Inductor, individual inductor, and method for manufacturing the same

Abstract

This invention provides a segmented inductor that suppresses the decrease in inductance and enables miniaturization, a method for manufacturing the same, and an inductor used therein. [Solution] The inductor (1) comprises a magnetic layer (2) and a plurality of wirings (3) embedded in the magnetic layer (2) and extending in the longitudinal direction. The plurality of wirings (3) are arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction. The magnetic layer (2) includes a plurality of wiring arrangement portions (7) in which the wirings (3) are arranged in regular parallel arrangements, and margin portions (8) arranged between adjacent wiring arrangement portions (7) in the parallel direction of the wirings (3), where the wirings (3) are omitted.

Description

Technical Field

[0001] The present invention relates to an inductor, a fragmented inductor, and a method for manufacturing the same.

Background Art

[0002] An inductor including a magnetic layer and a plurality of wirings embedded in the magnetic layer is known (see, for example, Patent Document 1 below). In the inductor described in Patent Document 1, the plurality of wirings are arranged in parallel at equal intervals in the lateral direction. The magnetic layer contains magnetic particles.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Depending on the use and purpose, there may be cases where the magnetic layer between adjacent wirings is cut in the thickness direction to manufacture a fragmented inductor smaller in size than the inductor.

[0005] In the inductor described in Patent Document 1, when the distance between two adjacent wirings is short, if the magnetic layer between the two adjacent wirings is cut, the distance from one side end face of the magnetic layer in the fragmented inductor after cutting to the end wiring arranged at one end in the lateral direction becomes excessively short. Then, the amount of magnetic particles existing between one side end face and the end wiring in the magnetic layer becomes excessively small. Therefore, there is a problem that the inductance of the fragmented inductor decreases.

[0006] On the other hand, when the distance between two adjacent wirings is long, there is a problem that miniaturization of the fragmented inductor after cutting cannot be achieved.

[0007] This invention provides a segmented inductor that suppresses the decrease in inductance and achieves miniaturization, a method for manufacturing the same, and an inductor used therein. [Means for solving the problem]

[0008] The present invention (1) includes an inductor comprising a magnetic layer and a plurality of wirings embedded in the magnetic layer and extending in the longitudinal direction, wherein the plurality of wirings are arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction, and the magnetic layer includes a plurality of wiring arrangement portions in which the wirings are arranged in regular parallel arrangements and margin portions arranged between adjacent wiring arrangement portions in the parallel direction of the wirings, in which the wirings are omitted.

[0009] In this inductor, the wiring is omitted in the margin portion of the magnetic layer. Therefore, by cutting the margin portion along the longitudinal direction, sufficient distance can be secured between the cut end face of the magnetic layer and the wiring adjacent to the cut end face. As a result, the amount of magnetic component present between the cut end face and the wiring in the magnetic layer becomes sufficient. Consequently, the decrease in inductance of the individual inductors after cutting can be suppressed.

[0010] On the other hand, in the wiring arrangement section, the wiring is arranged in regular parallel lines. Therefore, the wiring can be arranged compactly in the individual inductor. As a result, the size of the individual inductor after cutting can be reduced.

[0011] Therefore, this inductor can suppress the decrease in inductance of the individual inductors after cutting, and can also be made smaller.

[0012] Furthermore, the present invention (2) includes the inductor described in (1), wherein the plurality of wires in the wiring arrangement portion are arranged in parallel at equal intervals.

[0013] In the wiring configuration of this inductor, multiple wires are arranged in parallel at equal intervals. Therefore, the wiring can be arranged more compactly within the wiring configuration. Furthermore, the inductance of each wire can be made equal. As a result, the individual inductors after cutting can be made even smaller while maintaining equal inductance for each wire.

[0014] Furthermore, the present invention (3) includes a method for manufacturing a slicing inductor, comprising a first step of preparing the inductor described in (1) or (2), and a second step of cutting the margin portion.

[0015] In the manufacturing method for individualized inductors, the margin portion is cut, ensuring sufficient distance between the cut end face of the magnetic layer and the wiring adjacent to that end face. As a result, the amount of magnetic component present between the cut end face and the wiring in the magnetic layer becomes sufficient. Consequently, the decrease in inductance of the individualized inductor after the second process can be suppressed.

[0016] On the other hand, in the wiring arrangement section, the wiring is arranged in regular parallel lines. Therefore, the wiring can be arranged compactly in the individualized inductor. As a result, the individualized inductor can be miniaturized after the second process.

[0017] Therefore, this method for manufacturing individual inductors suppresses the decrease in inductance and enables the production of miniaturized individual inductors.

[0018] The present invention (4) includes a magnetic layer and a plurality of wirings embedded in the magnetic layer and extending in the longitudinal direction, the plurality of wirings arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction, wherein the magnetic layer includes a wiring arrangement portion in which the wirings are regularly arranged in parallel, the wirings include end wirings arranged at one end of the wiring arrangement portion in the parallel direction of the wirings, and the distance from one side end face of the magnetic layer to the end wirings in the parallel direction is 0.2 mm or more and 7 mm or less, and includes a sectional inductor.

[0019] In this fragmented inductor, since the distance from one end face of the magnetic layer to the end wiring is 0.2 mm or more, the amount of magnetic components present between the cut end face and the end wiring in the magnetic layer is sufficient. As a result, a decrease in the inductance of the fragmented inductor can be suppressed.

[0020] Also, in this fragmented inductor, since the distance from one end face of the magnetic layer to the end wiring is 7 mm or less, miniaturization of the fragmented inductor can be achieved.

[0021] Therefore, this fragmented inductor can be miniaturized while suppressing a decrease in inductance.

[0022] The present invention (5) includes the fragmented inductor according to (4), in which an end face of the wiring in the longitudinal direction has an exposed portion exposed from the magnetic layer.

[0023] The present invention (6) includes the fragmented inductor according to (4) or (5), in which an end face of the wiring in the longitudinal direction has a covered portion covered by the magnetic layer.

[0024] The present invention (7) includes the fragmented inductor according to any one of (4) to (6), which has a rectangular shape including a curved corner portion in a plan view.

[0025] The present invention (8) is the fragmented inductor according to (7), in which the curve is a curved line having a curvature radius of 0.1 mm or more and 5 mm or less.

[0026] If the curvature radius of the curve is 0.1 mm or more as described above, the shock resistance of the inductor can be improved.

[0027] If the curvature radius of the curve is 5 mm or less as described above, the vicinity region of the corner portion can be widened, and a mark can be installed in the empty space.

Advantages of the Invention

[0028] The method for manufacturing individual inductors of the present invention, using the inductor of the present invention, can produce individual inductors that suppress the decrease in inductance and are miniaturized.

[0029] The individualized inductor of the present invention achieves suppression of inductance reduction and miniaturization. [Brief explanation of the drawing]

[0030] [Figure 1] Figures 1A and 1B are plan views of the inductor and individualized inductor of the present invention, respectively. Figure 1A is an inductor. Figure 1B is a plurality of individualized inductors. [Figure 2] Figures 2A and 2B are cross-sectional views corresponding to Figures 1A and 1B, respectively. Figure 2A is an inductor. Figure 2B is a multi-piece inductor. [Figure 3] Figures 3A and 3B are cross-sectional views of modified inductors and individualized inductors, respectively. Figure 3A is an inductor. Figure 3B is a plurality of individualized inductors. [Figure 4] Figures 4A and 4B are cross-sectional views of an inductor and a modified version of a segmented inductor, respectively. Figure 4A is an inductor. Figure 4B is a segmented inductor. [Figure 5] Figures 5A and 5B are plan views of modified inductors and individualized inductors, respectively. Figure 5A is an inductor. Figure 4B is a second individualized inductor. [Figure 6] Figure 6 is a front view of the end face of the segmented inductor in the longitudinal direction in a modified example. [Modes for carrying out the invention]

[0031] One embodiment of the inductor and individualized inductor of the present invention will be described with reference to Figures 1A to 2B.

[0032] <Inductor 1> As shown in Figures 1A and 2A, the inductor 1 extends in a planar direction perpendicular to the thickness direction. The thickness direction is the depth direction of the paper in Figure 1A. The thickness direction is the vertical direction in Figure 2A. The planar direction includes a first direction and a second direction perpendicular to the first direction. The first direction is the vertical direction in Figure 1A. The first direction is the depth direction of the paper in Figure 2A. The second direction is the left-right direction in Figures 1A and 2A, respectively. The inductor 1 is a sheet that is approximately rectangular in plan view. The inductor 1 comprises a magnetic layer 2 and a plurality of wirings 3.

[0033] <Magnetic layer 2> The magnetic layer 2 has the same external shape as the inductor 1. The magnetic layer 2 has two main surfaces 4 facing each other in the thickness direction, two first side end surfaces 20A, 20B (see Figure 1A) facing each other in the first direction, and two second side end surfaces 6 facing each other in the second direction, all connected to each other. The first side end surfaces 20A, 20B (see Figure 1A) are aligned with the second direction. The second side end surfaces 6 are aligned with the first direction. The two second side end surfaces 6 include a second one-side end surface 61 located on one side in the second direction and a second other-side end surface 62 located on the other side in the second direction. As the material for the magnetic layer 2, for example, a magnetic composition containing magnetic particles as a magnetic component can be mentioned. A magnetic composition is described, for example, in Japanese Patent Application Publication No. 2020-150057. The thickness of the magnetic layer 2 is, for example, 1 μm or more, and for example, 5000 μm or less. The thickness of the magnetic layer 2 is the distance between the two main surfaces 4. This magnetic layer 2 includes a wiring arrangement portion 7, a margin portion 8, and a second margin portion 9, which will be described later.

[0034] <Wiring 3> The wiring 3 extends along a first direction. The first direction corresponds to the longitudinal direction of the wiring 3. Multiple wirings 3 are arranged in parallel at predetermined intervals in a cross-section along the thickness direction and the second direction. The cross-sections along the thickness direction and the second direction are the cross-sections drawn in Figure 2A. Therefore, the second direction corresponds to the parallel direction in which the wirings 3 are arranged in parallel. The wiring 3 is embedded in the magnetic layer 2. The configuration and dimensions of each of the multiple wirings 3 are described, for example, in Japanese Patent Application Publication No. 2020-150057. The radius R of the wiring 3 is, for example, 25 μm or more and, for example, 2000 μm or less. Next, the wiring arrangement portion 7 and the margin portion 8 will be described.

[0035] <Wiring arrangement part 7> Multiple wiring arrangement sections 7 are included in the magnetic layer 2 (three in this embodiment). The multiple wiring arrangement sections 7 are spaced apart in a second direction. Each of the multiple wiring arrangement sections 7 is arranged across the inductor 1 in a first direction. Wires 3 are arranged regularly in parallel in the wiring arrangement sections 7. Specifically, multiple (three in this embodiment) wires 3 are arranged in parallel at equal intervals P0 in the wiring arrangement sections 7. The dimensions of the wires 3 and the spacing P0 between two adjacent wires 3 are not limited. They are described, for example, in Japanese Patent Application Publication No. 2020-150057.

[0036] Multiple wires 3 are arranged in the wiring arrangement section 7. The multiple wires 3 include a first end wire 31, a second end wire 32, and an intermediate wire 33. The first end wire 31 is arranged at one end of the wiring arrangement section 7 in the second direction. The second end wire 32 is arranged at the other end of the wiring arrangement section 7 in the second direction. The intermediate wire 33 is arranged between the first end wire 31 and the second end wire 32. Therefore, in the wiring arrangement section 7, the first end wire 31, the intermediate wire 33, and the second end wire 32 are arranged in order toward the other side in the second direction.

[0037] <Margin section 8> The margin portion 8 is positioned between adjacent wiring arrangement portions 7. Specifically, the margin portion 8 connects two adjacent wiring arrangement portions 7 in the second direction. Multiple margin portions 8 (two in this embodiment) are included in the magnetic layer 2. The number of wiring arrangement portions 7 is one greater than the number of margin portions 8. Each of the multiple margin portions 8 is positioned across the inductor 1 in the first direction.

[0038] In the margin portion 8, the wiring 3 is omitted. Specifically, in an inductor 1 where all wiring 3 are arranged in parallel at equal intervals P0 in the second direction, one wiring 3 is removed for every predetermined number of wirings (four in this embodiment), and the area in the magnetic layer 2 where the wiring 3 is removed (and its vicinity) becomes the margin portion 8, and the area in the magnetic layer 2 other than the margin portion 8 becomes the wiring arrangement portion 7.

[0039] In the margin portion 8, no wiring 3 is placed, and only the magnetic layer 2 is placed. Furthermore, the margin portion 8 has a length in a second direction such that the distance L0 described later is secured.

[0040] <Second margin portion 9> The second margin portion 9 is located outside the outermost wiring arrangement portion 7 in the second direction. In other words, the second margin portion 9 is located at both ends of the inductor 1 in the second direction. Specifically, the second margin portion 9 is located on one side of the wiring arrangement portion 7 located on the far side in the second direction, and on the other side of the wiring arrangement portion 7 located on the far side in the second direction. In this embodiment, there are two second margin portions 9. No wiring 3 is placed in the second margin portion 9; only the magnetic layer 2 is placed there.

[0041] <Manufacturing method for individual inductors 10> Next, a method for manufacturing individual inductors 10 using inductor 1 will be described. This manufacturing method comprises a first step and a second step.

[0042] <1st process> In the first step, the inductor 1 shown in Figures 1A and 2A is prepared. The method for preparing the inductor 1 is not limited. A method for preparing the inductor 1 is described, for example, in Japanese Patent Application Publication No. 2020-150057.

[0043] <Second process> In the second step, the margin portion 8 is cut. Specifically, the approximate center portion 81 in the second direction of the margin portion 8 is cut along the first direction. More specifically, in the magnetic layer 2, the central portion 81 in the second direction between the second end wiring 32 and the first end wiring 31 which faces the second end wiring 32 in the second direction is cut. More specifically, the magnetic layer 2 is cut so as to pass through a point that is advanced from the second end wiring 32 by a length equal to the spacing P0 of the wiring 3 and the radius R of the wiring 3 (P0+R) to the other side in the second direction. Also, the magnetic layer 2 is cut so as to pass through a point that is advanced from the first end wiring 31 by a length equal to the spacing P0 of the wiring 3 and the radius R of the wiring 3 (P0+R) to the one side in the second direction.

[0044] For cutting the margin portion 8, non-contact cutting methods such as laser cutting can be used. For cutting the wiring 3, contact cutting methods such as punching using a die and dicing using a rotary cutter can be used. From the viewpoint of shortening the time of the second process, contact cutting is preferred, and from the viewpoint of improving product quality, punching is preferred.

[0045] By cutting the margin portion 8 as described above, one margin portion 8 is divided into two. In this embodiment, three individual inductors 10 are manufactured by cutting each of the two margin portions 8.

[0046] <Individualized inductor 10> The three sectional inductors 10 include a first sectional inductor 21, a second sectional inductor 22, and a third sectional inductor 23. The first sectional inductor 21 includes a wiring arrangement portion 7 located on the far right side of the inductor 1 in the second direction. The third sectional inductor 23 includes a wiring arrangement portion 7 located on the far left side of the inductor 1 in the second direction. The second sectional inductor 22 includes a wiring arrangement portion 7 located in the middle section in the second direction. The second sectional inductor 22, the first sectional inductor 21, and the third sectional inductor 23 will be described in order.

[0047] First, the second slab inductor 22 will be described in detail, followed by a brief explanation of the first slab inductor 21 and the third slab inductor 23. In the explanation of the first slab inductor 21 and the third slab inductor 23, the explanation of components common to the second slab inductor 22 will be omitted. Furthermore, components other than those specifically noted are the same as those in the inductor 1 described above.

[0048] <Second-piece inductor 22> The second sectional inductor 22 is a sheet that is approximately rectangular in plan view. The second sectional inductor 22 has a shorter length in the second direction than the inductor 1. The second sectional inductor 22 comprises a magnetic layer 2 and wiring 3. The wiring 3 is embedded in the magnetic layer 2.

[0049] <Magnetic layer 2 in the second piece inductor 22> The magnetic layer 2 in the second piece inductor 22 has the same external shape as the second piece inductor 22. The magnetic layer 2 has two main surfaces 4, two first side end faces 20A, 20B (see Figure 1A), and two second side end faces 6. The main surfaces 4 and the first side end faces 20A, 20B (see Figure 1A) are the same as those of the inductor 1. The two second side end faces 6 are both cut surfaces (cut side end faces) formed by cutting the margin portion 8. The two second side end faces 6 include a second one side end face 61 and a second other side end face 62. The magnetic layer 2 includes a wiring arrangement portion 7.

[0050] <Wiring arrangement portion 7 in the second piece inductor 22> One wiring arrangement section 7 is provided for each second-piece inductor 22. The wiring arrangement section 7 contains the first end wiring 31, the second end wiring 32, and the intermediate wiring 33.

[0051] <Distance L0 between the second end face 61 and the first end wiring 31> In the second direction, the distance L0 from the second one-side end face 61 of the magnetic layer 2 to the first end wiring 31 is 0.2 mm or more and 7 mm or less. If the distance L0 is less than 0.2 mm, the amount of magnetic particles present between the second one-side end face 61 and the first end wiring 31 in the magnetic layer 2 becomes excessively small, and the decrease in inductance of the second piece inductor 22 cannot be suppressed. If the distance L0 exceeds 7 mm, the second piece inductor 22 cannot be miniaturized. Preferably, the distance L0 is 0.4 mm or more, and also preferably 5 mm or less.

[0052] <Distance L0 between the second other end face 62 and the second end wiring 32> In the second direction, the distance L0 from the second other end face 62 of the magnetic layer 2 to the second end wiring 32 is 0.2 mm or more and 7 mm or less. If the distance L0 is less than 0.2 mm, the amount of magnetic particles present between the second other end face 62 and the second end wiring 32 in the magnetic layer 2 becomes excessively small, and the decrease in inductance of the second piece inductor 22 cannot be suppressed. If the distance L0 exceeds 7 mm, the second piece inductor 22 cannot be miniaturized. Preferably, the distance L0 is 0.4 mm or more, and also preferably 5 mm or less.

[0053] Furthermore, the difference between the maximum and minimum values ​​of the distances L1, L2, L3 from each of the first point P1, second point P2, and third point P3, which are spaced apart from each other in the first direction on the second other end face 62 of the magnetic layer 2, to each of the fourth point P4, fifth point P5, and sixth point P6 (none of which are shown) adjacent to each of the first point P1, second point P2, and third point P3 in the second direction on the second end wiring 32, is, for example, 2 mm or less, preferably 1 mm or less. If the above-mentioned difference is less than or equal to the above-mentioned upper limit, the variation in the inductance of the second piece inductor 22 in the first direction can be reduced.

[0054] <First-piece inductor 21> The first piece-formed inductor 21 comprises a magnetic layer 2 and wiring 3. The magnetic layer 2 has two main surfaces 4, two first side end faces 20A, 20B (see Figure 1A), and two second side end faces 6. The main surfaces 4, the first side end faces 20A, 20B (see Figure 1A), and the second side end face 61 are the same as those of the inductor 1. The second other side end face 62 is a cut surface (cut side end face) formed by cutting the margin portion 8. The magnetic layer 2 includes a wiring arrangement portion 7. The distance L0 from the second other side end face 62 to the second end wiring 32 is the same as described above. The distance L4 from the second side end face 61 to the first end wiring 31 is the same as the distance L0 described above. The distance L4 in the second piece-formed inductor 22 shown in Figures 1B and 2B is the same as the distance L4 in the inductor 1 shown in Figures 1A and 2A. Distance L4 is also the width of the second margin portion 9.

[0055] <Third-piece inductor 23> The third piece inductor 23 comprises a magnetic layer 2 and wiring 3. The magnetic layer 2 has two main surfaces 4, two first side end faces 20A, 20B (see Figure 1A), and two second side end faces 6. The main surfaces 4, the first side end faces 20A, 20B (see Figure 1A), and the second other side end face 62 are the same as those of the inductor 1. The second first side end face 61 is a cut surface (cut side end face) formed by cutting the margin portion 8. The magnetic layer 2 includes a wiring arrangement portion 7. The distance L0 from the second first side end face 61 to the first end wiring 31 is the same as described above. The distance L5 from the second other side end face 62 to the second end wiring 32 is the same as the distance L0 described above. The distance L5 in the third piece inductor 23 shown in Figures 1B and 2B is the same as the distance L5 in the inductor 1 shown in Figures 1A and 2A. Distance L5 is also the width of the second margin portion 9.

[0056] <Effects of one embodiment> In this inductor 1, the wiring 3 is omitted in the margin portion 8 of the magnetic layer 2. Therefore, by cutting the margin portion 8 along the first direction, a sufficient distance L0 can be secured between the second one-side end face 61 of the magnetic layer 2 and the first end wiring 31 in the second pieced inductor 22 and the third pieced inductor 23. As a result, the amount of magnetic particles present between the second one-side end face 61 and the first end wiring 31 in the magnetic layer 2 becomes sufficient. In addition, a sufficient distance L0 can be secured between the second other-side end face 62 of the magnetic layer 2 and the second end wiring 32 in the second pieced inductor 22 and the first pieced inductor 21. As a result, the amount of magnetic particles present between the second other-side end face 62 and the second end wiring 32 in the magnetic layer 2 becomes sufficient. As a result, the decrease in inductance of the pieced inductor 10 (first pieced inductor 21, second pieced inductor 22, third pieced inductor 23) after cutting can be suppressed.

[0057] On the other hand, in the wiring arrangement section 7, the wiring 3 is arranged in regular parallel patterns. Therefore, the wiring 3 can be arranged compactly in the wiring arrangement section 7. As a result, the individual inductors 10 after cutting can be made smaller.

[0058] Therefore, this inductor 1 can suppress the decrease in inductance of the individual inductors 10 after cutting, and can also be made smaller.

[0059] Furthermore, in the manufacturing method of the individualized inductor 10, the margin portion 8 is cut. As a result, the distance L0 between the second one-side end face 61 of the magnetic layer 2 and the first end wiring 31 in the second individualized inductor 22 and the third individualized inductor 23 can be sufficiently secured. The distance L0 between the second other-side end face 62 of the magnetic layer 2 and the second end wiring 32 in the second individualized inductor 22 and the first individualized inductor 21 can also be sufficiently secured. As a result, the decrease in inductance of the individualized inductor 10 after the second process can be suppressed.

[0060] On the other hand, in the wiring arrangement section 7, the wiring 3 is arranged in regular parallel patterns. Therefore, the wiring 3 can be arranged compactly in the individualized inductor 10. As a result, the individualized inductor 10 after the second process can be miniaturized.

[0061] Therefore, this method for manufacturing the individualized inductor 10 suppresses the decrease in inductance and enables the production of a miniaturized individualized inductor 10.

[0062] Furthermore, in this second pieced inductor 22, the distance L0 from the second one-side end face 61 to the first end wiring 31, and the distance L0 from the second other-side end face 62 to the second end wiring 32 are 0.2 mm or more, so the amount of magnetic particles present between the second one-side end face 61 and the first end wiring 31, and between the second other-side end face 62 and the second end wiring 32 is sufficient. Therefore, the decrease in inductance of the second pieced inductor 22 can be suppressed.

[0063] Furthermore, in the second piece inductor 22, the distance L0 described above is 7 mm or less, thus enabling miniaturization.

[0064] Therefore, this second piece inductor 22 can be miniaturized while suppressing a decrease in inductance.

[0065] The first slab-type inductor 21 and the third slab-type inductor 23 also exhibit the same effects as the second slab-type inductor 22.

[0066] <Variation> In the following modifications, the same reference numerals are used for components and processes as in the above-described embodiment, and their detailed descriptions are omitted. Furthermore, each modification can achieve the same effects and advantages as the first embodiment, unless otherwise specified. Moreover, the first embodiment and its modifications can be combined as appropriate.

[0067] In one embodiment, there is one intermediate wire 33. In a modified example, there are multiple intermediate wires 33. In one wiring arrangement section 7, multiple intermediate wires 33 are arranged in parallel at equal intervals P0 in the second direction.

[0068] As shown in Figure 3A, in the wiring arrangement portion 7 of the modified inductor 1, the multiple wires 3 are not separated by equal intervals P0, but by a first interval P1 and a second interval P2 that is longer than the first interval P1. In other words, one wiring arrangement portion 7 has multiple wires 3 that are separated from each other by different intervals P1 and P2. The first interval P1 and the second interval P2 are arranged alternately in the second direction. On the other hand, the second interval P2 is shorter than, for example, the second direction length of the margin portion 8.

[0069] One embodiment is preferable to the modified example. In the wiring arrangement portion 7 of the inductor 1 of this embodiment, multiple wires 3 are arranged in parallel at equal intervals P0. Therefore, the wires 3 can be arranged more compactly in the wiring arrangement portion 7. In addition, the inductance of each wire 3 can be made equal. As a result, the individualized inductor 10 can be made even smaller while the inductance of each wire 3 can be made equal.

[0070] Although not shown in the diagram, the number of margin portions 8 in the inductor 1 may be one.

[0071] Although not shown in the diagram, it is also possible to manufacture multiple second-piece inductors 22 by cutting a single inductor 1. In this case, the inductor 1 has four or more wiring arrangement portions 7 and three or more margin portions 8. Two or more second-piece inductors 22 are manufactured by cutting three or more margin portions 8.

[0072] In the modified example shown in Figure 4B, the spacing P1, P2, and P3 of the wiring in the multiple individualized inductors 10 are different. Specifically, the first spacing P1 of adjacent wiring 3 in the first individualized inductor 21, the second spacing P2 of adjacent wiring 3 in the second individualized inductor 22, and the third spacing P3 of adjacent wiring 3 in the third individualized inductor 23 are different.

[0073] In the first individual inductor 21, the multiple wirings 3 are arranged in parallel with equal intervals P1 between them. In the first individual inductor 21, the distance L1 between the second other end face 62 and the second end wiring 32 is 0.2 mm or more and 7 mm or less, and is also the same as, for example, the first interval P1 described above. Furthermore, the distance L1 between the second other end face 62 and the second end wiring 32 is the same as the distance L4 from the second one end face 61 to the first end wiring 31.

[0074] In the second segmented inductor 22, the multiple wirings 3 are arranged in parallel with equal spacing P2 between them. In the second segmented inductor 22, the distance L2 between the second other end face 62 and the second end wiring 32 is 0.2 mm or more and 7 mm or less, and is also the same as, for example, the second spacing P2 described above. Furthermore, the distance L2 between the second other end face 62 and the second end wiring 32 is the same as the distance L2 from the second one end face 61 to the first end wiring 31.

[0075] In the third segmented inductor 23, the multiple wirings 3 are arranged in parallel with equal spacing P3 between them. In the third segmented inductor 23, the distance L3 from the second one-side end face 61 to the first end wiring 31 is 0.2 mm or more and 7 mm or less, and is also the same as, for example, the third spacing P3 described above. Furthermore, the distance L3 between the second other-side end face 62 and the second end wiring 32 is the same as the distance L5 between the second other-side end face 62 and the second end wiring 32.

[0076] As shown in Figure 4A, the inductor 1 prepared in the first step includes a wiring arrangement portion 7 corresponding to the first individual inductor 21, a wiring arrangement portion 7 corresponding to the second individual inductor 22, and a wiring arrangement portion 7 corresponding to the third individual inductor 23, separated by a margin portion 8.

[0077] In the second step, the magnetic layer 2 is cut in the middle section between the second end wiring 32 and the first end wiring 31 which faces the second end wiring 32 in the second direction. More specifically, the magnetic layer 2 is cut so as to pass through a point that is advanced from the second end wiring 32 by a length equal to the first spacing P1 or the second spacing P2 plus the radius R of the wiring 3 to the other side in the second direction. Alternatively, the magnetic layer 2 is cut so as to pass through a point that is advanced from the first end wiring 31 by a length equal to the second spacing P2 or the third spacing P3 plus the radius R of the wiring 3 to the one side in the second direction.

[0078] In the second step, the margin portion 8 is cut, and the magnetic layer 2 and multiple wirings 3 are cut along the second direction (parallel direction). For example, the inductor 1 is cut in a rectangular shape in plan view. This yields a rectangular-shaped individual inductor 10 in plan view.

[0079] In this modified example, as shown in Figure 6, for example, the end faces of the wiring 3 in the longitudinal direction (first side end face and / or second side end face) include an exposed portion 35 and a covered portion 36. The exposed portion 35 is the portion of the end face of the wiring 3 that is exposed from the magnetic layer 2. The covered portion 36 is the portion of the end face of the wiring 3 that is covered by the magnetic layer 2 (deposits when cut).

[0080] To obtain the individualized inductor 10 of this modified form, the inductor 1 shown in Figure 5A is cut along the first and second directions, respectively. For cutting, punching and dicing are preferably used. For punching, a die with four curved corners (curved lines) is used.

[0081] The magnetic layer 2 and wiring 3 of the inductor 1 are cut so that one end and the other end in the first direction remain intact.

[0082] In the second direction, the magnetic layer 2 is cut such that the central part 81 of the margin portion 8 remains.

[0083] Along with cutting the margin portion 8, the second margin portion 9 is also cut. The second margin portion 9 is cut along the first direction. This leaves the outer end of the second margin portion 9 in the second direction.

[0084] The individualized inductor 10 obtained as described above is, for example, a roughly rectangular shape in plan view, with each of the four corners 11 having a curve (curved line). The radius of curvature of the corners 11 is, for example, 0.1 mm or more, preferably 0.2 mm or more. The radius of curvature of the corners 11 is, for example, 5 mm or less, preferably 4 mm or less.

[0085] If the radius of curvature of the corner portion 11 is greater than or equal to the lower limit described above, the shock resistance of the inductor 1 can be improved.

[0086] If the radius of curvature of the corner 11 is less than or equal to the upper limit mentioned above, the area near the corner 11 can be widened, and a mark (including the alignment mark 111) can be placed in the empty space.

[0087] The above invention is provided as an illustrative embodiment of the present invention, but this is merely illustrative and should not be interpreted restrictively. Modifications of the present invention that are obvious to those skilled in the art are included in the claims below. [Industrial applicability]

[0088] Inductors are used as electronic components in electrical circuits. [Explanation of Symbols]

[0089] 1 Inductor 2 magnetic layer 3. Wiring 7 Wiring arrangement part 8. Margin area 10-piece inductor 11 corners 21. First-piece inductor 22. Second-piece inductor 23 Third-piece inductor 35 Exposed part 36 Covered portion L0 distance L1 distance L2 distance L3 Distance P0 Equal interval

Claims

1. Magnetic layer and The magnetic layer is embedded in a plurality of wirings that extend in the longitudinal direction, and the plurality of wirings are arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction, The magnetic layer, The aforementioned wiring consists of multiple wiring arrangement sections arranged in parallel at equal intervals, It includes a margin portion where the wiring is omitted, which is arranged between adjacent wiring arrangement portions in the parallel direction of the aforementioned wiring, Of the adjacent wiring arrangement portions, one wiring arrangement portion and the other wiring arrangement portion each include a first end wiring and a second end wiring in the parallel direction of the wiring, An inductor in which the distance between the second end wiring in one of the aforementioned wiring arrangement portions and the first end wiring in the other aforementioned wiring arrangement portion is wider than the equal spacing of the plurality of wirings.

2. A first step of preparing the inductor described in claim 1, A method for manufacturing individual inductors, comprising a second step of cutting the margin portion.

3. Magnetic layer and The magnetic layer is embedded in a plurality of wirings that extend in the longitudinal direction, and the plurality of wirings are arranged in parallel at predetermined intervals in a direction perpendicular to the longitudinal direction, The magnetic layer includes a wiring arrangement portion in which the wiring is arranged in parallel at equal intervals, The wiring includes an end wire that is arranged at one end of the wiring arrangement portion in the parallel direction of the wiring, A sectional inductor in which, in the parallel direction, the distance from one end face of the magnetic layer to the end wiring is 0.2 mm or more and 7 mm or less.

4. The individualized inductor according to claim 3, wherein the end face of the wiring in the longitudinal direction has an exposed portion that is exposed from the magnetic layer.

5. The individualized inductor according to claim 3 or claim 4, wherein the end face of the wiring in the longitudinal direction has a covered portion that is covered by the magnetic layer.

6. A segmented inductor according to any one of claims 3 to 5, having a rectangular shape including curved corners in a plan view.

7. The individualized inductor according to claim 6, wherein the curve is a curved line with a radius of curvature of 0.1 mm or more and 5 mm or less.

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