Laminated coil component and method for manufacturing the same

Abstract

The present invention provides a multilayer coil component and a method for manufacturing the same, which allows for easy design changes to vary the inductance value. [Solution] In the laminated coil component 1, the coil conductor 5 includes some of the second wiring sections 6 and some of the pillar sections 8 of the multiple pairs provided within the base body 2. Therefore, the number of turns of the coil conductor and the magnetic path length differ from the configuration in which the coil conductor 5 includes all of the multiple second wiring sections 6 and all of the multiple pairs of pillar sections 8 provided within the base body 2, and consequently the inductance value also differs. In this case, the pairs of second wiring sections 6 and pillar sections 8 that do not constitute the coil conductor 5 remain within the base body 2 as non-coil conductors 9, so the design of the multiple second wiring sections 6 and the multiple pairs of pillar sections 8 can be unified, and it is not necessarily required to change the design.

Description

Technical Field

[0001] The present invention relates to a multilayer coil component and a method for manufacturing the same.

Background Art

[0002] As a conventional multilayer coil component, for example, the one described in Patent Document 1 is known. The multilayer coil component described in this document includes a body having a mounting surface and a main surface facing each other in the stacking direction, a coil conductor disposed inside the body and having a coil axis parallel to the mounting surface, and a pair of terminal electrodes disposed on the mounting surface of the body and electrically connected to a pair of end portions of the coil conductor, respectively.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the multilayer coil component according to the above-described prior art, in order to manufacture a plurality of types having different inductance values, it was necessary to redesign the entire component for each type of inductance value. The inventors have newly found a technique for facilitating design changes to vary the inductance value of the multilayer coil component.

[0005] One aspect of the present invention aims to provide a multilayer coil component and a method for manufacturing the same, in which design changes for varying the inductance value are easy.

Means for Solving the Problems

[0006] A laminated coil component according to one aspect of the present invention comprises a base body composed of a plurality of laminated insulating layers, having a mounting surface intersecting the lamination direction, a pair of end faces facing each other in a first direction parallel to the mounting surface, and a pair of side faces facing each other in a second direction perpendicular to the lamination direction and the first direction, a coil conductor provided within the base body and having a coil axis along the second direction with both ends drawn out to the mounting surface, and a pair of terminal electrodes provided on the mounting surface of the base body and connected to both ends of the coil conductor, the base body having at least one first wiring portion extending parallel to the mounting surface, and parallel to the mounting surface on the side further from the mounting surface than the first wiring portion and The device includes a plurality of second wiring sections extending along a first direction and arranged in parallel along a second direction, a plurality of pairs of pillar sections extending from both ends of each of the plurality of second wiring sections toward the mounting surface along the stacking direction, and a pair of lead conductors extending from two of the plurality of pairs of pillar sections toward the mounting surface and connecting to a pair of terminal electrodes, respectively, forming the ends of a coil conductor, wherein the coil conductor includes at least a part or all of one first wiring section, a part of a plurality of second wiring sections, a pair of parts of the plurality of pairs of pillar sections, and a pair of lead conductors, and the device is provided with non-coil conductors including pairs of second wiring sections and pillar sections that do not constitute a coil conductor.

[0007] In the above-described laminated coil component, since the coil conductor includes some of the second wiring sections and some of the pillar sections from among the multiple pairs provided within the element, the number of turns of the coil conductor and the magnetic path length differ from a configuration in which the coil conductor includes all of the multiple second wiring sections and all of the multiple pairs of pillar sections provided within the element, and therefore the inductance value also differs. In this case, since the pairs of second wiring sections and pillar sections that do not constitute the coil conductor are provided within the element as non-coil conductors, at least for the multiple second wiring sections and multiple pairs of pillar sections, no design changes are required from the configuration in which the coil conductor includes all of the multiple second wiring sections and all of the multiple pairs of pillar sections provided within the element. Therefore, the above-described laminated coil component facilitates design changes that result in different inductance values.

[0008] A method for manufacturing a laminated coil component according to one aspect of the present invention includes: a first step of preparing a first base layer including a plurality of lower wiring sections extending along a first direction within the layer and arranged in parallel along a second direction perpendicular to the first direction within the layer; a second step of laminating at least one second base layer on the first base layer, including a pair of pillar conductors provided at positions corresponding to both ends of each of the plurality of lower wiring sections; a third step of laminating a third base layer on the second base layer, including at least one upper wiring section connecting the pillar conductors of the second base layer and a pair of first lead conductors provided at positions corresponding to the pillar conductors; and a fourth base layer including a pair of second lead conductors. The third step includes a fourth step of stacking layers and a fifth step of providing a fifth element layer on the fourth element layer, the fifth element layer having a pair of terminal electrodes that are connected to a pair of second lead conductors, respectively, wherein in the third step, a pillar conductor connected to the upper wiring section of the third element layer and a pillar conductor connected to a pair of first lead conductors are determined from among a plurality of pillar conductors of the second element layer, and the upper wiring section and the pair of first lead conductors are positioned so as to be connected to the determined pillar conductors, or in the fourth step, a member connected to a pair of second lead conductors of the fourth element layer is determined from among the upper wiring section and first lead conductors of the third element layer, and the pair of second lead conductors are positioned so as to be connected to the determined member.

[0009] In the above-described method for manufacturing laminated coil components, in the third step, a pillar conductor connected to the upper wiring section of the third element layer and a pillar conductor connected to a pair of first lead conductors are determined from among a plurality of pillar conductors of the second element layer. Depending on the position of the upper wiring section and the pair of first lead conductors positioned to connect to the determined pillar conductor, the inductance value of the laminated coil component changes. Alternatively, in the fourth step, a member connected to a pair of second lead conductors of the fourth element layer is determined from among the upper wiring section and first lead conductors of the third element layer. Depending on the position of the pair of second lead conductors positioned to connect to the determined member, the inductance value of the laminated coil component changes. Therefore, the inductance value of the laminated coil component can be adjusted by changing the content of the third or fourth step while keeping the content of the preceding steps the same. Thus, the above-described method for manufacturing laminated coil components facilitates design changes that result in different inductance values. [Effects of the Invention]

[0010] According to one aspect of the present invention, a laminated coil component that allows for easy design changes to vary the inductance value and a method for manufacturing the same are provided. [Brief explanation of the drawing]

[0011] [Figure 1] This is a perspective view of a laminated coil component according to one embodiment. [Figure 2] Figure 1 is an exploded perspective view showing the configuration of each layer of the laminated coil component. [Figure 3] This figure shows the configuration of the wiring section of the first layer shown in Figure 2. [Figure 4] This figure shows the configuration of the wiring section of the second layer shown in Figure 2. [Figure 5] This figure shows the configuration of the wiring section of the third layer shown in Figure 2. [Figure 6] This figure shows the configuration of the wiring section of the fourth layer shown in Figure 2. [Figure 7] This figure shows the configuration of the wiring section of the fifth layer shown in Figure 2. [Figure 8] It is a flowchart showing the procedure of the manufacturing method of the laminated coil component shown in FIG. 1. [Figure 9] It is a side view of the laminated coil component shown in FIG. 1. [Figure 10] It is a perspective view showing the coil conductor and the non - coil conductor shown in FIG. 1. [Figure 11] It is a diagram showing the wiring part of the third base layer with different configurations. [Figure 12] It is a diagram showing the wiring part of the fourth base layer with different configurations. [Figure 13] It is a perspective view showing the coil conductor and the non - coil conductor with different configurations. [Figure 14] It is a diagram showing the wiring part of the third base layer with different configurations. [Figure 15] It is a diagram showing the wiring part of the fourth base layer laminated on the third base layer shown in FIG. 14. [Figure 16] It is a perspective view showing the coil conductor having the configuration shown in FIGS. 14 and 15.

Embodiments for Carrying out the Invention

[0012] Hereinafter, referring to the accompanying drawings, preferred embodiments of the present invention will be described in detail. In the description of the drawings, the same or corresponding elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0013] Referring to FIG. 1, the laminated coil component according to the present embodiment will be described. FIG. 1 is a perspective view of the laminated coil component according to an embodiment. As shown in FIG. 1, the laminated coil component 1 includes a base body 2, a pair of bottom electrodes 3 and 4, a coil conductor 5, and a non - coil conductor 9.

[0014] The base body 2 has a rectangular parallelepiped shape. The rectangular parallelepiped shape includes the shape of a rectangular parallelepiped with chamfered corners and ridge lines, and the shape of a rectangular parallelepiped with rounded corners and ridge lines. As an outer surface, the base body 2 has a pair of end faces 2a, 2b, a pair of main faces 2c, 2d, and a pair of side faces 2e, 2f. The end faces 2a, 2b face each other. The main faces 2c, 2d face each other. The side faces 2e, 2f face each other. Hereinafter, the opposing direction of the end faces 2a, 2b is defined as the first direction D1, the opposing direction of the side faces 2e, 2f is defined as the second direction D2, and the opposing direction of the main faces 2c, 2d is defined as the third direction D3. The first direction D1, the third direction D3, and the second direction D2 are substantially orthogonal to each other.

[0015] The end faces 2a, 2b extend in the third direction D3 so as to connect the main faces 2c, 2d. The end faces 2a, 2b also extend in the second direction D2 so as to connect the side faces 2e, 2f. The main faces 2c, 2d extend in the first direction D1 so as to connect the end faces 2a, 2b. The main faces 2c, 2d also extend in the second direction D2 so as to connect the side faces 2e, 2f. The side faces 2e, 2f extend in the first direction D1 so as to connect the end faces 2a, 2b. The side faces 2e, 2f also extend in the third direction D3 so as to connect the main faces 2c, 2d.

[0016] The main face 2d is the mounting surface of the base body 2. For example, when mounting the multilayer coil component 1 on another electronic device (for example, a circuit substrate or a multilayer electronic component) not shown in the figure, it is the face facing the other electronic device. The end faces 2a, 2b are surfaces continuous from the mounting surface (that is, the main face 2d).

[0017] The length of the base body 2 in the first direction D1 is longer than the length of the base body 2 in the third direction D3 and the length of the base body 2 in the second direction D2. The length of the base body 2 in the third direction D3 is shorter than the length of the base body 2 in the second direction D2. That is, in the present embodiment, the end faces 2a, 2b, the main faces 2c, 2d, and the side faces 2e, 2f have a rectangular shape. The length of the base body 2 in the third direction D3 may be equal to the length of the base body 2 in the second direction D2, or may be longer than the length of the base body 2 in the second direction D2.

[0018] In this embodiment, "equivalent" means not only being equal, but also including slight differences or manufacturing tolerances within a predetermined range. For example, if multiple values ​​fall within ±5% of the average of those multiple values, then those multiple values ​​are defined as equivalent.

[0019] As shown in Figure 2, the base body 2 has a configuration in which multiple base body layers are stacked in the third direction D3, and in this embodiment, the base body 2 is composed of nine base body layers 21 to 29. In other words, the stacking direction of the base body 2 coincides with the third direction D3. Wiring sections 6, 7, 8a to 8f that constitute the coil conductor 5 or non-coil conductor 9, which will be described later, are embedded in the base body layers 22 to 28. The base body 2 can be manufactured by sequentially stacking base body layers 22 to 29 on base body layer 21, as will be explained in the manufacturing method described later. In an actual base body 2, the multiple base body layers 21 to 29 may be integrated to the extent that the boundaries between the layers are not visible, or they may be integrated so that the boundaries between the layers are visible.

[0020] Each of the elemental layers 21-29 is mainly composed of an insulating material, for example, a resin material. The resin material includes, for example, at least one selected from liquid crystal polymer, polyimide resin, crystalline polystyrene, epoxy resin, acrylic resin, bismalade resin, and fluororesin. The resin material may or may not contain a filler. The filler is, for example, an inorganic filler. An example of an inorganic filler is silica. Each of the elemental layers 21-29 may also be composed of a magnetic material. The magnetic material includes, for example, a Ni-Cu-Zn ferrite material, a Ni-Cu-Zn-Mg ferrite material, or a Ni-Cu ferrite material. The magnetic material may also include, for example, an Fe alloy. Each of the elemental layers 21-29 may also contain a non-magnetic material, which may be a glass ceramic material or a dielectric material. Each of the wiring sections 6, 7, 8a-8f is composed of a conductive material (for example, Cu).

[0021] The base layer 21 is composed solely of the insulating material described above. The base layer 21 is located at the bottom of the base 2 and constitutes the main surface 2c.

[0022] As shown in Figures 2 and 3, the base layer 22 has a plurality of second wiring sections 6 (lower wiring sections) embedded in it, and the base layer 22 according to this embodiment contains five second wiring sections 6. The plurality of second wiring sections 6 all extend parallel to the first direction D1 and have the same length with respect to the first direction D1. The plurality of second wiring sections 6 are arranged at equal intervals with respect to the second direction D2. The plurality of second wiring sections 6 are spaced apart from the end faces 2a, 2b and sides 2e, 2f of the base 2. One end 6a of each second wiring section 6 in the direction of extension is located near the end face 2a, and the other end 6b is located near the end face 2b. The plurality of second wiring sections 6 are located on the main surface 2c side of the base 2 because the base layer 22 is laminated directly on the base layer 21 which constitutes the main surface 2c. The base layer 22 will also be referred to as the first base layer in the following description.

[0023] As shown in Figures 2 and 4, the base layers 23 to 26 each have embedded wiring sections 8a to 8d (pillar conductors) that constitute the pillar section 8 extending along the third direction D3. The wiring sections 8a to 8d are located in the same positions in all base layers 23 to 26 and overlap each other in the third direction D3. In the following description, base layers 23 to 26 will also be referred to as the second base layer.

[0024] Each wiring section 8a to 8d is composed of multiple pairs that form a pair with respect to the first direction D1, and in this embodiment, there are five pairs. Specifically, each wiring section 8a to 8d is arranged in two rows along the second direction D2 and is spaced equally apart with respect to the second direction D2. In the following description, the row of wiring sections 8a to 8d arranged in two rows on the end face 2a side will be referred to as the first row 8A, and the row on the end face 2b side will be referred to as the second row 8B. The wiring sections 8a to 8d of the first row 8A are positioned to correspond to one end 6a of the second wiring section 6, and the wiring sections 8a to 8d of the second row 8B are positioned to correspond to the other end 6b of the second wiring section 6.

[0025] As shown in Figures 2 and 5, the base layer 27 has a plurality of first wiring sections 7 embedded in it, and in this embodiment, the base layer 27 includes three first wiring sections 7. The base layer 27 will also be referred to as the third base layer in the following description. Each first wiring section 7 has a pair of ends 7a and 7b and an inclined section 7c interposed between the pair of ends 7a and 7b. The pair of ends 7a and 7b and the inclined section 7c are configured to be continuous, with the pair of ends 7a and 7b located on both sides of the inclined section 7c with respect to the first direction D1. The pair of ends 7a and 7b consist of a first end 7a located closer to the end face 2a of the base 2 and a second end 7b located closer to the end face 2b of the base 2. The pair of ends 7a and 7b are offset from each other with respect to the second direction D2 when viewed from the third direction D3. In this embodiment, when viewed from the third direction D3, the first end 7a is located closer to the side surface 2f than the second end 7b. The inclined portion 7c extends in a direction inclined by a predetermined angle with respect to the first direction D1, connecting a pair of ends 7a and 7b that are offset from each other with respect to the second direction D2. The inclination angle with respect to the first direction D1 is the same for all first wiring sections 7. That is, the inclined portions 7c of the first wiring sections 7 are parallel to each other.

[0026] The first end 7a of the first wiring section 7 overlaps with one of the first row 8A and one of the multiple second wiring sections 6 of the wiring sections 8a to 8d, when viewed from the third direction D3. The second end 7b of the first wiring section 7 overlaps with one of the second row 8B and one of the multiple second wiring sections 6 of the wiring sections 8a to 8d, when viewed from the third direction D3. In this embodiment, the second end 7b of the first wiring section 7A of the three first wiring sections 7 overlaps with the first wiring section 8a to 8d of the second row 8B counting from the side 2f, and also with the end 6b of the first second wiring section 6 counting from the side 2f, while the first end 7a overlaps with the second wiring section 8a to 8d of the first row 8A counting from the side 2f, and also with the end 6a of the second second wiring section 6 counting from the side 2f. Similarly, the second end 7b of the first wiring section 7B of the three first wiring sections 7 overlaps with the second wiring section 8a to 8d of the second row 8B, counting from the side 2f, and also overlaps with the end 6b of the second second wiring section 6, counting from the side 2f, while the first end 7a overlaps with the third wiring section 8a to 8d of the first row 8A, counting from the side 2f, and also overlaps with the end 6a of the third second wiring section 6, counting from the side 2f. The second end 7b of the first wiring section 7C, one of the three first wiring sections 7, overlaps with the third wiring section 8a to 8d from the side 2f side of the wiring sections 8a to 8d in the second row 8B, and also overlaps with the end 6b of the third second wiring section 6 from the side 2f side, while the first end 7a overlaps with the fourth wiring section 8a to 8d from the side 2f side of the wiring sections 8a to 8d in the first row 8A, and also overlaps with the end 6a of the fourth second wiring section 6 from the side 2f side.

[0027] Furthermore, a pair of wiring sections 8e (first lead-out wiring sections) are embedded in the base layer 27. One of the pair of wiring sections 8e is positioned to overlap with one of the wiring sections 8a to 8d of the first row 8A, and the other of the pair of wiring sections 8e is positioned to overlap with one of the wiring sections 8a to 8d of the second row 8B. In this embodiment, one of the pair of wiring sections 8e overlaps with the first wiring section 8a to 8d of the first row 8A, counting from the side 2f, and also overlaps with the end 6a of the first second wiring section 6, counting from the side 2f, thus forming the end 5a of the coil conductor 5. The other of the pair of wiring sections 8e overlaps with the fourth wiring section 8a to 8d of the second row 8B, counting from the side 2f, and also overlaps with the end 6b of the fourth second wiring section 6, counting from the side 2f, thus forming the end 5b of the coil conductor 5.

[0028] As shown in Figures 2 and 6, a pair of wiring sections 8f (second lead-out wiring sections) are embedded in the base layer 28. The pair of wiring sections 8f are positioned to overlap with the pair of wiring sections 8e of the base layer 27. Of the pair of wiring sections 8f, the wiring sections 8f on the end face 2a side and the side 2f side constitute the end 5a of the coil conductor 5, and the wiring sections 8f on the end face 2b side and the side 2e side constitute the end 5b of the coil conductor 5. In the following description, the base layer 28 will also be referred to as the fourth base layer.

[0029] As shown in Figures 2 and 7, the base layer 29 is provided with a pair of bottom electrodes 3 and 4 (terminal electrodes). From the viewpoint of the manufacturing procedure, the base layer 29 is located at the top of the base 2 and constitutes the main surface 2d. In other words, the pair of bottom electrodes 3 and 4 are provided on the main surface 2d of the base 2. The base layer 29 will also be referred to as the fifth base layer in the following description. Both the pair of bottom electrodes 3 and 4 are rectangular in shape when viewed from the third direction D3. The pair of bottom electrodes 3 and 4 may have the same shape and dimensions. In this embodiment, the pair of bottom electrodes 3 and 4 are aligned in the first direction D1, and the bottom electrode 3 located on the end face 2a side of the base 2 overlaps with the wiring portion 8f on the end face 2a side and the side 2f side of the pair of wiring portions 8f of the base layer 28, while the bottom electrode 4 located on the end face 2b side of the base 2 overlaps with the wiring portion 8f on the end face 2b side and the side 2e side of the pair of wiring portions 8f of the base layer 28. The pair of bottom electrodes 3 and 4 are embedded inside the base body 2 (more specifically inside the base body layer 29) and are exposed from the main surface 2d. The pair of bottom electrodes 3 and 4 may be partially or entirely provided on the main surface 2d of the base body 2.

[0030] The laminated coil component 1 can be manufactured by the manufacturing method shown in the flowchart of Figure 9.

[0031] First, in the first step S1, the base layer 21 and the first base layer 22 are prepared. In the first step S1, the first base layer 22 is stacked on top of the base layer 21. Alternatively, the first base layer 22 may be prepared in advance and stacked on top of the base layer 21.

[0032] Next, in the second step S2, the second elemental layers 23 to 26 are sequentially stacked on the first elemental layer 22. If the second elemental layers 23 to 26 consist of multiple layers, as in this embodiment, the second step S2 is repeated multiple times. That is, if the number of layers in the second elemental layer is N, the second step S2 is repeated N times. If the second elemental layer consists of a single layer, the second step S2 is performed only once and does not need to be repeated.

[0033] Subsequently, as the third step S3, the third elementary layer 27 is stacked on top of the second elementary layers 23-26 (specifically, on the uppermost second elementary layer 26). Furthermore, as the fourth step S4, the fourth elementary layer 28 is stacked on top of the third elementary layer 27. Finally, as the fifth step S5, the fifth elementary layer 29 is stacked on top of the fourth elementary layer 28. The bottom electrodes 3 and 4 may be provided on the fifth elementary layer 29 before stacking it, or they may be provided on the fifth elementary layer 29 after stacking it.

[0034] Next, the pillar portion 8 according to this embodiment will be described with reference to Figures 1 and 9.

[0035] In this embodiment, the wiring sections 8a to 8d of each base layer 23 to 26 are stacked to form 10 pillar sections 8. The pillar sections 8 are composed of multiple pairs that form a pair with respect to the first direction D1, and in this embodiment, there are 5 pairs. The 5 pairs of pillar sections 8 are aligned in two rows, the first row 8A and the second row 8B, along the second direction D2, similar to the wiring sections 8a to 8d.

[0036] Each of the pillar sections 8 is connected to both ends 6a and 6b of the second wiring section 6, as shown in Figure 9. Specifically, end 6a of the second wiring section 6 is connected to one end of the pillar section 8 (the end on the main surface 2c side), and end 6b of the second wiring section 6 is also connected to one end of the pillar section 8. Each of the pillar sections 8 extends from both ends 6a and 6b of the second wiring section 6 toward the main surface 2d of the base body 2. In other words, one second wiring section 6 spans two pillar sections 8. In this embodiment, the cross-sectional shape of the pillar section 8 in a cross section perpendicular to the third direction D3 is approximately rectangular (specifically, approximately square). The cross-sectional shape of the pillar section 8 may be, for example, circular, elliptical, or a polygon other than a quadrilateral.

[0037] In this embodiment, the first pillar portion 8 of the first row 8A, counting from the side 2f, has one end connected to the end 6a of the first second wiring portion 6, counting from the side 2f, and the other end connected to the bottom electrode 3 provided on the main surface 2d via wiring portions 8e and 8f that constitute the end 5a of the coil conductor 5. The second to fourth pillar portions 8 of the first row 8A, counting from the side 2f, have one end connected to the ends 6a of the second to fourth second wiring portions 6, counting from the side 2f, and the other end connected to the first end 7a of the first to third first wiring portions 7, counting from the side 2f. The fifth pillar section 8 from the side 2f side of the pillar section 8 in the first row 8A has one end connected to the end 6a of the fifth second wiring section 6 from the side 2f, and the other end extends toward the main surface 2d of the base body 2 and terminates within the base body 2.

[0038] In this embodiment, the first to third pillar sections 8 of the second row 8B, counting from the side 2f, have one end connected to the end 6b of the first to third second wiring sections 6, counting from the side 2f, and the other end connected to the second end 7b of the first to third first wiring sections 7, counting from the side 2f. The fourth pillar section 8 of the second row 8B, counting from the side 2f, has one end connected to the end 6b of the fourth second wiring section 6, counting from the side 2f, and the other end connected to the bottom electrode 4 provided on the main surface 2d via wiring sections 8e and 8f that constitute the end 5b of the coil conductor 5. The fifth pillar section 8 of the second row 8B, counting from the side 2f, has one end connected to the end 6b of the fifth second wiring section 6 counting from the side 2f, and the other end extends toward the main surface 2d of the base body 2 and terminates within the base body 2.

[0039] In this embodiment, the coil conductor 5 and the non-coil conductor 9 are adjacent to each other in the element 2 with respect to the second direction D2, as shown in Figure 10.

[0040] The coil conductor 5 is composed of parts of the wiring sections 6, 7, and 8a to 8f provided within the base body 2. The coil conductor 5 according to this embodiment is composed of parts of a plurality of second wiring sections 6, a pair of parts of a plurality of pairs of pillar sections 8, and all of a plurality of first wiring sections 7. More specifically, the coil conductor 5 is composed of four second wiring sections 6 located on the side 2f of the base body 2, four pairs of pillar sections 8 extending from both ends 6a and 6b of these four second wiring sections 6, and three first wiring sections 7.

[0041] The coil conductor 5 has a coil axis aligned with the second direction D2 and revolves around the coil axis. In this embodiment, the coil conductor 5 revolves around the coil axis for approximately 3.5 turns. Since both ends 5a and 5b of the coil conductor 5 are connected to the bottom electrodes 3 and 4, respectively, it functions as an inductor.

[0042] The non-coil conductor 9 is composed of wiring sections 6, 8a to 8d that do not constitute the coil conductor 5. In this embodiment, the non-coil conductor 9 is composed of parts of multiple second wiring sections 6 and pairs of parts of multiple pairs of pillar sections 8. More specifically, the non-coil conductor 9 is composed of one second wiring section 6 located on the side 2e of the base body 2, and a pair of pillar sections 8 extending from both ends 6a and 6b of this single second wiring section 6. The non-coil conductor 9 is not connected to either of the bottom electrodes 3 or 4 and does not function as an inductor. Furthermore, within the base body 2, the non-coil conductor 9 is not electrically connected to the coil conductor 5, and the non-coil conductor 9 and the coil conductor 5 are insulated from each other.

[0043] In the configuration shown in Figure 10, the second wiring section 6 included in the non-coil conductor 9 is located outside the multiple second wiring sections 6 included in the coil conductor 5.

[0044] Here, we will explain the inductance value of the multilayer coil component 1.

[0045] The inductance value of the laminated coil component 1 changes according to the number of turns (windings) of the coil conductor 5, and more specifically, it is proportional to the square of the number of turns, with the inductance value increasing as the number of turns increases. In the laminated coil component 1, five second wiring sections 6 are provided within the base body 2, so it is possible to form a coil conductor 5 with 4.5 turns in terms of design. The coil conductor 5 according to this embodiment is composed of only four second wiring sections 6, and its number of turns is 3.5 turns, which is less than 4.5 turns.

[0046] Furthermore, the inductance value of the laminated coil component 1 changes according to the magnetic path length of the coil conductor 5, and more specifically, it is inversely proportional to the magnetic path length, with the inductance value increasing as the magnetic path length decreases. Since the laminated coil component 1 has five second wiring sections 6 within the base body 2, it is possible to secure a magnetic path length Lmax for five second wiring sections 6 in terms of design. The coil conductor 5 according to this embodiment is composed of only four second wiring sections 6, and its magnetic path length L is shorter than the magnetic path length Lmax for five second wiring sections 6. As shown in Figure 3, the magnetic path length of the coil conductor 5 in this embodiment can be defined as the length in the second direction D2 of the rectangular formation region R that includes all of the multiple second wiring sections 6 when viewed from the third direction D3.

[0047] In the laminated coil component 1, the inductance value decreases as the number of turns decreases, while the inductance value increases as the magnetic path length shortens. Specifically, the inductance value decreases by about 60% when the number of turns decreases from 4.5 turns to 3.5 turns, and the inductance value increases by about 25% when the magnetic path length decreases from 5 to 4, resulting in an overall decrease of about 25% in the inductance value of the laminated coil component 1.

[0048] In other words, the inductance value of the laminated coil component 1 can be adjusted by changing both the number of turns and the magnetic path length of the coil conductor 5, or by changing only the number of turns of the coil conductor 5. The number of turns and the magnetic path length of the coil conductor 5 can be changed by adjusting the design of at least one of the base layer 27 in the third step S3 and the base layer 28 in the fourth step S4 of the manufacturing method shown in Figure 8.

[0049] For example, in the third step S3, the number of turns and magnetic path length of the coil conductor 5 can be changed by modifying the design of the wiring sections 7 and 8e of the third elemental layer 27. One method for modifying the design of the wiring sections 7 and 8e of the third elemental layer 27 is to prepare in advance several types of third elemental layers 27 with different positions of the wiring sections 7 and 8e, and then select one of the several types of third elemental layers 27 and stack it on the second elemental layers 23 to 26. Alternatively, in the third step S3, a third elemental layer 27 including the desired wiring sections 7 and 8e can be formed, and the formed third elemental layer 27 can be stacked on the second elemental layers 23 to 26.

[0050] The third elemental layer 27 in this embodiment includes three first wiring sections 7, but the number of turns of the coil conductor 5 changes by increasing or decreasing the number of first wiring sections 7. In this embodiment, the number of first wiring sections 7 is two less than the number of second wiring sections 6. The number of first wiring sections 7 may be one less, or two or more less. Also, the position of the pair of wiring sections 8e in the third elemental layer 27 can be freely determined. Depending on the position of the wiring sections 8e that constitute the ends 5a and 5b of the coil conductor 5, the number and arrangement of the pillar sections 8 that constitute the coil conductor 5 change, and as a result the magnetic path length L of the coil conductor 5 changes.

[0051] In the fourth step S4, the number of turns and magnetic path length L of the coil conductor 5 can be changed by modifying the design of the wiring section 8f of the fourth elemental layer 28. The position of the pair of wiring sections 8f in the fourth elemental layer 28 can be freely determined. That is, in the fourth step S4, the member to be connected to the pair of wiring sections 8f is determined from among the pair of wiring sections 8e and multiple first wiring sections 7 of the third elemental layer 27. Then, the pair of wiring sections 8f are positioned so that they are connected to the determined member. One method of positioning is to prepare in advance multiple types of fourth elemental layers 28 with different positions of the pair of wiring sections 8f, select the fourth elemental layer 28 to be connected to the determined member, and stack it on the third elemental layer 27. Alternatively, a fourth elemental layer 28 including the pair of wiring sections 8f connected to the determined member can be formed in the fourth step S4, and the formed fourth elemental layer 28 can be stacked on the third elemental layer 27.

[0052] Depending on the position of the wiring section 8f of the fourth element layer 28, the pillar section 8 used for leading out the coil conductor 5 changes. Depending on the position of the wiring section 8f that constitutes the ends 5a and 5b of the coil conductor 5, the number and arrangement of the first wiring section 7 and pillar section 8 that constitute the coil conductor 5 change, and as a result the number of turns and magnetic path length L of the coil conductor 5 change.

[0053] For example, in steps S3 and S4, the elemental layers 27 and 28 shown in Figures 11 and 12 can be applied, thereby changing the inductance value of the laminated coil component 1.

[0054] In the third sublayer 27 shown in Figure 11, the first end 7a of the first wiring section 7C, one of the three first wiring sections 7, overlaps with the fifth wiring section 8a to 8d from the side 2f side of the first row 8A, and also with the end 6a of the fifth second wiring section 6 from the side 2f side. Therefore, the inclination angle of the first wiring section 7C with respect to the first direction D1 is different from the inclination angle of the first wiring sections 7A and 7B with respect to the first direction D1, and the first wiring section 7C is not parallel to the first wiring sections 7A and 7B. In the third base layer 27 shown in Figure 11, one of the pair of wiring sections 8e is positioned to overlap with the first wiring section 8a to 8d from the side 2f side of the wiring sections 8a to 8d in the first row 8A, and the other of the pair of wiring sections 8e is positioned to overlap with the fifth wiring section 8a to 8d from the side 2f side of the base 2 in the wiring sections 8a to 8d of the second row 8B. In the fourth base layer 28 shown in Figure 12, the pair of wiring sections 8f are positioned to overlap with the pair of wiring sections 8e of the third base layer 27.

[0055] When the elemental layers 27 and 28 shown in Figures 11 and 12 are applied, the non-coil conductor 9 is sandwiched between the coil conductors 5, as shown in Figure 13. In the configuration shown in Figure 13, the second wiring section 6 included in the non-coil conductor 9 is located inside the multiple second wiring sections 6 included in the coil conductor 5. When the elemental layers 27 and 28 shown in Figures 11 and 12 are applied, the magnetic path length L of the coil conductor 5 is the same as the magnetic path length Lmax of five second wiring sections 6, and is longer than the magnetic path length of the coil conductor 5 shown in Figure 10, thus reducing the inductance value from the perspective of magnetic path length. The coil conductor 5 shown in Figure 13 is composed of only four second wiring sections 6, and its number of turns is 3.5 turns, which is the same number of turns as the configuration shown in Figure 10. Therefore, there is no increase or decrease in the inductance value from the perspective of the number of turns.

[0056] As described above, the inductance value of the laminated coil component 1 can be adjusted by changing at least one of the number of turns of the coil conductor 5 and the magnetic path length by adjusting the design of at least one of the base layer 27 applied in the third step S3 and the base layer 28 applied in the fourth step S4.

[0057] At this time, it is not necessarily required to redesign the second wiring section 6 of the first base layer 22 prepared in the first step S1 and the wiring sections 8a to 8d of the second base layers 23 to 26 that are laminated in the second step S2. In other words, the designs of the second wiring section 6 of the first base layer 22 and the wiring sections 8a to 8d of the second base layers 23 to 26 can be unified, thereby reducing manufacturing costs, improving work efficiency, and simplifying the work process. The second wiring section 6 of the first base layer 22 and the wiring sections 8a to 8d of the second base layers 23 to 26 that do not constitute coil conductors remain in the base 2 as non-coil conductors 9.

[0058] In the laminated coil component 1 and its manufacturing method described above, the coil conductor 5 includes some of the second wiring sections 6 and some of the pairs of pillar sections 8 provided within the base body 2. Therefore, the number of turns of the coil conductor and the magnetic path length differ from the configuration in which the coil conductor 5 includes all of the second wiring sections 6 and all of the pairs of pillar sections 8 provided within the base body 2, and consequently, the inductance value also differs. From the standpoint of the manufacturing method, in the fourth step S4, a member is selected from the second wiring sections 6 and wiring sections 8e of the third base body layer 27 to be connected to a pair of wiring sections 8f of the fourth base body layer 28. The inductance value of the laminated coil component changes depending on the position of the pair of wiring sections 8f that are positioned to be connected to the selected member. At this time, since the pairs of second wiring sections 6 and pillar sections 8 that do not constitute the coil conductor 5 remain within the base body 2 as non-coil conductors 9, the design of the multiple second wiring sections 6 and the multiple pairs of pillar sections 8 can be unified, and it is not necessarily required to change the design. From a manufacturing method perspective, only the fourth step S4 can be changed, while the processes from the first step S1 to the third step S3 can remain the same. Therefore, it is easy to make design changes to vary the inductance value of the laminated coil component 1.

[0059] Furthermore, in the laminated coil component 1 and its manufacturing method described above, the design of the wiring section 7 of the third base layer 27 formed in the third step S3 can also be standardized. In this case, the third base layer 27 includes four first wiring sections 7, as shown in Figure 14. The second end 7b of the first wiring section 7D, which is added to the first wiring sections 7A to 7C shown in Figure 5, overlaps with the fourth wiring section 8a to 8d of the second row 8B, counting from the side 2f, and the first end 7a overlaps with the fifth wiring section 8a to 8d of the first row 8A, counting from the side 2f. One of the pair of wiring sections 8e is positioned to overlap with the first wiring section 8a to 8d from the side 2f side among the wiring sections 8a to 8d of the first row 8A, and the other of the pair of wiring sections 8e is positioned to overlap with the fifth wiring section 8a to 8d from the side 2f side among the wiring sections 8a to 8d of the second row 8B.

[0060] At this time, the position in which the ends 5a and 5b of the coil conductor 5 are drawn out to the bottom electrodes 3 and 4 is determined according to the position of the pair of wiring sections 8f of the fourth element layer 28. As shown in Figures 15 and 16, for example, if the wiring section 8f constituting the end 5a of the coil conductor 5 is located in a position that overlaps with the first wiring section 8a to 8d of the first row 8A, counting from the side 2f side, then the coil conductor 5 is composed of all the wiring sections 6, 7, and 8a to 8f contained within the element 2. If the position of the wiring section 8f constituting the end 5a of the coil conductor 5 is changed to a position that overlaps with the second wiring section 8a to 8d of the first row 8A, counting from the side 2f side, then approximately one turn of wiring, including the first wiring section 7A and the second wiring section 6A, becomes a non-coil conductor 9, and the coil conductor 5 is composed of the remaining wiring sections 6, 7, and 8a to 8d contained within the element 2. In this case, the first wiring section 7A and the second wiring section 6A, which constitute the non-coil conductor 9, are electrically connected to the coil conductor 5. In this case, the magnetic path length L also changes as the number of turns of the coil conductor 5 changes relatively (specifically, it decreases by one turn).

[0061] In this specification, the coil conductor 5 can be considered as the wiring sections 6, 7, 8a-8d located between the two ends 5a, 5b from the viewpoint of the current path, and the non-coil conductor 9 can be considered as the wiring sections 6, 7, 8a-8d that are not located between the two ends 5a, 5b from the viewpoint of the current path. In this case, when a voltage is applied between the bottom electrodes 3, 4 (i.e., between the two ends 5a, 5b), the coil conductor 5 functions as an inductor, but the non-coil conductor 9 does not function as an inductor. The non-coil conductor 9 may be electrically connected to the coil conductor 5 within the element 2, or it may be insulated from the coil conductor 5 within the element 2.

[0062] Thus, the design of the wiring section 7 of the third elemental layer 27 formed in the third step S3 can also be standardized, and the number of turns of the coil conductor 5 and the magnetic path length can be changed only by designing the wiring section 8f of the fourth elemental layer 28 formed in the fourth step S4. Therefore, design changes that result in different inductance values ​​of the coil conductor 5 become even easier. Note that the length of the formation region R1 of the pair of wiring sections 8f with respect to the second direction D2, as viewed from the third direction D3, changes depending on the position of the wiring section 8f, but may be the same as or shorter than the magnetic path length Lmax.

[0063] As can be seen from the above description, this specification discloses the following: [Note 1] A base body comprising multiple stacked insulating layers, having a mounting surface intersecting the stacking direction, a pair of end faces facing each other in a first direction parallel to the mounting surface, and a pair of side faces facing each other in a second direction perpendicular to the stacking direction and the first direction, A coil conductor is provided within the aforementioned body, having a coil axis aligned with the second direction, and with both ends drawn out to the mounting surface, A pair of terminal electrodes are provided on the mounting surface of the base body and are connected to both ends of the coil conductor, respectively. Equipped with, The aforementioned base body is At least one first wiring section extending parallel to the mounting surface, A plurality of second wiring sections are provided, which extend parallel to the mounting surface and along the first direction, and are arranged in parallel along the second direction, on the side of the first wiring section that is further from the mounting surface, Multiple pairs of pillar portions extending from each of the multiple second wiring portions toward the mounting surface along the stacking direction, A pair of lead conductors that extend from two of the plurality of pillar portions to the mounting surface and connect to the pair of terminal electrodes respectively constitute both ends of the coil conductor. Includes, The coil conductor includes part or all of the plurality of first wiring sections, part of the plurality of second wiring sections, a pair of part of the plurality of pairs of pillar sections, and the pair of lead conductors. A laminated coil component in which a non-coil conductor, including a pair of the second wiring portion and the pillar portion that do not constitute the coil conductor, is provided within the main body. [Note 2] The laminated coil component according to Appendix 1, wherein the second wiring portion included in the non-coil conductor is located outside of the plurality of second wiring portions included in the coil conductor. [Note 3] The laminated coil component according to Appendix 1, wherein the second wiring portion included in the non-coil conductor is located inside a plurality of the second wiring portions included in the coil conductor. [Note 4] A laminated coil component according to any one of the appendices 1 to 3, wherein the number of the plurality of first wiring sections is two or more less than the number of the plurality of second wiring sections. [Note 5] A laminated coil component according to any one of the appendices 1 to 4, wherein the coil conductor and the non-coil conductor are electrically connected within the aforementioned body. [Note 6] A laminated coil component according to any one of the appendices 1 to 4, wherein the coil conductor and the non-coil conductor are insulated within the aforementioned body. [Note 7] A first step of preparing a first elemental layer which includes a plurality of lower wiring sections that extend along a first direction within the layer and are arranged in parallel along a second direction perpendicular to the first direction within the layer, The second step involves stacking at least one second elemental layer on the first elemental layer, which includes pairs of pillar conductors provided at positions corresponding to both ends of each of the plurality of lower wiring sections. A third step of stacking a third element layer on the second element layer, the third element layer including at least one upper wiring portion connecting the pillar conductors of the second element layer and a pair of first lead conductors provided at positions corresponding to the pillar conductors, A fourth step involves stacking a fourth element layer containing a pair of second lead conductors on the third element layer, A fifth step is to provide a fifth element layer on the fourth element layer, on which a pair of terminal electrodes connected to the pair of second lead conductors is provided, and Includes, A method for manufacturing a laminated coil component, comprising: in the third step, determining from among the plurality of pillar conductors of the second base layer which pillar conductor is connected to the upper wiring section of the third base layer and which pillar conductor is connected to the pair of first lead conductors, and positioning the upper wiring section and the pair of first lead conductors so as to be connected to the determined pillar conductor; or, in the fourth step, determining from among the upper wiring section and the first lead conductors of the third base layer which member is connected to the pair of second lead conductors of the fourth base layer, and positioning the pair of second lead conductors so as to be connected to the determined member. [Note 8] The method for manufacturing a laminated coil component according to Appendix 7, wherein in the fourth step, the first lead conductor is determined as a member to be connected to at least one of the pair of second lead conductors, and at least one of the pair of second lead conductors is positioned to be connected to the determined first lead conductor. [Note 9] The number of upper wiring sections is two or more fewer than the number of lower wiring sections. A method for manufacturing a laminated coil component according to Appendix 7 or 8, wherein a body comprising the first body layer, the second body layer, the third body layer, and the fourth body layer is provided with a coil conductor including a part of the plurality of lower wiring portions in the first body layer, a pair of part of the pillar portions composed of the pillar conductors in the second body layer, a part or all of the plurality of upper wiring portions in the third body layer and the pair of first lead conductors, and the pair of second lead conductors in the fourth body layer, and a non-coil conductor including the lower wiring portions and the pair of pillar portions that do not constitute the coil conductor. [Note 10] The number of upper wiring sections is one less than the number of lower wiring sections. A method for manufacturing a laminated coil component according to Appendix 7 or 8, wherein a coil conductor is provided within a body comprising the first body layer, the second body layer, the third body layer, and the fourth body layer, the coil conductor comprising all of the plurality of lower wiring portions in the first body layer, all pairs of pillar portions composed of the pillar conductors in the second body layer, all of the plurality of upper wiring portions in the third body layer and the pair of first lead conductors, and the coil conductor comprising the pair of second lead conductors in the fourth body layer. [Explanation of Symbols]

[0064] 1...Laminated coil component, 2...Base body, 3, 4...Bottom electrodes, 5...Coil conductor, 6...Second wiring section, 7...First wiring section, 8...Pillar section, 9...Non-coil conductor, 21~29...Base layer, D1...First direction, D2...Second direction, D3...Third direction.

Claims

1. A base body composed of multiple stacked insulating layers, having a mounting surface intersecting the stacking direction, a pair of end faces facing each other in a first direction parallel to the mounting surface, and a pair of side faces facing each other in a second direction perpendicular to the stacking direction and the first direction, A coil conductor is provided within the aforementioned body, having a coil axis aligned with the second direction, and with both ends extended out toward the mounting surface. A pair of terminal electrodes are provided on the mounting surface of the base body and are connected to both ends of the coil conductor, respectively. Equipped with, The aforementioned base body is At least one first wiring section extending parallel to the mounting surface, A plurality of second wiring sections are provided, which extend parallel to the mounting surface and along the first direction, and are arranged in parallel along the second direction, on the side of the first wiring section that is further from the mounting surface, Multiple pairs of pillar portions extending from each of the multiple second wiring portions toward the mounting surface along the stacking direction, A pair of lead conductors that extend from two of the plurality of pillar portions to the mounting surface and are connected to the pair of terminal electrodes respectively constitute both ends of the coil conductor. Includes, The coil conductor includes part or all of the plurality of first wiring sections, part of the plurality of second wiring sections, a pair of part of the plurality of pairs of pillar sections, and the pair of lead conductors. A laminated coil component in which a non-coil conductor, including a pair of the second wiring portion and the pillar portion that do not constitute the coil conductor, is provided within the main body.

2. The laminated coil component according to claim 1, wherein the second wiring portion included in the non-coil conductor is located outside the plurality of second wiring portions included in the coil conductor.

3. The laminated coil component according to claim 1, wherein the second wiring portion included in the non-coil conductor is located inside a plurality of the second wiring portions included in the coil conductor.

4. The laminated coil component according to claim 1, wherein the number of the plurality of first wiring sections is two or more less than the number of the plurality of second wiring sections.

5. The laminated coil component according to claim 1 or 2, wherein the coil conductor and the non-coil conductor are electrically connected within the substrate.

6. The laminated coil component according to claim 1, wherein the coil conductor and the non-coil conductor are insulated within the substrate.

7. A first step of preparing a first elemental layer which includes a plurality of lower wiring sections that extend along a first direction within the layer and are arranged in parallel along a second direction perpendicular to the first direction within the layer, The second step involves stacking at least one second elemental layer on the first elemental layer, which includes pairs of pillar conductors provided at positions corresponding to both ends of each of the plurality of lower wiring sections. A third step of stacking a third element layer on the second element layer, the third element layer including at least one upper wiring portion connecting the pillar conductors of the second element layer and a pair of first lead conductors provided at positions corresponding to the pillar conductors, A fourth step involves stacking a fourth element layer containing a pair of second lead conductors on the third element layer, A fifth step is to provide a fifth element layer on the fourth element layer, on which a pair of terminal electrodes connected to the pair of second lead conductors is provided, and Includes, A method for manufacturing a laminated coil component, comprising: in the third step, determining from among the plurality of pillar conductors of the second base layer which pillar conductor is connected to the upper wiring section of the third base layer and which pillar conductor is connected to the pair of first lead conductors, and positioning the upper wiring section and the pair of first lead conductors so as to be connected to the determined pillar conductor; or, in the fourth step, determining from among the upper wiring section and the first lead conductors of the third base layer which member is connected to the pair of second lead conductors of the fourth base layer, and positioning the pair of second lead conductors so as to be connected to the determined member.

8. The method for manufacturing a laminated coil component according to claim 7, wherein in the fourth step, the first lead conductor is determined as a member to be connected to at least one of the pair of second lead conductors, and at least one of the pair of second lead conductors is positioned to be connected to the determined first lead conductor.

9. The number of upper wiring sections is two or more fewer than the number of lower wiring sections. A method for manufacturing a laminated coil component according to claim 7, wherein the component, which comprises the first component, the second component, the third component, and the fourth component, is provided with a coil conductor including a portion of the plurality of lower wiring portions in the first component, a pair of portions of the pillar portions composed of the pillar conductors in the second component, a portion or all of the at least one upper wiring portion in the third component and the pair of first lead conductors, and the pair of second lead conductors in the fourth component, and a non-coil conductor including the lower wiring portion and the pair of pillar portions that do not constitute the coil conductor.

10. The number of upper wiring sections is one less than the number of lower wiring sections. A method for manufacturing a laminated coil component according to claim 7, wherein a coil conductor is provided within a component comprising the first component layer, the second component layer, the third component layer, and the fourth component layer, the coil conductor comprising all of the plurality of lower wiring portions in the first component layer, all pairs of pillar portions composed of the pillar conductors in the second component layer, all of the at least one upper wiring portion and the pair of first lead conductors in the third component layer, and the pair of second lead conductors in the fourth component layer.

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