Magnetically coupled coil component and method for manufacturing the same
The magnetically coupled coil component achieves precise conductor positioning through a base body design with a smaller first base portion, reducing DC resistance and enhancing insulation, addressing the issue of conductor protrusion and characteristic degradation.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TAIYO YUDEN KK
- Filing Date
- 2024-11-29
- Publication Date
- 2026-06-10
AI Technical Summary
The positioning of coil conductors in magnetically coupled coil components is not precise, leading to protrusion of conductor ends from external electrodes, which increases DC resistance and degrades characteristics.
A magnetically coupled coil component design with a base body having a first and second base portion, where the first coil conductor is covered by a smaller first base portion with a protruding portion between lead portions of the second coil conductor, ensuring accurate positioning and preventing protrusion from external electrodes.
The coil conductors are precisely positioned, reducing DC resistance and allowing for increased insulation between electrodes, while enabling larger external electrode areas without protrusion, thus improving the component's performance and reducing height.
Smart Images
Figure 2026094899000001_ABST
Abstract
Description
Technical Field
[0001] The disclosure in this specification mainly relates to a magnetically coupled coil component and a method for manufacturing the magnetically coupled coil component.
Background Art
[0002] A magnetically coupled coil component has two or more coil elements that are magnetically coupled to each other. The magnetically coupled coil component is used, for example, as a common mode choke coil, a transformer, or a coupled inductor. In a magnetically coupled coil component, as described in Japanese Patent Application Laid-Open No. 2016-131208, a plurality of coil conductors may be arranged in the longitudinal direction along the coil axis.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] A magnetically coupled coil component has four external electrodes connected to each end of two coil conductors. These four external electrodes may be provided on the mounting surface of the substrate. When the external electrodes are provided on the mounting surface of the substrate, each coil conductor is configured and arranged such that both ends are exposed from the mounting surface of the substrate. And each coil conductor is connected to the corresponding external electrode at both ends exposed from the mounting surface of the substrate.
[0005] When four external electrodes are provided on the mounting surface of the substrate, the area of each external electrode must be small enough to ensure insulation between adjacent external electrodes. Therefore, if the positioning of the coil conductor within the substrate is not precise, the ends of the coil conductor may protrude from the external electrodes. This protrusion of the coil conductor ends can lead to an increase in DC resistance (Rdc) and other characteristic degradation.
[0006] The object of the inventions disclosed herein is to solve or alleviate at least some of the problems described above. One specific object of the present invention is to provide a magnetically coupled coil component that can accurately position two coil conductors within a substrate. The various inventions disclosed herein may be collectively referred to as the “present invention.”
[0007] Any other object of the present invention will be made clear throughout the specification. The invention described in the claims may solve problems other than those identified in the "problems to be solved by the invention." [Means for solving the problem]
[0008] A magnetically coupled coil component according to one aspect of the present invention comprises a base body, a first coil conductor provided within the base body, a second coil conductor provided within the base body, and a first external electrode, a second external electrode, a third external electrode, and a fourth external electrode provided on the first surface of the base body. The base body has a first surface and a second surface facing the first surface in a first direction. The first coil conductor has a first circumferential portion extending in the circumferential direction around the coil axis, a first lead portion extending along the first direction from one end of the first circumferential portion to the first surface of the base body, and a second lead portion extending along the first direction from the other end of the first circumferential portion to the first surface of the base body. The first circumferential portion is provided within the base body so as to face the first surface. The second coil conductor has a second circumferential portion extending in the circumferential direction around the coil axis, a third lead portion extending in a first direction from one end of the second circumferential portion to the first surface of the base body, and a fourth lead portion extending in a first direction from the other end of the second circumferential portion to the first surface of the base body. The second circumferential portion is provided between the first circumferential portion and the second surface of the base body. The first external electrode is connected to one end of the first lead portion. The second external electrode is provided on the first surface of the base body, spaced apart from the first external electrode in a second direction perpendicular to the first direction, and connected to one end of the second lead portion. The third external electrode is provided on the first surface of the base body and connected to one end of the third lead portion. The fourth external electrode is provided on the first surface of the base body, spaced apart from the fourth external electrode in a second direction, and connected to one end of the fourth lead portion. The base body has a first base body portion and a second base body portion. The first base portion has a main body portion that covers the first coil conductor and a protruding portion that extends between the third lead portion and the fourth lead portion. The second base portion covers the second coil conductor. The dimensions of the first base portion are smaller than the dimensions of the second base portion in the second direction and in the third direction which is perpendicular to both the first and second directions. [Effects of the Invention]
[0009] According to one aspect of the present invention, in a magnetically coupled coil component, two coil conductors can be precisely positioned within a base body. [Brief explanation of the drawing]
[0010] [Figure 1]This is a schematic perspective view showing a magnetically coupled coil component according to one embodiment. [Figure 2] Figure 1 is a transmission view of a magnetically coupled coil component seen through a frontal view. [Figure 3] Figure 1 is a schematic perspective view showing the first base portion of the magnetically coupled coil component. [Figure 4] Figure 3 is a transparent plan view of the first base portion. [Figure 5] Figure 1 is a transparent plan view of a magnetically coupled coil component. [Figure 6] This is a flowchart illustrating the manufacturing process of a magnetically coupled coil component according to one embodiment of the present invention. [Figure 7a] This is a schematic diagram illustrating the process of placing the first coil conductor into a molding die, which is part of the manufacturing method for coil components. [Figure 7b] This is a schematic diagram illustrating the process of forming the first base part in the manufacturing method of coil components. [Modes for carrying out the invention]
[0011] Various embodiments of the present invention will be described below with reference to the drawings as appropriate. Components common to multiple drawings are denoted by the same reference numerals throughout the drawings. Note that, for the sake of clarity, the drawings are not necessarily drawn to an exact scale. The embodiments described below do not necessarily limit the invention as defined in the claims. The elements described in the embodiments below are not necessarily essential to the solution of the invention.
[0012] The outline of the magnetic coupling coil component 1 according to the first embodiment will be described with reference to Figures 1 and 2. Figure 1 is a perspective view of the magnetic coupling coil component 1 according to one embodiment of the present invention, and Figure 2 is a transmission view of the magnetic coupling coil component seen through from the front.
[0013] The magnetically coupled coil component 1 can be used as a choke coil, transformer, coupled inductor, and various other magnetically coupled coil components.
[0014] The magnetically coupled coil component 1 comprises a plurality of coil conductors provided on a base body 10. In the illustrated example, the magnetically coupled coil component 1 comprises two coil conductors. More specifically, the magnetically coupled coil component 1 shown in Figure 1 comprises a base body 10, a first coil conductor 25 provided within the base body 10, and a second coil conductor 35 provided within the base body 10. The first coil conductor 25 is magnetically coupled to the second coil conductor 35. The magnetically coupled coil component 1 further comprises a first external electrode 21 connected to one end of the first coil conductor 25, a second external electrode 22 connected to the other end of the first coil conductor 25, a third external electrode 23 connected to one end of the second coil conductor 35, and a fourth external electrode 24 connected to the other end of the second coil conductor 35. The first external electrode 21 and the second external electrode 22 are provided on the base body 10 so as to be spaced apart from each other in the L-axis direction. The third external electrode 23 and the fourth external electrode 24 are provided on the base 10 so as to be spaced apart from each other in the L-axis direction. The first external electrode 21 and the third external electrode 23 are provided on the base 10 so as to be spaced apart from each other in the W-axis direction. The second external electrode 22 and the fourth external electrode 24 are provided on the base 10 so as to be spaced apart from each other in the W-axis direction.
[0015] The magnetically coupled coil component 1 is mounted on a circuit board via a first external electrode 21, a second external electrode 22, a third external electrode 23, and a fourth external electrode 24. The circuit board on which the magnetically coupled coil component 1 is mounted can be installed in various electronic devices. Electronic devices on which the circuit board can be installed include smartphones, tablets, game consoles, automotive electronics, servers, and various other electronic devices.
[0016] In one aspect, the base body 10 is formed in a rectangular parallelepiped shape from an insulating material. For example, the dimension (length dimension) of the coil component 1 in the L-axis direction is in the range of 0.5 mm to 6.0 mm, the dimension (width dimension) in the W-axis direction is in the range of 0.3 mm to 4.5 mm, and the dimension (height dimension) in the T-axis direction is in the range of 0.3 mm to 4.5 mm. In one aspect, the length dimension of the coil component 1 may be larger than the width dimension. In this specification, when referring to a "rectangular parallelepiped" or "rectangular parallelepiped shape", it does not mean only a "rectangular parallelepiped" in a strictly mathematical sense. As will be described later, the corners and / or sides of the base body 10 may be curved. The dimensions and shape of the base body 10 are not limited to those specified in this specification.
[0017] The base body 10 has a first main surface 10a, a second main surface 10b, a first end surface 10c, a second end surface 10d, a first side surface 10e, and a second side surface 10f. The first main surface 10a and the second main surface 10b respectively form the surfaces at both ends of the base body 10 in the height direction (T-axis direction), the first end surface 10c and the second end surface 10d respectively form the surfaces at both ends of the base body 10 in the length direction (L-axis direction), and the first side surface 10e and the second side surface 10f respectively form the surfaces at both ends of the base body 10 in the width direction (W-axis direction). The first main surface 10a and the second main surface 10b face each other in the T-axis direction. As shown in FIG. 1, since the first main surface 10a is on the upper side of the base body 10, the first main surface 10a may be referred to as the "upper surface". Similarly, the second main surface 10b may be referred to as the "lower surface" or "bottom surface".
[0018] In the illustrated embodiment, the first external electrode 21, the second external electrode 22, the third external electrode 23, and the fourth external electrode 24 are provided on the upper surface 10a of the base body 10. When mounting the magnetic coupling type coil component 1 on a circuit board, it is arranged such that the upper surface 10a faces the circuit board. For this reason, the upper surface 10a of the base body 10 may also be referred to as the "mounting surface". In one embodiment, the first external electrode 21, the second external electrode 22, the third external electrode 23, and the fourth external electrode 24 are all provided on the base body 10 so as to contact only the upper surface 10a. In another embodiment, at least one of the first external electrode 21, the second external electrode 22, the third external electrode 23, and the fourth external electrode 24 may extend to a surface other than the upper surface 10a of the base body 10. For example, the first external electrode 21 may extend so as to contact not only the upper surface 10a but also the second side surface 10f.
[0019] There is a gap between the upper surface 10a and the lower surface 10b by the height dimension of the base body 10, there is a gap between the first end surface 10c and the second end surface 10d by the length dimension of the base body 10, and there is a gap between the first side surface 10e and the second side surface 10f by the width dimension of the base body 10. In this specification, unless otherwise understood from the context, the "length" direction, "width" direction, and "thickness" (or "height") direction of the magnetic coupling type coil component 1 are the L-axis direction, W-axis direction, and T-axis direction in FIG. 1, respectively.
[0020] The base body 10 is made of an insulating material with excellent insulation properties. The base body 10 may be made of a magnetic material. As the magnetic material for the base body 10, a soft magnetic alloy material, a composite magnetic material in which magnetic particles are dispersed in a resin, a ferrite material, or any other known magnetic material can be used.
[0021] The base body 10 has a first base portion 11 and a second base portion 12. Details of the first base portion 11 and the second base portion 12 will be described later.
[0022] In the illustrated embodiment, the first coil conductor 25 and the second coil conductor 35 are arranged along the coil axis Ax1. The coil axis Ax1 is a hypothetical axis extending along the T-axis. Since a portion of the insulating substrate 10 is interposed between the first coil conductor 25 and the second coil conductor 35, the first coil conductor 25 and the second coil conductor 35 are electrically insulated within the substrate 10.
[0023] The first coil conductor 25 has a first circumferential portion 25a, a first lead-out portion 25b connecting one end of the first circumferential portion 25a to the first external electrode 21, and a second lead-out portion 25c connecting the other end of the first circumferential portion 25a to the second external electrode 22.
[0024] The first circumferential portion 25a extends circumferentially around the coil axis Ax, which extends along the T-axis. The first circumferential portion 25a is provided within the base body 10 so as to face the upper surface 10a of the base body 10.
[0025] The first lead-out portion 25b extends from one end of the first circumferential portion 25a along the T-axis to the upper surface 10a of the base body 10. One end of the first lead-out portion 25b is exposed to the outside of the base body 10 from the upper surface 10a of the base body 10. The first lead-out portion 25b is connected to the first external electrode 21 at the exposed surface exposed from the upper surface 10a.
[0026] The second lead portion 25c extends from the other end of the first circumferential portion 25a along the T-axis to the upper surface 10a of the base body 10. The other end of the first circumferential portion 25a to which the second lead portion 25c is connected is spaced apart in the L-axis direction from one end of the first circumferential portion 25a to which the first lead portion 25b is connected. Therefore, the second lead portion 25c is also spaced apart from the first lead portion 25b in the L-axis direction. One end of the second lead portion 25c is exposed to the outside of the base body 10 from the upper surface 10a of the base body 10. The second lead portion 25c is connected to the second external electrode 22 at the exposed surface exposed from the upper surface 10a.
[0027] The second coil conductor 35 has a second circumferential portion 35a, a third lead portion 35b connecting one end of the second circumferential portion 35a to the third external electrode 23, and a fourth lead portion 35c connecting the other end of the second circumferential portion 35a to the fourth external electrode 24.
[0028] The second circumferential portion 35a extends in the circumferential direction around the coil axis Ax1. The second circumferential portion 35a is positioned between the first circumferential portion 25a and the lower surface 10b of the base body 10. The second circumferential portion 35a faces the lower surface 10a of the base body 10.
[0029] The third lead-out portion 35b extends from one end of the second circumferential portion 35a along the T-axis to the upper surface 10a of the base body 10. One end of the third lead-out portion 35b is exposed to the outside of the base body 10 from the upper surface 10a of the base body 10. The exposed surface of the third lead-out portion 35b that is exposed from the upper surface 10a is connected to the third external electrode 23.
[0030] The fourth lead-out portion 35c extends from the other end of the second circumferential portion 35a along the T-axis to the upper surface 10a of the base body 10. The other end of the second circumferential portion 35a to which the fourth lead-out portion 35c is connected is spaced apart in the L-axis direction from one end of the second circumferential portion 35a to which the third lead-out portion 35b is connected. Therefore, the fourth lead-out portion 35c is also spaced apart from the third lead-out portion 35b in the L-axis direction. One end of the fourth lead-out portion 35c is exposed to the outside of the base body 10 from the upper surface 10a of the base body 10. The fourth lead-out portion 35c is connected to the fourth external electrode 24 at the exposed surface exposed from the upper surface 10a.
[0031] The first coil conductor 25 and the second coil conductor 35 are made of a metallic material with excellent conductivity. For example, Ag or Cu can be used as the metallic material for the first coil conductor 25 and the second coil conductor 35. For example, the first coil conductor 25 and the second coil conductor 35 can be manufactured from a metal strip or wire using a winding machine. The surfaces of the first coil conductor 25 and the second coil conductor 35 may be covered with an insulating coating (not shown) made of an insulating material with excellent insulating properties. The insulating coating may be an oxide film formed on the surfaces of the first coil conductor 25 and the second coil conductor 35 during the heat treatment in the manufacturing process of the coil component 1. The insulating coating may be a coating film made of a resin with excellent insulating properties such as polyurethane, polyamide-imide, polyimide, polyester, or polyester-imide.
[0032] The first coil conductor 25 is covered by the first base portion 11 of the base body 10. The second coil conductor 35 is covered by the second base portion 12 of the base body 10. The first base portion 11 is configured such that its dimensions in the L-axis direction and the W-axis direction are smaller than those of the second base portion 12 in the L-axis direction and the W-axis direction.
[0033] In the illustrated embodiment, the second base portion 12 defines a part of the upper surface of the base 10 and has a recess that extends inward from the upper surface of the base 10 towards the interior of the base 10, and the first base portion 11 is housed in this recess. Therefore, the upper surface 10a of the base 10 is defined by the upper surface of the first base portion 11 and the upper surface of the second base portion 12.
[0034] The first base portion 11 will be further described with reference to Figures 3 and 4. As shown in Figures 3 and 4, the first base portion 11 has a main body portion 11a and a protruding portion 11b. The first coil conductor 25 is covered by the main body portion 11a. The protruding portion 11b protrudes from the main body portion 11a toward the negative side in the W-axis direction. With respect to the coil axis Ax1, the protruding portion 11b protrudes from the main body portion 11a toward the radially outward direction centered on the coil axis Ax1. Focusing on its relationship with the second coil conductor 35, the protruding portion 11b protrudes from the main body portion 11a so as to be interposed between the third lead portion 35b and the fourth lead portion 35c of the second coil conductor 35 in the L-axis direction.
[0035] As shown in Figure 4, the dimension D1 of the protrusion 11b in the L-axis direction may be equal to the distance D2 between the first lead portion 25b and the second lead portion 25c of the first coil conductor 25 in the L-axis direction.
[0036] In one embodiment, the protrusion 11b is configured and positioned to overlap with a portion of the third external electrode 23 and a portion of the fourth external electrode 24 when viewed from the T-axis direction (see Figure 5).
[0037] The main body portion 11a has a curved portion 11a1. When viewed from the T-axis direction, the curved portion 11a1 has an outer surface that extends in the circumferential direction around the coil axis Ax1.
[0038] Next, with further reference to Figure 5, the arrangement of the second coil conductor 35 in the base 10 will be described further. In one embodiment, both the third lead portion 35b and the fourth lead portion 35c of the second coil conductor 35 are configured and arranged to extend in the T-axis direction along the side surface of the projection 11b. The second coil conductor 35 is arranged in the base 10 such that at least one of the third lead portion 35b and the fourth lead portion 35c is in contact with the projection 11b. In the embodiment shown in Figure 5, the second coil conductor 35 is arranged in the base 10 such that the third lead portion 35b is in contact with the projection 11b while the fourth lead portion 35c is spaced away from the projection 11b. Both the third lead portion 35b and the fourth lead portion 35c may be in contact with the projection 11b.
[0039] In the embodiment shown in Figure 5, the protrusion 11b overlaps with the third external electrode 23 by a first overlap width L5 and with the fourth external electrode 24 by a second overlap width L6 in the L-axis direction. In one embodiment, the sum of the width L3 and the first overlap width L5 of the third lead-out portion 35b in the L-axis direction (L3+L5) is smaller than the width L1 of the third external electrode 23 in the second direction. The fourth lead-out portion 35c is spaced a first distance L7 from the protrusion 11b in the L-axis direction. The sum of the width L4, the second overlap width L6, and the first distance L7 of the fourth lead-out portion 35c in the L-axis direction (L4+L6+L7) is smaller than the width L2 of the fourth external electrode 24 in the L-axis direction.
[0040] In one embodiment, the second coil conductor 35 is positioned such that at least one of the third lead portion 35b and the fourth lead portion 35c is in contact with the curved portion 11a1 of the first base portion 11. In the embodiment shown in Figure 5, the fourth lead portion 35c is in contact with the curved portion 11a1. In one embodiment, when the third lead portion 35b is in contact with the protruding portion 11b, the fourth lead portion 35c is in contact with the curved portion 11a1. In another embodiment, the fourth lead portion 35c is in contact with the protruding portion 11b and the third lead portion 35b is in contact with the curved portion 11a1. When the second coil conductor 35 is positioned in the base portion 10 in a position slightly rotated clockwise around the coil axis Ax1 than the position shown in Figure 5, the fourth lead portion 35c is in contact with the protruding portion 11b and the third lead portion 35b is in contact with the curved portion 11a1.
[0041] As described above, in the magnetically coupled coil component 1, the first base portion 11 covering the first coil conductor 25 has a protruding portion 11b that protrudes between the third lead portion 35b and the fourth lead portion 35c of the second coil conductor 35. The interposition of the protruding portion 11b between the third lead portion 35b and the fourth lead portion 35c, which are spaced apart from each other in the L-axis direction, suppresses displacement of the installation position caused by the second coil conductor 35 rotating in the circumferential direction around the coil axis Ax1 or moving in the second direction from a predetermined installation position. Therefore, in the magnetically coupled coil component 1, the second coil conductor 35 can be accurately positioned within the base portion 10.
[0042] Furthermore, in the magnetically coupled coil component 1, the first coil conductor 25 is positioned within the first base portion 11, which has smaller dimensions in the L-axis and W-axis directions than the second base portion 12. Therefore, the gap between the first coil conductor 25 and the outer surface of the first base portion 11 is small. Thus, as long as the first coil conductor 25 is positioned within the first base portion 11, the deviation of the first coil conductor 25 from its predetermined installation position will not be large. In this way, by positioning the first coil conductor 25 within the first base portion 11, which is smaller than the second base portion 12, the first coil conductor 25 can be accurately positioned within the base 10.
[0043] As described above, with the magnetically coupled coil component 1, the first coil conductor 25 and the second coil conductor 35 can be precisely positioned within the base body 10, so that the first lead-out portion 25b, the second lead-out portion 25c, the third lead-out portion 35b, and the fourth lead-out portion 35c can be led to a position where they do not protrude from the corresponding first external electrode 21, the second external electrode 22, the third external electrode 23, and the fourth external electrode 24.
[0044] If the positioning accuracy of the first coil conductor 25 and the second coil conductor 35 is low, the widths of the first coil conductor 25 and the second coil conductor 35 need to be reduced in order to prevent each lead-out portion from protruding from the corresponding external electrode. In the magnetically coupled coil component 1 according to one embodiment of the present invention, the first coil conductor 25 and the second coil conductor 35 can be accurately positioned within the base body 10, so the widths of the first coil conductor 25 and the second coil conductor 35 (meaning the widths in the L-axis direction at the end faces exposed from the upper surface 10a of the base body 10, for example, widths L3 and L4) can be increased, and the DC resistance (Rdc) can be reduced.
[0045] Furthermore, in the magnetically coupled coil component 1, it is not necessary to increase the thickness (thickness in the T-axis direction) of the first coil conductor 25 and the second coil conductor 35 in order to ensure DC resistance. Therefore, according to one embodiment of the present invention, it is possible to reduce the height of the magnetically coupled coil component 1.
[0046] Furthermore, since the first coil conductor 25 and the second coil conductor 35 can be precisely positioned within the base body 10, even if the area of the first external electrode 21, second external electrode 22, third external electrode 23, and fourth external electrode 24 on the upper surface 10a of the base body 10 is reduced, the first lead-out section 25b, second lead-out section 25c, third lead-out section 35b, and fourth lead-out section 35c can be connected to the corresponding first external electrode 21, second external electrode 22, third external electrode 23, and fourth external electrode 24, respectively. As a result, the distance between the first external electrode 21, second external electrode 22, third external electrode 23, and fourth external electrode 24 on the upper surface 10a of the base body 10 can be increased, thereby improving the insulation between each external electrode.
[0047] In one embodiment of the present invention, the second coil conductor 35 can be positioned within the base 10 such that at least one of the third lead portion 35b and the fourth lead portion 35c is in contact with the curved portion 11a1 of the first base portion 11. Since the curved portion 11a1 restricts the radial inward movement of the second coil conductor 35 about the coil axis Ax1, positioning the second coil conductor 35 within the base 10 can be further improved by positioning the second coil conductor 35 such that at least one of the third lead portion 35b and the fourth lead portion 35c is in contact with the curved portion 11a1 of the first base portion 11.
[0048] According to one embodiment of the present invention, when viewed from the T-axis direction, the protruding portion 11b is positioned to overlap with a part of the third external electrode 23 and a part of the fourth external electrode 24. Therefore, the protruding portion 11b prevents the third lead-out portion 35b and the fourth lead-out portion 35c from protruding into the area between the third external electrode 23 and the fourth external electrode 24.
[0049] In one embodiment of the present invention, the protruding portion 11b overlaps with the third external electrode 23 by a first overlap width L5 in the L-axis direction and with the fourth external electrode 24 by a second overlap width L6. In one embodiment of the present invention, the sum of the width L3 and the first overlap width L5 of the third lead-out portion 35b in the L-axis direction (L3 + L5) is smaller than the width L1 of the third external electrode 23 in the second direction, so that the third lead-out portion 35b does not protrude from the third external electrode 23 on the opposite side of the protruding portion 11b in the L-axis direction. In one embodiment of the present invention, the fourth lead portion 35c is spaced a first distance L7 from the protruding portion 11b in the L-axis direction, and the sum of the width L4 of the fourth lead portion 35c in the L-axis direction, the second overlapping width L6, and the first distance L7 (L4 + L6 + L7) is smaller than the width L2 of the fourth external electrode 24 in the L-axis direction. Therefore, it is possible to prevent the fourth lead portion 35c from protruding from the fourth external electrode 24 on the opposite side of the protruding portion 11b in the L-axis direction.
[0050] According to one embodiment of the present invention, the dimension D1 of the protruding portion 11b in the L-axis direction can be made equal to the distance D2 between the first extension portion 25b and the second extension portion 25c. Since the third extension portion 35b extends along one end face of the protruding portion 11b in the L-axis direction, and the fourth extension portion 35c extends along the other end face of the protruding portion 11b in the L-axis direction, the dimension D1 is approximately equal to the distance between the third extension portion 35b and the fourth extension portion 35c in the L-axis direction. Therefore, according to one embodiment of the present invention, the distance between the third extension portion 35b and the fourth extension portion 35c in the L-axis direction can be made equal to the distance between the first extension portion 25b and the second extension portion 25c.
[0051] Next, an example of a method for manufacturing the magnetically coupled coil component 1 will be described following the flowchart in Figure 6. First, in step S1, the first coil conductor 25 is prepared. As described above, the first coil conductor 25 has a first circumferential portion 25a extending in the circumferential direction around the coil axis, a first lead portion 25b extending from one end of the first circumferential portion 25a in a direction parallel to the coil axis, and a second lead portion 25c extending from the other end of the first circumferential portion 25a in a direction parallel to the coil axis. The first coil conductor 25 can be made from a strip or wire made of conductive material using a commercially available spindle winding machine, a commercially available flyer winding machine, or any other known winding machine. The method for making the first coil conductor 25 is obvious to those skilled in the art, so a detailed explanation will be omitted.
[0052] Next, in step S2, primary molding is performed to form the first base portion 11. The first base portion 11 is formed, for example, by insert molding. When the first base portion 11 is formed by insert molding, as shown in Figure 7a, a first mold 50 provided with a cavity 51 is prepared, and the first coil conductor 25 prepared in step S1 is set in this cavity 51. Next, as shown in Figure 7b, a mixed composition containing a magnetic material and a resin is filled into the cavity 51. The mixed composition filled into the cavity 51 is, for example, a resin composition containing magnetic powder of a soft magnetic metal and a resin. The composition filled into this cavity 51 is pressed with a punch, and the mixed composition in the cavity 51 is heated at a molding temperature above the curing temperature of the resin contained in the mixed composition in the cavity 51, thereby forming the first base portion 11 with the first coil conductor 25 embedded inside. The first base portion 11 is removed from the first mold 50 for subsequent processes.
[0053] The first base portion 11 formed in this manner has a main body portion 11a and a protruding portion 11b, as described above. The first coil conductor 25 is covered by the main body portion 11a. The protruding portion 11b is formed to project radially outward from the main body portion 11a, centered on the coil axis Ax1, on the opposite side from the first lead portion 25b and the second lead portion 25c. Since the cavity 51 of the first mold 50 used in step S2 is formed to be slightly larger than the first coil conductor 25, the first coil conductor 25 can be accurately positioned within the first base portion 11.
[0054] Next, in step S3, the second coil conductor 35 is prepared. As described above, the second coil conductor 35 has a second circumferential portion 35a extending in the circumferential direction around the coil axis, a third lead portion 35b extending from one end of the second circumferential portion 35a in a direction parallel to the coil axis, and a fourth lead portion 35c extending from the other end of the second circumferential portion 35a in a direction parallel to the coil axis. The second coil conductor 35 can be made using a known winding machine, similar to the first coil conductor 25.
[0055] Next, in step S4, secondary molding is performed to form the second base portion 12. In secondary molding, a second mold (not shown) different from the first mold 50 used in primary molding is prepared. The second mold has a cavity formed in which the first base portion 11 and the second coil conductor 35 are installed. In step S4, the first base portion 11 and the second coil conductor 35 are placed on top of each other in the cavity of the second mold such that the coil axis of the second coil conductor 35 is parallel to the coil axis of the first coil conductor 25 embedded in the first base portion 11, and the protruding portion 11b of the first base portion 11 is interposed between the third lead portion 35b and the fourth lead portion 35c. Then, a mixed composition containing a magnetic material and a resin is filled into the cavity of the second mold in which the first base portion 11 and the second coil conductor 35 are installed. In secondary molding, the mixed composition filled into the cavity of the second mold may be the same as or different from the mixed composition filled into the cavity 51 of the first mold 50 in primary molding. Next, the composition filled into the cavity of the second mold is pressed together with the first base portion 11 and the second coil conductor 35 using a punch. Next, the composition in the cavity is heated at a molding temperature higher than the curing temperature of the resin contained in the composition in the cavity, thereby forming a composite molded body in which the first base portion 11 and the second base portion 12 are combined. If the magnetic material contains epoxy resin, the molding temperature can be set to approximately 150°C. In this way, in step S4, a composite molded body in which the first base portion 11 and the second base portion 12 are combined is obtained.
[0056] Next, the composite molded body formed as described above is removed from the second mold, and one side of the composite molded body removed from the second mold is ground with a cutting blade or laser to expose the end faces of the first pull-out portion 25b, the second pull-out portion 25c, the third pull-out portion 35b, and the fourth pull-out portion 35c. This grinding yields a base body 10 having the first base body portion 11 and the second base body portion 12.
[0057] Next, a conductive paste is applied to cover the exposed surfaces of the first, second, third, and fourth lead portions 25b, 25c, 35b, and 4th lead portions 35c, which are exposed from one surface (upper surface 10a) of the substrate 10, thereby forming the first external electrode 21, second external electrode 22, third external electrode 23, and fourth external electrode 24. This conductive paste contains a conductive material with excellent conductivity, such as Ag, Pd, Cu, Al, Ni, or alloys thereof. A plating layer may be formed on the surface of the first external electrode 21 and the second external electrode 22. There may be two or more plating layers. The two plating layers may include a Ni plating layer and a Sn plating layer provided outside the Ni plating layer.
[0058] As described above, the magnetically coupled coil component 1 is manufactured.
[0059] According to the above manufacturing method, the first base portion 11 is manufactured using a first mold 50 having a cavity 51 that is slightly larger than the first coil conductor 25, so that the displacement of the first coil conductor 25 from a predetermined installation position within the first base portion 11 can be reduced.
[0060] Furthermore, according to the above manufacturing method, in secondary molding, the first base portion 11 and the second coil conductor 35 are stacked and installed in the cavity of the second mold such that the protruding portion 11b of the first base portion 11 is interposed between the third draw-out portion 35b and the fourth draw-out portion 35c, and the second base portion 12 is manufactured by filling the cavity with magnetic material. Therefore, in the secondary molding process, the movement of the second coil conductor 35 (especially rotational movement around the coil axis) is restricted by the protruding portion 11b. Thus, the deviation of the second coil conductor 35 from its predetermined installation position within the second base portion 12 can be reduced.
[0061] As described above, according to the above manufacturing method, a magnetically coupled coil component 1 can be manufactured in which the first coil conductor 25 and the second coil conductor 35 are precisely positioned within the base body 10.
[0062] Some of the steps included in the manufacturing method described herein may be omitted as appropriate. In the manufacturing method of coil component 1, steps not explicitly described herein may be performed as necessary. Some of the steps included in the above manufacturing method of coil component 1 may be performed in any order, as long as they do not depart from the spirit of the present invention. Some of the steps included in the above manufacturing method of coil component 1 may be performed simultaneously or in parallel, if possible.
[0063] The dimensions, materials, and arrangements of each component described in the various embodiments described above are not limited to those explicitly described in each embodiment, and each component can be modified to have any dimensions, materials, and arrangements that fall within the scope of the present invention.
[0064] Components not explicitly described herein may be added to each of the embodiments described above, and some of the components described in each embodiment may be omitted.
[0065] In this specification, notations such as "Part 1," "Part 2," and "Part 3" are used to identify components and do not necessarily limit their number, order, or content. Furthermore, the numbers used to identify components are used on a context-by-context basis, and a number used in one context does not necessarily indicate the same component in another context. Moreover, this does not prevent a component identified by one number from also performing the function of a component identified by another number.
[0066] This specification also discloses the following technologies: [Note 1] A substrate (10) having a first surface (10a) and a second surface (10b) facing the first surface in a first direction (T-axis), A first coil conductor (25) provided within the base body, having a first circumferential portion (25a) provided facing the first surface and extending in the circumferential direction around the coil axis (Ax1), a first lead portion (25b) extending along the first direction from one end of the first circumferential portion to the first surface of the base body, and a second lead portion (25c) extending along the first direction from the other end of the first circumferential portion to the first surface of the base body, A second coil conductor (35) provided within the base body, having a second circumferential portion (35a) provided between the first circumferential portion and the second surface of the base body and extending in the circumferential direction around the coil axis, a third lead portion (35b) extending in the first direction from one end of the second circumferential portion to the first surface of the base body, and a fourth lead portion (35c) extending in the first direction from the other end of the second circumferential portion to the first surface of the base body, A first external electrode (21) is provided on the first surface of the substrate and connected to one end of the first lead-out portion, A second external electrode (22) is provided on the first surface of the substrate, spaced apart from the first external electrode in a second direction (L-axis) perpendicular to the first direction, and connected to one end of the second lead-out portion. A third external electrode (23) is provided on the first surface of the substrate and connected to one end of the third lead-out portion, A fourth external electrode (24) is provided on the first surface of the substrate, spaced apart from the third external electrode in the second direction, and connected to one end of the fourth lead-out portion. Equipped with, The base body comprises a first base body portion (11) having a main body portion (11a) that covers the first coil conductor and a protruding portion (11b) that protrudes between the third lead portion and the fourth lead portion, and a second base body portion (12) that covers the second coil conductor. The dimensions of the first base portion are smaller than the dimensions of the second base portion in the second direction (L-axis) and in the third direction (W-axis) which is perpendicular to both the first and second directions. Magnetic coupling coil component (1). [Note 2] The main body portion of the first base portion covers the first circumferential portion and has a curved portion (11a1) having an outer surface that extends in the circumferential direction when viewed from the first direction. At least one of the third and fourth extensions is in contact with the curved portion. Magnetic coupling coil component as described in Appendix 1. [Note 3] The protruding portion is in contact with at least one of the third and fourth drawer portions. Magnetic coupling coil components as described in Appendix 1 or Appendix 2. [Note 4] When viewed from the first direction, the protruding portion overlaps with a part of the third external electrode and a part of the fourth external electrode. A magnetically coupled coil component as described in any one of the items from Appendix 1 to Appendix 3. [Note 5] The third pull-out portion is in contact with the protruding portion, When viewed from the first direction, the protruding portion overlaps with the third external electrode by a first overlap width (L5) in the second direction. The sum of the width (L3) of the third lead-out portion in the second direction and the first overlapping width (L3 + L5) is smaller than the width (L1) of the third external electrode in the second direction. A magnetically coupled coil component as described in any one of the items from Appendix 1 to Appendix 4. [Note 6] When viewed from the first direction, the protruding portion overlaps with the fourth external electrode by a second overlap width (L6) in the second direction, and is spaced apart from the fourth lead-out portion by a first interval (L7). The sum of the width of the fourth extension in the second direction (L4), the second overlapping width, and the first interval (L4 + L6 + L7) is smaller than the width of the fourth external electrode in the second direction. A magnetically coupled coil component as described in any one of the items from Appendix 1 to Appendix 5. [Note 7] The dimension (D1) of the protrusion in the second direction is smaller than the distance (D2) between the first and second pull-out sections when viewed from the first direction. A magnetically coupled coil component as described in any one of the items from Appendix 1 to Appendix 6. [Note 8] The aforementioned protruding portion is in contact with the third and fourth pull-out portions. Magnetic coupling coil component as described in Appendix 7. [Note 9] Step (S1) of preparing a first coil conductor having a first circumferential portion extending around a first coil axis, a first lead portion extending from one end of the first circumferential portion along a first direction parallel to the first coil axis, and a second lead portion extending from the other end of the first circumferential portion, which is located spaced apart from the one end of the first circumferential portion in a second direction perpendicular to the first direction, Step (S2) of filling a first mold (50) on which the first coil conductor is installed with a first magnetic material to form a first base body having a main body that covers the first coil conductor and a protruding portion that protrudes from the main body in a third direction perpendicular to the first and second directions, Step (S3) of preparing a second coil conductor having a second circumferential portion extending around a second coil axis, a third lead portion extending from one end of the second circumferential portion in a direction parallel to the second coil axis, and a fourth lead portion extending from the other end of the second circumferential portion in a direction parallel to the second coil axis, Step (S4) of installing the first base portion and the second coil conductor in the second mold such that the second coil axis is parallel to the first direction and the protruding portion of the first base portion is interposed between the third and fourth draw-out portions, Step (S4) is to fill the second mold with the second magnetic material to form a composite molded body in which the first base part and the second base part are combined, Step (S5) of exposing the first pull-out portion, the second pull-out portion, the third pull-out portion, and the fourth pull-out portion from the first surface of the base body consisting of the first base body portion and the second base body portion, Step (S6) of forming on the first surface of the substrate a first external electrode covering the exposed surface of the first extraction portion, a second external electrode covering the exposed surface of the second extraction portion, a third external electrode covering the exposed surface of the third extraction portion, and a fourth external electrode covering the exposed surface of the fourth extraction portion. A method for manufacturing a magnetically coupled coil component. [Explanation of symbols]
[0067] 1. Magnetically coupled coil component 10 Base 11. First base section 11a Main body 11a1 Curved section 11b Projection 12 Second base section 21 1st external electrode 22 2nd external electrode 23 Third external electrode 24 4th external electrode 25 First coil conductor 25a First lap 25b 1st drawer 25c 2nd drawer 35. Second coil conductor 35a Second lap section 35b 3rd drawer 35c 4th drawer
Claims
1. A substrate having a first surface and a second surface facing the first surface in a first direction, A first coil conductor provided within the base body, having a first circumferential portion provided opposite the first surface and extending in the circumferential direction around the coil axis, a first lead portion extending in the first direction from one end of the first circumferential portion to the first surface of the base body, and a second lead portion extending in the first direction from the other end of the first circumferential portion to the first surface of the base body, A second coil conductor provided within the base body, comprising: a second circumferential portion provided between the first circumferential portion and the second surface of the base body and extending in the circumferential direction around the coil axis; a third lead portion extending along the first direction from one end of the second circumferential portion to the first surface of the base body; and a fourth lead portion extending along the first direction from the other end of the second circumferential portion to the first surface of the base body; A first external electrode is provided on the first surface of the substrate and connected to one end of the first lead-out portion, A second external electrode is provided on the first surface of the substrate, spaced apart from the first external electrode in a second direction perpendicular to the first direction, and connected to one end of the second lead-out portion. A third external electrode is provided on the first surface of the substrate and connected to one end of the third lead-out portion, A fourth external electrode is provided on the first surface of the substrate, spaced apart from the third external electrode in the second direction, and connected to one end of the fourth lead-out portion. Equipped with, The base body comprises a first base body portion having a main body portion that covers the first coil conductor and a protruding portion that extends between the third lead portion and the fourth lead portion, and a second base body portion that covers the second coil conductor. The dimensions of the first base portion are smaller than the dimensions of the second base portion in the second direction and in a third direction perpendicular to both the first and second directions. Magnetic coupling coil component.
2. The main body portion of the first base portion covers the first circumferential portion and has a curved portion having an outer surface that extends in the circumferential direction when viewed from the first direction. At least one of the third and fourth extensions is in contact with the curved portion. The magnetically coupled coil component according to claim 1.
3. The protruding portion is in contact with at least one of the third and fourth drawer portions. A magnetically coupled coil component according to claim 1 or 2.
4. When viewed from the first direction, the protruding portion overlaps with a part of the third external electrode and a part of the fourth external electrode. A magnetically coupled coil component according to claim 1 or 2.
5. The third pull-out portion is in contact with the protruding portion, When viewed from the first direction, the protruding portion overlaps with the third external electrode by a first overlap width in the second direction. The sum of the width of the third lead-out portion in the second direction and the first overlapping width is smaller than the width of the third external electrode in the second direction. A magnetically coupled coil component according to claim 1 or 2.
6. When viewed from the first direction, the protruding portion overlaps with the fourth external electrode by a second overlap width in the second direction and is spaced apart from the fourth lead-out portion by a first distance. The sum of the width of the fourth extension in the second direction, the second overlapping width, and the first interval is smaller than the width of the fourth external electrode in the second direction. A magnetically coupled coil component according to claim 1 or 2.
7. The dimensions of the protrusion in the second direction are smaller than the distance between the first and second pull-out sections when viewed from the first direction. A magnetically coupled coil component according to claim 1 or 2.
8. The aforementioned protruding portion is in contact with the third and fourth drawer portions. The magnetically coupled coil component according to claim 7.
9. A step of preparing a first coil conductor having a first circumferential portion extending around a first coil axis, a first lead portion extending from one end of the first circumferential portion along a first direction parallel to the first coil axis, and a second lead portion extending from the other end of the first circumferential portion, which is located at a position spaced apart from the one end of the first circumferential portion in a second direction perpendicular to the first direction, A step of filling a first mold in which the first coil conductor is installed with a first magnetic material to form a first base body having a main body that covers the first coil conductor and a protruding portion that protrudes from the main body in a third direction perpendicular to the first and second directions, A step of preparing a second coil conductor having a second circumferential portion extending around a second coil axis, a third lead portion extending from one end of the second circumferential portion in a direction parallel to the second coil axis, and a fourth lead portion extending from the other end of the second circumferential portion in a direction parallel to the second coil axis, A step of installing the first base portion and the second coil conductor in the second mold such that the second coil axis is parallel to the first direction and the protruding portion of the first base portion is interposed between the third and fourth draw-out portions, A step of forming a composite molded body in which the first base portion and the second base portion are combined by filling the second mold with the second magnetic material, A step of exposing the first pull-out portion, the second pull-out portion, the third pull-out portion, and the fourth pull-out portion from the first surface of the base body consisting of the first base body portion and the second base body portion, The process involves forming on the first surface of the substrate a first external electrode covering the exposed surface of the first lead portion, a second external electrode covering the exposed surface of the second lead portion, a third external electrode covering the exposed surface of the third lead portion, and a fourth external electrode covering the exposed surface of the fourth lead portion. A method for manufacturing a magnetically coupled coil component.