlikely to concentrate locally on, for example, the third ridge portion 14c and the fourth ridge portion 14d of the second main surface 12b. Therefore, when mounting the inductor component 1A, the inductor component 1A is unlikely to chip or crack on the second main surface 12b side due to the load applied to the inductor component 1A from the mounting machine.

[0159] In the inductor component, the second main surface 12b does not have to be parallel to the flat portion 12aa of the first main surface 12a.

[0160] FIG. 3 is a schematic cross-sectional view showing another example of an inductor component of the present invention.

[0161] In the inductor component 1B shown in FIG. 3, the second main surface 12b is not parallel to the flat portion 12aa of the first main surface 12a.

[0162] In the example shown in FIG. 3, the second main surface 12b is concave toward the first main surface 12a.

[0163] When mounting the inductor component 1B, if the inductor component 1B is picked up from the second main surface 12b side by a mounting machine, the load applied to the inductor component 1B may tend to concentrate locally on the second main surface 12b, here, on the third ridge line portion 14c and the fourth ridge line portion 14d. Therefore, when mounting the inductor component 1B, the load applied to the inductor component 1B from the mounting machine may make the inductor component 1B more likely to chip or crack on the second main surface 12b side than when mounting the inductor component 1A.

[0164] For these reasons, inductor component 1A is less susceptible to defects such as chipping or cracking on second main surface 12b side due to the load applied during mounting, as compared to inductor component 1B.

[0165] Although an example in which the coil axis direction is parallel to the width direction W has been shown above, the coil axis direction may be parallel to the length direction L or parallel to the height direction T.

[0166] When the coil axis direction is parallel to the length direction L or the width direction W, it is preferable that the flat portion 12aa of the first main surface 12a is parallel to the coil axis direction.

[0167] When the coil axis direction is parallel to the height direction T, it is preferable that the flat portion 12aa of the first main surface 12a is perpendicular to the coil axis direction.

[0168] The inductor component 1A is manufactured, for example, by the following method.

[0169] <Step of Producing Mother Laminate> First, for example, an insulating paste containing a glass material mainly composed of borosilicate glass is repeatedly applied by screen printing, etc. to form an insulating paste layer. The insulating paste layer formed here will later become the insulating layer 15a.

[0170] Next, a photosensitive conductive paste layer is formed on the insulating paste layer by, for example, applying a photosensitive conductive paste mainly composed of Ag by screen printing or the like. Furthermore, the photosensitive conductive paste layer is irradiated with ultraviolet light or the like through a photomask, and then developed with an alkaline solution or the like to form a coil conductor layer, an external conductor layer, and an extraction conductor layer connected to the coil conductor layer and the external conductor layer on the insulating paste layer. In this manner, the coil conductor layer, the extraction conductor layer, and the external conductor layer are formed at multiple locations by photolithography. The coil conductor layer formed here will later become the first coil wiring 21a. The extraction conductor layer formed here will later become the first extraction wiring 22a that connects the first coil wiring 21a and the first external electrode 30a (specifically, the first electrode layer 31a). The external conductor layer formed here will later become a part of the first electrode layer 31a that constitutes the first external electrode 30a, and a part of the third electrode layer 31c that constitutes the second external electrode 30b.

[0171] In addition, when forming the coil conductor layer, the lead-out conductor layer, and the external conductor layer, instead of exposure using a photomask, for example, DI exposure (also called direct image exposure or direct writing) without using a photomask may be performed.

[0172] Next, for example, a photosensitive insulating paste is applied by screen printing or the like to form a new insulating paste layer on the already formed insulating paste layer. Furthermore, the newly formed insulating paste layer is irradiated with ultraviolet light or the like through a photomask, and then developed with an alkaline solution or the like to form via holes and openings in the insulating paste layer. In this manner, an insulating paste layer having via holes and openings at multiple locations is formed by photolithography. The insulating paste layer formed here includes an insulating paste layer that will later become the insulating layer 15b. The via holes formed here overlap a part of the already formed coil conductor layer. The openings formed here overlap an already formed external conductor layer.

[0173] When forming the insulating paste layer provided with the via holes and the openings, for example, DI exposure without using a photomask may be performed instead of exposure using a photomask.

[0174] Next, for example, a photosensitive conductive paste mainly composed of Ag is applied by screen printing or the like to form a new photosensitive conductive paste layer inside the via hole and the opening, and on the already formed insulating paste layer. Furthermore, the photosensitive conductive paste layer is irradiated with ultraviolet light or the like through a photomask, and then developed with an alkaline solution or the like to form a connection conductor layer inside the via hole, and a new coil conductor layer connected to the connection conductor layer is formed on the insulating paste layer, and a new external conductor layer connected to the already formed external conductor layer is formed inside the opening, and a new external conductor layer is further formed on the external conductor layer. In this manner, the coil conductor layer, the connection conductor layer, and the external conductor layer are formed by photolithography. The connection conductor layer formed here will later become a connection conductor that connects the coil wirings adjacent to each other in the coil axis direction.

[0175] When forming the coil conductor layer, the connection conductor layer, and the external conductor layer, for example, DI exposure without using a photomask may be performed instead of exposure using a photomask.

[0176] Thereafter, the above steps are repeated to form insulating paste layers, coil conductor layers, connecting conductor layers, and external conductor layers into a predetermined laminated structure. For example, the coil conductor layers formed here include a coil conductor layer that will later become the second coil wiring 21b.

[0177] When forming the coil conductor layer that will later become the second coil wiring 21b and the external conductor layer that is the same layer as the coil conductor layer, a lead-out conductor layer connected to the coil conductor layer and the external conductor layer is also formed. The lead-out conductor layer formed here will later become the second lead-out wiring 22b that connects the second coil wiring 21b and the second external electrode 30b (specifically, the third electrode layer 31c).

[0178] Finally, a new insulating paste layer is formed by repeatedly applying an insulating paste containing a glass material mainly composed of borosilicate glass by screen printing, etc. The insulating paste layers formed here include insulating paste layers that will later become insulating layer 15c and insulating layer 15d.

[0179] In this manner, a mother laminate is produced.

[0180] The method for forming the conductor patterns of the coil conductor layer, the lead-out conductor layer, the connection conductor layer, and the external conductor layer is not limited to the photolithography method described above, and may be, for example, a method in which a conductive paste is printed and laminated using a screen printing plate having openings in the shape of the conductor pattern, a method in which a conductor film is formed by a sputtering method, a vapor deposition method, a foil pressing method, or the like, and then the conductor film is etched to have the shape of the conductor pattern, or a method in which a negative pattern is formed by a semi-additive method, a plating film is formed, and then unnecessary portions of the plating film are removed by etching or the like to have the shape of the conductor pattern.

[0181] When forming the conductor patterns of the coil conductor layer, the lead-out conductor layer, the connection conductor layer, and the external conductor layer, the conductor patterns are formed in multiple stages to realize a high aspect ratio, thereby reducing loss due to resistance at high frequencies. The method of forming the conductor patterns in multiple stages is not particularly limited, and may be, for example, a method of repeatedly overlapping the conductor patterns by repeating the steps using the photolithography method as described above, a method of repeatedly overlapping the conductor patterns formed by the semi-additive method, a method of overlapping in no particular order the conductor pattern formed by the semi-additive method and the conductor pattern formed by etching a plating film separately grown by plating, or a method of further growing the plating film formed by the semi-additive method by plating.

[0182] The conductive material constituting the conductor patterns of the coil conductor layer, the lead-out conductor layer, the connection conductor layer, and the external conductor layer is not limited to a photosensitive conductive paste mainly composed of metal, such as the above-mentioned photosensitive conductive paste mainly composed of Ag, but may be a conductor containing a metal such as Ag, Au, Cu, etc., formed by a sputtering method, a vapor deposition method, a foil pressing method, a plating method, etc.

[0183] The method for forming the insulating paste layer is not limited to the above-mentioned photolithography method, and may be, for example, a method of pressing a sheet made of an insulating material, a method of spin-coating an insulating material, or a method of spray-coating an insulating material.

[0184] The method for forming the insulating paste layer having via holes and openings is not limited to the above-mentioned photolithography method, and may be, for example, a method in which an insulating film is formed by pressing a sheet made of an insulating material, spin coating an insulating material, spray coating an insulating material, or the like, and then the insulating film is subjected to laser processing, drilling processing, or the like to form via holes and openings.

[0185] The insulating material constituting the insulating paste layer is not limited to the above-mentioned glass material mainly composed of borosilicate glass, but may be, for example, a ceramic material, an organic material such as an epoxy resin, a fluororesin, or a polymer resin, a composite material such as a glass epoxy resin, etc. As the insulating material, a material having a small dielectric constant and a small dielectric loss is particularly preferable.

[0186] <Process for forming element body, coil, and external electrodes> First, the mother laminate is cut by dicing or the like to be divided into a plurality of unfired laminates.

[0187] The unsintered laminate has an insulating paste lamination portion formed by laminating insulating paste layers, a coil conductor lamination portion formed by laminating coil conductor layers so that adjacent coil conductor layers are electrically connected via connecting conductor layers, and an external conductor lamination portion formed by laminating external conductor layers.

[0188] When the green laminate is cut into individual pieces, the external conductor laminate portion is exposed at two locations on at least the bottom surface of the insulating paste laminate portion included in the cut surface of the green laminate. The bottom surface of the insulating paste laminate portion will later become the first main surface 12a of the element body 10.

[0189] Next, the green laminate is fired to produce a laminate.

[0190] When the green laminate is fired, the insulating paste layers become insulating layers, and the insulating paste laminate portion becomes an insulator included in the element body 10. When the green laminate is fired, the coil conductor layers become coil wiring, and the coil conductor laminate portion becomes the coil 20. When the green laminate is fired, one of the two external conductor laminate portions becomes the first electrode layer 31a of the first external electrode 30a, and the other becomes the third electrode layer 31c of the second external electrode 30b.

[0191] Next, the corners and ridges of the element body 10 may be rounded by, for example, barrel polishing the obtained laminate.

[0192] Finally, the first electrode layer 31a and the third electrode layer 31c are used as Ag base electrode layers, and a Ni-plated electrode layer and a Sn-plated electrode layer are formed in order on the surface of each Ag base electrode layer by plating. Of the two Ni-plated electrode layers formed here, one becomes the second electrode layer 31b of the first external electrode 30a, and the other becomes the fourth electrode layer 31d of the second external electrode 30b. Of the two Sn-plated electrode layers formed here, one becomes another electrode layer of the first external electrode 30a different from the first electrode layer 31a and the second electrode layer 31b, and the other becomes another electrode layer of the second external electrode 30b different from the third electrode layer 31c and the fourth electrode layer 31d. The thicknesses of the Ni-plated electrode layer and the Sn-plated electrode layer are, for example, 2 μm or more and 10 μm or less.

[0193] In this manner, the first external electrode 30a and the second external electrode 30b are formed, each of which has, in order from the coil 20 side, an Ag base electrode layer, a Ni plated electrode layer, and a Sn plated electrode layer.

[0194] The method for forming the external electrode is not limited to the method of plating the external conductor lamination portion exposed on the cut surface (at least the bottom surface of the insulating paste lamination portion) of the unsintered laminate as described above, but may also be a method of exposing the external conductor lamination portion on the cut surface (at least the bottom surface of the insulating paste lamination portion) of the unsintered laminate as described above, and then immersing (dipping) the exposed portion of the external conductor lamination portion in a conductive paste, or forming a film of conductive paste on the exposed portion of the external conductor lamination portion by a sputtering method, and then performing a plating process.

[0195] In this manner, the inductor component 1A is manufactured.

[0196] In the inductor component 1A, as described above (see FIG. 2), the first main surface 12a is recessed toward the second main surface 12b so that the third point E3 is located closer to the second main surface 12b than the imaginary line F, and further the fourth point E4 is located closer to the second main surface 12b than the imaginary line F. There are no particular limitations on the method for making the first main surface 12a recessed in this way, and the following methods can be mentioned, for example.

[0197] In the first method, in the <step of producing a mother laminate>, a part of the outer edge of each of the multiple insulating paste layers in the laminated structure is formed into a concave shape, so that the bottom surface of the insulating paste laminated portion in the unfired laminate obtained in the <step of forming an element body, a coil, and an external electrode> is made concave. Thereafter, when the unfired laminate with the concave bottom surface of the insulating paste laminated portion is fired, the first main surface 12a of the obtained element body 10 becomes concave.

[0198] As a second method, in the <step of forming the element body, coil, and external electrodes>, the fired laminate is subjected to polishing, laser processing, or the like to make the first main surface 12a of the element body 10 concave.

[0199] The inductor component 1A is manufactured to have, for example, a 0402 (0.4 mm×0.2 mm×0.2 mm) size. Note that the size of the inductor component 1A is not limited to the 0402 (0.4 mm×0.2 mm×0.2 mm) size.

[0200] The present specification discloses the following:

[0201] <1> An element body including an insulator; A coil provided inside the element body; a first external electrode electrically connected to the coil; the element body has a first end face and a second end face facing each other in a longitudinal direction, a first main face and a second main face facing each other in a height direction perpendicular to the longitudinal direction, and a first side face and a second side face facing each other in a width direction perpendicular to the longitudinal direction and the height direction, the first end surface and the first main surface intersect at a first ridge portion, the second end surface and the first main surface intersect at a second ridge portion, the first external electrode has a first electrode layer embedded in the element body such that at least a portion of the first electrode layer is exposed from the element body; the first electrode layer extends from the first ridge line portion toward the second ridge line portion at a position away from the second ridge line portion and is exposed on the first main surface and is not exposed on the second main surface; An inductor component, in which, in a cross section including the first electrode layer among cross sections along the length direction and the height direction, when a first point corresponding to the first ridge portion, a second point corresponding to the second ridge portion, and a third point corresponding to the tip of the first electrode layer located on the first main surface on the side of the second ridge portion are defined, the third point is located on the second main surface side of a virtual straight line connecting the first point and the second point.

[0202] <2> The distance between the third point and the virtual straight line in the height direction is 2 μm or more and 12 μm or less. <1> 2. An inductor component according to claim 1 .

[0203] <3> a distance in the height direction between the third point and the virtual straight line is 1% or more and 7% or less of a maximum dimension in the height direction of the inductor component; <1> or <2> 2. An inductor component according to claim 1 .

[0204] <4> a distance between the third point and the second main surface in the height direction is smaller than a distance between the first point and the second main surface in the height direction; <1> ~ <3> 2. An inductor component according to claim 1 .

[0205] <5> The shortest distance between the third point and the surface of the coil is 25 μm or less. <1> ~ <4> 2. An inductor component according to claim 1 .

[0206] <6> the first electrode layer further extends from the first main surface to the first end surface via the first ridge portion and is exposed at the first end surface; <1> ~ <5> 2. An inductor component according to claim 1 .

[0207] <7> The first external electrode further includes a second electrode layer provided outside the element body so as to cover the first electrode layer. <1> ~ <6> 2. An inductor component according to claim 1 .

[0208] <8> a second external electrode provided at a position spaced apart from the first external electrode and electrically connected to the coil; the second external electrode has a third electrode layer embedded in the element body so that at least a portion of the third electrode layer is exposed from the element body; the third electrode layer extends from the second ridge line portion toward the first ridge line portion at a position away from the first electrode layer and is exposed on the first principal surface, and is not exposed on the second principal surface; when a fourth point corresponding to a tip end of the third electrode layer located on the first principal surface on a side of the first ridge line portion is defined in a cross section including the first electrode layer and the third electrode layer among cross sections along the length direction and the height direction, the fourth point is located on the second principal surface side with respect to the virtual straight line. <1> ~ <7> 2. An inductor component according to claim 1 .

[0209] <9> The distance between the fourth point and the virtual straight line in the height direction is 2 μm or more and 12 μm or less. <8> 2. An inductor component according to claim 1 .

[0210] <10> a distance in the height direction between the fourth point and the virtual straight line is 1% or more and 7% or less of a maximum dimension in the height direction of the inductor component; <8> or <9> 2. An inductor component according to claim 1 .

[0211] <11> a distance between the fourth point and the second main surface in the height direction is smaller than a distance between the second point and the second main surface in the height direction; <8> ~ <10> 2. An inductor component according to claim 1 .

[0212] <12> The shortest distance between the fourth point and the surface of the coil is 25 μm or less. <8> ~ <11> 2. An inductor component according to claim 1 .

[0213] <13> the third electrode layer further extends from the first main surface to the second end surface via the second ridge portion and is exposed at the second end surface. <8> ~ <12> 2. An inductor component according to claim 1 .

[0214] <14> The second external electrode further includes a fourth electrode layer provided outside the element body so as to cover the third electrode layer. <8> ~ <13> 2. An inductor component according to claim 1 .

[0215] <15> the first main surface has a flat portion located between the first external electrode and the second external electrode, The second main surface is parallel to the flat portion of the first main surface. <8> ~ <14> 2. An inductor component according to claim 1 . [Explanation of symbols]

[0216] 1A, 1B inductor components 10 Base 11a First end surface 11b Second end surface 12a First main surface 12aa Flat portion of first principal surface 12b Second main surface 13a 1st side 13b Second side 14a First Ridge 14b Second ridge 14c 3rd ridgeline section 14d 4th ridgeline section 15a, 15b, 15c, 15d Insulating layers 20 Coil 21a First coil wiring 21b Second coil wiring 22a 1st lead out wiring 22b 2nd lead out wiring 30a 1st external electrode 30b 2nd external electrode 31a 1st electrode layer 31b Second electrode layer 31c 3rd electrode layer 31d 4th electrode layer C Coil shaft E1 1st point E2 2nd point E3 3rd point E4 Point 4 F Imaginary line G1 Distance in height between the third point and the imaginary line G2 Distance in height between the 4th point and the imaginary line H is the maximum height dimension of the inductor component J1: Distance in the height direction between the third point and the second principal surface J2: Distance in the height direction between the first point and the second principal surface J3: Distance in the height direction between the fourth point and the second principal surface J4: Distance in the height direction between the second point and the second principal surface K1 Shortest distance between the third point and the surface of the coil K2: The shortest distance between the 4th point and the surface of the coil L Length direction T Height direction W Width direction

Claims

1. An element body including an insulator; A coil provided inside the element body; a first external electrode electrically connected to the coil; the element body has a first end face and a second end face facing each other in a longitudinal direction, a first main face and a second main face facing each other in a height direction perpendicular to the longitudinal direction, and a first side face and a second side face facing each other in a width direction perpendicular to the longitudinal direction and the height direction, the first end surface and the first main surface intersect at a first ridge portion, the second end surface and the first main surface intersect at a second ridge portion, the first external electrode has a first electrode layer embedded in the element body such that at least a portion of the first electrode layer is exposed from the element body; the first electrode layer extends from the first ridge line portion toward the second ridge line portion at a position away from the second ridge line portion and is exposed on the first main surface, and is not exposed on the second main surface; An inductor component, in which, in a cross section including the first electrode layer among cross sections along the length direction and the height direction, a first point corresponding to the first ridge portion, a second point corresponding to the second ridge portion, and a third point corresponding to the tip of the first electrode layer located on the first main surface on the side of the second ridge portion are defined, and the third point is located on the second main surface side of a virtual straight line connecting the first point and the second point.

2. The inductor component according to claim 1 , wherein a distance in the height direction between the third point and the virtual straight line is not less than 2 μm and not more than 12 μm.

3. The inductor component according to claim 1 , wherein a distance in the height direction between the third point and the virtual straight line is 1% to 7% of a maximum dimension in the height direction of the inductor component.

4. The inductor component according to claim 1 , wherein a distance in the height direction between the third point and the second main surface is smaller than a distance in the height direction between the first point and the second main surface.

5. The inductor component according to claim 1 , wherein the shortest distance between the third point and a surface of the coil is 25 μm or less.

6. The inductor component according to claim 1 , wherein the first electrode layer further extends from the first main surface to the first end face via the first ridge portion and is exposed at the first end face.

7. 2. The inductor component according to claim 1, wherein the first external electrode further comprises a second electrode layer provided outside the element body so as to cover the first electrode layer.

8. a second external electrode provided at a position spaced apart from the first external electrode and electrically connected to the coil; the second external electrode has a third electrode layer embedded in the element body so that at least a portion of the third electrode layer is exposed from the element body; the third electrode layer extends from the second ridge line portion toward the first ridge line portion at a position away from the first electrode layer and is exposed to the first main surface, and is not exposed to the second main surface; An inductor component as described in any one of claims 1 to 7, wherein, in a cross section along the length direction and the height direction that includes the first electrode layer and the third electrode layer, when a fourth point corresponding to the tip of the third electrode layer located on the first main surface on the side of the first ridge portion is defined, the fourth point is located on the second main surface side of the virtual straight line.

9. The inductor component according to claim 8 , wherein a distance in the height direction between the fourth point and the virtual straight line is not less than 2 μm and not more than 12 μm.

10. The inductor component according to claim 8 , wherein a distance in the height direction between the fourth point and the virtual straight line is 1% to 7% of a maximum dimension in the height direction of the inductor component.

11. The inductor component according to claim 8 , wherein a distance in the height direction between the fourth point and the second main surface is smaller than a distance in the height direction between the second point and the second main surface.

12. The inductor component according to claim 8 , wherein the shortest distance between the fourth point and a surface of the coil is 25 μm or less.

13. The inductor component according to claim 8 , wherein the third electrode layer further extends from the first main surface to the second end face via the second ridge portion and is exposed at the second end face.

14. 9. The inductor component according to claim 8, wherein the second external electrode further comprises a fourth electrode layer provided outside the element body so as to cover the third electrode layer.

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

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