Inductor components

Abstract

To provide an inductor component capable of ensuring a high self resonant frequency and suppressing the generation of stray capacitance.SOLUTION: An inductor component includes an element assembly made of an insulator, and a coil conductor provided inside the element assembly. The coil conductor includes: a plurality of conductor patterns provided on each of a plurality of virtual inner surfaces lined up at intervals in an axial direction of the coil conductor to form a part of an annular path; and a connection conductor electrically connecting two adjacent conductor patterns among the plurality of conductor patterns. At least one conductor pattern among the plurality of conductor patterns includes a first conductor pattern and a second conductor pattern that are lined up in the axial direction and are in contact with each other. In a cross section including an axis of the coil conductor, a center of the first conductor pattern in a direction orthogonal to the axial direction is present at a position different from a position of a center of the second conductor pattern in the direction orthogonal to the axial direction.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to an inductor component in which a coil conductor is provided inside a base body.

Background Art

[0002] In an inductor component in which a coil conductor is provided inside a base body, it is required to have a high Q value. In order to increase the Q value of the inductor component, for example, it is conceivable to thicken each of a plurality of conductor patterns constituting the coil conductor.

[0003] An example of an inductor component having a coil conductor made of thick conductor patterns is disclosed in Patent Document 1. In the electronic component disclosed in Patent Document 1, in the manufacturing process, after a lower conductor pattern layer is formed, an upper conductor pattern layer is formed on the lower conductor pattern layer. Thereby, a conductor pattern having a thickness obtained by combining the thickness of the lower conductor pattern layer and the thickness of the upper conductor pattern layer, that is, a thick conductor pattern is formed.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] There are limitations on the size of the base body. Also, there are limitations on the length of the coil conductor provided inside the base body. Therefore, in order to thicken the conductor patterns constituting the coil conductor without increasing the size of the base body, it is conceivable to narrow the interval between the windings of the coil conductor. Here, the interval between the windings of the coil conductor is the interval between two adjacent conductor patterns in a plurality of conductor patterns constituting the coil conductor.

[0006] However, if the spacing between two adjacent conductor patterns becomes too narrow, the stray capacitance between the two conductor patterns may increase. An increase in stray capacitance may lower the self-resonant frequency (SRF) of the inductor component. A decrease in the self-resonant frequency may lower the Q-factor of the inductor component.

[0007] The purpose of this disclosure is to provide an inductor component that can ensure a high self-resonant frequency and suppress the generation of stray capacitance. [Means for solving the problem]

[0008] An inductor component according to one aspect of the present invention is A base body made of an insulator, The above-mentioned body comprises a coil conductor provided inside, The coil conductor comprises a plurality of conductor patterns provided on each of a plurality of virtual inner surfaces arranged at intervals in the axial direction of the coil conductor so as to form part of an annular trajectory, and a connecting conductor that electrically connects two adjacent conductor patterns among the plurality of conductor patterns. At least one of the plurality of conductor patterns comprises a first conductor pattern and a second conductor pattern that are aligned in the axial direction and in contact with each other. In a cross-section including the axis of the coil conductor, the center of the first conductor pattern in a direction perpendicular to the axial direction is at a different position from the center of the second conductor pattern in a direction perpendicular to the axial direction. [Effects of the Invention]

[0009] According to this disclosure, it is possible to provide an inductor component that can ensure a high self-resonant frequency and suppress the generation of stray capacitance. [Brief explanation of the drawing]

[0010] [Figure 1] External perspective view of an inductor component according to the first embodiment of this disclosure [Figure 2]External perspective view of the coil conductor and external electrodes [Figure 3] External perspective view of the coil conductor and external electrodes [Figure 4] Schematic cross-sectional view showing the A-A cross-section of FIG. 1 [Figure 5] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 6] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 7] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 8] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 9] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 10] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 11] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 12] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 13] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 14] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 15] Schematic cross-sectional view for explaining the manufacturing method of the inductor component [Figure 16] Schematic cross-sectional view showing the cross-section corresponding to the A-A cross-section of FIG. 1 in the inductor component according to the second embodiment of the present disclosure [Figure 17] Schematic cross-sectional view showing the cross-section corresponding to the A-A cross-section of FIG. 1 in the inductor component according to the third embodiment of the present disclosure [Figure 18] Schematic cross-sectional view showing the cross-section corresponding to the A-A cross-section of FIG. 1 in the inductor component according to the fourth embodiment of the present disclosure [Figure 19] Schematic cross-sectional view showing the cross-section corresponding to the A-A cross-section of FIG. 1 in the inductor component according to the fifth embodiment of the present disclosure

Modes for Carrying Out the Invention

[0011] Hereinafter, an example of the present disclosure will be described with reference to the accompanying drawings. The following description is merely illustrative in nature and is not intended to limit the present disclosure, its applications, or its uses. Also, the drawings are schematic, and the ratios of each dimension etc. do not necessarily match the actual ones. Further, in the following description, terms indicating a specific direction or position (terms including, for example, "upper", "lower", "right", "left", "front", "rear") are used as necessary. However, the use of terms indicating a specific direction or position is for facilitating the understanding of the present disclosure with reference to the drawings, and the technical scope of the present disclosure is not limited by the meanings of those terms.

[0012] <First Embodiment> FIG. 1 is an external perspective view of an inductor component according to the first embodiment of the present disclosure.

[0013] As shown in FIG. 1, an inductor component 10 according to the first embodiment of the present disclosure includes a body 20. In the first embodiment, the body 20 has a rectangular parallelepiped shape. In the first embodiment, the body 20 includes an upper surface 21 facing upward, a lower surface 22 facing downward, a front surface 23, a rear surface 24, a left surface 25, and a right surface 26 connecting between the upper surface 21 and the lower surface 22. The front surface 23 faces forward, and the rear surface 24 faces rearward. The left surface 25 faces leftward, and the right surface 26 faces rightward. Each of the front surface 23, the rear surface 24, the left surface 25, and the right surface 26 extends downward from the upper surface 21 perpendicular to the upper surface 21 and extends upward from the lower surface 22 perpendicular to the lower surface 22. The vertical direction, the front-rear direction, and the left-right direction are directions orthogonal to each other.

[0014] The body 20 has a laminated structure formed by laminating a plurality of insulator layers (not shown). The body 20 is composed of an insulator. In the first embodiment, the insulator layers are laminated in a direction (front-rear direction) orthogonal to the front surface 23 and the rear surface 24. Note that, depending on firing etc., the interfaces between the plurality of insulator layers may not be clear in the body 20.

[0015] Figure 2 is a perspective view of the coil conductor and external electrodes. Figure 3 is a perspective view of the coil conductor and external electrodes. In Figures 2 and 3, the contour of the base body 20 is shown by a dashed line, indicating the relative positions of the coil conductor 40 and external electrodes 31 and 32 with respect to the base body 20.

[0016] As shown in Figures 2 and 3, the inductor component 10 includes a coil conductor 40 inside the main body 20. The coil conductor 40 includes a plurality (seven in the first embodiment) of conductor patterns 411 to 417 and one or more (six in the first embodiment) of connecting conductors 421 to 426. Hereinafter, the conductor patterns 411 to 417 will also be collectively referred to as conductor pattern 41, and the connecting conductors 421 to 426 will also be collectively referred to as connecting conductor 42.

[0017] Each of the multiple conductor patterns 41 extends along one of the interfaces between the insulating layers to form part of an annular trajectory. The interface can also be described as a virtual inner surface 20A that extends vertically and horizontally within the body 2, as shown in Figure 1. In Figure 1, only one virtual inner surface 20A is shown exemplarily, but a virtual inner surface 20A is set for each of the conductor patterns 41. In the first embodiment, seven virtual inner surfaces 20A are set, corresponding to each of the seven conductor patterns 411 to 417. The seven virtual inner surfaces 20A are spaced apart in the front-to-back direction. Thus, the seven conductor patterns 411 to 417 are spaced apart in the front-to-back direction. The annular trajectory only needs to be annular and can be any shape. For example, the annular trajectory is not limited to the shape shown in Figures 2 and 3, but may be circular, square, or the like.

[0018] Each of the multiple connecting conductors 42 electrically connects two adjacent conductor patterns among the multiple conductor patterns 41. In the first embodiment, the multiple connecting conductors 42 are via-hole conductors that penetrate any of the insulating layers in the thickness direction (front-to-back direction). The multiple connecting conductors 42 are not limited to via-hole conductors, but may be formed, for example, by printing on the insulating layer.

[0019] The coil conductor 40 is configured to extend in a spiral shape by alternately connecting multiple conductor patterns 41 and one or more connecting conductors 42.

[0020] Each of the multiple conductor patterns 41 has a relatively wide pad 43 at the connection point with the connecting conductor 42.

[0021] Conductor pattern 411, connecting conductor 421, conductor pattern 412, connecting conductor 422, conductor pattern 413, connecting conductor 423, and conductor pattern 414 are connected in sequence. Furthermore, conductor pattern 414, connecting conductor 424, conductor pattern 415, connecting conductor 425, conductor pattern 416, connecting conductor 426, and conductor pattern 417 are connected in sequence. This constitutes the coil conductor 40. Each connecting conductor 42 is connected to an adjacent conductor pattern 41 via a pad 43.

[0022] The number of conductor patterns 41 sequentially connected to constitute the coil conductor 40, the number of connecting conductors 42, and the number of turns of the coil conductor 40 are not limited to those shown in the figure and can be any number. The number of layers of insulating material can also be any number.

[0023] As shown in Figure 1, the inductor component 10 includes external electrodes 31 and 32. External electrode 31 is provided continuously from the left side of the lower surface 22 to the lower part of the left side surface 25. External electrode 32 is provided continuously from the right side of the lower surface 22 to the lower part of the right side surface 26. Each of the external electrodes 31 and 32 has an L-shape. The portion of external electrode 31 provided on the lower surface 22 and the portion of external electrode 32 provided on the lower surface 22 are spaced apart.

[0024] External electrode 31 is exposed to the outside of the base body 20 on the bottom surface 22 and the left side surface 25. External electrode 32 is exposed to the outside of the base body 20 on the bottom surface 22 and the right side surface 26. In the first embodiment, each of the external electrodes 31 and 32 is embedded inside the base body 20, except for the exposed portion. The surfaces of the external electrodes 31 and 32 that are exposed from the base body 20 may be covered with plating such as Ni or Sn.

[0025] As shown in Figure 3, the lead conductor pattern 33 extending integrally from the conductor pattern 417 is connected to the external electrode 31. As shown in Figure 2, the lead conductor pattern 34 extending integrally from the conductor pattern 411 is connected to the external electrode 32. In other words, one end of the coil conductor 40 is electrically connected to the external electrode 31 via the lead conductor pattern 33, and the other end of the coil conductor 40 is electrically connected to the external electrode 32 via the lead conductor pattern 34. The coil conductor 40 may also be electrically connected to the external electrodes 31 and 32 in parts other than one end and the other end.

[0026] In the first embodiment, when the inductor component 10 is mounted on a circuit board (not shown), the lower surface 22 is the mounting surface that faces the circuit board. In the first embodiment, the axial direction 101 of the coil conductor 40 is parallel to the mounting surface. That is, in the first embodiment, the coil conductor 40 is a so-called transverse winding.

[0027] The configuration of the multiple conductor patterns 41 will be described below, primarily with reference to Figure 4. Figure 4 is a schematic cross-sectional view showing cross-section AA in Figure 1. In other words, Figure 4 shows cross-section 20B of the inductor component 10 shown in Figure 1. In Figure 1, cross-section 20B is indicated by a dashed line.

[0028] As shown in Figures 2 to 4, each of the plurality of conductor patterns 41 comprises conductor patterns 41A and 41B that are aligned in the axial direction 101 of the coil conductor 40 and in contact with each other. In the first embodiment, the axial direction 101 of the coil conductor 40 is the front-to-back direction. Conductor pattern 41A is an example of a first conductor pattern. Conductor pattern 41B is an example of a second conductor pattern. In the first embodiment, conductor pattern 41A is located in one direction of the axial direction 101 (forward), and conductor pattern 41B is located in the other direction of the axial direction 101 (rear).

[0029] In the first embodiment, each of the conductor patterns 411 to 417 has the same configuration. Therefore, in the following description, the configurations of conductor patterns 41A and 41B provided by conductor pattern 411 will be described. The other conductor patterns 412 to 417 will be mentioned as needed.

[0030] As shown in Figure 4, in a cross-section including the axis of the coil conductor 40 shown by the dashed line in Figure 4, the width W1 of conductor pattern 41A is the same as the width W2 of conductor pattern 41B. The width W1 is the length of the coil conductor 40 along the radial direction 102 in conductor pattern 41A. The width W2 is the length of the coil conductor 40 along the radial direction 102 in conductor pattern 41B. The radial direction 102 of the coil conductor 40 is the direction in which the coil conductor 40 radiates outwards from the center of the coil conductor 40 when viewed from the axial direction 101.

[0031] The statement that the width W1 of conductor pattern 41A and the width W2 of conductor pattern 41B are the same does not mean that widths W1 and W2 are exactly the same, but also includes the statement that widths W1 and W2 are approximately the same.

[0032] The thickness T1 of conductor pattern 41A is the same as the thickness T2 of conductor pattern 41B. Thickness T1 is the length parallel to the axial direction 101 in conductor pattern 41A. Thickness T2 is the length parallel to the axial direction 101 in conductor pattern 41B.

[0033] The statement that the thickness T1 of conductor pattern 41A and the thickness T2 of conductor pattern 41B are the same does not mean that thickness T1 and thickness T2 are exactly the same, but also includes the statement that thickness T1 and thickness T2 are approximately the same.

[0034] In the cross-section of the coil conductor 40, shown by the dashed line in Figure 4, the center C1 of the conductor pattern 41A in the direction perpendicular to the axial direction 101 is at a different position from the center C2 of the conductor pattern 41B in the direction perpendicular to the axial direction 101. Hereafter, the center C1 of the conductor pattern 41A in the direction perpendicular to the axial direction 101 will be referred to as center C1. The center C2 of the conductor pattern 41B in the direction perpendicular to the axial direction 101 will be referred to as center C2. In other words, the fact that center C1 and center C2 are at different positions means that, as viewed from the axial direction 101, the center C1 of the conductor pattern 41A is at a different position from the center C2 of the conductor pattern 41B. Center C1 is at the midpoint between one end and the other end of the radial direction 102 in the conductor pattern 41A. Center C2 is at the midpoint between one end and the other end of the radial direction 102 in the conductor pattern 41B.

[0035] In the first embodiment, in all conductor patterns 411 to 417, the center C2 of conductor pattern 41B is located on the left side surface 25 side than the center C1 of conductor pattern 41A. That is, in all conductor patterns 411 to 417, the center C1 is shifted in the same direction relative to the center C2. Conversely, the center C2 of conductor pattern 41B may be located on the right side surface 26 side than the center C1 of conductor pattern 41A.

[0036] Next, the manufacturing method of the inductor component 10 will be explained with reference to Figures 5 to 15. Figures 5 to 15 are schematic cross-sectional views illustrating the manufacturing method of the inductor component. Figures 5 to 15 correspond to the conductor pattern 411 of the inductor component 10 shown in Figures 1 to 3. Below, the manufacturing method of the portion of the inductor component 10 corresponding to the conductor pattern 411 will be explained. The explanation of the manufacturing method of the portion of the inductor component 10 corresponding to the conductor patterns 412 to 417 will be omitted and will be mentioned as necessary.

[0037] As shown in Figure 5, an insulating layer 51 that does not contain magnetic material is formed on the substrate 60, and a conductive material 71 is formed on the insulating layer 51. The substrate 60 is made of, for example, sintered ferrite and is in the shape of a flat plate. The insulating layer 51 is made of, for example, a polyimide resin or an inorganic material that does not contain magnetic material.

[0038] The insulating layer 51 made of polyimide resin is formed, for example, as follows: The polyimide resin is coated onto the substrate 60 by printing, coating, etc. This forms the insulating layer 51 on the substrate 60. The insulating layer 51 made of inorganic material is formed on the substrate 60 by a dry process such as vapor deposition, sputtering, or chemical vapor deposition (CVD).

[0039] The conductive material 71 is coated onto the insulating layer 51 by printing, coating, or other means. The conductive material 71 is a photosensitive substance such as photosensitive Ag paste.

[0040] As detailed below, the conductor pattern 41A is formed on the insulating layer 51 by patterning, for example, using photolithography.

[0041] As shown in Figure 6, a photomask 81 is placed on the conductive material 71. The photomask 81 has an opening 81A that has the same shape as the conductive pattern 41A of the conductive pattern 411. In other words, the photomask 81 masks the portion of the conductive pattern 411 that is not shaped like the conductive pattern 41A.

[0042] Next, the photomask 81 side is exposed. In the first embodiment, the conductive material 71 is negative type. Therefore, the solubility of the exposed portion of the conductive material 71 (the portion exposed through the opening 81A) decreases. On the other hand, the solubility of the unexposed portion of the conductive material 71 (the portion masked by the photomask 81) does not decrease. Thus, when developed after exposure, only the exposed portion of the conductive material 71 remains undissolved. As a result, as shown in Figure 7, the conductive pattern 41A of the conductive pattern 411 is formed on the insulating layer 51.

[0043] The conductive material 71 may be positive type. In this case, the photomask 81 masks the portion of the conductive pattern 41A of the conductive pattern 411.

[0044] Next, as shown in Figure 8, an insulating layer 52 is formed on the insulating layer 51. The insulating layer 52, like the insulating layer 51, is made of a polyimide resin or inorganic material that does not contain magnetic material. The conductor pattern 41A of the conductor pattern 411 is covered by the insulating layer 52.

[0045] Next, as shown in Figure 9, the upper surface of the conductor pattern 41A of the conductor pattern 411 is exposed by washing away the insulating layer 52 with a solvent or by polishing the insulating layer 52.

[0046] Next, as shown in Figure 10, the conductive material 72 is coated onto the insulating layer 52 by printing, coating, or the like, similar to the conductive pattern 41A. The conductive material 72 is the same material as the conductive material 71.

[0047] The conductor pattern 41B is formed on the insulating layer 52, similar to the conductor pattern 41A, for example by patterning using photolithography. This is described in detail below.

[0048] As shown in Figure 11, a photomask 82 is placed on the conductive material 72. The photomask 82 has an opening 82A that has the same shape as the conductor pattern 41B of the conductor pattern 411. In other words, the photomask 82 masks the portion of the conductor pattern 411 excluding the shape of the conductor pattern 41B. The opening 82A is located offset from the conductor pattern 41A formed on the insulating layer 51. However, the conductor pattern 41A formed on the insulating layer 51 is exposed through the opening 82A.

[0049] Next, the photomask 82 side is exposed. In the first embodiment, the conductive material 72 is negative type. Therefore, the solubility of the exposed portion of the conductive material 72 (the portion exposed through the opening 82A) decreases. On the other hand, the solubility of the unexposed portion of the conductive material 72 (the portion masked by the photomask 82) does not decrease. Therefore, when developed after exposure, only the exposed portion of the conductive material 72 remains undissolved. Here, as mentioned above, the conductor pattern 41A formed on the insulating layer 51 is exposed through the opening 82A. Therefore, the undissolved conductive material 72 is connected to the conductor pattern 41A exposed from the insulating layer 52. As a result, as shown in Figure 12, the conductor pattern 41B of the conductor pattern 411 is formed on the insulating layer 52 in a state where it is connected to the conductor pattern 41A. In other words, a conductor pattern 411 comprising the conductor pattern 41A and the conductor pattern 41B is formed.

[0050] The conductive material 72 may be positive type. In this case, the photomask 82 masks the portion of the conductive pattern 41B of the conductive pattern 411.

[0051] Next, as shown in Figure 13, an insulating layer 53 is formed on the insulating layer 52. The insulating layer 53, like the insulating layers 51 and 52, is made of a polyimide resin or inorganic material that does not contain magnetic material. The conductor pattern 41B of the conductor pattern 411 is covered by the insulating layer 53.

[0052] Next, as shown in Figure 14, a photomask 83 is placed on the insulating layer 53. In a plan view from the stacking direction of the insulating layers 51, 52, 53 and the photomask 83, the photomask 83 has a circular mask portion 83A, and the portion 83B excluding the mask portion 83A is open. In a plan view, the mask portion 83A overlaps with a part of the conductor pattern 41B covered by the insulating layer 53. The shape of the photomask 83 in a plan view is not limited to a circle; for example, it may be a rectangle or other shape.

[0053] Next, the photomask 83 side is exposed. In the first embodiment, the material constituting the insulating layer 53 is negative type. Therefore, the solubility of the exposed portion 83B in the insulating layer 53 decreases. On the other hand, the solubility of the unexposed mask portion 83A (the portion masked by the photomask 83) in the insulating layer 53 does not decrease. Therefore, when developed after exposure, the exposed portion 83B in the insulating layer 53 remains undissolved, while the mask portion 83A dissolves. As a result, as shown in Figure 15, a circular hole 53A is formed in the insulating layer 53, and a part of the conductor pattern 41B is exposed through the hole 53A.

[0054] The insulating layer 53 may be of the positive type. In this case, the photomask 83 has a circular or other type of hole in the portion corresponding to the mask portion 83A, and the portion excluding the hole becomes the mask portion.

[0055] Next, the process described with reference to Figures 5 to 15 is performed again. In the state shown in Figure 15, conductive material is formed on the insulating layer 53 in the same manner as described in Figure 5. At this time, the conductive material flows into the hole 53A. The conductive material that flows into the hole 53A forms the connecting conductor 421, which is a via hole conductor. Subsequently, the conductor pattern 412 is formed by performing the process described with reference to Figures 6 to 15.

[0056] Subsequently, the process described with reference to Figures 5 to 15 is repeated. This sequentially forms the connecting conductor 422, conductor pattern 413, connecting conductor 423, conductor pattern 414, connecting conductor 424, conductor pattern 415, connecting conductor 425, conductor pattern 416, connecting conductor 426, and conductor pattern 417.

[0057] According to the first embodiment, when viewed from the axial direction 101, in a conductor pattern having conductor patterns 41A and 41B among a plurality of conductor patterns 41 (hereinafter referred to as the predetermined conductor pattern), the center C1 of conductor pattern 41A is at a different position from the center C2 of conductor pattern 41B. As a result, when viewed from the axial direction 101 of the coil conductor 40, the area of ​​contact between the predetermined conductor pattern and a conductor pattern provided adjacent to the predetermined conductor pattern at a distance from the predetermined conductor pattern (hereinafter referred to as the adjacent conductor pattern) can be reduced.

[0058] For example, when viewed from the axial direction 101, the opposing area between conductor pattern 41A (an example of a first conductor pattern) of conductor pattern 412 (an example of a predetermined conductor pattern) and conductor pattern 41B (an example of a second conductor pattern) of conductor pattern 411 (an example of an adjacent conductor pattern) can be reduced.

[0059] Furthermore, for example, when viewed from the axial direction 101, the opposing area between conductor pattern 41B (an example of a second conductor pattern) of conductor pattern 413 (an example of a predetermined conductor pattern) and conductor pattern 41A (an example of a first conductor pattern) of conductor pattern 414 (an example of an adjacent conductor pattern) can be reduced.

[0060] Furthermore, even if, for example, the adjacent conductor pattern does not have a first conductor pattern and a second conductor pattern, the aforementioned opposing area can be reduced. Specifically, when viewed from the axial direction 101, the opposing area between the conductor pattern located on the adjacent conductor pattern side of the first and second conductor patterns of a predetermined conductor pattern and the adjacent conductor pattern can be reduced.

[0061] The small opposing area reduces the stray capacitance generated between two adjacent conductor patterns. As a result, the decrease in the self-resonant frequency of the inductor component 10 can be suppressed, and the Q value of the inductor component 10 can be maintained at a high level.

[0062] According to the first embodiment, the width W1 of the conductor pattern 41A and the width W2 of the conductor pattern 41B are the same. According to the first embodiment, the manufacturing of the inductor component 10 is easier compared to a configuration in which the width W1 of the conductor pattern 41A is different from the width W2 of the conductor pattern 41B. For example, in the manufacturing process of the inductor component 10, the photomask used to form the conductor pattern 41A and the photomask used to form the conductor pattern 41B can be the same photomask.

[0063] According to the first embodiment, the thickness T1 of the conductor pattern 41A and the thickness T2 of the conductor pattern 41B are the same. According to the first embodiment, the manufacturing of the inductor component 10 is easier compared to a configuration in which the thickness T1 of the conductor pattern 41A is different from the thickness T2 of the conductor pattern 41B. For example, in the manufacturing process of the inductor component 10, the photomask used to form the conductor pattern 41A and the photomask used to form the conductor pattern 41B can be photomasks of the same thickness.

[0064] According to the first embodiment, in all conductor patterns 411 to 417, the center C1 of conductor pattern 41A is offset in the same direction relative to the center C2 of conductor pattern 41B. According to the first embodiment, the manufacturing of the inductor component 10 is easier compared to a configuration in which, in at least some of the multiple conductor patterns 41, the center C1 of conductor pattern 41A is offset in different directions relative to the center C2 of conductor pattern 41B. For example, according to the first embodiment, in the manufacturing process of the inductor component 10, a common photomask can be used to form each of the multiple conductor patterns 41.

[0065] In the first embodiment and the embodiments described later, an example is described in which all of the conductor patterns 411 to 417 include conductor pattern 41A and conductor pattern 41B. However, only a portion of the conductor patterns 411 to 417 may include conductor pattern 41A and conductor pattern 41B. In this case, there may be one or more conductor patterns 41 that include conductor pattern 41A and conductor pattern 41B.

[0066] If, among a plurality of conductor patterns 41, two or more conductor patterns 41 comprise conductor pattern 41A and conductor pattern 41B, then in all of the two or more conductor patterns 41 within that portion, the center C1 may be shifted in the same direction relative to the center C2. In this case, the magnitude of the shift between the center C1 and the center C2 may differ in each of the two or more conductor patterns 41 within that portion. Of course, in each of the two or more conductor patterns 41 within that portion, the center C1 may be shifted in different directions relative to the center C2.

[0067] <Second Embodiment> Figure 16 is a schematic cross-sectional view showing a cross-section corresponding to the AA section in Figure 1 of an inductor component according to the second embodiment of this disclosure. The difference between the inductor component 10A according to the second embodiment and the inductor component 10 according to the first embodiment is that the width W1 of the conductor pattern 41A and the width W2 of the conductor pattern 41B are different. The differences from the first embodiment will be described below. Similarities with the inductor component 10 according to the first embodiment are given the same reference numerals, and their descriptions will be omitted in principle, and will be described as necessary.

[0068] As shown in Figure 16, in each conductor pattern 41 of the inductor component 10A, the width W1 of conductor pattern 41A is greater than the width W2 of conductor pattern 41B. Conversely, the width W2 of conductor pattern 41B may be greater than the width W1 of conductor pattern 41A. In each conductor pattern 41 of the inductor component 10A, the thickness T1 of conductor pattern 41A is the same as the thickness T2 of conductor pattern 41B, but they may be different.

[0069] According to the second embodiment, the width W1 of conductor pattern 41A and the width W2 of conductor pattern 41B are different. For example, as shown in Figure 16, in conductor pattern 411, conductor pattern 41B is narrower than conductor pattern 41A. In this case, when viewed from the axial direction 101, the opposing area between conductor pattern 41B of conductor pattern 411 and conductor pattern 41A of conductor pattern 412 adjacent to conductor pattern 411 can be reduced by the amount by which the width W2 of conductor pattern 41B is shorter. The same applies when conductor pattern 41A is narrower than conductor pattern 41B.

[0070] In the second embodiment, an example is described in which the width W1 is greater than the width W2 in all of the multiple conductor patterns 41. However, it is also possible that the width W1 is greater than the width W2 in some of the multiple conductor patterns 41, and the width W1 is smaller than the width W2 in the other conductor patterns 41 excluding that part.

[0071] In the second embodiment, an example is described in which the widths W1 and W2 are different in all of the multiple conductor patterns 41. However, the widths W1 and W2 may be different in some of the multiple conductor patterns 41, and the widths W1 and W2 may be the same or approximately the same in the other conductor patterns 41 excluding that part.

[0072] <Third Embodiment> Figure 17 is a schematic cross-sectional view showing a cross-section corresponding to the AA section in Figure 1 of the inductor component according to the third embodiment of this disclosure. The difference between the inductor component 10B according to the third embodiment and the inductor component 10 according to the first embodiment is that the thickness T1 of the conductor pattern 41A and the thickness T2 of the conductor pattern 41B are different. The differences from the first embodiment will be described below. Similarities with the inductor component 10 according to the first embodiment are given the same reference numerals, and their descriptions will be omitted in principle, and will be described as necessary.

[0073] As shown in Figure 17, in each conductor pattern 41 of the inductor component 10B, the thickness T1 of conductor pattern 41A is greater than the thickness T2 of conductor pattern 41B. Conversely, the thickness T2 of conductor pattern 41B may be greater than the thickness T1 of conductor pattern 41A. In each conductor pattern 41 of the inductor component 10A, the width W1 of conductor pattern 41A is the same as the width W2 of conductor pattern 41B, but they may be different.

[0074] According to the third embodiment, in the manufacturing process of the inductor component 10B, the stacked structure of the conductor pattern 41 of the manufactured inductor component 10B can be stabilized by stacking the thicker conductor pattern of the conductor patterns 41A and 41B first.

[0075] In the third embodiment, an example is described in which the thickness T1 is greater than the thickness T2 in all of the multiple conductor patterns 41. However, the thickness T1 may be greater than the thickness T2 in some of the multiple conductor patterns 41, and the thickness T1 may be less than the thickness T2 in the other conductor patterns 41 excluding that part.

[0076] In the third embodiment, an example is described in which the thickness T1 and thickness T2 are different in all of the multiple conductor patterns 41. However, the thickness T1 and thickness T2 may be different in some of the multiple conductor patterns 41, and the thickness T1 and thickness T2 may be the same or approximately the same in the other conductor patterns 41 excluding that part.

[0077] <Fourth Embodiment> Figure 18 is a schematic cross-sectional view showing a cross-section corresponding to the AA section in Figure 1 of the inductor component according to the fourth embodiment of this disclosure. The difference between the inductor component 10C according to the fourth embodiment and the inductor component 10 according to the first embodiment is that the direction in which the center C1 of the conductor pattern 41A is offset from the center C2 of the conductor pattern 41B is not constant. The differences from the first embodiment will be described below. Similarities with the inductor component 10 according to the first embodiment are given the same reference numerals, and their descriptions are generally omitted, and will be described as necessary.

[0078] In the inductor component 10C, in some of the multiple conductor patterns 41, the center C1 of conductor pattern 41A is offset in a first direction relative to the center C2 of conductor pattern 41B. Furthermore, in the inductor component 10C, in at least one of the conductor patterns 41 that is different from the aforementioned multiple conductor patterns 41, the center C1 of conductor pattern 41A is offset in a second direction relative to the center C2 of conductor pattern 41B. The second direction is different from the first direction.

[0079] For example, as shown in Figure 18, in the inductor component 10C, in conductor patterns 411, 414, and 417, the center C1 of conductor pattern 41A is shifted to the right side 26 relative to the center C2 of conductor pattern 41B. Also, in conductor pattern 413, the center C1 of conductor pattern 41A is shifted to the left side 25 relative to the center C2 of conductor pattern 41B. Furthermore, in conductor patterns 412 and 415, the center C1 of conductor pattern 41A is shifted inward in the radial direction 102 of the coil conductor 40 relative to the center C2 of conductor pattern 41B. Also, in conductor pattern 416, the center C1 of conductor pattern 41A is shifted outward in the radial direction 102 of the coil conductor 40 relative to the center C2 of conductor pattern 41B.

[0080] In other words, in the inductor component 10C, there are four directions in which the center C1 of conductor pattern 41A is offset from the center C2 of conductor pattern 41B in the seven conductor patterns 411 to 417. In this case, one of the four directions (the direction toward the right side 26, the direction toward the left side 25, the direction toward the inside of the radial direction 102 of the coil conductor 40, and the direction toward the outside of the radial direction 102 of the coil conductor 40) corresponds to the first direction, and one of the other three corresponds to the second direction.

[0081] In the inductor component 10C, the mode of displacement of the center C1 of the conductor pattern 41A relative to the center C2 of the conductor pattern 41B is not limited to the mode shown in Figure 18.

[0082] For example, in Figure 18, there are four directions in which the center C1 of the conductor pattern 41A is offset from the center C2 of the conductor pattern 41B in the inductor component 10C, but there may be two, three, or five or more such directions.

[0083] Furthermore, the manner of the positional displacement may be random, as shown in Figure 18, or it may have a certain regularity, different from Figure 18. An example of a manner with a certain regularity is as follows: In conductor patterns 411, 413, 415, and 417, the center C1 of conductor pattern 41A is shifted to the right side 26 relative to the center C2 of conductor pattern 41B. On the other hand, in conductor patterns 412, 414, and 416, the center C1 of conductor pattern 41A is shifted to the left side 25 relative to the center C2 of conductor pattern 41B.

[0084] In a configuration where the center C1 of conductor pattern 41A is offset in the same direction relative to the center of conductor pattern 41B in all conductor patterns 41, there is a risk of uneven distribution of internal stress in the inductor component. According to the fourth embodiment, the center C1 of conductor pattern 41A is offset in multiple directions relative to the center C2 of conductor pattern 41B. As a result, in the inductor component 10C, the internal stress generated based on conductor pattern 41A and the internal stress generated based on conductor pattern 41B can cancel each other out. Consequently, the uneven distribution of internal stress in the inductor component 10C can be reduced.

[0085] <Fifth Embodiment> Figure 19 is a schematic cross-sectional view showing a cross-section corresponding to the AA section in Figure 1 of an inductor component according to the fifth embodiment of this disclosure. The difference between the inductor component 10D according to the fifth embodiment and the inductor component 10 according to the first embodiment is that the conductor patterns located at both ends in the axial direction of the coil conductor 40 are located radially outward of the coil conductor 40 than the conductor patterns adjacent to those conductor patterns. The differences from the first embodiment will be described below. Similarities with the inductor component 10 according to the first embodiment are given the same reference numerals, and their descriptions will be omitted in principle, and will be described as necessary.

[0086] As shown in Figure 19, in the inductor component 10D, the conductor patterns 411 and 417 are located at both ends of the coil conductor 40 in the axial direction 101. In other words, in the inductor component 10D shown in Figure 19, the conductor patterns 411 and 417 correspond to the conductor patterns at both ends.

[0087] The conductor pattern 41A of conductor pattern 411 and the conductor pattern 41B of conductor pattern 417 are located on the outermost side of the coil conductor 40 in the axial direction 101. In conductor pattern 411, the conductor pattern 41B is located further inward in the axial direction 101 of the coil conductor 40 than the conductor pattern 41A. In conductor pattern 417, the conductor pattern 41A is located further inward in the axial direction 101 of the coil conductor 40 than the conductor pattern 41B. Therefore, in the inductor component 10D shown in Figure 19, the conductor pattern 41A of conductor pattern 411 and the conductor pattern 41B of conductor pattern 417 correspond to the first conductor pattern. Furthermore, in the inductor component 10D shown in Figure 19, the conductor pattern 41B of conductor pattern 411 and the conductor pattern 41A of conductor pattern 417 correspond to the second conductor pattern.

[0088] The center C3 of conductor pattern 41A in conductor pattern 411 is located further out in the radial direction 102 of the coil conductor 40 than the center C4 of conductor pattern 41B in conductor pattern 411. The center C5 of conductor pattern 41B in conductor pattern 417 is located further out in the radial direction 102 of the coil conductor 40 than the center C6 of conductor pattern 41A in conductor pattern 417. In other words, the center of the first conductor pattern in the double-ended conductor pattern is located further out in the radial direction 102 of the coil conductor 40 than the center of the second conductor pattern in the double-ended conductor pattern.

[0089] The magnetic flux 103 generated in the coil conductor 40 spreads radially 102 along the coil conductor 40 at one end of the axial direction 101 of the coil conductor 40 (near the conductor pattern 417 in the configuration shown in Figure 19), and proceeds axially 101 from the inside to the outside of the coil conductor 40. The magnetic flux 103 generated in the coil conductor 40 narrows radially 102 along the coil conductor 40 at the other end of the axial direction 101 of the coil conductor 40 (near the conductor pattern 411 in the configuration shown in Figure 19), and proceeds axially 101 from the outside to the inside of the coil conductor 40.

[0090] According to the fifth embodiment, the conductor patterns 411 and 417 are located at the ends of the coil conductor 40 in the axial direction 101. In this case, in the conductor pattern 411, the center C3 of the conductor pattern 41A located outside the axial direction 101 is located further out in the radial direction 102 of the coil conductor 40 than the center C4 of the conductor pattern 41B located inside the axial direction 101. In the conductor pattern 417, the center C5 of the conductor pattern 41B located outside the axial direction 101 is located further out in the radial direction 102 of the coil conductor 40 than the center C6 of the conductor pattern 41A located inside the axial direction 101. This reduces the shielding of magnetic flux 103 moving from the inside to the outside of the coil conductor 40 and magnetic flux 103 moving from the outside to the inside of the coil conductor by the conductor pattern 41A of the conductor pattern 411 and the conductor pattern 41B of the conductor pattern 417. As a result, the efficiency of obtaining the L value of the inductor component 10D can be increased.

[0091] <Variation> In the embodiments described above, examples are shown where the axial direction 101 of the coil conductor 40 is parallel to the mounting surface, that is, where the coil conductor 40 is horizontally wound. However, the coil conductor 40 is not limited to horizontal winding. For example, the axial direction 101 of the coil conductor 40 may be perpendicular to the mounting surface. In other words, the coil conductor 40 may be a so-called vertical winding.

[0092] In the embodiments described above, examples are shown in which each of the external electrodes 31 and 32 has an L-shape, but the shape of the external electrodes 31 and 32 is not limited to an L-shape.

[0093] For example, each of the external electrodes 31 and 32 may be provided only on the lower surface 22 of the base body 2.

[0094] Furthermore, for example, the external electrode 31 may be provided so as to cover the left side of the base body 2, and the external electrode 32 may be provided so as to cover the right side of the base body 2. Specifically, the external electrode 31 may consist of the entire left side surface 25 and portions extending from the edge of the left side surface 25 to the upper surface 21, lower surface 22, front side surface 23, and rear side surface 24. The external electrode 32 may consist of the entire right side surface 26 and portions extending from the edge of the right side surface 26 to the upper surface 21, lower surface 22, front side surface 23, and rear side surface 24.

[0095] The inductor components described above can also be expressed as follows.

[0096] (1) An inductor component according to one aspect of the present disclosure is A base body made of an insulator, The above-mentioned body comprises a coil conductor provided inside, The coil conductor comprises a plurality of conductor patterns provided on each of a plurality of virtual inner surfaces arranged at intervals in the axial direction of the coil conductor so as to form part of an annular trajectory, and a connecting conductor that electrically connects two adjacent conductor patterns among the plurality of conductor patterns. At least one of the plurality of conductor patterns comprises a first conductor pattern and a second conductor pattern that are aligned in the axial direction and in contact with each other. In a cross-section including the axis of the coil conductor, the center of the first conductor pattern in a direction perpendicular to the axial direction is at a different position from the center of the second conductor pattern in a direction perpendicular to the axial direction.

[0097] (2) In the inductor component of (1), In a cross-section including the shaft, the width of the first conductor pattern, which is the length of the coil conductor in the first conductor pattern along the radial direction, may be the same as the width of the second conductor pattern, which is the length of the coil conductor in the second conductor pattern along the radial direction.

[0098] (3) In the inductor component of (1), In a cross-section including the shaft, the width of the first conductor pattern, which is the length of the coil conductor in the first conductor pattern along the radial direction, may be different from the width of the second conductor pattern, which is the length of the coil conductor in the second conductor pattern along the radial direction.

[0099] (4) In any one of the inductor components from (1) to (3), The thickness of the first conductor pattern, which is the length parallel to the axial direction in the first conductor pattern, may be the same as the thickness of the second conductor pattern, which is the length parallel to the axial direction in the second conductor pattern.

[0100] (5) In any one of the inductor components from (1) to (3), The thickness of the first conductor pattern, which is the length parallel to the axial direction in the first conductor pattern, may be different from the thickness of the second conductor pattern, which is the length parallel to the axial direction in the second conductor pattern.

[0101] (6) In any one of the inductor components from (1) to (5), At least two of the plurality of conductor patterns may include a first conductor pattern located in one of the axial directions and a second conductor pattern located in the other of the axial directions. In all of the at least two conductor patterns, the center of the first conductor pattern in the direction perpendicular to the axial direction may be shifted in the same direction with respect to the center of the second conductor pattern in the direction perpendicular to the axial direction.

[0102] (7) In any one of the inductor components from (1) to (5), At least two of the plurality of conductor patterns may include a first conductor pattern located in one of the axial directions and a second conductor pattern located in the other of the axial directions. In some of the conductor patterns among the at least two conductor patterns, the center of the first conductor pattern in the direction perpendicular to the axial direction may be shifted in a first direction relative to the center of the second conductor pattern in the direction perpendicular to the axial direction. In at least one of the two conductor patterns other than the aforementioned partial conductor patterns, the center of the first conductor pattern in the direction perpendicular to the axial direction may be shifted in a second direction different from the first direction with respect to the center of the second conductor pattern in the direction perpendicular to the axial direction.

[0103] (8) In any one of the inductor components from (1) to (7), In the two end-conductor patterns located at both ends of the coil conductor in the axial direction among the plurality of conductor patterns, the first conductor pattern of the end-conductor pattern may be located on the outermost side in the axial direction of the coil conductor, and the second conductor pattern of the end-conductor pattern may be located inward in the axial direction from the first conductor pattern of the end-conductor pattern. The center of the first conductor pattern in the end-ended conductor pattern, in a direction perpendicular to the axial direction, may be located radially outward of the coil conductor than the center of the second conductor pattern in the end-ended conductor pattern, in a direction perpendicular to the axial direction.

[0104] Furthermore, by appropriately combining any of the various embodiments described above, the effects of each embodiment can be achieved.

[0105] Although the present invention has been fully described in relation to preferred embodiments with reference to the drawings as appropriate, various modifications and alterations will be obvious to those skilled in the art. Such modifications and alterations should be understood to be included within the scope of the invention as defined in the appended claims, as long as they do not fall outside that scope. [Explanation of Symbols]

[0106] 10 Inductor Components 20 base body 20A Virtual interior 40 Coil Conductors 41 Conductor Pattern 411 Conductor Pattern (Both Ends Conductor Pattern) 417 Conductor Pattern (Both Ends Conductor Pattern) 41A Conductor pattern (First conductor pattern) 41B Conductor pattern (second conductor pattern) 42 Connecting conductors 101 Axis 102 Radial

Claims

1. A base body made of an insulator, The above-mentioned body comprises a coil conductor provided inside, The coil conductor comprises a plurality of conductor patterns provided on each of a plurality of virtual inner surfaces arranged at intervals in the axial direction of the coil conductor so as to form part of an annular trajectory, and a connecting conductor that electrically connects two adjacent conductor patterns among the plurality of conductor patterns. At least one of the plurality of conductor patterns comprises a first conductor pattern and a second conductor pattern that are aligned in the axial direction and in contact with each other. In a cross-section including the axis of the coil conductor, the center of the first conductor pattern in the direction perpendicular to the axial direction is at a different position from the center of the second conductor pattern in the direction perpendicular to the axial direction. At least two of the plurality of conductor patterns include a first conductor pattern located in one of the axial directions and a second conductor pattern located in the other of the axial directions. In some of the conductor patterns among the at least two conductor patterns, the center of the first conductor pattern in the direction perpendicular to the axial direction is shifted in a first direction relative to the center of the second conductor pattern in the direction perpendicular to the axial direction. An inductor component in which, in at least one of the two conductor patterns other than the aforementioned partial conductor patterns, the center of the first conductor pattern in the direction perpendicular to the axial direction is shifted in a second direction different from the first direction with respect to the center of the second conductor pattern in the direction perpendicular to the axial direction.

2. A base body made of an insulator, The above-mentioned body comprises a coil conductor provided inside, The coil conductor comprises a plurality of conductor patterns provided on each of a plurality of virtual inner surfaces arranged at intervals in the axial direction of the coil conductor so as to form part of an annular trajectory, and a connecting conductor that electrically connects two adjacent conductor patterns among the plurality of conductor patterns. At least one of the plurality of conductor patterns comprises a first conductor pattern and a second conductor pattern that are aligned in the axial direction and in contact with each other. In a cross-section including the axis of the coil conductor, the center of the first conductor pattern in the direction perpendicular to the axial direction is at a different position from the center of the second conductor pattern in the direction perpendicular to the axial direction. In the two end-conductor patterns located at both ends of the coil conductor in the axial direction among the plurality of conductor patterns, the first conductor pattern of the end-conductor pattern is located on the outermost side in the axial direction of the coil conductor, and the second conductor pattern of the end-conductor pattern is located inward in the axial direction from the first conductor pattern of the end-conductor pattern. An inductor component in which the center of the first conductor pattern in the direction perpendicular to the axial direction of the end-ended conductor pattern is located radially outward of the coil conductor than the center of the second conductor pattern in the direction perpendicular to the axial direction of the end-ended conductor pattern.

3. The inductor component according to claim 1 or 2, wherein, in a cross-section including the shaft, the width of the first conductor pattern, which is the length along the radial direction of the coil conductor in the first conductor pattern, is the same as the width of the second conductor pattern, which is the length along the radial direction in the second conductor pattern.

4. In a cross-section including the shaft, the width of the first conductor pattern, which is the length along the radial direction of the coil conductor in the first conductor pattern, is different from the width of the second conductor pattern, which is the length along the radial direction in the second conductor pattern, according to claim 1 or 2.

5. The inductor component according to claim 1 or 2, wherein the thickness of the first conductor pattern, which is a length parallel to the axial direction in the first conductor pattern, is the same as the thickness of the second conductor pattern, which is a length parallel to the axial direction in the second conductor pattern.

6. The inductor component according to claim 1 or 2, wherein the thickness of the first conductor pattern, which is a length parallel to the axial direction in the first conductor pattern, is different from the thickness of the second conductor pattern, which is a length parallel to the axial direction in the second conductor pattern.

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