Coil component, coil array sheet, method for producing coil component, and electronic / electric device

Abstract

A coil component 100A comprising: a coil part 10 that includes a first spiral conductor part 11 which has a spiral shape when viewed in in a first direction (Z1-Z2 direction); a body part 30 that contacts and covers the coil part in a manner such that both ends of the coil part 10 are exposed, and that contains a magnetic powder; a separate conductor part 400 that has a portion which is embedded in the body part 30 and that is separate from the coil part 10; and a pair of external electrodes (first terminal part 41, second terminal part 42) that respectively contact both ends of the coil part 10 which are exposed from the body part 30, and that are electrically connected via the coil part 10, wherein, when a plane that is along the first direction (Z1-Z2 direction) and that is shared with the first spiral conductor part 11 is defined as a first plane, the separate conductor part 400 includes a first separate conductor part 401 which has a first exposed surface 401a that is exposed from the body part 30 in an in-plane direction of the first plane, and the first separate conductor part 401 contacts one of the pair of external electrodes (first terminal part 41, second terminal part 42) at the first exposed surface 401a.

Description

Coil component, coil array sheet, coil component manufacturing method, and electronic / electrical device

[0001] The present invention relates to a coil component, a coil array sheet, a method for manufacturing a coil component, and an electronic / electrical device in which the coil component is mounted.

[0002] Patent Document 1 discloses a coil component including a main body, a coil section disposed within the main body and including a lead pattern, external electrodes disposed on a first surface of the main body, and a plurality of connection vias disposed within the main body, connecting the external electrodes and the lead pattern and integrating them, wherein the area of ​​the end face of a lower portion of the connection vias relatively closer to the external electrodes is different from the area of ​​the end face of an upper portion of the connection vias relatively closer to the lead pattern. Patent Document 2 discloses a manufacturing method for preventing coil misalignment using a guide member and an electronic component in which a portion of the guide member remains inside the main body. Patent Document 3 discloses a manufacturing method for preventing coil misalignment using a bridge pattern portion when compressing a magnetic layer, and an electronic component in which the bridge pattern portion remains inside the main body. Patent Document 4 discloses a manufacturing method for preventing coil misalignment using holes and pillar members when thermocompressing a multilayer coil. Patent Document 5 discloses a manufacturing method for supplying current to each coil via a lead wire.

[0003] US Patent Application Publication No. 2022 / 0189680 JP 2018-170494 A JP 2018-101797 A JP 2000-68143 A JP 2013-197588 A

[0004] In coil components, the magnetic properties of the product change significantly depending on the magnetic field generated around the connection electrodes and support members. Furthermore, when the coil is covered with a main body containing magnetic powder, it is desirable to ensure sufficient positioning accuracy of the coil relative to the main body and to reduce the resistance at the connection interface between the connection electrodes and the lead-out parts.

[0005] The present invention aims to provide a coil component, a coil array sheet, a method for manufacturing a coil component, and electronic / electrical equipment that can achieve sufficient positioning accuracy of the coil portion relative to the main body portion and stable magnetic characteristics.

[0006] In one aspect, the present invention, provided to solve the above-mentioned problems, comprises a coil portion including a first spiral conductor portion having a spiral shape when viewed in a first direction, a main body portion that contacts and covers the coil portion so that both ends of the coil portion are exposed and contains magnetic powder, a separate conductor portion that has a portion embedded in the main body portion and is spaced apart from the coil portion, and a pair of external electrodes that contact both ends of the coil portion exposed from the main body portion and are electrically connected through the coil portion, wherein when a surface shared with the first spiral conductor portion among the surfaces along the first direction is defined as a first surface, the separate conductor portion includes a first separate conductor portion having a first exposed surface that is exposed from the main body portion in an in-plane direction of the first surface, and the first separate conductor portion is a coil component that contacts one of the pair of external electrodes at the first exposed surface.

[0007] In the above coil component, the coil portion further includes a second spiral conductor portion having a spiral shape aligned with the first spiral conductor portion in the first direction, and a via conductor portion that contacts one end of the first spiral conductor portion and one end of the second spiral conductor portion to electrically connect the first spiral conductor portion and the second spiral conductor portion in the first direction, and when a surface along the first direction that is shared with the second spiral conductor portion is defined as a second surface, the separate conductor portion has a second exposed surface exposed from the main body portion in an in-plane direction of the second surface, and includes a second separate conductor portion within the main body portion that is electrically independent of the first separate conductor portion, and the second separate conductor portion may contact the other of the pair of external electrodes at the second exposed surface.

[0008] Another aspect of the present invention is a coil component comprising: a coil portion including a first spiral conductor portion having a spiral shape when viewed in a first direction; a main body portion that contacts and covers the coil portion so that both ends of the coil portion are exposed, and that contains magnetic powder; and a pair of external electrodes that contact both ends of the coil portion exposed from the main body portion and are electrically connected through the coil portion, wherein the coil portion further includes a first lead-out portion that contacts the other end of the first spiral conductor portion and one of the pair of external electrodes, and when a surface that is shared with the first spiral conductor portion among the surfaces along the first direction is defined as a first surface, the first lead-out portion has a first lead-out exposed surface that is exposed from the main body portion, and the first lead-out exposed surface extends along the intersection line between the surface of the main body portion and the first surface.

[0009] In the above coil component, the coil portion further includes a second spiral conductor portion having a spiral shape aligned with the first spiral conductor portion in the first direction, a via conductor portion that contacts one end of the first spiral conductor portion and one end of the second spiral conductor portion to electrically connect the first spiral conductor portion and the second spiral conductor portion in the first direction, and a second lead-out portion that contacts the other end of the second spiral conductor portion and the other of the pair of external electrodes, and when the surface shared with the second spiral conductor portion among the surfaces along the first direction is defined as the second surface, the second lead-out portion may have a second lead-out exposed surface exposed from the main body portion, and the second lead-out exposed surface may extend along the intersection line between the surface of the main body portion and the second surface.

[0010] Another aspect of the present invention is a coil component comprising: a coil portion including a first spiral conductor portion having a spiral shape when viewed in a first direction; a main body portion that contacts and covers the coil portion so that both ends of the coil portion are exposed, and that contains magnetic powder; and a pair of external electrodes that contact both ends of the coil portion exposed from the main body portion and are electrically connected through the coil portion, wherein at least one of the ends of the coil portion extends on the surface of the main body portion along a line intersecting a surface of the main body portion and a first plane along the first direction that is shared with the first spiral conductor portion.

[0011] In the coil component, the envelope shape of the main body may be a substantially rectangular parallelepiped, and the first separate conductor may be exposed from the main body on a side of the rectangular parallelepiped.

[0012] In the coil component, the envelope shape of the main body may be a substantially rectangular parallelepiped, and the second separate conductor may be exposed from the main body on a side of the rectangular parallelepiped.

[0013] In the above coil component, the main body portion has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and the point on the intersection line between the outer surface and the first surface that is farthest from the first spiral conductor portion may be included in the first exposed surface.

[0014] In the above coil component, the main body portion has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and the point on the intersection line between the outer surface and the second surface that is farthest from the second spiral conductor portion may be included in the second exposed surface.

[0015] In the coil component, the envelope shape of the main body may be a substantially rectangular parallelepiped.

[0016] In the above coil component, the main body portion has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and the point on the intersection line between the outer surface and the first surface that is farthest from the first spiral conductor portion may be included in the exposed surface from the main body portion at both ends of the coil portion.

[0017] In the above coil component, a contact surface between the first separate conductor portion and the main body portion may have a curvature in the first plane toward a corner of the rectangular parallelepiped.

[0018] In the above coil component, a contact surface between the second separate conductor portion and the main body portion may have a curvature in the second plane toward a corner of the rectangular parallelepiped.

[0019] In the above coil component, both ends of the coil portion may be wider in width within the first plane as they become farther away from the first spiral conductor portion.

[0020] In the above coil component, both ends of the coil portion may be wider in width within the second plane as they become farther away from the second spiral conductor portion.

[0021] In the coil component, the separate conductor portion may be made of Cu or a Cu alloy.

[0022] Another aspect of the present invention is a coil array sheet comprising: a plurality of coil sections each including a first spiral conductor section having a spiral shape when viewed in a first direction; and a connecting section connecting the plurality of coil sections; wherein an outer end of the spiral in the first spiral conductor section faces one side of a second direction, which is one of in-plane directions having the first direction as a normal; and the plurality of coil sections include a first array in which the plurality of first spiral conductor sections are arranged in a third direction, which is another of the in-plane directions having the first direction as a normal and which intersects with the second direction; the connecting section has a first connecting section including a plurality of first connecting sections each connected to one of the outer ends of the plurality of first spiral conductor sections; and a first bridge section connecting the plurality of first connecting sections and extending in the third direction as a whole; and the first bridge section has a first deflection suppression section which includes a portion extending in a direction intersecting with the third direction and suppresses deflection of the first bridge section in directions other than the third direction.

[0023] In the above coil array sheet, the coil section further includes a second spiral conductor section having a spiral shape aligned with the first spiral conductor section in the first direction, and a via conductor section that contacts one end of the first spiral conductor section and one end of the second spiral conductor section to electrically connect the first spiral conductor section and the second spiral conductor section in the first direction, an outer end of the spiral of the second spiral conductor section faces the other side in the second direction, and the plurality of coil sections are formed by a plurality of the second spiral conductor sections aligned in the third direction, The connecting portion may include a first array and a second array aligned in the first direction, and the connecting portion may have a second connecting portion including a plurality of second connecting portions each connected to one of the outer ends of a plurality of the second spiral conductor portions, and a second bridge portion connecting the plurality of second connecting portions and extending in the third direction as a whole, and the second bridge portion may have a second deflection suppression portion including a portion extending in a direction intersecting the third direction and suppressing deflection of the second bridge portion in directions other than the third direction.

[0024] In the above coil array sheet, the first deflection suppressing portion may have a crank portion including a portion extending in a direction intersecting the third direction.

[0025] In the coil array sheet, the direction intersecting the third direction may include a component in the first direction.

[0026] In the coil array sheet, the direction intersecting the third direction may include a component in the second direction.

[0027] In the coil array sheet, the first deflection suppression portion may include a frame-shaped portion having a polygonal envelope shape when viewed in the first direction or the second direction.

[0028] In the above coil array sheet, the first array may be a two-dimensional array in which the first spiral conductor portions are also arranged in a fourth direction, another in-plane direction normal to the first direction and intersecting the third direction, and the connecting portion may include a plurality of the first bridge portions and a first auxiliary bridge portion connecting two adjacent first bridge portions in the fourth direction, and the first auxiliary bridge portion may have a first auxiliary deflection suppression portion that includes a portion extending in a direction intersecting its extension direction and suppresses deflection of the first auxiliary bridge portion.

[0029] In the above coil array sheet, the first array may be a two-dimensional array in which the first spiral conductor portions are also aligned in a fourth direction, which is another in-plane direction normal to the first direction, and the second array may be a two-dimensional array in which the second spiral conductor portions are also aligned in the fourth direction, and the connecting portion may include a plurality of the first bridge portions and the second bridge portions, as well as a first auxiliary bridge portion connecting two of the first bridge portions adjacent to each other in the fourth direction and a second auxiliary bridge portion connecting two of the second bridge portions adjacent to each other in the fourth direction, the first auxiliary bridge portion having a first auxiliary deflection suppression portion that includes a portion extending in a direction intersecting the extension direction and suppresses deflection of the first auxiliary bridge portion, and the second auxiliary bridge portion having a second auxiliary deflection suppression portion that includes a portion extending in a direction intersecting the extension direction and suppresses deflection of the second auxiliary bridge portion.

[0030] In the above coil array sheet, the first connecting portion, when viewed in the first direction, forms a first closed path that contains at least one of the first spiral conductor portion, and the first closed path may have at least one of the first deflection suppression portion and the first auxiliary deflection suppression portion.

[0031] In the above coil array sheet, the first connecting portion, when viewed in the first direction, forms a first closed path that contains at least one of the first spiral conductor portion, and the first closed path has at least one of the first deflection suppression portion and the first auxiliary deflection suppression portion, and the second connecting portion, when viewed in the first direction, forms a second closed path that contains at least one of the second spiral conductor portion, and the second closed path has at least one of the second deflection suppression portion and the second auxiliary deflection suppression portion.

[0032] In the coil array sheet, the first bridge portion and the second bridge portion may have an overlapping portion when viewed in the first direction.

[0033] In the coil array sheet, the first auxiliary bridge portion and the second auxiliary bridge portion may have an overlapping portion when viewed in the first direction.

[0034] In the coil array sheet, the connecting portion may have a portion made of a plating deposit.

[0035] and a cutting step of cutting the magnetic sheet at least in the first direction to form a plurality of coil chips, each of which includes one of the coil sections and a material containing the magnetic powder located around it. The method for manufacturing a coil component includes: a conductor forming step of forming a conductor on an insulating sheet; a removal step of removing at least a portion of an exposed portion of the insulating sheet that is not covered by the conductor, thereby producing a coil array sheet including: a plurality of coil sections, each of which has a portion made of the conductor and includes a spiral conductor section that is spiral-shaped when viewed in a first direction; and a connecting portion connecting the plurality of coil sections; a molding step of covering the coil array sheet with a material containing magnetic powder and molding it to form a magnetic sheet whose thickness direction is the first direction; and a cutting step of cutting the magnetic sheet at least in the first direction to form a plurality of coil chips, each of which includes one of the coil sections and a material containing the magnetic powder located around the coil section. The connecting portion has a plurality of closed paths, each of which includes one or more of the spiral conductor sections when viewed in the first direction. The plurality of closed paths has a deflection suppression portion that includes a portion extending in a direction intersecting the extension direction of the closed path and that suppresses deflection of the coil array sheet.

[0036] In the method for manufacturing the coil component, the spiral conductor includes a plurality of first spiral conductors provided on a first surface, which is one of the surfaces of the insulating sheet, and a plurality of second spiral conductors provided on a second surface, which is the other of the surfaces of the insulating sheet; the connecting portions include first connecting portions provided on the first surface and connecting the plurality of first spiral conductors together, and second connecting portions provided on the second surface and connecting the plurality of second spiral conductors together; the insulating sheet has a through hole; in the conductor forming step, a via conductor is formed inside the through hole as a part of the conductor, electrically connecting an end portion on an inner circumferential side of the first spiral conductor and an end portion on an inner circumferential side of the second spiral conductor; The coil array sheet may further include an insulating step of forming an insulating layer on the surface of the coil array sheet before the cutting step, an outer coat forming step of forming an outer coat made of an insulator on the surface of the magnetic sheet before the cutting step, and an electrode forming step of forming a pair of external electrodes on the surface of the coil chip and electrically connecting one of the pair of external electrodes to the other of the pair of external electrodes through the coil portion of the coil chip, wherein each of the plurality of closed paths of the first connecting portion may include one or more spiral conductor portions when viewed in the first direction, and each of the plurality of closed paths of the second connecting portion may include one or more spiral conductor portions when viewed in the first direction.

[0037] In the above-described method for manufacturing a coil component, the deflection suppression portion may have a crank portion including a portion extending in a direction intersecting the direction in which the closed path extends.

[0038] In the above-mentioned method for manufacturing a coil component, the insulating sheet may have a connecting portion through hole at a position sandwiched between the first connecting portion and the second connecting portion, and in the conductor forming step, a via connecting portion connecting the first connecting portion and the second connecting portion may be formed inside the connecting portion through hole as another part of the conductor.

[0039] In the above-described method for manufacturing a coil component, the deflection suppression portion may include a frame-shaped portion having a polygonal envelope shape when viewed in the first direction.

[0040] In the above-mentioned method for manufacturing a coil component, the frame-shaped portion may be provided at the boundary portion of two closed paths that each contain two adjacent spiral conductor portions in a direction perpendicular to the first direction.

[0041] In the above-mentioned method for manufacturing a coil component, the two closed paths that contain each of the two spiral conductor portions adjacent to each other in a direction perpendicular to the first direction may have a shared portion, and the deflection suppression portion may be provided in the shared portion.

[0042] In the above-mentioned method for manufacturing a coil component, the closed path of the first connecting portion and the closed path of the second connecting portion may have an overlapping portion that overlaps when viewed in the first direction.

[0043] In the above-mentioned method for manufacturing a coil component, the deflection suppression portion may be arranged to include the overlapping portion and have a crank portion including a portion extending in a direction intersecting the extension direction of the closed path, and the crank portion may be arranged so as to be sandwiched between the two overlapping portions when viewed in the first direction.

[0044] In the above-described method for manufacturing a coil component, the closed path may have a rectangular envelope shape when viewed in the first direction.

[0045] In the above-described method for manufacturing a coil component, the coil chip may include a portion of the connecting portion, and the portion of the connecting portion may be electrically independent from the coil portion.

[0046] Another aspect of the present invention is an electronic or electrical device incorporating the above-described coil component, wherein the coil component is connected to a substrate at terminals provided on both ends of the coil portion exposed from the main body. The electronic or electrical device according to the present invention includes the above-described coil component, and therefore has excellent overall characteristics as an inductance element.

[0047] According to the present invention, a coil component, a coil array sheet, a method for manufacturing a coil component, and an electronic / electrical device are provided that can achieve sufficient positioning accuracy of the coil portion relative to the main body portion and stable magnetic properties.

[0048] 7A . FIG. 7B is a perspective view conceptually illustrating the shape of a coil component according to an embodiment of the present invention. FIG. 7C is an XY plan view illustrating the structure of a coil conductor included in the coil component according to an embodiment of the present invention. FIG. 7D is an XY plan view illustrating the structure of a first spiral conductor included in the coil component according to an embodiment of the present invention. FIG. 7E is an XZ cross-sectional view taken along line A-A' in FIG. 3 . FIG. 7F is a YZ cross-sectional view taken along line B-B' in FIG. 3 . FIG. 7G is an explanatory diagram of an example (conductor forming step, removal step) of a manufacturing method of a coil component according to an embodiment of the present invention. FIG. 7H is an explanatory diagram of an example (conductor forming step, removal step) of a manufacturing method of a coil array sheet. FIG. 7H is a YZ cross-sectional view taken along line C-C' in FIG. 7A . FIG. 7I is an explanatory diagram of an example (shaping step) of a manufacturing method of a coil component according to an embodiment of the present invention. FIG. 7J is an explanatory diagram of an example (cutting step) of a manufacturing method of a coil component according to an embodiment of the present invention (details of the cutting position). FIG. 7I is a plan view illustrating a coil array sheet according to another example (part 1). FIG. 7I is a plan view illustrating a coil component according to another example (part 1). FIG. 7I is a plan view illustrating a coil array sheet according to another example (part 2). FIG. 7I is a plan view illustrating a coil component according to another example (part 2). 10 is a plan view illustrating a coil array sheet according to another example (part 3). FIG. 11 is a plan view illustrating a coil array sheet according to another example (part 3). FIG. 12 is a plan view illustrating a coil component according to another example (part 3). FIG. 13 is a plan view illustrating a coil component according to another example (part 3). FIG. 14 is a plan view illustrating a coil array sheet according to another example (part 4). FIG. 15 is a plan view illustrating a coil array sheet according to another example (part 4). FIG. 16 is a plan view illustrating a coil component according to another example (part 4). FIG. 17 is a plan view illustrating a coil array sheet according to another example (part 5). FIG. 18 is a plan view illustrating a coil component according to another example (part 5). FIG. 19 is a plan view illustrating a coil array sheet according to another example (part 6). FIG. 19 is a plan view illustrating a coil array sheet according to another example (part 6).FIG. 10 is a plan view illustrating a coil array sheet according to another example (No. 7). FIG. 11 is a plan view illustrating a coil array sheet according to another example (No. 7). FIG. 12 is a plan view illustrating a coil component according to another example (No. 7). FIG. 13 is a plan view illustrating a coil array sheet according to another example (No. 8). FIG. 14 is a plan view illustrating a coil array sheet according to another example (No. 8). FIG. 15 is a plan view illustrating a coil component according to another example (No. 8). FIG. 16 is a plan view illustrating a coil array sheet according to another example (No. 9). FIG. 17 is a plan view illustrating a coil array sheet according to another example (No. 9). FIG. 18 is a plan view illustrating a coil component according to another example (No. 9). FIG. 19 is a plan view illustrating a coil component according to another example (No. 9). FIG. 11 is a plan view illustrating a coil array sheet according to another example (No. 10). FIG. 12 is a plan view illustrating a coil array sheet according to another example (No. 10). FIG. 13 is a plan view illustrating a coil component according to another example (No. 10). FIG. 14 is a plan view illustrating a coil component according to another example (No. 10). FIG. 15 is a plan view illustrating a coil component according to another example (No. 11). 11A and 11B are plan views illustrating a coil array sheet according to another example (No. 11), and a coil component according to another example (No. 11).

[0049] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0050] FIG. 1 is a perspective view conceptually illustrating the shape of a coil component according to an embodiment of the present invention. FIG. 2 is a view illustrating the structure of a coil conductor included in a coil component according to an embodiment of the present invention. For convenience of explanation, in FIG. 2, the coil conductor and separate conductor are depicted with solid lines, the main body is depicted with dashed lines, and other components are not shown. FIG. 3 is an XY plan view illustrating the structure of a first spiral conductor included in a coil component according to an embodiment of the present invention. FIG. 4 is an XY plan view illustrating the structure of a second spiral conductor included in a coil component according to an embodiment of the present invention. FIGS. 5 and 6 are cross-sectional views illustrating the structure of a coil portion included in a coil component according to an embodiment of the present invention. Note that FIG. 2 is a view seen from the Z1 side in the Z1-Z2 direction. FIG. 3 is a plan view seen from the Z1 side in the Z1-Z2 direction, in which the coil conductor and separate conductor are depicted with solid lines and other parts are depicted with dashed lines. FIG. 4 is a plan view seen from the Z2 side in the Z1-Z2 direction, in which the coil conductor and separate conductor are depicted with solid lines and other parts are depicted with dashed lines. In Fig. 5, the main body, terminals, and exterior coating are indicated by dashed lines, and the cross section taken along line A-A' in Fig. 3 is shown as an XZ cross section. In Fig. 6, the main body and exterior coating are indicated by dashed lines, and the cross section taken along line B-B' in Fig. 3 is shown as a YZ cross section.

[0051] (Overall structure) A coil component 100A according to one embodiment of the present invention comprises a coil portion 10 having a coil conductor portion 20, a main body portion 30, a first terminal portion 41, a second terminal portion 42, exterior coatings 50, 60, and separate conductor portions 400 (first separate conductor portion 401, second separate conductor portion 402).

[0052] 2 and 3, the coil portion 10 has a coil conductor portion 20 including a first coil conductor portion 201 having a spiral-shaped first spiral conductor portion 11 that extends around an axis O along a first direction (Z1-Z2 direction) from an inner circumferential end portion 12, which is the inner circumferential end of a pair of ends of the first spiral conductor portion 11, toward an outer circumferential end portion 13, which is the outer circumferential end of the pair of ends of the first spiral conductor portion 11. In FIG. 2, the first spiral conductor portion 11 has conductors arranged in a spiral shape that extends clockwise from the inner circumferential end portion 12 toward the outer circumferential end portion 13, which is the outer circumferential end of the pair of ends of the first spiral conductor portion 11, away from the axis O. In this specification, the "spiral direction" of the spiral portion means the direction from the inner circumferential end portion to the outer circumferential end portion. Furthermore, "viewed in the first direction" means that it may be viewed from the Z1 side in the Z1-Z2 direction, or from the Z2 side in the Z1-Z2 direction.

[0053] The conductor (conductive material) constituting the coil conductor portion 20 is not limited as long as it has appropriate conductivity. Specific examples of the conductor constituting the coil conductor portion 20 include metals such as copper, copper alloys, aluminum, and aluminum alloys. The coil conductor portion 20 can be manufactured using a film formation technique such as plating. The coil portion 10 has an insulating coil insulation portion (not shown in FIGS. 1 to 4 ) on the surface of the coil conductor portion 20. This coil insulation portion ensures insulation between adjacent conductors (between the surfaces of the conductors facing each other) in the coil conductor portion 20. The coil insulation portion is made of, for example, a resin material. The ends (first lead-out exposed surface 140, second lead-out exposed surface 240) of the two ends (first lead-out portion 14, second lead-out portion 24) of the coil conductor portion 20 are not provided with coil insulation, and the coil portion 10 can be electrically connected to other components at these ends.

[0054] 2 and 4, the coil conductor portion 20 includes a second coil conductor portion 202 having a second spiral conductor portion 21 arranged alongside the first spiral conductor portion 11 in the first direction. The second spiral conductor portion 21 has a spiral shape around an axis O along the first direction (Z1-Z2 direction), from one end (inner peripheral end portion 22) which is the inner peripheral end of the second spiral conductor portion 21 to the other end (outer peripheral end portion 23) which is the outer peripheral end of the second spiral conductor portion 21, moving away from the axis O. In the second spiral conductor portion 21, the conductor is arranged in a spiral shape moving away from the axis O in the opposite direction to the first spiral conductor portion 11 (counterclockwise in FIG. 2) when viewed from the Z1 side in the Z1-Z2 direction.

[0055] The average value of the separation distance in the first direction (Z1-Z2 direction) between the first spiral conductor portion 11 and the second spiral conductor portion 21 is not particularly limited. The smaller this separation distance, the easier it is to reduce the height (dimension in the Z1-Z2 direction) of the coil component 100A. However, if the separation distance is too small, the insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21 is likely to deteriorate. From the viewpoint of achieving both a low profile (low height) of the coil component 100A and high insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21, it may be preferable that the separation distance be 0.4 μm or more and 20 μm or less. In order to reduce variation in the separation distance and more reliably support the coil in the same plane during manufacturing, the separation distance is more preferably 1.0 μm or more, and even more preferably 5.0 μm or more.

[0056] The inner peripheral end 12, which is one end of the first spiral conductor portion 11, and the inner peripheral end 22, which is one end of the second spiral conductor portion 21, are electrically connected by a via conductor portion VP. Starting from the connection portion to the via conductor portion VP, the first spiral conductor portion 11 and the second spiral conductor portion 21 spiral in opposite directions. The via conductor portion VP may be composed of the same conductor as the coil conductor portion 20. In a specific example, the via conductor portion VP is made of the same material as the first spiral conductor portion 11 and the second spiral conductor portion 21, and is manufactured simultaneously with the first spiral conductor portion 11 and the second spiral conductor portion 21. In this case, the via conductor portion VP is integrated with one inner peripheral end portion 12 of the first spiral conductor portion 11 and one inner peripheral end portion 22 of the second spiral conductor portion 21.

[0057] A first lead 14 is connected to the outer circumferential end 13, which is the other end of the first spiral conductor 11, as a part of the first coil conductor 201, and a second lead 24 is connected to the outer circumferential end 23, which is the other end of the second spiral conductor 21, as a part of the second coil conductor 202. Therefore, the outer circumferential end 13 of the first spiral conductor 11 is essentially the interface with the first lead 14, and the outer circumferential end 23 of the second spiral conductor 21 is essentially the interface with the second lead 24. In a specific example, the first lead 14 and the second lead 24 are made of the same material as the first spiral conductor 11 and the second spiral conductor 21, and are manufactured simultaneously with the first spiral conductor 11 and the second spiral conductor 21. That is, the first coil conductor portion 201 is manufactured as a single unit, and the second coil conductor portion 202 is also manufactured as a single unit. In this case, the first lead portion 14 is seamlessly integrated with the outer peripheral end portion 13 of the first spiral conductor portion 11, and the second lead portion 24 is seamlessly integrated with the outer peripheral end portion 23 of the second spiral conductor portion 21.

[0058] That is, in this embodiment, the coil conductor 20 has a first coil conductor 201 having a first spiral conductor 11 and a first lead-out portion 14, a second coil conductor 202 having a second spiral conductor 21 and a second lead-out portion 24, and a via conductor VP, all of which are formed from a common conductive material. As shown in Figures 3 and 4, each turn of the first spiral conductor 11 and each turn of the second spiral conductor 21 are positioned so as to be aligned in the first direction (Z1-Z2 direction).

[0059] (Main Body) The main body 30 contains magnetic powder and has outer surfaces 30a, 30b, 30c, and 30d, which have multiple surfaces extending in a first direction, and a pair of intersecting surfaces 30e and 30f aligned in the first direction. The main body 30 covers at least a portion of the coil 10 with the two intersecting surfaces 30e and 30f. In this embodiment, the envelope shape of the main body 30 is a substantially rectangular parallelepiped, and includes multiple surfaces: two outer surfaces 30a and 30b aligned in the X1-X2 direction, two outer surfaces 30c and 30d aligned in the Y1-Y2 direction, and two intersecting surfaces 30e and 30f aligned in the first direction. The outer surfaces 30a, 30b, 30c, and 30d and the intersecting surfaces 30e and 30f that form the main body are referred to as the surface of the main body. Furthermore, main body 30 encompasses portions of first lead portion 14 other than the outermost end face (X2 side in the X1-X2 direction) of first lead portion 14 and the outermost end face (X1 side in the X1-X2 direction) of second lead portion 24, which are located at the ends of coil portion 10. First lead portion 14 has a first lead-out exposed surface 140 exposed from main body 30. When the surface along the first direction that is shared with first spiral conductor portion 11 is defined as first surface F1 (see FIGS. 5 and 6 ), first lead-out exposed surface 140 extends along the intersection line between the surface of main body 30 and first surface F1. Similarly, the second drawer portion 24 has a second drawer exposed surface 240 exposed from the main body portion 30, and when the surface along the first direction that is shared with the second spiral conductor portion 21 is defined as the second surface F2 (see Figures 5 and 6), the second drawer exposed surface 240 extends along the intersection line between the surface of the main body portion 30 and the second surface F2.

[0060] The structure of the magnetic powder is not limited. This structure may include a crystalline phase or an amorphous phase. Here, a crystalline material is defined as a material consisting of a crystalline phase, an amorphous material as a material consisting of an amorphous phase, and a composite material as a material consisting of a crystalline phase and an amorphous material. If the diffraction spectrum obtained by a general X-ray diffraction method includes a sharp diffraction peak that can identify the type of crystalline phase, the material contains a crystalline phase. Also, if the diffraction spectrum obtained by a general X-ray diffraction method includes a broad peak indicating an amorphous phase, the material contains an amorphous phase. If the DSC curve obtained by differential thermal analysis includes a peak indicating crystallization, i.e., heat generation associated with a phase change from an amorphous phase to a crystalline phase, the material also contains an amorphous phase.

[0061] The material system of the magnetic powder is not limited. Specific examples of crystalline materials include Fe—Si—Cr alloys, Fe—Ni alloys, Fe—Co alloys, Fe—V alloys, Fe—Al alloys, Fe—Si alloys, Fe—Si—Al alloys, pure iron, and ferrite. Carbonyl iron powder is preferred as pure iron powder. Specific examples of amorphous materials include Fe—Si—B alloys, Fe—P—C alloys, and Co—Fe—Si—B alloys. Specific examples of composite materials include Fe—Zr alloys, Fe—Zr—B alloys, Fe—Si—B—Nb—Cu alloys, and Fe—Si—B—P—Cu alloys. When the magnetic powder is a metal powder containing Fe, the synergistic effect of improving magnetic properties is particularly large.

[0062] The chemical composition of the magnetic powder is not limited. For example, an Fe—Si—Cr alloy may be composed of 1.0 to 10.0 mass% Si, 1.0 to 10.0 mass% Cr, and the balance consisting of Fe and impurities. Also, for example, an Fe—Ni alloy may be composed of 1.0 to 99.0 mass% Ni, and the balance consisting of Fe and impurities. Furthermore, for example, an Fe—P—C alloy may be composed of 1.0 to 13.0 atomic% P, 1.0 to 13.0 atomic% C, and the balance consisting of Fe and impurities. This Fe—P—C alloy may contain one or more optional elements selected from the group consisting of Ni, Sn, Cr, B, and Si. In this case, for example, the amount of Ni may be 0 to 10.0 atomic %, the amount of Sn may be 0 to 3.0 atomic %, the amount of Cr may be 0 to 6.0 atomic %, the amount of B may be 0 to 9.0 atomic %, and the amount of Si may be 0 to 7.0 atomic %. The amount of Fe is preferably 65 atomic % or more. Furthermore, for example, the Fe-Si-B-Nb-Cu alloy may be composed of 1.0 to 16.0 atomic % Si, 1.0 to 15.0 atomic % B, 0.50 to 5.0 atomic % Nb, 0.50 to 5.0 atomic % Cu, and the balance consisting of Fe and impurities. In this case, the amount of Fe is preferably 65 atomic % or more.

[0063] The shape of the magnetic powder is not limited. The magnetic powder may be spherical, elliptical, scaly, or irregularly shaped. The manufacturing method for obtaining these shapes is also not limited.

[0064] The particle size distribution of the magnetic powder is not limited. The particle size distribution of the magnetic powder can be obtained, for example, by analyzing an image (secondary electron image) obtained by capturing an image of a cut surface of the main body 30 using a scanning electron microscope. For example, the average equivalent circle diameter of the magnetic powder may be 0.50 to 50.0 μm. The distribution of equivalent circle diameters may include multiple peaks.

[0065] The magnetic powder may be subjected to a surface insulating treatment. When the magnetic powder is subjected to a surface insulating treatment, the insulation resistance of the main body 30 is improved. The type of surface insulating treatment to be applied to the magnetic powder is not limited. Examples include phosphate treatment, phosphate salt treatment, and oxidation treatment. The magnetic powder may have an insulating coating on the surface of the magnetic particles. This insulating coating may contain at least one element selected from the group consisting of Si, P, and B, and O (oxygen).

[0066] The magnetic powder may be a mixture of a plurality of powder materials. The magnetic powder is preferably a ferromagnetic material, and more preferably a soft magnetic material.

[0067] The main body 30 may further contain an optional auxiliary material. The optional auxiliary material may be, for example, a binder material or a modifier. The binder material binds together particles of the magnetic powder and the like contained in the main body 30. This binder material is preferably an insulating material to impart insulation resistance to the main body 30.

[0068] The binder material may be an organic material or an inorganic material. The organic material may be a resin material. Examples of the resin material include acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, melamine resin, and polyester resin. The inorganic material may be a glass-based material such as water glass. The binder material may be a product of a reaction such as thermal decomposition, or may be a mixture of multiple materials.

[0069] The modifier improves the flowability of the powder, adjusts the hardening speed of the binder material, etc. The modifier may be a glass-based material.

[0070] There are no limitations on the dimensions of the main body 30. For example, the maximum dimension of the main body 30 may be 3.2 mm or less.

[0071] 2 , the outermost end face (first exposed lead surface 140) of the first drawn portion 14 (on the X2 side in the X1-X2 direction) and the outermost end face (second exposed lead surface 240) of the second drawn portion 24 (on the X1 side in the X1-X2 direction), which are located at the end of the coil portion 10, are exposed from the main body portion 30 on side surfaces of the main body portion 30 aligned in the X1-X2 direction. A first terminal portion 41 is provided so as to be in electrical contact with the first exposed lead surface 140, and a second terminal portion 42 is provided so as to be in electrical contact with the second exposed lead surface 240. The first terminal portion 41 and the second terminal portion 42 are an example of a pair of external electrodes.

[0072] The first terminal 41 has a side surface portion 41a (see FIG. 1) that covers the side surface of the main body 30 on the X2 side in the X1-X2 direction. The second terminal 42 has a side surface portion 42a (see FIG. 1) that covers the side surface of the main body 30 on the X1 side in the X1-X2 direction. The first terminal 41 may have a bottom surface portion that is provided so as to cover a portion of the bottom surface (the surface on the Z2 side in the Z1-Z2 direction) of the main body 30. The second terminal 42 may have a bottom surface portion that is provided on the bottom surface of the main body 30 so as to cover a portion of the bottom surface while being spaced apart from the bottom surface portion of the first terminal 41. These bottom surface portions face the board during use.

[0073] The positions of the first terminal portion 41 and the second terminal portion 42 are not limited to the above positions. The first terminal portion 41 and the second terminal portion 42 may be formed to cover a portion of the top surface (the surface on the Z1 side in the Z1-Z2 direction) of the main body portion 30. Alternatively, the first terminal portion 41 and the second terminal portion 42 may be provided on only a portion of the bottom surface (the surface on the Z2 side in the Z1-Z2 direction) of the main body portion 30. In this case, the coil conductor portion 20 may have connecting conductive portions (not shown) that connect the two ends of the coil portion 10 (the first drawn-out portion 14, the second drawn-out portion 24) to the bottom surface of the main body portion 30 through the inside of the main body portion 30. In this case, the two ends of the coil portion 10 (the first drawn-out exposed surface 140, the second drawn-out exposed surface 240) may not be exposed on the side surfaces of the main body portion 30, and the connecting conductive portions may be exposed on the bottom surface of the main body portion 30.

[0074] The materials and configurations of the first terminal 41 and the second terminal 42 are not limited as long as they have appropriate conductivity. One non-limiting example of the first terminal 41 and the second terminal 42 is a layer having a Cu-plated / Ni-plated / Sn-plated structure from the side proximal to the surface of the main body 30. The first terminal 41 and the second terminal 42 may be composed of a coated electrode in which a conductive material such as silver is dispersed in a resin or the like. Alternatively, the first terminal 41 and the second terminal 42 may be a combination of plating and a coated electrode.

[0075] (External Coating) Insulating external coatings 50, 60 are provided as insulating layers on one intersecting surface 30f located on the Z2 side of the main body 30 in the Z1-Z2 direction and on the side surfaces aligned in the Y1-Y2 direction. The external coatings 50, 60 may be provided on the mounting surface of the coil component 100A (the surface on the side of one intersecting surface 30e located on the Z1 side of the main body 30 in the Z1-Z2 direction). For example, if each of the first terminal 41 and the second terminal 42 has a bottom surface extending over a portion of the main body 30 on the side of the one intersecting surface 30e, an insulating external coating may be provided on a portion of the one intersecting surface 30e of the main body 30 where the bottom surface is not provided. The external coatings 50, 60 may include a layer made of resin with an average thickness of 0.10 μm to 10.0 μm. This makes it easy to maintain the magnetic properties of the coil component 100A, improve the reliability of the coil component 100A by increasing the insulation of the surface of the coil component 100A, and improve the appearance of the coil component 100A. Furthermore, the coil component 100A does not need to be provided with the exterior coatings 50, 60. The exterior coatings 50, 60 can be formed at any position on the surface of the main body 30 depending on the purpose.

[0076] (Dummy Conductor Portion) The coil component 100A according to this embodiment may be provided with a non-spiral-shaped first dummy conductor portion 72 and a second dummy conductor portion 71. As shown in Figures 5 and 6, the first dummy conductor portion 72 faces the first lead portion 14 in the first direction (Z1-Z2 direction) with the first insulating portion 90 interposed therebetween, and has a portion in contact with the first insulating portion 90. Furthermore, the first dummy conductor portion 72 is spaced apart from the second coil conductor portion 202 in a direction intersecting the first direction (specifically, the X1-X2 direction).

[0077] The presence of the first dummy conductor portion 72 means that a member made of a conductor is located in the first direction of the first lead-out portion 14, similar to the first spiral conductor portion 11. Therefore, when an external force is applied along the first direction to arrange magnetic powder around the coil portion 10, pressure variations are unlikely to occur, and therefore deformation of the coil portion 10 is unlikely to occur.

[0078] Furthermore, in this example, since no conductive material exists between the first dummy conductor 72 and the first lead-out portion 14, when the coil portion 10 is viewed alone, the first dummy conductor 72 is electrically insulated from the first lead-out portion 14. Therefore, the first dummy conductor 72 is electrically insulated from both the first coil conductor portion 201 and the second coil conductor portion 202.

[0079] 5, the outer end (the X2 side in the X1-X2 direction) of the first dummy conductor 72 (the dummy portion exposed surface 720) is exposed, but this is not limiting. For example, an insulating layer made of the second insulating portion 80 may be provided so as to be in contact with the dummy portion exposed surface 720.

[0080] The second dummy conductor 71 has a configuration similar to that of the first dummy conductor 72. That is, the second dummy conductor 71 faces the second lead-out portion 24 in the first direction (Z1-Z2 direction) across the first insulating portion 90, has a portion in contact with the first insulating portion 90, and is spaced apart from the first coil conductor 201 in a direction intersecting the first direction (specifically, the X1-X2 direction). By arranging the second dummy conductor 71 in this manner, the second dummy conductor 71 is also electrically insulated from both the first coil conductor 201 and the second coil conductor 202. The first dummy conductor 72 and the first coil conductor 201 are electrically connected to each other by the first terminal 41, and therefore do not necessarily need to be insulated from each other.

[0081] Similarly, the second dummy conductor 71 and the second coil conductor 202 are electrically connected to each other by the second terminal 42, and therefore do not necessarily need to be insulated from each other. Therefore, the first dummy conductor 72 and the first coil conductor 201 may be in direct contact with each other or may be electrically connected through a conductor in a via. Such an electrical connection is effective in widening the current path of the coil and reducing the DCR.

[0082] (Separate Conductor Portion) The separate conductor portion 400 has a portion embedded in the main body portion 30 and is provided at a distance from the coil portion 10. The separate conductor portion 400 may be formed using the same material and in the same manufacturing process as the coil conductor portion 20. The separate conductor portion 400 is formed using, for example, Cu or a Cu alloy.

[0083] The separate conductor portion 400 includes a first separate conductor portion 401 having a first exposed surface 401a exposed from the main body portion 30 in an in-plane direction of a first plane F1 (see FIGS. 5 and 6 ), which is defined as a plane shared with the first spiral conductor portion 11 among planes along the first direction (Z1-Z2 direction). In the coil device 100A shown in FIGS. 2 and 3 , the first separate conductor portion 401 is provided at each of the four corners of the main body portion 30. Each first separate conductor portion 401 has a first exposed surface 401a exposed from each of adjacent outer surfaces constituting the corners of the main body portion 30. In other words, on the intersection line between the outer surfaces 30a, 30b, 30c, and 30d of the main body portion 30 and the first plane F1, the point farthest from the first spiral conductor portion 11 is included in the first exposed surface 401a. Each of the four first separate conductors 401 contacts either the first terminal 41 or the second terminal 42, which is an external electrode, on the first exposed surface 401 a. The envelope shape of the main body 30 of the coil component 100 according to this embodiment is a substantially rectangular parallelepiped, and the first separate conductors 401 are exposed from the main body 30 on the sides of this rectangular parallelepiped. Specifically, the first separate conductor portion 401 is exposed from the main body portion 30 at the edge forming the intersection between the outer surface 30a and the outer surface 30c, the edge forming the intersection between the outer surface 30a and the outer surface 30d, the edge forming the intersection between the outer surface 30b and the outer surface 30c, the edge forming the intersection between the outer surface 30b and the outer surface 30d, the edge forming the intersection between the intersecting plane 30e and the outer surface 30a, the edge forming the intersection between the intersecting plane 30e and the outer surface 30b, the edge forming the intersection between the intersecting plane 30e and the outer surface 30c, and the edge forming the intersection between the intersecting plane 30e and the outer surface 30d.

[0084] The separate conductor portion 400 also includes a second separate conductor portion 402 having a second exposed surface 402a exposed from the main body portion 30 in the in-plane direction of a second plane F2 (see FIGS. 5 and 6 ), which is defined as a plane shared with the second spiral conductor portion 21 among the planes along the first direction (Z1-Z2 direction). In the coil device 100A shown in FIGS. 2 and 4 , the second separate conductor portion 402 is provided at each of the four corners of the main body portion 30. The second separate conductor portion 402 is electrically independent from the first separate conductor portion 401 within the main body portion 30; in other words, the first separate conductor portion 401 and the second separate conductor portion 402 are electrically insulated from each other. When viewed in the first direction (Z1-Z2 direction), the second separate conductor portion 402 is provided at a position overlapping the first separate conductor portion 401. Each second separate conductor 402 has a second exposed surface 402a exposed from each of adjacent outer surfaces constituting a corner of the main body 30. That is, the second exposed surface 402a includes the point furthest from the second spiral conductor 21 on the intersection line between the outer surfaces 30a, 30b, 30c, and 30d of the main body 30 and the second surface F2. Each of the four second separate conductors 402 contacts either the first terminal 41 or the second terminal 42, which is an external electrode, on the second exposed surface 402a. The envelope shape of the main body 30 of the coil device 100 according to this embodiment is a substantially rectangular parallelepiped, and the second separate conductors 402 are exposed from the main body 30 on the sides of this rectangular parallelepiped. Specifically, the second separate conductor portion 402 is exposed from the main body portion 30 at the edge forming the intersection between the outer surface 30a and the outer surface 30c, the edge forming the intersection between the outer surface 30a and the outer surface 30d, the edge forming the intersection between the outer surface 30b and the outer surface 30c, the edge forming the intersection between the outer surface 30b and the outer surface 30d, the edge forming the intersection between the intersecting plane 30f and the outer surface 30a, the edge forming the intersection between the intersecting plane 30f and the outer surface 30b, the edge forming the intersection between the intersecting plane 30f and the outer surface 30c, and the edge forming the intersection between the intersecting plane 30f and the outer surface 30d.

[0085] In this way, since the first exposed surface 401a of the first separate conductor portion 401 and the second exposed surface 402a of the second separate conductor portion 402 are exposed from the main body portion 30, the adhesion of the first terminal portion 41 and the second terminal portion 42 provided on the outer surfaces 30a, 30b of the main body portion 30 is improved.

[0086] For example, a first terminal 41 is provided on the outer surface 30a of the main body 30, and a second terminal 42 is provided on the outer surface 30b of the main body 30. A first drawn-out exposed surface 140 of the first drawn-out portion 14 is exposed on the outer surface 30a of the main body 30. Furthermore, an end of the first dummy conductor 72 (a dummy portion exposed surface 720) may also be exposed on the outer surface 30a of the main body 30. When connecting the first terminal 41 to the outer surface 30a, the first drawn-out exposed surface 140 and the dummy portion exposed surface 720, which are made of a metal material, have better adhesion to the first terminal 41 than the portions where the magnetic powder is exposed.

[0087] In this embodiment, the first separate conductor 401 and the second separate conductor 402 made of a metallic material are provided on the outer surface 30a at positions corresponding to the corners of the main body 30, and the first exposed surface 401a and the second exposed surface 402a are exposed from the outer surface 30a, so that good adhesion can be obtained even in these portions with the first terminal 41. Therefore, the adhesion of the first terminal 41 to the main body 30 is improved compared to when the first separate conductor 401 and the second separate conductor 402 are not provided.

[0088] The adhesion of the second terminal 42 is similar to that of the first terminal 41. That is, first separate conductors 401 and second separate conductors 402 made of a metallic material are provided at positions on the outer surface 30b corresponding to the corners of the main body 30. Therefore, the second exposed surface 240 of the second lead 24 is exposed on the outer surface 30b. The end of the second dummy conductor 71 (dummy exposed surface 710) may also be exposed on the outer surface 30b. Furthermore, in addition to these, the first exposed surface 401a of the first separate conductor 401 and the second exposed surface 402a of the second separate conductor 402 are exposed on the outer surface 30b. Therefore, the adhesion of the second terminal 42 to the main body 30 is improved compared to when the first separate conductor 401 and the second separate conductor 402 are not provided.

[0089] Furthermore, in the coil component 100A, the separate conductor portion 400 is provided at a corner of the main body portion 30 (at a position distal to the first spiral conductor portion 11 and the second spiral conductor portion 21), and therefore the effect of the separate conductor portion 400 on the coil characteristics can be suppressed compared to when a separate conductor portion is provided in another part.

[0090] (Method of Manufacturing Coil Component) The method of manufacturing the coil component according to this embodiment is not particularly limited. One non-limiting example of the manufacturing method is as follows. FIGS. 7 to 10 are explanatory views of an example of a method of manufacturing a coil component according to an embodiment of the present invention. FIGS. 7 to 10 show an example of a manufacturing method using coil component 100A as an example. Note that in explanatory views of a coil array sheet such as FIG. 7A, the shape of the coil differs from that in drawings showing the coil component alone such as FIG. 12, but the shape of the coil does not affect the explanation of the method of manufacturing a coil component using a coil array sheet. The method of manufacturing coil component 100A according to this embodiment includes a conductor forming step, a removing step, a shaping step, and a cutting step, which will be described below.

[0091] First, as shown in the XY plan view of FIG. 7A, multiple spiral portions (first spiral conductor portion 11, second spiral conductor portion 21) are formed. Specifically, first, a conductor layer (seed layer) is formed on both sides (the Z1 side and the Z2 side in the Z1-Z2 direction) of the surface of an insulating sheet substrate 91. Next, as shown in FIG. 7B, conductor portions such as each portion constituting the coil conductor portion 20 (the first spiral conductor portion 11 and the second spiral conductor portion 21, the first lead portion 14 and the second lead portion 24, etc.), the first dummy conductor portion 72, and the second dummy conductor portion 71 are formed on the conductor layer, thereby obtaining a product 500a of the conductor formation step.

[0092] The method for forming the conductor is not limited. For example, an insulating layer pattern that is a negative pattern of the conductor may be formed on a conductor layer on the insulating sheet substrate 91, and an electroplating process may be performed to pass current through the conductor layer, thereby depositing a plating deposit on the conductor layer exposed around the negative pattern, thereby forming a conductor having a desired shape. In this plating process, the plating deposit can be filled into the through holes in the sheet substrate 91 to form via conductor portions VP.

[0093] Next, at least a portion of the exposed portion of the sheet base material 91 of the product 500a of the conductor formation step that is not covered by the conductor in the Z1-Z2 direction is removed (removal step). Specifically, the sheet base material 91 is removed so as to include the region of the sheet base material 91 that is surrounded by the inner edge of the first spiral conductor portion 11 when viewed in the first direction (Z1-Z2 direction). As described above, when a negative pattern made of an insulating layer is used in the conductor formation step, the insulating layer is first removed, and then the conductor layer that is exposed in the Z1-Z2 direction due to the removal of the insulating layer is removed. In this way, a portion of the sheet base material 91 is exposed in the Z1-Z2 direction, and a process of removing this exposed portion is performed.

[0094] The specific removal process for the sheet substrate 91 is appropriately set depending on the constituent material of the sheet substrate 91. Removal processes are roughly classified into dry processes such as plasma etching and wet processes such as wet etching. A portion of the sheet substrate 91 may be removed by the removal process, with a remaining portion remaining unremoved. For example, the sheet substrate 91 may be made of a composite material having a matrix portion made of an organic material and an inorganic material dispersed in the matrix portion, and the sheet substrate 91 may be removed by removing the matrix portion made of the organic material in the removal process.

[0095] Through the above steps, a coil array sheet 500A is obtained, the XY plan view of which is shown in Fig. 7A and the XZ cross section taken along line CC' of Fig. 7A is shown in Fig. 7C. The detailed structure of the coil array sheet 500A will be described later.

[0096] Next, as shown in FIG. 8 , the coil array sheet 500A is covered with a material containing magnetic powder (magnetic material 300) and molded to form a magnetic sheet 510 with its thickness direction in the first direction (Z1-Z2 direction) (molding step). An example of this molding step is a molding process in which the coil array sheet 500A is surrounded by the magnetic material 300. Specific examples of molding processes include placing the coil array sheet 500A formed in the previous steps in a mold and compressing the magnetic material 300, or transfer molding the magnetic material 300 or a raw material for that material. Prior to this molding step, an insulating step may be performed in which an insulating layer made of a second insulating portion 80 is formed on the surface of the coil array sheet 500A. This can improve the insulation between the coil conductors 20 and the magnetic powder inside the magnetic material 300, even if the magnetic powder is conductive.

[0097] Next, as shown in FIG. 9 , the magnetic sheet 510 is cut in at least a first direction (Z1-Z2 direction) to form multiple coil chips, each including one coil portion 10 and the magnetic material 300 surrounding it (cutting step). Specifically, as shown in FIG. 9 , the magnetic sheet 510 is divided at predetermined positions. In this step, the magnetic sheet 510 is diced along the extension direction of the connecting portion 150. The dashed-dotted line in FIG. 9 indicates the division line (center line of division) created by dicing. Dicing forms a product C1, which includes each coil portion 10 and a main body portion 30 formed by dividing the magnetic material 300 covering the coil portion 10.

[0098] 10, one region of the multiple products formed by dividing the wafer by dicing is indicated by a two-dot chain line. One product C1 formed by dicing includes a portion that remains unremoved by dicing. This remaining portion becomes the separate conductor portion 400.

[0099] In addition, in the dicing in the cutting step, the connecting portions 150 may be entirely removed (by crushing, cutting, or grinding) so that no part of the connecting portions 150 remains in the product C1. In this case, the magnetic sheet 510 may be divided and some of the connecting portions 150 may remain in the remaining part other than the product C1.

[0100] Next, an exterior coating (such as the exterior coating 60) made of an insulator is applied to a portion of the surface of the product C1 (exterior coating formation step). The surface to be coated with the exterior coating is a surface of the outer surface of the product C1 on which electrodes will not be formed in a later step. In this embodiment, the exterior coating is applied to the outer surfaces of the product C1 other than the outer surfaces where the first exposed drawer surface 140 and the second exposed drawer surface 240 are exposed. FIG. 12 shows that the exterior coating 60 is applied to the outer surface of the product C1 in the Y1-Y2 direction. Note that the formation of this exterior coating may be performed before or during the cutting step, depending on the surface to be coated with the exterior coating.

[0101] Next, the first terminal 41 and the second terminal 42, which are external electrodes, are formed on the surface of the product C1, including the conductive surface that is not coated with an exterior coating (electrode formation step). The method for forming the first terminal 41 and the second terminal 42 is not limited, and examples include a plating process and a printing process using a conductive paste. In this way, the coil component 100A according to this embodiment is manufactured.

[0102] (Coil Array Sheet) Here, we will explain the coil array sheet 500A used in the manufacturing method of the coil component 100A according to this embodiment. The coil array sheet 500A is a two-dimensional array of coil conductor sections 20 including a first spiral conductor section 11 and a second spiral conductor section 21. In Fig. 7A , the multiple coil conductor sections 20 are aligned in a third direction (specifically, the Y1-Y2 direction), which is one of the in-plane directions having the first direction as the normal line, and also aligned in a fourth direction (specifically, the X1-X2 direction), which is another of the in-plane directions having the first direction as the normal line. The coil array sheet 500A includes a plurality of coil conductor sections 20, first connecting sections 150A and second connecting sections 150B (hereinafter, the first connecting sections 150A and the second connecting sections 150B will be collectively referred to as connecting sections 150) that connect the plurality of coil conductor sections 20, and first dummy conductor sections 72 and second dummy conductor sections 71. The detailed structure of the coil array sheet 500A will be described below.

[0103] First, the coil array sheet 500A has a plurality of coil sections 10, each including a first spiral conductor section 11 when viewed in a first direction (Z1-Z2 direction), and a first connecting section 150A connecting the plurality of coil sections 10. The outer end of the spiral in the first spiral conductor section 11 faces one side (the X2 side in FIG. 7A ) of a second direction (the X1-X2 direction in FIG. 7A ), which is one of the in-plane directions normal to the first direction (the Z1-Z2 direction).

[0104] The multiple coil sections 10 also include a first array in which multiple first spiral conductor sections 11 are arranged in a third direction (Y1-Y2 direction in Figure 7A) that is another in-plane direction normal to the first direction (Z1-Z2 direction) and intersects with the second direction (X1-X2 direction in Figure 7A).

[0105] The first coupling portion 150A includes a plurality of first connection portions 161 each connected to one of the outer ends of the plurality of first spiral conductor portions 11, and a first bridge portion 151A connecting the plurality of first connection portions 161 and extending in the third direction (the Y1-Y2 direction in FIG. 7A ) as a whole. The first connection portion 161 includes the first lead-out portion 14. The first coupling portion 150A also includes a plurality of first bridge portions 151A, and has a first auxiliary bridge portion 152A connecting two adjacent first bridge portions 151A.

[0106] The first bridge portion 151A has a first deflection suppression portion 550A that includes an intersection portion 560, which is a portion extending in a direction intersecting the third direction (the Y1-Y2 direction in Figure 7A), and suppresses deflection of the first bridge portion 151A.

[0107] The coil array sheet 500A also includes a plurality of coil sections 10, each including a second spiral conductor section 21, as viewed in the first direction (Z1-Z2 direction), and second connecting sections 150B connecting the plurality of coil sections 10. The first connecting sections 150A and the second connecting sections 150B may be connected by via connecting sections VPC (see FIG. 20 ) made of a conductor. The via connecting sections VPC can be formed in the same manner as the via conductor sections VP. For example, when the via conductor sections VP are formed by plating, by providing connecting section through-holes in the sheet base material 91 at positions corresponding to the via connecting sections VPC, the via connecting sections VPC can be formed by filling the connecting section through-holes with plating deposits during plating.

[0108] The outer end of the spiral in the second spiral conductor portion 21 faces one side (X1 side in FIG. 7A) in the second direction (X1-X2 direction in FIG. 7A). The plurality of coil portions 10 also includes a second array in which the plurality of second spiral conductor portions 21 are arranged in a third direction (Y1-Y2 direction in FIG. 7A).

[0109] The second coupling portion 150B includes a plurality of second connection portions 162 each connected to one of the outer ends of the plurality of second spiral conductor portions 21, and a second bridge portion 151B connecting the plurality of second connection portions 162 and extending in the third direction (e.g., the Y1-Y2 direction) as a whole. The second connection portion 162 includes the second lead-out portion 24. The second coupling portion 150B also includes a plurality of second bridge portions 151B, and has a second auxiliary bridge portion 152B connecting two adjacent second bridge portions 151B.

[0110] The second bridge portion 151B has a second deflection suppression portion 550B that includes an intersection portion 560, which is a portion that extends in a direction that intersects with the third direction (e.g., the Y1-Y2 direction), and suppresses deflection of the second bridge portion 151B.

[0111] The second spiral conductor portion 21 is provided on the opposite side of the first spiral conductor portion 11 with the first insulating portion 90 (see FIG. 5 ) in between. Therefore, the second connecting portion 162, the second bridge portion 151B, the second auxiliary bridge portion 152B, and the second deflection suppressing portion 550B are also provided on the opposite side of the first insulating portion 90 from the first connecting portion 161, the first bridge portion 151A, the first auxiliary bridge portion 152A, and the first deflection suppressing portion 550A. Hereinafter, the first bridge portion 151A and the second bridge portion 151B will be collectively referred to as the bridge portion 151. Furthermore, the first auxiliary bridge portion 152A and the second auxiliary bridge portion 152B will be collectively referred to as the auxiliary bridge portion 152. Furthermore, the first deflection suppression unit 550A and the second deflection suppression unit 550B are collectively referred to as the deflection suppression unit 550. As described above, deflection of the coil array sheet 500A may be suppressed even in the portion where the first connecting unit 150A and the second connecting unit 150B are connected in the Z1-Z2 direction by the via connecting unit VPC. In this case, the first connecting unit 150A, the second connecting unit 150B, and the via connecting unit VPC are integrated to form the deflection suppression unit 550. Note that in FIG. 7A, the first connecting unit 150A and the second connecting unit 150B of the coil array sheet 500A have overlapping portions when viewed in the first direction, so essentially only the first connecting unit 150A is shown.

[0112] In this coil array sheet 500A, the connecting portion 150 has a plurality of closed paths. The first connecting portion 150A has a first closed path, and the second connecting portion 150B has a second closed path. In the coil array sheet 500A, the first closed path and the second closed path have overlapping portions when viewed in the first direction, so FIG. 7A shows essentially only the first closed path. When viewed in the first direction (Z1-Z2 direction), each of the plurality of closed paths contains one or more spiral conductor portions. In the plurality of closed paths, the deflection suppression portion 550 includes an intersection portion 560 that extends in a direction intersecting the extension direction of the closed paths. For example, in the coil array sheet 500A shown in FIG. 7A, the first bridge portion 151A, which forms multiple closed paths, extends in the Y1-Y2 direction, and the intersection portion 560 is a portion extending in, for example, the X1-X2 direction, intersecting the Y1-Y2 direction. The intersection portion 560 bends at both ends from the X1-X2 direction and connects to the first bridge portion 151A extending in the Y1-Y2 direction, forming a crank portion. Thus, the deflection suppression portion 550 of the coil array sheet 500 has a crank portion including the intersection portion 560. The direction intersecting this third direction (Y1-Y2 direction), i.e., the direction in which the intersection portion 560 extends, may be the first direction (Z1-Z2 direction) or a direction intersecting the first direction. A specific example of such an intersecting direction is the second direction (X1-X2 direction), which is the direction in which the outer peripheral end portions 13 and 23 face.

[0113] The deflection suppression portion 550 of the coil array sheet 500A can increase the rigidity of the connecting portion 150. Increasing the rigidity of the connecting portion 150 suppresses deformation (warping) of the coil array sheet 500A during the process of manufacturing the coil array sheet 500A and during the process of manufacturing the coil component 100 from the coil array sheet 500A, making it less likely that the multiple coil conductor portions 20 of the coil array sheet 500A will shift from their predetermined positions. As a result, the magnetic and electrical characteristics of the coil component 100 are less likely to vary, thereby improving the quality of the coil component 100.

[0114] For example, the coil array sheet 500A may be formed by plating a sheet-like substrate provided with a negative insulating pattern, such as the coil conductors 20. In this case, the plating process forms a structure (corresponding to the product 500a (see FIG. 7B ) of the conductor forming step) having a sheet-like substrate (e.g., the aforementioned sheet substrate 91) and a plurality of coil conductors 20 and connecting portions 150 formed with plating deposits on both sides of the substrate. This structure before plating (hereinafter referred to as the "structure α") consists of a portion where plating deposits are formed during plating and that is essentially made of the substrate (hereinafter referred to as the "substrate portion"), and a portion where a negative pattern is provided on at least one side of the substrate (hereinafter referred to as the "negative pattern portion"). Note that when the plating process is performed by electroplating, the substrate portion has a conductor layer formed on the substrate. If the substrate of the structure α has a certain degree of rigidity (including the rigidity of the conductor layer, if provided), the rigidity of the substrate prevents the entire structure α from deforming, even when the structure α is lifted, for example, for transportation.

[0115] However, if the rigidity of the substrate is reduced, for example, due to a thinner substrate in response to demands for miniaturization of the coil component 100, it becomes difficult for the substrate to suppress deformation of the structure α. Specifically, when subjected to an external force (including its own weight) that deforms the structure α, the substrate portion has particularly low rigidity compared to the negative pattern portion and therefore easily deflects, resulting in deformation of the entire structure α. This deflection of the substrate due to the external force may narrow the spacing between adjacent negative pattern portions sandwiching the substrate portion. If the structure α is plated in this state, the width of the formed plating deposit will be unexpectedly narrow in some areas. In these areas, the cross-sectional area of ​​the conductor made of the plating deposit will be relatively small, which may cause a local increase in resistance and result in degradation of the magnetic and electrical properties of the coil component 100 formed from the coil array sheet 500A.

[0116] In the coil array sheet 500A according to this embodiment, in the state of the structure α, a portion (substrate deflection suppression portion) corresponding to the deflection suppression portion 550 is provided in the substrate portion. Therefore, deflection of the substrate portion is suppressed compared to when the substrate deflection suppression portion is not provided. Specifically, in the structure α, the substrate portion does not extend uniformly, and the substrate deflection suppression portion has a portion (intersection portion) that extends in a different direction from the other portions (normal portions). In the absence of the substrate deflection suppression portion, when an external force is applied to the structure α in a direction perpendicular to the extension direction of the normal portions of the substrate portion in the in-plane direction of the substrate, the normal portions deflect so as to narrow the spacing between adjacent negative pattern portions sandwiching the normal portions. In contrast, when the structure α includes the substrate deflection suppression portion, even if an external force is applied to the structure α in a direction that deflects the normal portions, the external force does not act in a direction that deflects the substrate, but rather in a direction that elongates the substrate. Therefore, even when subjected to the external force, the negative pattern portions adjacent to each other across the substrate deflection suppression portion are unlikely to be displaced relative to each other. As a result, the spacing between the negative pattern portions adjacent to each other across the normal portion is also maintained. Therefore, the coil component 100A formed from the coil array sheet 500A according to this embodiment is unlikely to suffer from quality degradation due to a narrowing of the width of the plating deposit.

[0117] Furthermore, when a molding process is performed to surround the coil array sheet 500A with the magnetic material 300 as a manufacturing process for the coil component 100A, stress is applied to the coil array sheet 500A during material filling. For example, when compression molding is performed, the magnetic material 300 is caused to flow and spread into the cavity of the mold while a compressive force is applied between the mold and the coil array sheet 500A. This causes stress to be applied to the coil array sheet 500 during material filling. In particular, when the material in the cavity flows and spreads into the cavity, the material moves from the cavity toward the coil array sheet 500A, resulting in a strong stress being applied toward the coil array sheet 500A. In this embodiment, the deflection suppression section 550 is provided in the coil array sheet 500A, so deformation of the coil array sheet 500A is suppressed even when the coil array sheet 500A is pressed by the material. In other words, misalignment of the coil sections 10 in the coil array sheet 500A is effectively suppressed.

[0118] In the coil array sheet 500A shown in FIG. 7A , a deflection suppression section 550 is provided at each intersection between a plurality of bridge sections 151 extending in the Y1-Y2 direction and a plurality of auxiliary bridge sections 152 extending in the X1-X2 direction. The deflection suppression section 550 may include a frame-shaped portion having a polygonal envelope shape when viewed in a first direction. In FIG. 7A , this frame-shaped portion has a quadrangular (rectangular) envelope shape when viewed in the first direction. By including a frame-shaped portion in the deflection suppression section 550, the deflection suppression section 550 can efficiently have an intersection section 560. In FIG. 7A , for the bridge sections 151 extending in the Y1-Y2 direction, the frame-shaped portion becomes the intersection section 560 extending in the X1-X2 direction. Note that for the auxiliary bridge sections 152 extending in the X1-X2 direction, the frame-shaped portion becomes the intersection section 580 extending in the Y1-Y2 direction in the auxiliary deflection suppression section 570. As shown in Figure 7A, the above-mentioned frame-shaped portion may be provided at the boundary between two closed paths that contain two adjacent spiral conductors (first spiral conductor 11, second spiral conductor 21) in directions perpendicular to the first direction (X1-X2 direction, Y1-Y2 direction). In this case, one frame-shaped portion can efficiently improve the positional stability of multiple closed paths. In Figure 7A, one frame-shaped portion is arranged so as to be located at the boundary between four spiral conductors, each consisting of two spiral conductors adjacent in the X1-X2 direction and two spiral conductors adjacent in the Y1-Y2 direction.

[0119] By providing the deflection suppression section 550 including the intersection section 560, stress is distributed at the intersection section 560, and deflection of the coil array sheet 500A is suppressed compared to when a simple lattice type is formed by the bridge section 151 and the auxiliary bridge section 152.

[0120] 9 and 10 , depending on the position at which the magnetic sheet 510 is diced, a portion of the deflection suppression section 550 remains in the divided product C1, and this remaining portion becomes the separate conductor section 400 of the coil component 100A. When the first spiral conductor section 11 is provided with the first deflection suppression section 550A, a portion of the first deflection suppression section 550A remains after dicing to become the first separate conductor section 401. When the second spiral conductor section 21 is provided with the second deflection suppression section 550B, a portion of the second deflection suppression section 550B remains after dicing to become the second separate conductor section 402. In the coil component 100A, the corners of the rectangular frame (frame-shaped portion) of the deflection suppression section 550 remain at the four corners of the main body section 30, resulting in the coil component 100A being configured as a rectangular separate conductor section 400 when viewed in the first direction (Z1-Z2 direction).

[0121] (Another Example: Part 1) Fig. 11 is a plan view illustrating a coil array sheet according to another example (part 1). Fig. 12 is a plan view illustrating a coil component according to another example (part 1). In Fig. 11, a coil array sheet 500B according to another example (part 1) and one region of a plurality of products C2 formed by dividing the sheet by dicing are indicated by a two-dot chain line. Fig. 12 is a plan view seen from the Z1 side in the Z1-Z2 direction, with the coil conductor portion indicated by a solid line and other portions indicated by dashed lines.

[0122] In the coil array sheet 500B shown in FIG. 11 , curves are provided at the corners of the rectangular frame (frame-shaped portion) of the deflection suppression section 550. The deflection suppression section 550 may be provided with at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. As a result, in the coil device 100B shown in FIG. 12 , the separate conductor sections 400 are configured to be arc-shaped and provided at the four corners of the main body section 30 when viewed in the first direction (Z1-Z2 direction). That is, the contact surfaces between the separate conductor sections 400 and the main body section 30 have curvatures toward the corners of the approximately rectangular parallelepiped main body section 30 within the first plane F1 (see FIGS. 5 and 6 ).

[0123] (Another Example: Part 2) Fig. 13 is a plan view illustrating a coil array sheet according to another example (part 2). Fig. 14 is a plan view illustrating a coil component according to another example (part 2). In Fig. 13, a coil array sheet 500C according to another example (part 2) and one region of a plurality of products C3 formed by dividing the sheet by dicing are indicated by a two-dot chain line. Fig. 14 is a plan view seen from the Z1 side in the Z1-Z2 direction, with the coil conductor portion indicated by a solid line and the other portions indicated by dashed lines.

[0124] In the coil array sheet 500C shown in FIG. 13, the intersections 560 of the deflection suppression sections 550 are arranged non-parallel to the Y1-Y2 direction. The deflection suppression sections 550 may include at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. Specifically, the edges of the bridge sections 151 on the coil section 10 side are inclined with respect to the Y1-Y2 direction. As a result, in the coil component 100C shown in FIG. 14, when viewed in the first direction (Z1-Z2 direction), separate conductor sections 400 are formed on the outer surfaces 30a and 30b of the main body section 30, respectively, extending from the outer surface 30c to the outer surface 30d. The inclined edges of the bridge sections 151 remain on the side opposite the exposed surface of each separate conductor section 400. That is, both ends of the coil portion 10 become wider in the first plane F1 (see FIGS. 5 and 6) as they move away from the first spiral conductor portion 11, and also become wider in the second plane F2 (see FIGS. 5 and 6) as they move away from the second spiral conductor portion 21. Note that the portion of the bridge portion 151 that is not parallel to the Y1-Y2 direction may be linear or curved.

[0125] (Another Example: Part 3) Figures 15 and 16 are plan views illustrating a coil array sheet according to another example (Part 3). Figures 17 and 18 are plan views illustrating a coil component according to another example (Part 3). In Figure 16, a coil array sheet 500D according to another example (Part 3) and the regions of multiple products C4 formed by dividing the sheet by dicing are indicated by two-dot chain lines. Figures 17 and 18 are plan views as seen from the Z1 side in the Z1-Z2 direction, with coil conductors indicated by solid lines and other parts indicated by dashed lines.

[0126] In the coil array sheet 500D shown in FIGS. 15 and 16 , the intersections 560 of the deflection suppression sections 550 are provided as steps in the Y1-Y2 direction. The deflection suppression sections 550 may be at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. In the coil array sheet 500D, the deflection suppression sections 550 are provided in the bridge sections 151 of the first spiral conductor section 11 and the second spiral conductor section 21. In addition, when viewed in the first direction (Z1-Z2 direction), the intersection 560 provided in the bridge portion 151 of the first spiral conductor portion 11 and the intersection 560 provided in the bridge portion 151 of the second spiral conductor portion 21 may be arranged so as not to overlap.

[0127] The deflection suppression sections 550 are provided so as to correspond to every other space between adjacent coil sections 10 in the Y1-Y2 direction. Therefore, in the multiple products C4 divided by dicing, the arrangement of the separate conductor sections 400 formed by parts of the deflection suppression sections 550 remaining in the main body section 30 is line-symmetrical with respect to the Y1-Y2 direction. Therefore, from the coil array sheet 500D, coil components 100D-1 (see FIG. 17) and 100D-2 (see FIG. 18) are manufactured, in which the arrangements of the separate conductor sections 400 are line-symmetrical with each other.

[0128] (Another Example: No. 4) Figures 19 and 20 are plan views illustrating a coil array sheet according to another example (No. 4). Figures 21 and 22 are plan views illustrating a coil component according to another example (No. 4). In Figure 20, a coil array sheet 500E according to another example (No. 4) and the regions of multiple products C5 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figures 21 and 22 are plan views as seen from the Z1 side in the Z1-Z2 direction, with coil conductors indicated by solid lines and other parts indicated by dashed lines.

[0129] 19 and 20 , like the coil array sheet 500A, the first connecting portion 150A has a first closed path, and the second connecting portion 150B has a second closed path. In the coil array sheet 500E, the first closed path and the second closed path have overlapping portions when viewed in the first direction, but also have non-overlapping portions. Therefore, in FIGS. 19 and 20 , only the non-overlapping portion of the second closed path is shown. In the coil array sheet 500E, the deflection suppression portion 550 is provided to include the overlapping portions, and has a crank portion including an intersection portion 560 that extends and bends away from the direction in which the closed paths (the first closed path and the second closed path) extend. The crank portion is positioned so as to be sandwiched between the two overlapping portions when viewed in the first direction.

[0130] In the coil array sheet 500E, the intersections 560 of the deflection suppression sections 550 are provided as steps in the Y1-Y2 direction. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. The deflection suppression sections 550 include both a first deflection suppression section 550A and a second deflection suppression section 550B. Note that the intersections 560 provided in the bridge sections 151 of the first spiral conductor section 11 and the intersections 560 provided in the bridge sections 151 of the second spiral conductor section 21 may be provided so as not to overlap when viewed in the first direction (Z1-Z2 direction).

[0131] Furthermore, the coil array sheet 500E is provided with an auxiliary deflection suppression section 570 that suppresses deflection using the first auxiliary bridge section 152A and the second auxiliary bridge section 152B. Specifically, the X1 side end of the first auxiliary bridge section 152A in the X1-X2 direction and the X2 side end of the second auxiliary bridge section 152B in the X1-X2 direction are connected by an intersection 680 formed of a via connection section VPC (see FIG. 20 ) extending in the Z1-Z2 direction. As a result, the end of the first auxiliary bridge section 152A extending in the X1-X2 direction and the end of the second auxiliary bridge section 152B extending in the X1-X2 direction form the auxiliary deflection suppression section 570 having a crank structure that bends in the Z1-Z2 direction. The auxiliary deflection suppression section 570 suppresses deflection of the auxiliary bridge section 152.

[0132] The deflection suppression units 550 are provided so as to correspond to every other space between adjacent coil units 10 in the Y1-Y2 direction. Therefore, in the multiple products C5 divided by dicing, the arrangement of the separate conductor units 400 formed by the portions of the deflection suppression units 550 remaining in the main body unit 30 is line-symmetrical in the Y1-Y2 direction. Therefore, from the coil array sheet 500E, coil components 100E-1 (see FIG. 21) and 100E-2 (see FIG. 22) are manufactured, in which the arrangement of the separate conductor units 400 is line-symmetrical to each other. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor units 400 may be configured so that portions of the deflection suppression units 550 remain on both the outer surface 30a side and the outer surface 30b side of the main body unit 30.

[0133] (Another Example: No. 5) Figures 23 and 24 are plan views illustrating a coil array sheet according to another example (No. 5). Figures 25 and 26 are plan views illustrating a coil component according to another example (No. 5). In Figure 24, a coil array sheet 500F according to another example (No. 5) and the regions of multiple products C6 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figures 25 and 26 are plan views as seen from the Z1 side in the Z1-Z2 direction, with coil conductors indicated by solid lines and other parts indicated by dashed lines.

[0134] In the coil array sheet 500F shown in Figures 23 and 24, the intersections 560 of the deflection suppression sections 550 are provided as steps in the Y1-Y2 direction. The deflection suppression sections 550 may be at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. In the coil array sheet 500F, the deflection suppression sections 550 are provided in the bridge sections 151 of the first spiral conductor section 11 and the second spiral conductor section 21. In addition, when viewed in the first direction (Z1-Z2 direction), the intersection 560 provided in the bridge portion 151 of the first spiral conductor portion 11 and the intersection 560 provided in the bridge portion 151 of the second spiral conductor portion 21 may be arranged so as not to overlap.

[0135] Furthermore, the coil array sheet 500F is provided with an auxiliary deflection suppression section 570. The intersection 580 of the auxiliary deflection suppression section 570 is provided as a step in the Y1-Y2 direction midway through the auxiliary bridge section 152 extending in the X1-X2 direction. The auxiliary deflection suppression section 570 may include at least one of a first auxiliary deflection suppression section 570A and a second auxiliary deflection suppression section 570B. In the example shown in FIGS. 23 and 24 , the auxiliary deflection suppression section 570 has a crank structure formed by the X1-side end of the first auxiliary bridge section 152A extending in the X1-X2 direction, the X1-side end of the second auxiliary bridge section 152B extending in the X1-X2 direction, and the intersection 580 formed of a part of the first bridge section 151A extending in the Y1-Y2 direction. In the coil array sheet 500F, the auxiliary deflection suppression section 570 is provided on the auxiliary bridge section 152 of each of the first spiral conductor section 11 and the second spiral conductor section 21.

[0136] The deflection suppression units 550 are provided so as to correspond to every other space between adjacent coil units 10 in the Y1-Y2 direction. Therefore, in the multiple products C6 divided by dicing, the arrangement of the separate conductor units 400 formed by the portions of the deflection suppression units 550 remaining in the main body unit 30 is line-symmetrical in the Y1-Y2 direction. Therefore, from the coil array sheet 500F, coil components 100F-1 (see FIG. 25) and 100F-2 (see FIG. 26) are manufactured, in which the arrangements of the separate conductor units 400 are line-symmetrical to each other. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor units 400 may be configured so that portions of the deflection suppression units 550 remain on both the outer surface 30a side and the outer surface 30b side of the main body unit 30.

[0137] (Another Example: No. 6) Figures 27 and 28 are plan views illustrating a coil array sheet according to another example (No. 6). Figure 29 is a plan view illustrating a coil component according to another example (No. 6). In Figure 28, a coil array sheet 500G according to another example (No. 6) and the regions of multiple products C7 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figure 29 is a plan view seen from the Z1 side in the Z1-Z2 direction, with the coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0138] In the coil array sheet 500G shown in Figures 27 and 28, the intersections 560 of the deflection suppression sections 550 are provided as steps in the Y1-Y2 direction. The deflection suppression sections 550 may be at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. In the coil array sheet 500G, the deflection suppression sections 550 are provided in the bridge sections 151 of the first spiral conductor section 11 and the second spiral conductor section 21.

[0139] Furthermore, the coil array sheet 500G is provided with an auxiliary deflection suppression section 570. The intersection 580 of the auxiliary deflection suppression section 570 is provided as a step in the Y1-Y2 direction midway through the auxiliary bridge section 152 extending in the X1-X2 direction. The auxiliary deflection suppression section 570 may be at least one of a first auxiliary deflection suppression section 570A and a second auxiliary deflection suppression section 570B. Specifically, the intersection 580 is provided by a portion of the auxiliary bridge section 152 extending in the X1-X2 direction that is bent midway and extends in the Y1-Y2 direction. In the coil array sheet 500G, the auxiliary deflection suppression section 570 is provided in the auxiliary bridge section 152 of each of the first spiral conductor section 11 and the second spiral conductor section 21.

[0140] The deflection suppression sections 550 are provided corresponding to the positions of the multiple coil sections 10 aligned in the Y1-Y2 direction. Therefore, in the multiple products C7 divided by dicing, the arrangement of the separate conductor sections 400 formed by the portions of the deflection suppression sections 550 remaining on the main body section 30 is the same. Therefore, coil components 100G (see FIG. 29) are manufactured from the coil array sheet 500G. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor sections 400 may be formed by leaving portions of the deflection suppression sections 550 on both the outer surface 30a side and the outer surface 30b side of the main body section 30.

[0141] (Another Example: No. 7) Figures 30 and 31 are plan views illustrating a coil array sheet according to another example (No. 7). Figure 32 is a plan view illustrating a coil component according to another example (No. 7). In Figure 31, a coil array sheet 500H according to another example (No. 7) and regions of multiple products C8 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figure 32 is a plan view seen from the Z1 side in the Z1-Z2 direction, with coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0142] In the coil array sheet 500H shown in Figures 30 and 31, the intersections 560 of the deflection suppression sections 550 are provided as steps in the Y1-Y2 direction. The deflection suppression sections 550 may be at least one of a first deflection suppression section 550A and a second deflection suppression section 550B. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. In the coil array sheet 500H, the deflection suppression sections 550 are provided in the bridge sections 151 of the first spiral conductor section 11 and the second spiral conductor section 21. Furthermore, when viewed in the first direction (Z1-Z2 direction), the intersection 560 provided in the bridge portion 151 of the first spiral conductor portion 11 and the intersection 560 provided in the bridge portion 151 of the second spiral conductor portion 21 are arranged so as not to overlap.

[0143] Furthermore, the coil array sheet 500H is provided with an auxiliary deflection suppression section 570. The intersection 580 of the auxiliary deflection suppression section 570 is provided as a step in the Y1-Y2 direction midway through the auxiliary bridge section 152 extending in the X1-X2 direction. The auxiliary deflection suppression section 570 may be at least one of a first auxiliary deflection suppression section 570A and a second auxiliary deflection suppression section 570B. Specifically, the intersection 580 is provided as a portion of the auxiliary bridge section 152 extending in the X1-X2 direction that is bent midway and extends in the Y1-Y2 direction. In the coil array sheet 500H, the auxiliary deflection suppression section 570 is provided in the auxiliary bridge section 152 of each of the first spiral conductor section 11 and the second spiral conductor section 21. Furthermore, when viewed in the first direction (Z1-Z2 direction), the intersection 580 provided in the auxiliary bridge portion 152 of the first spiral conductor portion 11 and the intersection 580 provided in the auxiliary bridge portion 152 of the second spiral conductor portion 21 are arranged so as not to overlap.

[0144] The deflection suppression sections 550 are provided corresponding to the positions of the multiple coil sections 10 aligned in the Y1-Y2 direction. Therefore, in the multiple products C8 divided by dicing, the arrangement of the separate conductor sections 400 formed by the portions of the deflection suppression sections 550 remaining on the main body section 30 is the same. Therefore, the coil component 100H (see FIG. 32) is manufactured from the coil array sheet 500H. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor sections 400 may be formed by leaving portions of the deflection suppression sections 550 on both the outer surface 30a side and the outer surface 30b side of the main body section 30.

[0145] (Another Example: No. 8) Figures 33 and 34 are plan views illustrating a coil array sheet according to another example (No. 8). Figure 35 is a plan view illustrating a coil component according to another example (No. 8). In Figure 34, a coil array sheet 500I according to another example (No. 8) and the regions of multiple products C9 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figure 35 is a plan view seen from the Z1 side in the Z1-Z2 direction, with the coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0146] 33 and 34, the first connecting portion 150A and the second connecting portion 150B are arranged with a shift in the X1-X2 direction and the Y1-Y2 direction when viewed in the first direction. Specifically, with respect to the first bridge portion 151A, the second bridge portion 151B is located on the X2 side in the X1-X2 direction, and with respect to the first auxiliary bridge portion 152A, the second auxiliary bridge portion 152B is located on the Y2 side in the Y1-Y2 direction. The first bridge portion 151A and the second auxiliary bridge portion 152B have an overlapping portion in the Z1-Z2 direction, and a via connection portion VPC connecting the first bridge portion 151A and the second auxiliary bridge portion 152B is located in this portion. Furthermore, the first auxiliary bridge portion 152A and the second bridge portion 151B have an overlapping portion in the Z1-Z2 direction, and a via connection portion VPC connecting the first auxiliary bridge portion 152A and the second bridge portion 151B is located in this portion. An intersection portion 680 formed by the first bridge portion 151A and the via connection portion VPC, and the second auxiliary bridge portion 152B form a crank portion consisting of the Y1-Y2 direction, the Z1-Z2 direction, and the X1-X2 direction, and the intersection portion 680 formed by the first auxiliary bridge portion 152A and the via connection portion VPC, and the second bridge portion 151B form a crank portion consisting of the X1-X2 direction, the Z1-Z2 direction, and the Y1-Y2 direction.

[0147] In the coil array sheet 500I, the area where the first connecting portion 150A and the second connecting portion 150B do not overlap is larger when viewed in the first direction (Z1-Z2 direction) than in other coil array sheets. In this configuration, the structure α that provides the coil array sheet 500I is less likely to have a portion that is essentially made of the substrate (substrate portion), and many of the portions have a negative pattern portion with a negative pattern on at least one side. Therefore, the structure α that provides the coil array sheet 500I is less likely to experience a problem in which the width of the conductor made of plating deposits narrows due to bending of the substrate portion. Therefore, the coil component 100I (see FIG. 35) formed from the coil array sheet 500I is particularly less likely to have reduced magnetic and electrical properties.

[0148] In the multiple products C9 divided by dicing, the arrangement of the separate conductor portions 400 formed by the portions of the deflection suppression portions 550 remaining on the main body portion 30 is all the same. Therefore, coil components 100I (see FIG. 35 ) are manufactured from the coil array sheet 500I. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor portions 400 may be formed by leaving portions of the deflection suppression portions 550 on both the outer surface 30a side and the outer surface 30b side of the main body portion 30.

[0149] (Another Example: No. 9) Figures 36 and 37 are plan views illustrating a coil array sheet according to another example (No. 9). Figures 38 and 39 are plan views illustrating a coil component according to another example (No. 9). In Figure 37, a coil array sheet 500J according to another example (No. 9) and regions of multiple products C10 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figures 38 and 39 are plan views as seen from the Z1 side in the Z1-Z2 direction, with coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0150] In the coil array sheet 500J shown in Figures 36 and 37, the intersections 560 of the deflection suppression section 550 are provided as steps in the Y1-Y2 direction. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. The coil array sheet 500J has only the first spiral conductor section 11. Therefore, only the first deflection suppression section 550A is provided as the deflection suppression section 550. The intersections 560, which are portions of the first bridge sections 151A that are bent midway and extend in the X1-X2 direction, are aligned with the positions of the corners of the main body section 30 formed by dicing.

[0151] Furthermore, the coil array sheet 500J is provided with a first auxiliary deflection suppression section 570A. An intersection 580 of the first auxiliary deflection suppression section 570A is provided as a step in the Y1-Y2 direction midway through the first auxiliary bridge section 152A extending in the X1-X2 direction. Specifically, the intersection 580 is provided as a portion that bends midway through the first auxiliary bridge section 152A extending in the X1-X2 direction and extends in the Y1-Y2 direction.

[0152] The first deflection suppression units 550A are provided so as to correspond to every other space between adjacent coil units 10 in the Y1-Y2 direction. Therefore, in the multiple products C10 divided by dicing, the arrangement of the separate conductor units 400 (first separate conductor units 401) formed by the portions of the first deflection suppression units 550A remaining in the main body unit 30 is line-symmetrical in the Y1-Y2 direction. Therefore, the coil array sheet 500J produces coil components 100J-1 (see FIG. 38) and 100J-2 (see FIG. 39) in which the arrangements of the separate conductor units 400 (first separate conductor units 401) are line-symmetrical to each other. By adjusting the cutting width and cutting position during dicing, the separate conductor units 400 may be configured so as to leave portions of the deflection suppression units 550 on both the outer surface 30a side and the outer surface 30b side of the main body unit 30.

[0153] (Another Example: No. 10) Figures 40 and 41 are plan views illustrating a coil array sheet according to another example (No. 10). Figures 42 and 43 are plan views illustrating a coil component according to another example (No. 10). In Figure 41, a coil array sheet 500K according to another example (No. 10) and regions of multiple products C11 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figures 42 and 43 are plan views as seen from the Z1 side in the Z1-Z2 direction, with coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0154] In the coil array sheet 500K shown in Figures 40 and 41, the intersections 560 of the deflection suppression section 550 are provided as steps in the Y1-Y2 direction. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. The coil array sheet 500K has only the first spiral conductor section 11. Therefore, only the first deflection suppression section 550A is provided as the deflection suppression section 550. The intersections 560, which are portions of the first bridge sections 151A that are bent midway and extend in the X1-X2 direction, are aligned with the outer surface 30a of the main body section 30 formed by dicing.

[0155] Furthermore, the coil array sheet 500K is provided with a first auxiliary deflection suppression section 570A. An intersection 580 of the first auxiliary deflection suppression section 570A is provided as a step in the Y1-Y2 direction midway through the first auxiliary bridge section 152A extending in the X1-X2 direction. Specifically, the intersection 580 is provided as a portion of the first auxiliary bridge section 152A extending in the X1-X2 direction that is bent midway and extends in the Y1-Y2 direction.

[0156] The first deflection suppression units 550A are provided so as to correspond to every other space between adjacent coil units 10 in the Y1-Y2 direction. Therefore, in the multiple products C11 divided by dicing, the arrangement of the separate conductor units 400 (first separate conductor units 401) formed by the portions of the first deflection suppression units 550A remaining in the main body unit 30 is line-symmetrical in the Y1-Y2 direction. Therefore, the coil array sheet 500K produces coil components 100K-1 (see FIG. 42) and 100K-2 (see FIG. 43) in which the arrangements of the separate conductor units 400 (first separate conductor units 401) are line-symmetrical to each other. By adjusting the dicing cutting width and cutting position, the separate conductor units 400 may be configured so as to leave portions of the deflection suppression units 550 on both the outer surface 30a side and the outer surface 30b side of the main body unit 30.

[0157] (Another Example: 11) Figures 44 and 45 are plan views illustrating a coil array sheet according to another example (11). Figure 46 is a plan view illustrating a coil component according to another example (10). In Figure 45, a coil array sheet 500L according to another example (10) and regions of multiple products C12 formed by dividing the sheet by dicing are indicated by dashed double-dashed lines. Figure 46 is a plan view seen from the Z1 side in the Z1-Z2 direction, with coil conductor portions indicated by solid lines and other portions indicated by dashed lines.

[0158] In the coil array sheet 500L shown in Figures 44 and 45, the intersections 560 of the deflection suppression section 550 are provided as steps in the Y1-Y2 direction. Specifically, the intersections 560 are provided as portions of the bridge sections 151 extending in the Y1-Y2 direction that are bent midway and extend in the X1-X2 direction. The coil array sheet 500L has only the first spiral conductor section 11. Therefore, only the first deflection suppression section 550A is provided as the deflection suppression section 550. The intersections 560, which are portions of the first bridge sections 151A that are bent midway and extend in the X1-X2 direction, are aligned along the outer surface 30a of the main body section 30 formed by dicing and are centered in the Y1-Y2 direction.

[0159] Furthermore, the coil array sheet 500L is provided with a first auxiliary deflection suppression section 570A. An intersection 580 of the first auxiliary deflection suppression section 570A is provided as a step in the Y1-Y2 direction midway through the first auxiliary bridge section 152A extending in the X1-X2 direction. Specifically, the intersection 580 is provided as a portion that bends midway through the first auxiliary bridge section 152A extending in the X1-X2 direction and extends in the Y1-Y2 direction.

[0160] The first deflection suppression portions 550A are provided corresponding to the positions of the multiple coil portions 10 aligned in the Y1-Y2 direction. Therefore, in the multiple products C12 divided by dicing, the arrangement of the separate conductor portions 400 (first separate conductor portions 401) formed by the portions of the first deflection suppression portions 550A remaining on the main body portion 30 is the same. Therefore, coil components 100L (see FIG. 46) are manufactured from the coil array sheet 500L. Note that by adjusting the cutting width and cutting position during dicing, the separate conductor portions 400 (first separate conductor portions 401) may be formed by leaving portions of the deflection suppression portions 550 on both the outer surface 30a side and the outer surface 30b side of the main body portion 30.

[0161] According to the above-described method for manufacturing coil components using the coil array sheets 500A to 500L, the provision of the deflection suppression portion 550 makes it possible to suppress deformation due to deflection even when stress is applied to the coil array sheets 500A to 500L during the manufacturing process, thereby effectively suppressing misalignment of each coil portion 10 in the coil array sheets 500A to 500L. Furthermore, the provision of the first separate conductor portion 401 in the main body portion 30 improves adhesion of the first terminal portion 41 to the main body portion 30, and the provision of the second separate conductor portion 402 improves adhesion of the second terminal portion 42 to the main body portion 30.

[0162] In the above manufacturing method, by adjusting the cutting width, cutting position, etc. of the dicing, the connecting portion 150 may be cut off without remaining in the main body portion 30. In this case, a part of the connecting portion 150 is not left in the main body portion 30, but a part of the connecting portion 150 may be included in the remaining portion that does not become a coil component.

[0163] (Electronic / Electrical Device) An electronic / electrical device according to one embodiment of the present invention is an electronic / electrical device that incorporates the coil components 100A-100L according to one embodiment of the present invention described above. The coil components 100A-100L are connected to a substrate via terminals (such as the first terminals 41) provided at both ends of the coil portion 10 exposed from the main body 30. Because the electronic / electrical device according to one embodiment of the present invention incorporates the coil components 100A-100L according to one embodiment of the present invention, the connection stability and reliability of the coil components 100A-100L to the electronic / electrical device are high, thereby improving the reliability of the electronic / electrical device. Furthermore, because the coil components 100A-100L are easily adapted for high-density packaging, devices incorporating these components are particularly easy to miniaturize. Furthermore, even if a large current flows through the device or high frequency is applied, problems caused by deterioration in the function of the coil components 100A-100L or heat generation are unlikely to occur.

[0164] The above-described embodiments and examples are provided to facilitate understanding of the present invention and are not intended to limit the present invention. Therefore, the elements disclosed in the above embodiments are intended to encompass all design modifications and equivalents within the technical scope of the present invention. For example, in the coil components 100A-100L described above, the second direction in which the outer peripheral end portions 13, 23 face and the fourth direction in which the two-dimensional array coil array sheets 500A-500L are arranged are both the X1-X2 direction. However, this is not limiting. The multiple coil conductors 20 may be arranged in orthogonal directions within the XY plane, with the outer peripheral end portions 13, 23 facing in a direction other than the X1-X2 direction and the Y1-Y2 direction of the XY plane. Alternatively, the outer peripheral end portions 13, 23 may face the X1-X2 direction, but the multiple coil conductors 20 may be arranged in a direction other than the X1-X2 direction, resulting in two non-orthogonal directions within the XY plane.

[0165] 100A, 100B, 100C, 100D-1, 100D-2, 100E-1, 100E-2, 100F-1, 100F-2, 100G, 100H, 100I, 100J-1, 100J-2, 100K-1, 100K-2, 100L: coil component 10: coil portion 11: first spiral conductor portion 12, 22: inner peripheral end portion 13, 23: outer peripheral end portion 14: first lead-out portion 20: coil conductor portion 21: second spiral conductor portion 24: second lead-out portion 30: main body portion 30a, 30b, 30c, 30d: outer surface 30e, 30f: intersecting surface 41: first terminal portion 41a, 42a: side surface portion 42: Second terminal portion 50, 60: Exterior coating 71: Second dummy conductor portion 72: First dummy conductor portion 80: Second insulating portion 90: First insulating portion 91: Sheet base material 140: First exposed lead surface 150: Connecting portion 150A: First connecting portion 150B: Second connecting portion 151: Bridge portion 151A: First bridge portion 151B: Second bridge portion 152: Auxiliary bridge portion 152A: First auxiliary bridge portion 152B: Second auxiliary bridge portion 161: First connecting portion 162: Second connecting portion 201: First coil conductor portion 202: Second coil conductor portion 240: Second exposed lead surface 300: Magnetic material 400: Separate conductor portion 401: First separate conductor portion 401a: First exposed surface 402: Second separate conductor portion 402a: Second exposed surface 500a: Product of conductor forming step 500A, 500B, 500C, 500D, 500E, 500F, 500G, 500H, 500I, 500J, 500K, 500L: Coil array sheet 510: Magnetic sheet 550: Deflection restraining portion 550A: First deflection restraining portion 550B: Second deflection restraining portion 560, 580: Intersection portion 570: Auxiliary deflection restraining portion 570A: First auxiliary deflection restraining portion 570B: Second auxiliary deflection restraining portion 680: Intersection portion 710, 720: Dummy portion exposed surface C1, C2, C3, C4, C5, C6, C7, C8, C9, C10, C11, C12: Product F1: First surface F2: Second surface O: Shaft VP: Via conductor portion VPC: Via connection portion

Claims

1. A coil component comprising: a coil portion including a first spiral conductor portion having a spiral shape when viewed in a first direction; a main body portion which contacts and covers the coil portion so that both ends of the coil portion are exposed, and which contains magnetic powder; a separate conductor portion which has a portion embedded in the main body portion and is spaced apart from the coil portion; and a pair of external electrodes which contact both ends of the coil portion exposed from the main body portion and are electrically connected through the coil portion, wherein when a surface shared with the first spiral conductor portion among surfaces along the first direction is defined as a first surface, the separate conductor portion includes a first separate conductor portion having a first exposed surface exposed from the main body portion in an in-plane direction of the first surface, and the first separate conductor portion contacts one of the pair of external electrodes at the first exposed surface.

2. The coil component according to claim 1, wherein the coil portion further includes: a second spiral conductor portion having a spiral shape aligned with the first spiral conductor portion in the first direction; and a via conductor portion contacting one end of the first spiral conductor portion and one end of the second spiral conductor portion to electrically connect the first spiral conductor portion and the second spiral conductor portion in the first direction; and when a surface shared with the second spiral conductor portion among the surfaces along the first direction is defined as a second surface, the separate conductor portion has a second exposed surface exposed from the main body portion in an in-plane direction of the second surface, and includes a second separate conductor portion within the main body portion that is electrically independent of the first separate conductor portion, and the second separate conductor portion contacts the other of the pair of external electrodes at the second exposed surface.

3. A coil component comprising: a coil section including a first spiral conductor section having a spiral shape when viewed in a first direction; a main body section including magnetic powder and in contact with and covering the coil section so that both ends of the coil section are exposed; and a pair of external electrodes in contact with both ends of the coil section exposed from the main body section and electrically connected through the coil section, wherein the coil section further includes a first lead-out section in contact with the other end of the first spiral conductor section and one of the pair of external electrodes, and when a surface shared with the first spiral conductor section among surfaces along the first direction is defined as a first surface, the first lead-out section has a first lead-out exposed surface exposed from the main body section, and the first lead-out exposed surface extends along an intersection line between a surface of the main body section and the first surface.

4. The coil component according to claim 3, wherein the coil portion further includes: a second spiral conductor portion having a spiral shape aligned with the first spiral conductor portion in the first direction; a via conductor portion in contact with one end of the first spiral conductor portion and one end of the second spiral conductor portion to electrically connect the first spiral conductor portion and the second spiral conductor portion in the first direction; and a second lead-out portion in contact with the other end of the second spiral conductor portion and the other of the pair of external electrodes, wherein when a surface shared with the second spiral conductor portion among the surfaces along the first direction is defined as a second surface, the second lead-out portion has a second lead-out exposed surface exposed from the main body portion, and the second lead-out exposed surface extends along an intersection line between a surface of the main body portion and the second surface.

5. A coil component comprising: a coil portion including a first spiral conductor portion having a spiral shape when viewed in a first direction; a main body portion containing magnetic powder and in contact with and covering the coil portion so that both ends of the coil portion are exposed; and a pair of external electrodes in contact with both ends of the coil portion exposed from the main body portion and electrically connected through the coil portion, wherein at least one of the ends of the coil portion extends on the surface of the main body portion along a line intersecting a surface of the main body portion and a first plane along the first direction shared with the first spiral conductor portion.

6. The coil component according to claim 1, wherein the envelope shape of the main body is a substantially rectangular parallelepiped, and the first separate conductor is exposed from the main body on a side of the rectangular parallelepiped.

7. A coil component as described in claim 2, wherein the envelope shape of the main body is a substantially rectangular parallelepiped, and the second separate conductor is exposed from the main body on a side of the rectangular parallelepiped.

8. A coil component as described in claim 1, wherein the main body has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and a point on the intersection line between the outer surface and the first surface that is farthest from the first spiral conductor portion is included in the first exposed surface.

9. A coil component as described in claim 2, wherein the main body has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and a point on the intersection line between the outer surface and the second surface that is farthest from the second spiral conductor portion is included in the second exposed surface.

10. A coil component according to any one of claims 3 to 5, wherein the envelope shape of the main body is a substantially rectangular parallelepiped.

11. A coil component as described in claim 3 or claim 5, wherein the main body portion has an envelope shape having a pair of intersecting surfaces aligned in the first direction and an outer surface located between the pair of intersecting surfaces, and the point on the intersection line between the outer surface and the first surface that is farthest from the first spiral conductor portion is included in the exposed surfaces from the main body portion at both ends of the coil portion.

12. The coil component according to claim 6, wherein a contact surface between said first separate conductor portion and said main body portion has a curvature within said first plane toward a corner of said rectangular parallelepiped.

13. The coil component according to claim 7, wherein a contact surface between said second separate conductor portion and said main body portion has a curvature in said second plane toward a corner of said rectangular parallelepiped.

14. A coil component according to any one of claims 1 to 5, wherein both ends of the coil portion become wider in width within the first plane as they move away from the first spiral conductor portion.

15. A coil component according to claim 2 or 4, wherein both ends of said coil portion become wider in width within said second plane as they move away from said second spiral conductor portion.

16. A coil component according to claim 1 or 2, wherein the separate conductor portion is made of Cu or a Cu alloy.

17. A coil array sheet comprising: a plurality of coil sections including a first spiral conductor section having a spiral shape when viewed in a first direction; and connecting sections connecting the plurality of coil sections, wherein an outer end of the spiral in the first spiral conductor section faces one side of a second direction which is one of in-plane directions having the first direction as a normal line, and the plurality of coil sections include a first array in which the plurality of first spiral conductor sections are arranged in a third direction which is another of the in-plane directions having the first direction as a normal line and which intersects with the second direction, and the connecting section has a first connecting section including a plurality of first connecting sections respectively connected to one of the outer ends of the plurality of first spiral conductor sections, and a first bridge section connecting the plurality of first connecting sections and extending in the third direction as a whole, and the first bridge section has a first deflection suppression section which includes a portion extending in a direction intersecting the third direction and suppresses deflection of the first bridge section in directions other than the third direction.

18. The coil portion further includes: a second spiral conductor portion having a spiral shape aligned with the first spiral conductor portion in the first direction; and a via conductor portion in contact with one end of the first spiral conductor portion and one end of the second spiral conductor portion to electrically connect the first spiral conductor portion and the second spiral conductor portion in the first direction; an outer end of the spiral in the second spiral conductor portion faces the other side of the second direction; the multiple coil portions include the first array and a second array aligned in the first direction, in which the multiple second spiral conductor portions are aligned in the third direction; and the connecting portion has a second connecting portion including a multiple second connecting portion respectively connected to one of the outer ends of the multiple second spiral conductor portions and a second bridge portion connecting the multiple second connecting portions and extending in the third direction as a whole; The coil array sheet according to claim 17, wherein the second bridge portion has a second deflection suppression portion including a portion extending in a direction intersecting the third direction and suppressing deflection of the second bridge portion in a direction other than the third direction.

19. A coil array sheet as described in claim 17, wherein the first deflection suppression portion has a crank portion including a portion extending in a direction intersecting the third direction.

20. The coil array sheet according to claim 19, wherein the direction intersecting the third direction includes a component in the first direction.

21. The coil array sheet according to claim 19, wherein the direction intersecting the third direction includes a component in the second direction.

22. A coil array sheet as described in claim 17, wherein the first deflection suppression portion includes a frame-shaped portion having a polygonal envelope shape when viewed in the first direction or the second direction.

23. The coil array sheet of claim 17, wherein the first array is a two-dimensional array in which the first spiral conductor portions are also arranged in a fourth direction, another of the in-plane directions normal to the first direction and intersecting the third direction, the connecting portion includes a plurality of the first bridge portions and a first auxiliary bridge portion connecting two of the first bridge portions adjacent to each other in the fourth direction, and the first auxiliary bridge portion has a first auxiliary deflection suppression portion including a portion extending in a direction intersecting the extension direction thereof and suppressing deflection of the first auxiliary bridge portion.

24. The coil array sheet of claim 18, wherein the first array is a two-dimensional array in which the first spiral conductor portions are also aligned in a fourth direction, which is another in-plane direction normal to the first direction; the second array is a two-dimensional array in which the second spiral conductor portions are also aligned in the fourth direction; the connecting portion includes a plurality of the first bridge portions and the second bridge portions, and includes a first auxiliary bridge portion connecting two of the first bridge portions adjacent to each other in the fourth direction and a second auxiliary bridge portion connecting two of the second bridge portions adjacent to each other in the fourth direction; the first auxiliary bridge portion has a first auxiliary deflection suppression portion including a portion extending in a direction intersecting the extension direction and suppressing deflection of the first auxiliary bridge portion; and the second auxiliary bridge portion has a second auxiliary deflection suppression portion including a portion extending in a direction intersecting the extension direction and suppressing deflection of the second auxiliary bridge portion.

25. A coil array sheet as described in claim 23, wherein the first connecting portion, when viewed in the first direction, forms a first closed path that contains at least one of the first spiral conductor portion, and the first closed path has at least one of the first deflection suppression portion and the first auxiliary deflection suppression portion.

26. A coil array sheet as described in claim 24, wherein the first connecting portion, when viewed in the first direction, forms a first closed path containing at least one of the first spiral conductor portion, the first closed path having at least one of the first deflection suppression portion and the first auxiliary deflection suppression portion, and the second connecting portion, when viewed in the first direction, forms a second closed path containing at least one of the second spiral conductor portion, and the second closed path having at least one of the second deflection suppression portion and the second auxiliary deflection suppression portion.

27. A coil array sheet as described in claim 18, wherein the first bridge portion and the second bridge portion have overlapping portions when viewed in the first direction.

28. A coil array sheet as described in claim 24, wherein the first auxiliary bridge portion and the second auxiliary bridge portion have overlapping portions when viewed in the first direction.

29. A coil array sheet according to any one of claims 17 to 28, wherein the connecting portion has a portion made of a plating deposit.

30. A method for manufacturing a coil component comprising: a conductor forming step of forming a conductor in an insulating sheet; a removing step of removing at least a portion of an exposed portion of the insulating sheet that is not covered by the conductor, to produce a coil array sheet including a plurality of coil portions including a spiral conductor portion that has a spiral shape when viewed in a first direction, and a connecting portion connecting between the plurality of coil portions; a molding step of covering the coil array sheet with a material containing magnetic powder and molding it to form a magnetic sheet whose thickness direction is in the first direction; and a cutting step of cutting the magnetic sheet at least toward the first direction to form a plurality of coil chips including one of the coil portions and a material containing the magnetic powder located around it, wherein the connecting portion has a plurality of closed paths, each of the plurality of closed paths containing one or more of the spiral conductor portions when viewed in the first direction, and the plurality of closed paths having a deflection suppressing portion that includes a portion extending in a direction intersecting an extension direction of the closed path and suppresses deflection of the coil array sheet.

31. The spiral conductor portion includes a plurality of first spiral conductor portions provided on a first surface, which is one of the surfaces of the insulating sheet, and a plurality of second spiral conductor portions provided on a second surface, which is the other of the surfaces of the insulating sheet; the connecting portion includes a first connecting portion provided on the first surface and connecting the plurality of first spiral conductor portions, and a second connecting portion provided on the second surface and connecting the plurality of second spiral conductor portions; the insulating sheet has a through hole, and in the conductor forming step, a via conductor portion is formed inside the through hole as a part of the conductor, the via conductor portion electrically connecting an inner peripheral end of the first spiral conductor portion and an inner peripheral end of the second spiral conductor portion; an insulating step before the molding step, an outer coat forming step of forming an outer coat made of an insulator on the surface of the magnetic sheet; 31. The method for manufacturing a coil component according to claim 30, further comprising: an electrode forming step of forming a pair of external electrodes on a surface of the coil chip and electrically connecting one of the pair of external electrodes to the other of the pair of external electrodes through the coil portion of the coil chip; wherein each of the multiple closed paths of the first connecting portion contains one or more spiral conductor portions when viewed in the first direction; and each of the multiple closed paths of the second connecting portion contains one or more spiral conductor portions when viewed in the first direction.

32. The method of manufacturing a coil component according to claim 30, wherein the deflection restraint portion has a crank portion including a portion extending in a direction intersecting the extension direction of the closed path.

33. A method for manufacturing a coil component as described in claim 31, wherein the insulating sheet has a connecting portion through hole at a position sandwiched between the first connecting portion and the second connecting portion, and in the conductor forming step, a via connecting portion connecting the first connecting portion and the second connecting portion is formed inside the connecting portion through hole as another part of the conductor.

34. The method for manufacturing a coil component according to claim 30, wherein the deflection suppression portion includes a frame-shaped portion having a polygonal envelope shape when viewed in the first direction.

35. A method for manufacturing a coil component as set forth in claim 34, wherein the frame-shaped portion is provided at a boundary portion of two closed paths that respectively contain two adjacent spiral conductor portions in a direction perpendicular to the first direction.

36. A method for manufacturing a coil component as described in claim 30, wherein the two closed paths each containing two adjacent spiral conductor portions in a direction perpendicular to the first direction have a shared portion, and the deflection suppression portion is provided on the shared portion.

37. A method for manufacturing a coil component as set forth in claim 31, wherein the closed path of the first connecting portion and the closed path of the second connecting portion have an overlapping portion that overlaps when viewed in the first direction.

38. A method for manufacturing a coil component as described in claim 37, wherein the deflection suppression portion is provided to include the overlapping portion and has a crank portion including a portion extending in a direction intersecting the extension direction of the closed path, and the crank portion is positioned so as to be sandwiched between two of the overlapping portions when viewed in the first direction.

39. The method of manufacturing a coil component according to claim 30, wherein the closed path has a rectangular envelope shape when viewed in the first direction.

40. The method for manufacturing a coil component according to claim 30, wherein the coil chip includes a portion of the connecting portion, and the portion of the connecting portion is electrically independent from the coil portion.

41. An electronic or electrical device incorporating the coil component described in claim 1, wherein the coil component is connected to a substrate via terminal portions provided on both ends of the coil portion exposed from the main body portion.

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