Stacked component aligning method, method for manufacturing stacked electronic component, and stacked component aligning device

Abstract

A stacked component aligning method according to the present disclosure comprises: a preparation step for preparing a stacked component having a plurality of magnetic layers and a plurality of dielectric layers that are alternately stacked; a housing step for preparing a housing member that includes a first inner wall and a second inner wall, the first inner wall having a recessed part that is inclined with respect to a first reference line orthogonal to the second inner wall in a plan view, and housing the stacked component in the recessed part; and a rolling step in which a magnet for applying a magnetic field moves along a direction intersecting the first reference line and causes the stacked component to roll.

Description

Method for aligning laminated components, method for manufacturing laminated electronic components, and apparatus for aligning laminated components

[0001] The present invention relates to a method for aligning laminated components, a method for manufacturing laminated electronic components, and an apparatus for aligning laminated components.

[0002] A conventional method for aligning laminated components, a method for manufacturing laminated electronic components, and an apparatus for aligning laminated components are described in, for example, Patent Document 1.

[0003] Japanese Patent Application Laid-Open No. 2003-007574

[0004] A method for aligning laminated components according to one embodiment of the present disclosure includes a preparation step of preparing a laminated component having a plurality of alternatingly stacked magnetic layers and a plurality of dielectric layers; an accommodating step of preparing a container member having a first inner wall and a second inner wall, the first inner wall having a recess that is inclined relative to a first reference line perpendicular to the second inner wall in a planar view, and accommodating the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field along a direction that intersects the first reference line.

[0005] A method for aligning laminated components according to one embodiment of the present disclosure includes a preparation step of preparing a laminated component having a plurality of alternatingly stacked magnetic layers and a plurality of dielectric layers; an accommodation step of preparing a housing member having a recess including a first inner wall and a second inner wall, wherein the first inner wall is arc-shaped in a plan view and a straight line connecting both ends of the first inner wall intersects with the second inner wall, and accommodating the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field along a direction intersecting a first reference line that is perpendicular to the second inner wall.

[0006] An alignment device for stacked components according to one embodiment of the present disclosure includes a storage member having a first inner wall and a second inner wall, the first inner wall being inclined relative to a first reference line perpendicular to the second inner wall in a plan view, the storage member having a recess for storing stacked components, and a magnet that moves in a direction intersecting the first reference line and applies a magnetic field to cause the stacked components to roll.

[0007] An alignment device for stacked components according to one embodiment of the present disclosure includes a housing member including a first inner wall and a second inner wall, wherein the first inner wall is arc-shaped in a plan view and a straight line connecting both ends of the first inner wall has a recess that intersects with the second inner wall, and a magnet that moves in a direction intersecting a first reference line that is perpendicular to the second inner wall and applies a magnetic field to roll the stacked components.

[0008]

[0014] Objects, features, and advantages of the present disclosure will become more apparent from the following detailed description and drawings.

[0015] FIG. 1 is a schematic perspective view of a laminated electronic component according to an embodiment of the present disclosure.

[0016] FIG. 2 is a schematic view of an element body according to an embodiment of the present disclosure, showing a laminate section, a side margin section, and a cover section as a single unit.

[0017] FIG. 3 is a schematic perspective view of each component of the element body, showing the laminate section, the side margin section, and the cover section as separated.

[0018] FIG. 4 is a flowchart showing a method for manufacturing a laminated electronic component according to an embodiment of the present disclosure.

[0019] FIG. 5 is a schematic view of ceramic sheets and magnetic material sheets arranged thereon, showing a first ceramic sheet and a first magnetic material sheet, a perspective view showing a second ceramic sheet and a second magnetic material sheet, and a perspective view showing a third ceramic sheet.

[0020] FIG. 6 is a schematic perspective view of a base laminate component according to an embodiment of the present disclosure.

[0021] FIG. 7 is a schematic perspective view of a base laminate component according to an embodiment of the present disclosure.

[0022] FIG. 8 is a schematic perspective view of a laminate component according to an embodiment of the present disclosure.

[0023] FIG. 9 is a view showing an accommodating member and a laminate component accommodated in the accommodating member according to an embodiment of the present disclosure.

[0024] FIG. 10 is an enlarged view of a recess provided in the accommodating member according to an embodiment of the present disclosure.

[0025] FIG. 11 is a view showing a recess according to a modified example. 9 is a schematic cross-sectional view of the recess taken along line X-X in FIG. 8. FIG. 10 is a schematic view of a rolling step according to an embodiment of the present disclosure. FIG. 11 is a schematic view of a rolling step according to an embodiment of the present disclosure. FIG. 12 is a schematic view of a rolling step according to an embodiment of the present disclosure. FIG. 13 is a schematic view of a processing step according to an embodiment of the present disclosure. FIG. 14 is a schematic view of a processing step according to an embodiment of the present disclosure. FIG. 15 is a schematic perspective view of an element precursor according to an embodiment of the present disclosure. FIG. 16 is a view of a modified example of the recess according to an embodiment of the present disclosure. FIG. 17 is a view of a modified example of the recess according to an embodiment of the present disclosure. FIG. 18 is a view of a modified example of the rolling step according to an embodiment of the present disclosure. FIG. 19 is a view of a modified example of the rolling step according to an embodiment of the present disclosure.FIG. 1 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 2 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 3 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 4 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 5 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 6 is a diagram illustrating a modified example of a recess according to an embodiment of the present disclosure. FIG. 7 is a diagram illustrating a rolling rate of stacked components using an alignment device according to an embodiment of the present disclosure. FIG. 8 is a diagram illustrating a modified example of a containing member according to an embodiment of the present disclosure. FIG. 9 is a diagram illustrating a modified example of a containing member according to an embodiment of the present disclosure. FIG. 10 is a diagram illustrating a rolling rate of stacked components using an alignment device according to an embodiment of the present disclosure. FIG. 11 is a diagram illustrating a first magnet and a second magnet in a modified example of a rolling process according to an embodiment of the present disclosure. FIG. 12 is a diagram illustrating a first magnet and a second magnet in a modified example of a rolling process according to an embodiment of the present disclosure. FIG. 13 is a diagram illustrating a first magnet and a second magnet in a modified example of a rolling process according to an embodiment of the present disclosure. FIG. 14 is a diagram illustrating a first magnet and a second magnet in a modified example of a rolling process according to an embodiment of the present disclosure. 10A and 10B are diagrams illustrating a first magnet and a second magnet in a modified example of a rolling process according to an embodiment of the present disclosure;

[0009] There is known a method for aligning chip components having internal electrodes so that the internal electrodes face in a predetermined direction.

[0010] Patent document 1 describes a method in which a pallet with a concave pocket larger than the planar dimensions of the chip component is prepared, and with the chip component placed in the pocket, a magnet is moved in a direction parallel to the bottom surface of the pocket, thereby rolling the chip component so that the orientation of the internal electrode is perpendicular to the bottom surface of the pocket.

[0011] To increase the probability of rolling the laminated component, it is necessary to apply a stronger magnetic force or increase the number of times and duration that the magnetic force is applied. In this case, the internal electrodes or the entire laminated component will become magnetized, which can cause problems such as attracting unwanted objects in the surrounding area or adhering to metal equipment used in subsequent processes, making them difficult to handle.

[0012] Hereinafter, with reference to the drawings, a description will be given of a multilayer electronic component 1 according to an embodiment of the present disclosure and a method for manufacturing the multilayer electronic component 1. Note that, although a multilayer ceramic capacitor will be described below as an example of the multilayer electronic component 1, the multilayer electronic component 1 to which the present disclosure is directed is not limited to a multilayer ceramic capacitor and can be applied to various other multilayer electronic components such as a multilayer piezoelectric element, a multilayer thermistor element, a multilayer coil, and a multilayer ceramic multilayer substrate.

[0013] The drawings used in the following description are schematic, and the dimensional ratios and the like in the drawings do not necessarily correspond to the actual ones. Furthermore, the embodiments described in this specification are merely illustrative, and different embodiments and modified examples may be partially substituted with each other. Furthermore, different embodiments and modified examples may be partially combined with each other.

[0014] [Laminated Electronic Component] Fig. 1 is a schematic diagram of a laminated electronic component 1 according to an embodiment of the present disclosure. The laminated electronic component 1 has an element body 2 and external electrodes 3. The shape of the element body 2 is set as appropriate, but as an example, the element body 2 has a substantially rectangular parallelepiped shape. As an example, the external electrodes 3 are located on a pair of end faces of the element body 2 and may be formed to extend around to other faces adjacent to the end faces. The external electrode located on one end face is referred to as external electrode 3a, and the external electrode located on the other end face is referred to as external electrode 3b.

[0015] For convenience, the drawings may be illustrated with a Cartesian coordinate system consisting of a first direction, a second direction, and a third direction. In the laminated electronic component 1 according to the present disclosure, any direction may be the first direction, the second direction, or the third direction. For convenience, however, the stacking direction of the internal electrode layers 212 and the ceramic dielectric layers 211 (described later) is defined as the first direction. Furthermore, a direction intersecting the first direction and substantially parallel to the short-side direction of the element body 2, which has a substantially rectangular parallelepiped shape, is defined as the second direction. Furthermore, a direction intersecting the second direction and substantially parallel to the long-side direction of the element body 2, which has a substantially rectangular parallelepiped shape, is defined as the third direction. For convenience, the first direction may be referred to as the up-down direction, the second direction as the left-right direction, and the third direction as the front-to-back direction.

[0016] The element body 2 has a substantially rectangular parallelepiped shape and six faces. The faces located at the top and bottom of the element body 2 in the first direction are defined as main faces, the faces located at the left and right of the element body 2 in the second direction are defined as side faces, and the faces located at the front and back of the element body 2 in the third direction are defined as end faces.

[0017] The definitions of the main surface, side surface, and end surface are similarly defined for the laminate section 21, which will be described later and which constitutes the element body 2. The definitions of the main surface, side surface, and end surface are similarly defined for the element body precursor 200, which will be described later, before firing. The definitions of the main surface, side surface, and end surface are similarly defined for the laminate component 50, which will be described later, before firing. The definitions of the main surface, side surface, and end surface are similarly defined for the mother laminate component 500, which will be described later, before firing.

[0018] In this specification, the "main surface," "side surface," and "end surface" do not necessarily have to be strictly flat. For example, the main surface, side surface, and end surface may each have partial irregularities or may be slightly warped overall.

[0019] The external electrodes 3 are formed from a conductive material and function as terminals of the laminated electronic component 1. Examples of conductive materials that can be used to form the external electrodes 3 include metals such as nickel (Ni), copper (Cu), palladium (Pd), tin (Sn), zinc (Zn), platinum (Pt), silver (Ag), and gold (Au), as well as alloys of these metals.

[0020] The external electrode 3 may have a single-layer structure or a multi-layer structure. For example, a multi-layer external electrode 3 may have a two-layer structure consisting of a base film and a surface film, or a three-layer structure consisting of a base film, an intermediate film, and a surface film. The base film may be a baked film made of a metal primarily containing, for example, Ni, Cu, Pd, Pt, Ag, Au, or an alloy thereof. The base film may also be formed as a plated film. The intermediate film may be a plated film made of a metal or alloy primarily containing, for example, Pt, Pd, Au, Cu, Ni, or the like. The surface film may be a plated film made of a metal or alloy primarily containing, for example, Cu, Sn, Pd, Au, Zn, or the like.

[0021] 2A and 2B are schematic diagrams of the element body 2. The element body 2 has a laminated portion 21, a side margin portion 22, and a cover portion 23. FIG. 2A is a schematic diagram showing the laminated portion 21, the side margin portion 22, and the cover portion 23 as a single unit, while FIG. 2B is a schematic diagram showing the laminated portion 21, the side margin portion 22, and the cover portion 23 in a separated state. FIGS. 2A and 2B are both diagrams showing the element body 2 before and after firing. Although the element body 2 after firing has shrunk due to firing, it has substantially the same structure as the element body 2 before firing.

[0022] The multilayer section 21 has a plurality of ceramic dielectric layers 211 and a plurality of internal electrode layers 212. The plurality of ceramic dielectric layers 211 and the plurality of internal electrode layers 212 are alternately stacked in a first direction. The plurality of ceramic dielectric layers 211 may contain various ceramic dielectric materials. Examples of ceramic dielectric materials include barium titanate (BaTiO ３ ) and calcium zirconate (CaZrO ３ The internal electrode layers 212 may contain various metals such as Ni, Pd, Ag, and Cu.

[0023] The multiple internal electrode layers 212 are alternately exposed from a pair of end faces of the laminated portion 21 and connected to the external electrodes 3. Of the multiple internal electrode layers 212, those connected to the external electrode 3a are referred to as internal electrode layers 212a, and those connected to the external electrode 3b are referred to as internal electrode layers 212b.

[0024] The side margins 22 are located on both side surfaces of the laminated portion 21 in the second direction. The side margins 22 may contain various ceramic dielectrics. For example, the main component of the side margins 22 may be the same as the main component of the ceramic dielectric layers 211 of the laminated portion 21. In this case, compared to a case where the main components of the ceramic dielectric layers 211 of the laminated portion 21 and the side margins 22 are different, manufacturing efficiency is improved and reliability is improved by reducing internal stress in the element body 2.

[0025] The cover portion 23 is located on both main surfaces of the laminate portion 21 in the first direction. The cover portion 23 may contain various ceramic dielectrics. For example, the main component of the cover portion 23 may be the same as the main component of the ceramic dielectric layers 211 of the laminate portion 21. In this case, compared to when the main components of the ceramic dielectric layers 211 of the laminate portion 21 and the cover portion 23 are different, manufacturing efficiency is improved and internal stress in the element body 2 is reduced, thereby improving reliability.

[0026] With the above configuration, when a voltage is applied between the external electrodes 3 a and 3 b in the laminated electronic component 1, the voltage is applied to the plurality of ceramic dielectric layers 211 between the internal electrode layers 212 a and 212 b, causing the laminated electronic component 1 to store electric charge according to the voltage between the external electrodes 3 a and 3 b.

[0027] The configuration of the laminated electronic component 1 is not limited to a specific configuration, and any known configuration can be appropriately adopted depending on the size and performance required of the laminated electronic component 1. For example, the number of stacked internal electrode layers 212 in the laminate section 21 can be determined appropriately. For example, the longitudinal direction and lateral direction of the element body 2, which has a substantially rectangular parallelepiped shape, may be reversed. In other words, the second direction may be the longitudinal direction, and the third direction may be the lateral direction.

[0028] [Method for Manufacturing a Laminated Electronic Component and Method for Aligning the Laminated Components] Figure 3 is a flowchart showing a method for manufacturing the laminated electronic component 1. Figures 4A to 4C, 5 to 8, 9A, 9B, 10, 11A to 11D, 12A to 12C, and 13 are diagrams specifically illustrating each step of the method for manufacturing the laminated electronic component 1. The method for manufacturing the laminated electronic component 1 will be described below with reference to Figures 4A to 4C, 5 to 8, 9A, 9B, 10, 11A to 11D, 12A to 12C, and 13. The method for manufacturing the laminated electronic component 1 of the present disclosure also includes a method for aligning laminate components 50, which serve as precursors of the laminated electronic component 1. Therefore, the present disclosure includes a method for aligning laminate components 50 and an alignment device used in the alignment method.

[0029] Note that the embodiments and modifications according to the present disclosure are merely illustrative. Therefore, different embodiments or modifications may be partially substituted with each other. Also, different embodiments or modifications may be partially combined with each other.

[0030] (Preparation Step) In the preparation step, a laminate component 50 having a plurality of dielectric layers 51 and a plurality of magnetic layers 52 alternately stacked is prepared.

[0031] First, to prepare the laminate component 50, a base laminate component 500 is prepared in which a plurality of ceramic sheets 400 and a plurality of magnetic material sheets 410 are alternately laminated. The base laminate component 500 is formed by laminating a plurality of first ceramic sheets 401, second ceramic sheets 402, third ceramic sheets 403, first magnetic material sheets 411, and second magnetic material sheets 412.

[0032] 4A to 4C show ceramic sheets 400 and magnetic sheets 410 arranged thereon. Fig. 4A is a perspective view showing first ceramic sheets 401 and first magnetic sheets 411, Fig. 4B is a perspective view showing second ceramic sheets 402 and second magnetic sheets 412, and Fig. 4C is a perspective view showing third ceramic sheet 403.

[0033] The first ceramic sheet 401 and the second ceramic sheet 402 become the ceramic dielectric layers 211 of the laminated portion 21 after firing. The third ceramic sheet 403 becomes the cover portion 23 after firing. The first magnetic material sheet 411 and the second magnetic material sheet 412 become the internal electrode layers 212 after firing. The first ceramic sheet 401, the second ceramic sheet 402, and the third ceramic sheet 403 may be collectively referred to as ceramic sheets 400. The first magnetic material sheet 411 and the second magnetic material sheet 412 may be collectively referred to as magnetic material sheets 410.

[0034] The ceramic sheet 400 is placed on, for example, a carrier film. This placement is performed using, for example, a die coater, but is not limited to this. For example, it may be performed using a doctor blade coater or a gravure coater. The thickness of the ceramic sheet 400 can be set as appropriate. For example, the thickness of the ceramic sheet 400 may be approximately 1 to 10 μm. The thinner the ceramic sheet, the greater the capacitance of the laminated electronic component 1 can be.

[0035] The ceramic sheet 400 may be made of various ceramic dielectric materials. As an example, the ceramic sheet 400 may be made of BaTiO ３ The ceramic powder mixture with additives added is wet-pulverized and mixed in a bead mill, and the pulverized and mixed slurry is then mixed with a polyvinyl butyral binder, a plasticizer, and an organic solvent to produce the ceramic powder mixture.

[0036] Next, as shown in Figures 4A and 4B, a first magnetic sheet 411 is placed on the first ceramic sheet 401 prepared above, with a gap therebetween. The first magnetic sheet 411 becomes the internal electrode layer 212a after firing. A second magnetic sheet 412 is placed on the second ceramic sheet 402, with a gap therebetween. The second magnetic sheet 412 becomes the internal electrode layer 212b after firing.

[0037] 4A and 4B show two types of conductor patterns with different polarities printed on a magnetic sheet 410. The magnetic sheet 410 can be formed by, for example, screen printing or gravure printing.

[0038] The magnetic sheet 410 may be made of various magnetic materials. For example, the magnetic sheet 410 may be made of a conductive paste containing various conductive materials such as Ni, Pd, Ag, and Cu. However, the magnetic sheet 410 is not limited to this example and may be made of, for example, a ferromagnetic insulating material.

[0039] The third ceramic sheet 403 corresponding to the cover portion 23 after firing may not necessarily have the magnetic material sheet 410 formed thereon. However, this is not limiting, and for example, the third ceramic sheet 403 may have a magnetic material sheet 410 disposed thereon that will become a dummy electrode layer after firing. The dummy electrode layer is an electrode layer formed so that electrode layers connected to different external electrodes 3 do not overlap and so that no capacitance is generated.

[0040] The thickness of the magnetic material sheet 410 can be set as appropriate. As long as the characteristics of the multilayer ceramic capacitor are ensured, the thinner the magnetic material sheet 410, the more internal defects caused by internal stress can be reduced. For example, in a capacitor with a high number of layers, the thickness of the magnetic material sheet 410 may be 1 μm or less. Furthermore, the spacing between the first magnetic material sheet 411 and the second magnetic material sheet 412 does not necessarily have to be constant and can be set as appropriate. For example, the spacing between the first magnetic material sheet 411 and the second magnetic material sheet 412 may be different.

[0041] The first ceramic sheet 401 on which the first magnetic material sheet 411 is formed may be referred to as the first sheet, the second ceramic sheet 402 on which the second magnetic material sheet 412 is formed may be referred to as the second sheet, and the third ceramic sheet 403 may be referred to as the third sheet.

[0042] Next, the prepared first, second, and third sheets are laminated together to produce a mother laminate component 500. FIG. 5 is a schematic perspective view of the mother laminate component 500. For ease of explanation, each ceramic sheet 400 is shown exploded in FIG. 5. However, in an actual mother laminate component 500, the ceramic sheets 400 are pressure-bonded together by hydrostatic pressure, uniaxial pressure, or the like, to form an integrated component. This results in a high-density mother laminate component 500.

[0043] In the mother laminate component 500, first sheets and second sheets corresponding to the fired laminate portion 21 are alternately stacked in the first direction. In addition, in the mother laminate component 500, third sheets corresponding to the fired cover portion 23 are stacked on the top and bottom surfaces in the first direction of the alternately stacked first and second sheets, respectively. The numbers of first sheets, second sheets, and third sheets can each be changed as appropriate.

[0044] Next, the base laminate component 500 is cut to form an unsintered laminate component 50 having side and end surfaces on which the magnetic material sheets 410 are exposed. FIG. 6 shows a perspective view and cutting lines of the base laminate component 500. The base laminate component 500 is cut along cutting lines CL1 and CL2 while attached to tape, which serves as a holding member. This separates the base laminate component 500, resulting in a plurality of laminate components 50 as shown in FIG. 7.

[0045] The cut surfaces of the base laminate component 500 formed by cutting along the cutting line CL1 become the side surfaces of the laminate component 50 in the second direction. The cut surfaces of the base laminate component 500 formed by cutting along the cutting line CL2 become the end surfaces of the laminate component 50 in the third direction. The magnetic material sheets 410 are exposed from the side surfaces and end surfaces of the laminate component 50.

[0046] The configuration of the cutting blade used to cut the base laminate component 500 may be changed as appropriate. For example, the cutting blade may be a press-cutting blade or a rotary blade. Furthermore, the base laminate component 500 may be cut using a technique that does not require a cutting blade, such as laser cutting or water jet cutting.

[0047] The cut laminate component 50 includes a plurality of dielectric layers 51 and a plurality of magnetic layers 52 that are alternately stacked. The dielectric layers 51 correspond to the ceramic sheets 400 in the base laminate component 500. The magnetic layers 52 correspond to the magnetic sheets 410 in the base laminate component 500.

[0048] The laminate component 50 has a pair of main surfaces, a pair of side surfaces, and a pair of end surfaces. As an example, the laminate component 50 in one embodiment of the present disclosure is substantially rectangular. The distance between the pair of main surfaces of the laminate component 50 is defined as T, the distance between the pair of side surfaces as W, and the distance between the pair of end surfaces as L. The sizes of L, W, and T may be set as appropriate. For example, as in one embodiment of the present disclosure, T<W<L may be satisfied.

[0049] Note that "substantially rectangular parallelepiped" does not necessarily mean that the shape is rectangular parallelepiped in the strict sense; for example, each surface may have some irregularities or may be curved. For example, if the main surface is not strictly flat and there are multiple Ts, the largest distance can be defined as T. Also, if the side surface is not strictly flat and there are multiple Ws, it can be defined in the same way as T. Also, if the end surface is not strictly flat and there are multiple Ls, it can be defined in the same way as T.

[0050] 7 , a plurality of magnetic layers 52 are exposed from both sides of a pair of side surfaces of the laminate component 50 formed by cutting. Furthermore, a plurality of stacked magnetic layers 52 are alternately exposed from both sides of a pair of end surfaces of the laminate component 50 formed by cutting. In other words, the plurality of stacked magnetic layers 52 are exposed, separated by polarity, from both sides of the pair of end surfaces.

[0051] (Accommodating Step) In the accommodating step, an accommodating member 6 having a recess 61 is prepared, and the stack component 50 is accommodated in the recess 61 .

[0052] Figure 8 is a diagram showing a housing member 6 according to one embodiment of the present disclosure and a stack component 50 housed in the housing member 6. The housing member 6 has a recess 61, and the stack component 50 is housed in the recess 61. The housing member 6 may have multiple recesses 61. Figures 9A and 9B are enlarged views of one of the multiple recesses 61 in the housing member 6. Figure 9A shows the recess 61 according to one embodiment of the present disclosure, and Figure 9B shows the recess 61 according to a modified example of the present disclosure.

[0053] When the accommodating member 6 is viewed from above, the outer edge of the opening surface 63 of the recess 61 is formed by a plurality of inner walls. For example, as shown in FIG. 9A , the plurality of inner walls may include a first inner wall 611 and a second inner wall 612. A reference line perpendicular to the second inner wall 612 in the plan view is defined as RL1. The reference line RL1 may also be referred to as the first reference line. In the plan view, the first inner wall 611 is inclined with respect to the reference line RL1. In this case, the inclination angle of the first inner wall 611 with respect to the reference line RL1 is defined as θ1.

[0054] 9A , the multiple inner walls of recess 61 may include a third inner wall 613 facing first inner wall 611, and may also include a fourth inner wall 614 facing second inner wall 612. Note that "facing" means that the two inner walls face each other, and the facing inner walls do not necessarily have to be parallel to each other in a plan view or a cross-sectional view.

[0055] 9A , the first inner wall 611 may intersect with the second inner wall 612 and the fourth inner wall 614, and the third inner wall 613 may intersect with the second inner wall 612 and the fourth inner wall 614. Note that "intersect" means that the two inner walls intersect, and the two inner walls do not need to be perpendicular to each other in a plan view.

[0056] A reference line perpendicular to the fourth inner wall 614 in a plan view is defined as RL2. The reference line RL2 may be referred to as a second reference line. In a plan view, the third inner wall 613 may be inclined with respect to the reference line RL2. In this case, the inclination angle of the third inner wall 613 with respect to the reference line RL2 may be defined as θ2.

[0057] The recess 61 of the present disclosure is not limited to the example shown in Fig. 9A. For example, as shown in Fig. 9B, the first inner wall 611 may not intersect with the second inner wall 612. In other words, the first inner wall 611 and the second inner wall 612 may be connected via another inner wall.

[0058] 9B , the inner wall located between the first inner wall 611 and the second inner wall 612 is referred to as a fifth inner wall 615. The inner wall located between the third inner wall 613 and the fourth inner wall 614 is referred to as a sixth inner wall 616. In other words, the fifth inner wall 615 intersects with the first inner wall 611 and the second inner wall 612. The sixth inner wall 616 intersects with the third inner wall 613 and the fourth inner wall 614.

[0059] 9B . For example, the recess 61 may have a plurality of inner walls, including a fifth inner wall 615, between the first inner wall 611 and the second inner wall 612. The fifth inner wall 615 does not necessarily need to be parallel to the reference line RL1, and may be inclined with respect to the reference line RL1.

[0060] At the outer edge of the recess 61, the width of the recess 61 in a direction substantially parallel to the reference line RL1 may be defined as X, and the length of the recess 61 in a direction intersecting the reference line RL1 may be defined as Y. If the recess 61 has multiple widths, the largest width may be defined as X. If the recess 61 has multiple lengths, the largest length may be defined as Y. Note that "substantially parallel" does not necessarily mean strictly parallel.

[0061] Fig. 10 is a schematic cross-sectional view of the recess 61 taken along the line X-X in Fig. 8. The recess 61 has a bottom 62 and an opening surface 63. The "opening surface" is the planar space surrounded by the outer edge of the recess 61 when the housing member 6 is viewed from above.

[0062] 10 , in one embodiment of the recess 61 according to the present disclosure, when the stack component 50 is accommodated, the opening surface 63 of the recess 61 is located lower than the open surface of the stack component 50. In other words, the opening surface 63 of the recess 61 is located closer to the bottom 62 than the open surface of the stack component 50. In other words, the open surface of the stack component 50 protrudes from the recess 61.

[0063] In this case, in the attachment step described below, the outer edge of the recess 61 of the housing member 6 does not interfere when attaching the laminate component 50 to the adhesive sheet 8, making it easier to attach the laminate component 50 to the adhesive sheet 8. Furthermore, since there is no need to remove the laminate component 50 from the recess 61 when attaching the laminate component 50 to the adhesive sheet 8, the manufacturing process can be further simplified.

[0064] In the processing step described below, it is necessary to align the open surfaces of the multiple laminate components 50 because processing is performed on the open surfaces of the laminate components 50. However, if the laminate components 50 are randomly placed in the recess 61, the laminate components 50 will either be placed with their main surfaces facing the bottom 62 of the recess 61, or with their side surfaces facing the bottom 62.

[0065] The "open surface" of the laminate component 50 in the accommodation step refers to the surface that can be observed when the laminate component 50 accommodated in the recess 61 is viewed from above.

[0066] (Rolling Step) In the rolling step, a magnetic field is applied to roll the stacked components 50. This rolling step allows the orientation of the open faces of the stacked components 50 to be aligned.

[0067] 11A to 11D schematically show the rolling process, with the magnet 9 moving in the order shown in Fig. 11A to Fig. 11D. In other words, as shown in Fig. 11A and Fig. 11B, the magnet 9 moves toward the first inner wall 611 of the recess 61 along a direction intersecting the reference line RL1. The direction in which the magnet 9 moves is indicated by an arrow in Fig. 11A.

[0068] The magnets 9 are arranged so that their opposite magnetic poles face each other along a direction intersecting the reference line RL1. In the example shown in FIGS. 11A to 11D , the north pole of the magnet 9 is located on the side closer to the recess 61, and the south pole is located on the side farther from the recess 61. Note that the positions of the north and south poles may be reversed. With the magnets 9 arranged in this manner, a magnetic field is generated in which magnetic flux lines point from the north pole to the south pole. In other words, the magnetic flux lines of the magnetic field generated by the magnets 9 intersect with the first inner wall 611 of the recess 61 in a plan view. Note that the magnetic flux lines of the magnetic field generated by the magnets 9 do not have to be perpendicular to the first inner wall 611. As an example, the magnetic flux lines of the magnetic field generated by the magnets 9 may be perpendicular to the reference line RL1.

[0069] The laminate component 50 including the magnetic layer 52 is attracted to the magnet 9. Therefore, as shown in Figures 11A and 11B, when the magnet 9 approaches the recess 61, the laminate component 50 moves closer to the magnet 9 inside the recess 61 and comes into contact with the first inner wall 611.

[0070] Furthermore, the magnetic flux lines directed from the north pole to the south pole of the magnet 9 intersect with the first inner wall 611 of the recess 61. In the embodiment shown in Figures 11A to 11D, the magnetic flux lines are directed along the second inner wall 612 of the recess 61. In other words, the magnetic field of the magnet 9 at this time acts in a direction substantially parallel to the second inner wall 612 of the recess 61.

[0071] In this case, the magnetic layers 52 are aligned parallel to the magnetic flux lines, and therefore the main surfaces of the laminate component 50, which are generally parallel to the magnetic layers 52, are aligned parallel to the magnetic flux lines. As a result, the main surfaces of the laminate component 50 are aligned along the second inner walls 612. In other words, the end faces of the laminate component 50 face in a direction that intersects with the second inner walls 612. In the example shown in FIGS. 11A to 11D , the end faces of the laminate component 50 are aligned in a direction perpendicular to the second inner walls 612.

[0072] 11C , magnet 9 passes under stacked component 50 housed in recess 61. When the north pole of magnet 9 that has moved is positioned under stacked component 50, the magnetic flux lines from the north pole to the south pole are oriented in a direction perpendicular to opening surface 63 of recess 61. In other words, the magnetic field of magnet 9 at this time acts in a direction perpendicular to opening surface 63 of recess 61.

[0073] In this case, the magnetic layers 52 are aligned parallel to the magnetic flux lines, causing the laminate component 50 to roll. Specifically, as shown in FIG. 11C , the main surfaces of the laminate component 50, which are generally parallel to the magnetic layers 52, roll so that they are parallel to the magnetic flux lines. As a result, one side surface of the laminate component 50 faces the bottom 62 of the recess 61, and the other side surface of the laminate component 50 becomes an open surface. As a result, the laminate component 50, which originally has an open main surface, becomes an open surface as the laminate component 50 rolls within the recess 61 due to the action of the magnetic field from the magnet 9, and the laminate component 50, which originally has an open side surface, remains as it is.

[0074] 11C , the magnet 9 passes below the recess 61. In other words, the magnet 9 passes on the bottom 62 side of the recess 61. However, the movement of the magnet 9 is not limited to this example. For example, the magnet 9 may pass above the recess 61. In other words, the magnet 9 may pass on the opening surface 63 side of the recess 61. In this case, the accommodating member 6 may further have a lid member, which will be described later. The lid member overlaps at least a portion of the opening surface 63 of the recess 61.

[0075] 11D , magnet 9 moves in a direction intersecting reference line RL1, moving away from first inner wall 611. At this time, stacked component 50 is attracted to magnet 9 inside recess 61, and therefore moves away from first inner wall 611.

[0076] In the insertion process, the laminate component 50 is inserted into the recess 61 so that its side surface is aligned with the second inner wall 612. Here, for example, if the first inner wall 611 and the second inner wall 612 are perpendicular to each other, the first inner wall 611 will be parallel to the end face of the laminate component 50. Therefore, at the point shown in FIG. 11B , the entire end face of the laminate component 50, attracted by the magnet 9, will be in contact with the first inner wall 611. Therefore, the static friction force is large, and the energy required to roll the laminate component 50 is large. Therefore, in order to roll the laminate component 50 with a high probability, it is necessary to apply a strong magnetic force or increase the number of times and duration for which the magnetic force is applied. As a result, a problem may occur in which the magnetic layer 52 or the entire laminate component 50 becomes magnetized.

[0077] On the other hand, according to one embodiment of the present disclosure, when the side surface of the laminate component 50 is accommodated in the recess 61 so as to be aligned with the second inner wall 612, the first inner wall 611 is not parallel to the end surface of the laminate component 50. Therefore, at the time shown in FIG. 11B , a portion of the end surface of the laminate component 50 attracted by the magnet 9 comes into contact with the first inner wall 611.

[0078] Because the first inner wall 611 is inclined with respect to the reference line RL1, the contact area between the laminate component 50 and the first inner wall 611 at the time shown in FIG. 11B is smaller than when the first inner wall 611 and the second inner wall 612 are perpendicular to each other. Therefore, the frictional force generated by contact between the laminate component 50 and the first inner wall 611 is reduced, allowing the laminate component 50 to roll with less energy. As a result, the possibility of the magnetic layer 52 or the entire laminate component 50 becoming magnetized is reduced. Furthermore, in the embodiment shown in FIG. 9A , the first inner wall 611 intersects with the second inner wall 612 and the fourth inner wall 614. In other words, the entire inner wall between the second inner wall 612 and the fourth inner wall 614 is inclined with respect to the reference line RL1. Therefore, the contact area is more likely to be smaller than when a portion of the inner wall located between the second inner wall 612 and the fourth inner wall 614 is inclined with respect to the reference line RL1, as in one embodiment shown in Figure 9B.

[0079] 11A to 11D , the magnet 9 is moved relative to the stack components 50 housed in the recess 61, and a magnetic field is applied to the stack components 50, causing the stack components 50 to roll. However, applying a magnetic field only once does not necessarily cause all of the stack components 50 housed in the housing member 6 to roll, and there is a possibility that some stack components 50 will remain unrolled.

[0080] In such a case, the magnet 9 can be moved again in the direction opposite to the direction of movement of the magnet 9 shown in Figures 11A to 11D so as to move closer to the third inner wall 613. In other words, the magnet 9 can be moved back and forth between the front and rear of the recess 61 in a direction intersecting the reference line RL1. As a result, a magnetic field can be applied to the stacked component 50 again, providing the stacked component 50 with another opportunity to roll.

[0081] In this case, when the third inner wall 613 is inclined with respect to the reference line RL2 that is perpendicular to the fourth inner wall 614 in a plan view, the contact area between the laminate component 50 and the third inner wall 613 is smaller than when the third inner wall 613 and the fourth inner wall 614 are perpendicular to each other. Therefore, the frictional force generated by contact between the laminate component 50 and the third inner wall 613 is reduced, allowing the laminate component 50 to roll with less energy.

[0082] Furthermore, in the embodiment, an example has been described in which only the housing member 6 is used to house the stack component 50, but this is not limiting. For example, the housing member 6 may further include a lid member. The lid member is arranged so as to overlap at least a portion of the opening surface 63 of the recess 61 in a plan view. This configuration can reduce the possibility of the stack component 50 flying out of the recess 61 when rolling during the rolling process.

[0083] Furthermore, the distance between the lid member and the bottom 62 of the recess 61 may be smaller than the distance L between the end faces of the laminate component 50. In this configuration, the possibility that the end faces of the laminate component 50 will roll to form open surfaces during the rolling process can be reduced, and the possibility that the side faces of the laminate component 50 will roll to form open surfaces can be increased.

[0084] (Processing Step) In the processing step, processing is performed on the surface of the laminate component 50. For example, as shown in Figures 12A to 12C, a functional member 404 is attached to the side surface of the laminate component 50.

[0085] 12A to 12C are diagrams schematically illustrating the processing steps, and the process proceeds in the order of FIGS. 12A to 12C. First, as shown in FIG. 12A, functional member 404 is placed on flat plate 420. One side of laminate component 50, which was the open surface in the rolling step, is attached to adhesive sheet 8, and the other side is placed facing functional member 404. Flat plate 420 may be a rigid body such as metal or resin, or an elastic body such as rubber, and can be selected appropriately depending on the characteristics of functional member 404.

[0086] Examples of functional member 404 include a protective ceramic green sheet, a protective ceramic paste, and a terminal electrode paste. For example, functional member 404 may be made of various ceramic dielectric materials, similar to ceramic sheet 400. In one example, functional member 404 is made of the same material as ceramic sheet 400. Functional member 404 is formed into a sheet using, for example, a roll coater or a doctor blade.

[0087] Next, as shown in FIG. 12B , the side surface of the laminate component 50 is pressed against the functional member 404. This causes the functional member 404 to adhere to the side surface of the laminate component 50. Then, as shown in FIG. 12C , when the laminate component 50 is lifted from the functional member 404, only the functional member 404 attached to the side surface is released from the elastic body and remains on the laminate component 50 side. Alternatively, the flat plate 420 may be made of an elastic material so that the functional member 404 is punched out when the side surface of the laminate component 50 is pressed against the functional member 404. This allows the functional member 404 to be provided on one side surface of the laminate component 50, which will become the side margin portion 22 after firing. The functional member 404 is also provided on the other side surface of the laminate component 50 using the same or a similar process.

[0088] Through the above steps, an element body precursor 200 as shown in Fig. 13 can be obtained. The element body precursor 200 becomes the element body 2 after a firing step described below. The shape and size of the element body precursor 200 can be set appropriately depending on the shape and properties of the element body 2 after firing.

[0089] 2A and 2B is produced by firing the obtained unfired element precursor 200. The firing can be carried out, for example, in a reducing atmosphere or a low oxygen partial pressure atmosphere.

[0090] (Terminal Forming Step) In the terminal forming step, external electrodes 3 are formed on the end faces of the element body 2 obtained in the firing step.

[0091] First, an unsintered electrode material is applied so as to cover both end faces in the third direction of the element body 2. The unsintered electrode material applied to the element body 2 is baked, for example, in a reducing atmosphere or a low-oxygen partial pressure atmosphere, to form a base film on the element body 2. Then, an intermediate film and a surface film are formed on the base film baked on the element body 2 by a plating process such as electrolytic plating, thereby completing the external electrode 3.

[0092] Note that some of the processing in the terminal formation step may be performed before the firing step. For example, before the firing step, unfired electrode material may be applied to both end faces in the third direction of the unfired element precursor 200, and in the firing step, the unfired electrode material may be baked simultaneously with firing the element precursor 200 to form an undercoat film for the external electrode 3. The undercoat film may also be formed by plating. The plating may be electrolytic plating or electroless plating. Through the above steps, the laminate electronic component 1 shown in FIG. 1 can be obtained.

[0093] As described above, the method for manufacturing a laminated electronic component according to an embodiment of the present disclosure includes the above-described preparation step, accommodation step, rolling step, attachment step, firing step, and terminal formation step. Therefore, the method for manufacturing a laminated electronic component according to an embodiment of the present disclosure can reduce the possibility of the internal electrode layers 212 or the entire laminated electronic component 1 becoming magnetized, thereby reducing the possibility of defects occurring.

[0094] 8 , 9A, and 9B , the first inner wall 611 of the recess 61 of the accommodation member 6 prepared in the accommodation step is inclined with respect to the reference line RL1, but this is not limiting. The design of the first inner wall 611 can be modified as appropriate within a configuration that can reduce the contact area with the stack component 50. For example, in a modification of the present disclosure, the first inner wall 611 may be arc-shaped.

[0095] 14A to 14C show a modified example of the present disclosure, each of which shows a recess 61 of a housing member 6 according to one modified example of the present disclosure and a stack component 50 housed in the recess 61.

[0096] In a modified example shown in Fig. 14A , the first inner wall 611 may have an arc shape in a plan view. In this case, a straight line C connecting both ends of the first inner wall 611 in a plan view intersects with the second inner wall 612. In the modified example shown in Fig. 14A , the first inner wall 611 has a convex shape extending outward from the recess 61. In other words, the center of the first inner wall 611 in a plan view is located outside the straight line C connecting both ends of the first inner wall 611.

[0097] It should be noted that the shape of the first inner wall 611 of the present disclosure is not limited to the configuration shown in Fig. 14A . For example, as shown in Fig. 14B , the first inner wall 611 may have an arc shape that is convex toward the inside of the recess 61. In other words, the center of the first inner wall 611 in plan view may be located inside a straight line C that connects both ends of the first inner wall 611.

[0098] 14A and 14B , the straight line C connecting both ends of the first inner wall 611 and the second inner wall 612 are orthogonal to each other, but this is not limiting. For example, as shown in Fig. 14C , the first inner wall 611 may be arc-shaped and inclined toward a reference line RL1 that is orthogonal to the second inner wall 612. In this case, the straight line C connecting both ends of the first inner wall 611 is not orthogonal to the second inner wall 612 and is inclined with respect to the reference line RL1.

[0099] 14A-14C, in one modification of the present disclosure, the third inner wall 613 may also be arcuate and have the same or similar shape as the first inner wall 611.

[0100] 15A to 15D show the rolling process in the modified example shown in Figures 14A to 14C. The magnet 9 moves in the order shown in Figures 15A to 15D. In other words, the magnet 9 moves toward the first inner wall 611 of the recess 61 along a direction intersecting the reference line RL1 or the straight line C, as shown in Figures 15A and 15B.

[0101] The laminate component 50 including the magnetic layer 52 is attracted to the magnet 9. Therefore, as shown in Figures 15A and 15B, when the magnet 9 approaches the recess 61, the laminate component 50 moves closer to the magnet 9 inside the recess 61 and comes into contact with the first inner wall 611.

[0102] 15C , when the magnet 9 passes under the laminate component 50 housed in the recess 61, the side surface on which the magnetic layer 52 is exposed is attracted to the magnet 9. Therefore, the laminate component 50 rolls so that one side surface faces the bottom 62 of the recess 61. At this time, the other side surface of the laminate component 50 becomes an open surface. As a result, the side surface of the laminate component 50 becomes an open surface due to the rotation within the recess 61, and the laminate component 50 that originally had an open side surface remains that way.

[0103] 15D , magnet 9 moves away from first inner wall 611 along a direction intersecting reference line RL1 or line C. At this time, stacked component 50 is attracted to magnet 9 inside recess 61, and therefore moves away from first inner wall 611.

[0104] Here, for example, if the entire first inner wall 611 is perpendicular to the second inner wall 612, the entire end face of the laminate component 50 will be in contact with the first inner wall 611 at the time shown in FIG. 15B . Therefore, the static friction force is large, and a large amount of energy is required for the laminate component 50 to roll. Therefore, to ensure a high probability of rolling of the laminate component 50, it is necessary to apply a strong magnetic force or increase the number of times and duration for which the magnetic force is applied. As a result, a problem may occur in which the magnetic layer 52 or the entire laminate component 50 becomes magnetized.

[0105] On the other hand, according to one embodiment of the present disclosure, because the first inner wall 611 is arc-shaped, the contact area between the laminate component 50 and the first inner wall 611 is smaller than when the entire first inner wall 611 is perpendicular to the second inner wall 612. This reduces the frictional force generated by contact between the laminate component 50 and the first inner wall 611, allowing the laminate component 50 to roll with less energy. As a result, the possibility that the magnetic layer 52 or the entire laminate component 50 will become magnetized can be reduced.

[0106] 9A, 9B, and 10, an example has been shown in which the X and Y values ​​of the recess 61 of the storage member 6 prepared in the storage step are predetermined values, but the present invention is not limited to this example. The X and Y values ​​of the recess 61 can be changed as appropriate.

[0107] For example, X may be greater than W and less than L of the stack component 50. In other words, W<X<L may be satisfied. In this case, the stack component 50 is accommodated so that its longitudinal direction is aligned with the second inner wall 612 of the recess 61. Therefore, the accommodation directions of the multiple stack components 50 can be aligned in a plan view.

[0108] In order for the stacked component 50 to roll around a rotation axis parallel to the third direction in the rolling step described below, the width of the recess 61 needs to be designed to be larger than the diagonal distance of the cross section of the stacked component 50 from the third direction. In other words, √(W ２ +T ２ ) < X. Also, X must be 1.04 × √(W ２ +T２ ) or larger. In other words, 1.04 × √(W ２ +T ２ )<X. In this configuration, the space in which the stack component 50 rolls is wider, making it easier for the stack component 50 to roll.

[0109] Furthermore, X may be in a relationship with θ1, which is the inclination angle of the first inner wall 611 with respect to the reference line RL1, such that X<Wsin(90-θ1)+Lcos(90-θ1). Figures 16A to 16C show a recess 61 according to a modified example of the present disclosure. Figure 16A shows a recess 61 in which X<Wsin(90-θ1)+Lcos(90-θ1), Figure 16B shows a recess 61 in which X=Wsin(90-θ1)+Lcos(90-θ1), and Figure 16C shows a recess 61 in which X>Wsin(90-θ1)+Lcos(90-θ1).

[0110] When X≧W sin(90−θ1)+L cos(90−θ1), the width of the recess 61 is large, and therefore the stack component 50 may be accommodated at various angles when accommodated in the recess 61. In this case, the entire end face of the stack component 50 may come into contact with the first inner wall 611, as shown in, for example, Figures 16B and 16C.

[0111] 16A , when X<W sin(90−θ1)+L cos(90−θ1), the width of the recess 61 is narrow, which makes it possible to more firmly fix the angle of the stack component 50 when the stack component 50 is accommodated in the recess 61. In this case, for example, as shown in FIG. 16A , only a portion of the end face of the stack component 50 comes into contact with the first inner wall 611.

[0112] Therefore, by using the recess 61 that satisfies X<W sin(90-θ1)+L cos(90-θ1), the contact area between the laminate component 50 and the first inner wall 611 is reduced. As a result, the frictional force generated by contact between the laminate component 50 and the first inner wall 611 is reduced, allowing the laminate component 50 to roll with less energy.

[0113] 9A and 9B , the example in which θ1, which is the inclination angle of the first inner wall 611 with respect to the reference line RL1 in the recess 61, is a predetermined value is shown, but this example is not limiting. The value of θ1 of the recess 61 can be changed as appropriate. For example, the value of θ1 may be greater than 0° and less than or equal to 15°. Alternatively, the value of θ1 may be greater than or equal to 7° and less than or equal to 13°.

[0114] FIG. 17 shows the results of an investigation into the rolling rate of stacked components 50 when using an alignment device according to an embodiment of the present disclosure, using Examples 1 to 3 and a Comparative Example, each with a different value of θ1. In the investigation shown in FIG. 17 , 100 stacked components 50 were used. The 100 stacked components 50 were each housed in a recess 61 of a housing member 6. Next, a magnetic field was applied by moving a magnet 9 back and forth across the recess 61 in a direction intersecting the reference line RL1, causing the stacked components 50 to roll. The number of times the magnet 9 reciprocated was counted until the open surfaces of all 100 stacked components 50 were aligned. In other words, in the investigation shown in FIG. 17 , the number of times the magnet 9 reciprocated was counted for each Example with a different value of θ1, to achieve a rolling rate of 100%.

[0115] In the comparative example, θ1 is 0°, in other words, the first inner wall 611 and the second inner wall 612 are perpendicular to each other in the comparative example. θ1 in Example 1 is 5°. θ2 in Example 2 is 10°. θ1 in Example 3 is 15°.

[0116] 17 , in the comparative example, the rolling rate was 92% even when the magnet 9 was reciprocated 10 times. On the other hand, in Examples 1 to 3, the rolling rate was 100% when the magnet 9 was reciprocated 5 to 7 times. Therefore, when θ1 is greater than 0° and equal to or less than 15°, the laminate component 50 is more likely to roll than when θ1 is 0°.

[0117] 17 , the number of reciprocating motions of the magnet 9 required to reach a rolling rate of 100% was five in Example 2, while it was seven in Examples 1 and 3. Therefore, Example 2 required fewer reciprocating motions of the magnet 9 required to reach a rolling rate of 100% compared to Examples 1 and 3. In other words, the closer θ1 of the recess 61 is to 10°, the easier it is for the stacked component 50 to roll. Specifically, when θ1 is in the range of 7° to 13°, the stacked component 50 rolls more easily.

[0118] Note that the magnitude of θ1 is not limited to this example. Figures 18A to 18C show recessed portions 61 according to an embodiment of the present disclosure. Figure 18A shows an example in which θ1 is smaller than arctan(W / L), Figure 18B shows an example in which θ1 is the same as arctan(W / L), and Figure 18C shows an example in which θ1 is larger than arctan(W / L).

[0119] 18A to 18C, the diagonal of the open surface of the stack component 50 when viewed in plan from the first direction is designated D1. The straight line perpendicular to D1 is designated D2. In the example shown in FIGS. 18A to 18C, the angle Z between D2 and the reference line RL1 is equal to arctan(W / L). In other words, in the example shown in FIGS. 18A to 18C, Z = arctan(W / L).

[0120] 18C , when θ1>arctan(W / L) is satisfied, the inclination of the first inner wall 611 with respect to the reference line RL1 is large. In this case, when the laminate component 50 is attracted to the magnet 9 and a portion of the end face comes into contact with the first inner wall 611, the contact point with the first inner wall 611 may move closer to the second inner wall 612. In this case, the laminate component 50 may rotate counterclockwise when viewed from the first direction, and the end face of the laminate component 50 may come into contact with both the first inner wall 611 and the second inner wall 612.

[0121] 18A , when θ1<arctan(W / L) is satisfied, the inclination of the first inner wall 611 with respect to the reference line RL1 is small. In this case, if the stacked component 50 is attracted to the magnet 9 and a portion of its end face comes into contact with the first inner wall 611, the stacked component 50 may rotate clockwise as viewed from the first direction, starting from the point of contact with the first inner wall 611. As a result, the end face of the stacked component 50 may come into contact with the first inner wall 611, and the side face may come into contact with the second inner wall 612. Therefore, because the end face comes into contact only with the first inner wall 611, the stacked component 50 is more likely to roll than in the case of FIG. 18C .

[0122] As shown in FIG. 18B, when θ1=arctan(W / L), the laminate component 50 can rotate in either the counterclockwise or clockwise direction when viewed from the first direction.

[0123] For example, in one modification of the present disclosure, θ1 may be less than arctan(W / L) as shown in Fig. 18A. Specifically, when arctan(W / L) = 20°, θ1 may be less than 20°.

[0124] [Modification 4] In the embodiment of the present disclosure described in Fig. 10, the bottom 62 of the recess 61 in a cross-sectional view from a direction intersecting the reference line RL1 is flat, but this is not limiting. For example, in a modification of the present disclosure, the bottom 62 of the recess 61 in a cross-sectional view from a direction intersecting the reference line RL1 may have an arc shape. Fig. 19 shows a cross-sectional view of a storage member 6 in a modification of the present disclosure.

[0125] With this configuration, the amount of movement of the center of gravity of the laminate component 50 when the laminate component 50 rolls is smaller than in the embodiment shown in Fig. 10. Furthermore, according to the modified example shown in Fig. 19, before the laminate component 50 rolls, the contact area between the laminate component 50 and the bottom 62 is smaller than in the embodiment shown in Fig. 10, and the static friction force is also smaller. From the above, according to the modified example of the present disclosure, the laminate component 50 can be rolled with less energy, making it easier to roll the laminate component 50.

[0126] Furthermore, according to one modified example of the present disclosure, the contact area between the stack component 50 and the bottom 62 of the recess 61 is reduced, thereby reducing the possibility that impurities such as dust present in the recess 61 will adhere to the stack component 50. Therefore, even if the side surface on which the magnetic layer 52 is exposed after rolling faces the bottom 62 of the recess 61, the possibility that impurities present on the bottom 62 will adhere to the side surface can be reduced, thereby reducing the possibility of defects occurring.

[0127] Furthermore, because the bottom 62 of the recess 61 is arc-shaped, the direction and angle of the stack component 50 accommodated in the recess 61 moves to an energetically stable state. Therefore, according to one modified example of the present disclosure, the direction and angle of the accommodated stack component 50 can be aligned.

[0128] Specifically, the direction perpendicular to the pair of end faces of the laminate component 50 is aligned so as to be approximately parallel to the second inner wall 612 of the recess 61. At this time, the direction perpendicular to the pair of end faces of the laminate component 50 is approximately perpendicular to the reference line RL1. In this case, when the magnet 9 is brought closer from the first inner wall 611 side in the subsequent rolling process, the possibility of the end faces of the laminate component 50 coming into contact with the first inner wall 611 over the entire surface is reduced, and the contact area can be reduced.

[0129] It should be noted that the term "arc-shaped" does not necessarily mean a semicircular shape. For example, as shown in Fig. 19, the bottom 62 of the recess 61 may be elliptical. Furthermore, the bottom 62 of the recess 61 and the second inner wall 612 may be formed so as not to be clearly distinguishable from each other, and for example, the second inner wall 612 and the bottom 62 may be formed continuously by a smooth curve.

[0130] 19, the inner wall and the bottom 62 of the recess 61 are formed of the same housing member 6, but this is not limiting. For example, the housing member 6 may be formed of a plurality of housing members.

[0131] 20A and 20B show a housing member 6 having a first housing member 64 and a second housing member 65 as a modified example of the present disclosure. Fig. 20A is a perspective view of each of the first housing member 64 and the second housing member 65. Fig. 20B is a cross-sectional view taken from a direction intersecting with the reference line RL1 when the first housing member 64 is overlapped on the second housing member 65.

[0132] As can be seen from Fig. 20A, the first accommodating member 64 has a through hole 641 that forms the inner wall of the recess 61. In other words, the inner surface of the through hole 641 forms the inner wall of the recess 61. The second accommodating member 65 has a groove 651 that forms the bottom 62 of the recess 61. Furthermore, in a planar perspective view, the through hole 641 of the first accommodating member 64 and the groove 651 of the second accommodating member 65 overlap. Furthermore, as can be seen from Fig. 20B, because the surface of the groove 651 is arc-shaped, the bottom 62 of the recess 61 also has an arc-shaped configuration in a cross-sectional view taken from a direction intersecting with the reference line RL1.

[0133] In this way, by dividing the housing member 6 into two members, the member forming the inner wall of the recess 61 and the member forming the bottom 62 of the recess 61 can be made of different members, and the two members can be detached. Therefore, compared to when the inner wall and bottom 62 of the recess 61 are made of a single member, even if impurities such as dust accumulate inside the recess 61, the impurities can be easily removed by detaching the two members.

[0134] Figure 21 shows the results of investigating the rolling rate of stacked components 50 when using an alignment device according to an embodiment of the present disclosure, using examples 4 and 5, each with a different value of θ1. The investigation shown in Figure 21 is the same as the investigation shown in Figure 17. However, examples 4 and 5 differ from examples 1 to 3 in that bottom 62 of recess 61 is arc-shaped.

[0135] 21 , in Example 4, the rolling rate reached 100% after six reciprocating motions of magnet 9. Thus, in Example 4, the number of reciprocating motions of magnet 9 required to reach a rolling rate of 100% was fewer than in Comparative Example 1. Therefore, when bottom 62 of recess 61 is arc-shaped, stacked component 50 rolls more easily than when it is flat.

[0136] Furthermore, in Example 5, the rolling rate reached 100% after two reciprocating movements of magnet 9. Therefore, in Example 5, the number of reciprocating movements of magnet 9 required to reach a rolling rate of 100% was smaller than in Example 4. Therefore, when bottom 62 of recess 61 is arc-shaped, stacked component 50 rolls more easily when first inner wall 611 is inclined with respect to reference line RL1, compared to when first inner wall 611 is perpendicular to reference line RL1.

[0137] 11A to 11C and 15A to 15D, an example in which one magnet 9 reciprocates between the front and rear of the recess 61 in a direction intersecting the reference line RL1 during the rolling process has been shown, but the present invention is not limited to this example. For example, the magnet 9 may include multiple magnets including a first magnet 91 and a second magnet 92, as shown in FIGS. 22A to 22G.

[0138] 22A to 22G show a first magnet 91 and a second magnet 92 according to a modified example of the present disclosure. The first magnet 91 and the second magnet 92 according to this modified example of the present disclosure move in the order shown in FIGS. 22A to 22G. In other words, the first magnet 91 first moves toward the first inner wall 611 of the recess 61 in a direction intersecting the reference line RL1, as shown in FIGS. 22A and 22B. The direction in which the first magnet 91 moves is indicated by an arrow in FIG. 22A.

[0139] The laminate component 50 including the magnetic layer 52 is attracted to the first magnet 91. Therefore, as shown in Figures 22A and 22B, when the first magnet 91 approaches the recess 61, the laminate component 50 moves closer to the first magnet 91 inside the recess 61 and comes into contact with the first inner wall 611.

[0140] 22C , when the first magnet 91 passes under the stacked component 50 housed in the recess 61, the side on which the magnetic layer 52 is exposed is attracted to the magnet 91, causing the stacked component 50 to roll so that one side faces the bottom 62 of the recess 61. However, the probability of the stacked component 50 rolling varies depending on the magnetic force and moving speed of the first magnet 91, the shape of the stacked component 50, and the like. Therefore, the stacked component 50 may not roll due to the action of the magnet 9 alone.

[0141] 22D , after the first magnet 91 has moved away from the recess 61, the second magnet 92 is moved in the same direction as the movement of the first magnet 91, and is brought closer to the first inner wall 611 of the recess 61. In other words, after the first magnet 91 has passed through the recess 61, the second magnet 92 moves closer to the first inner wall 611 of the recess 61.

[0142] At this time, the first magnet 91 moves away from the recess 61, and the stacked component 50 is attracted to the first magnet 91 inside the recess 61 and moves away from the first inner wall 611. After that, as shown in Figure 22E, the second magnet 92 approaches the recess 61, and the stacked component 50 moves closer to the first magnet 91 inside the recess 61 and comes into contact with the first inner wall 611 again.

[0143] 22F , when the second magnet 92 passes under the laminate component 50 housed in the recess 61, the side on which the magnetic layer 52 is exposed is attracted to the magnet 9, and the laminate component 50 rolls so that one side faces the bottom 62 of the recess 61. Then, as shown in FIG. 22G , the second magnet 92 moves away from the recess 61 and the first inner wall 611 in a direction intersecting the reference line RL1.

[0144] In this manner, in this modified example of the present disclosure, the magnetic field is applied twice using the first magnet 91 and the second magnet 92, thereby providing two opportunities for the laminated component 50 to roll. Therefore, according to this modified example of the present disclosure, it is possible to improve the likelihood that the laminated component 50 will roll.

[0145] 22D and 22E , in one modified example of the present disclosure, the number of times of contact with the first inner wall 611 increases. Because the first inner wall 611 is inclined from the reference line RL1, in this modified example of the present disclosure, the contact area with the inner wall that comes into contact with the first inner wall 611 more frequently can be reduced, thereby reducing the frictional force that is generated and enabling the stack component 50 to roll with less energy.

[0146] [Alignment Apparatus] The present disclosure includes an alignment apparatus used in the above-described [Method for Manufacturing a Laminated Electronic Component and Method for Aligning a Laminated Component]. Fig. 23 is a perspective view schematically showing an alignment apparatus 10 according to an embodiment of the present disclosure. The alignment apparatus 10 according to an embodiment of the present disclosure includes, for example, the above-described housing member 6 and magnet 9.

[0147] 23 shows an example in which the housing member 6 includes a first housing member 64 and a second housing member 65, and the magnet 9 shown in FIG. 23 shows an example in which the magnet 9 includes a first magnet 91 and a second magnet 92. However, the alignment device 10 of the present disclosure is not limited to the example shown in FIG. 23. In the alignment device 10 of the present disclosure, the housing member 6 and the magnet 9 may be partially interchanged between the different embodiments or modified examples described above. Also, different embodiments or modified examples may be partially combined.

[0148] The above-described laminate component aligning method, laminate electronic component manufacturing method, and laminate component aligning device can reduce the possibility of defects occurring in the laminate components and laminate electronic components.

[0149] The present disclosure can be implemented in the following configurations (1) to (16).

[0150] (1) A method for aligning laminated components, comprising: a preparation step of preparing a laminated component having a plurality of magnetic layers and a plurality of dielectric layers stacked alternately; an accommodation step of preparing a container member including a first inner wall and a second inner wall, the first inner wall having a recess that is inclined with respect to a first reference line that is perpendicular to the second inner wall in a plan view, and accommodating the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field along a direction that intersects the first reference line.

[0151] (2) A method for aligning laminated components, comprising: a preparation step of preparing a laminated component having a plurality of magnetic layers and a plurality of dielectric layers stacked alternately; an accommodating step of preparing a container member having a first inner wall and a second inner wall, the first inner wall being arc-shaped in a plan view, and having a recess in which a straight line connecting both ends of the first inner wall intersects with the second inner wall, and accommodating the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field along a direction intersecting a first reference line that is perpendicular to the second inner wall.

[0152] (3) The method for aligning stacked components according to the above configuration (1) or (2), wherein the bottom of the recess is arc-shaped in a cross-sectional view taken along a direction intersecting the first reference line.

[0153] (4) The method for aligning stacked components according to any one of the above configurations (1) to (3), wherein the recess further includes a third inner wall facing the first inner wall and a fourth inner wall facing the second inner wall, and the first inner wall intersects with the second inner wall and the fourth inner wall.

[0154] (5) The method for aligning stacked components according to any one of the above configurations (1) to (4), wherein the inclination angle of the first inner wall relative to the first reference line in a plan view is greater than 0° and not greater than 15°.

[0155] (6) The method for aligning stacked components according to any one of the above configurations (1) to (5), wherein the inclination angle of the first inner wall relative to the first reference line in a plan view is equal to or greater than 7° and equal to or less than 13°.

[0156] (7) The method for aligning stacked components according to any one of the above configurations (1) to (6), wherein the magnets include a first magnet and a second magnet, and in the rolling step, after the first magnet passes through the recess, the second magnet moves so as to approach the first inner wall of the recess.

[0157] (8) The method for aligning stacked components according to any one of the above configurations (1) to (7), wherein the recess further includes a third inner wall facing the first inner wall and a fourth inner wall facing the second inner wall, the third inner wall is inclined with respect to a second reference line perpendicular to the fourth inner wall in a plan view, and the magnet reciprocates in front of and behind the recess along a direction intersecting the first reference line.

[0158] (9) The laminate component has a substantially rectangular parallelepiped shape having a pair of main surfaces, a pair of side surfaces, and a pair of end surfaces, and where L is the distance between the pair of end surfaces, W is the distance between the pair of side surfaces, and T is the distance between the pair of main surfaces, a width X of the recess in a direction substantially parallel to the first reference line satisfies the following formulas (1) and (2): W<X<L (1) 1.04×√(W ２ +T ２ ) <X (2) The method for aligning stacked components according to any one of the above configurations (1) to (8).

[0159] (10) The method for aligning laminated electronic components according to the above configuration (9), wherein the inclination angle of the first inner wall with respect to the first reference line is θ, the width X further satisfies the following formula (3): X<W sin(90-θ)+L cos(90-θ) (3).

[0160] (11) The method for aligning laminated electronic components according to any one of the above configurations (1) to (10), wherein the angle θ further satisfies the following formula (4): θ<arctan(W / L) (4).

[0161] (12) The method for aligning laminated electronic components according to any one of the above configurations (1) to (11), wherein the direction of the magnetic flux lines of the magnets is along the second inner wall.

[0162] (13) A method for manufacturing a laminated electronic component, including the method for aligning laminated components according to any one of the above configurations (1) to (12), and performing a processing treatment on the surfaces of the laminated components, and then firing the laminated components.

[0163] (14) An apparatus for aligning stacked components, comprising: a container member including a first inner wall and a second inner wall, the first inner wall being inclined relative to a first reference line perpendicular to the second inner wall in a plan view, the container member having a recess for accommodating stacked components; and a magnet that moves in a direction intersecting the first reference line and applies a magnetic field to cause the stacked components to roll.

[0164] (15) An apparatus for aligning stacked components, comprising: a housing member including a first inner wall and a second inner wall, the first inner wall having an arc shape in a plan view, and a recess in which a straight line connecting both ends of the first inner wall intersects with the second inner wall; and a magnet that moves in a direction intersecting a first reference line that is perpendicular to the second inner wall and applies a magnetic field to cause the stacked components to roll.

[0165] (16) The stacked component aligning device according to the above configuration (14) or (15), wherein the accommodating members include a first accommodating member and a second accommodating member, the first accommodating member having a through hole that forms the first inner wall and the second inner wall of the recess, the second accommodating member having a groove that forms the bottom of the recess and overlaps with the through hole of the first accommodating member in a planar perspective view, and the groove has an arc shape in a cross-sectional view taken from a direction intersecting the first reference line.

[0166] Although the embodiments of the present disclosure have been described in detail above, the present disclosure is not limited to the above-described embodiments, and various modifications and improvements are possible within the scope of the gist of the present disclosure. It goes without saying that all or part of the components constituting each of the above-described embodiments can be combined as appropriate within the scope of not contradicting each other.

[0167] 1: Laminated electronic component 2: Element body 21: Laminated portion 211: Ceramic dielectric layer 212: Internal electrode layer 22: Side margin portion 23: Cover portion 200: Element body precursor 3: External electrode 400: Ceramic sheet 404: Functional member 410: Magnetic material sheet 50: Laminated component 51: Dielectric layer 52: Magnetic material layer 500: Base laminated component 6: Housing member 61: Recess 611: First inner wall 612: Second inner wall 613: Third inner wall 614: Fourth inner wall 62: Bottom 63: Opening surface 64: First housing member 65: Second housing member 8: Adhesive sheet 9: Magnet 91: First magnet 92: Second magnet 10: Alignment device

Claims

1. A method for aligning laminated components, comprising: a preparation step of preparing a laminated component having a plurality of alternating magnetic layers and a plurality of dielectric layers; a storage step of preparing a storage member having a first inner wall and a second inner wall, the first inner wall having a recess that is inclined with respect to a first reference line perpendicular to the second inner wall in a planar view, and storing the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field in a direction that intersects with the first reference line.

2. A method for aligning laminated components, comprising: a preparation step of preparing a laminated component having a plurality of alternating magnetic layers and a plurality of dielectric layers; a storage step of preparing a storage member having a recess including a first inner wall and a second inner wall, the first inner wall being arc-shaped in a plan view and a straight line connecting both ends of the first inner wall intersecting the second inner wall, and storing the laminated component in the recess; and a rolling step of rolling the laminated component by moving a magnet that applies a magnetic field along a direction intersecting a first reference line that is perpendicular to the second inner wall.

3. The method for aligning stacked components according to claim 1 or 2, wherein the bottom of the recess is arc-shaped when viewed in cross section from a direction intersecting the first reference line.

4. A method for aligning stacked components as described in any one of claims 1 to 3, wherein the recess further includes a third inner wall opposite the first inner wall and a fourth inner wall opposite the second inner wall, and the first inner wall intersects with the second inner wall and the fourth inner wall.

5. A method for aligning stacked components according to any one of claims 1 to 4, wherein an inclination angle of the first inner wall with respect to the first reference line in a plan view is greater than 0° and equal to or less than 15°.

6. A method for aligning stacked components according to any one of claims 1 to 5, wherein an inclination angle of the first inner wall with respect to the first reference line in a plan view is equal to or greater than 7° and equal to or less than 13°.

7. A method for aligning laminated components as described in any one of claims 1 to 6, wherein the magnets include a first magnet and a second magnet, and in the rolling step, after the first magnet has passed through the recess, the second magnet moves so as to approach the first inner wall of the recess.

8. A method for aligning stacked components as claimed in any one of claims 1 to 7, wherein the recess further includes a third inner wall facing the first inner wall and a fourth inner wall facing the second inner wall, the third inner wall being inclined with respect to a second reference line perpendicular to the fourth inner wall in a plan view, and the magnet reciprocates between the front and rear of the recess in a direction intersecting the first reference line.

9. The laminate component has a substantially rectangular parallelepiped shape having a pair of main surfaces, a pair of side surfaces, and a pair of end surfaces, and where the distance between the pair of end surfaces is L, the distance between the pair of side surfaces is W, and the distance between the pair of main surfaces is T, the width X of the recess in a direction substantially parallel to the first reference line satisfies the following formulas (1) and (2): W<X<L ... (1) 1.04×√(W ２ +T ２ ) <X (2) The method for aligning stacked components according to any one of claims 1 to 8.

10. The method for aligning laminated electronic components according to claim 9, wherein the inclination angle of the first inner wall with respect to the first reference line is θ, and the width X further satisfies the following formula (3): X<W sin(90-θ)+L cos(90-θ)...(3).

11. The method for aligning laminated electronic components according to any one of claims 1 to 10, wherein the θ further satisfies the following formula (4): θ<arctan(W / L) (4).

12. The method for aligning laminated electronic components according to any one of claims 1 to 11, wherein the direction of the magnetic flux lines of the magnets is along the second inner wall.

13. A method for manufacturing laminated electronic components, comprising the method for aligning laminated components according to any one of claims 1 to 12, and processing the surfaces of the laminated components, and then firing the laminated components.

14. An aligning device for laminated components, comprising: a container member including a first inner wall and a second inner wall, the first inner wall being inclined relative to a first reference line perpendicular to the second inner wall in a plan view, and having a recess for accommodating a laminated component; and a magnet that moves in a direction intersecting the first reference line and applies a magnetic field to cause the laminated components to roll.

15. An aligning device for stacked components, comprising: a container member including a first inner wall and a second inner wall, the first inner wall being arc-shaped in a plan view, and a straight line connecting both ends of the first inner wall having a recess that intersects with the second inner wall; and a magnet that moves in a direction intersecting a first reference line that is perpendicular to the second inner wall, and applies a magnetic field to cause the stacked components to roll.

16. The device for aligning stacked components as described in claim 14 or 15, wherein the accommodating members comprise a first accommodating member and a second accommodating member, the first accommodating member having a through hole forming the first inner wall and the second inner wall of the recess, the second accommodating member having a groove forming a bottom of the recess and overlapping with the through hole of the first accommodating member in a planar perspective, and the groove is arc-shaped in a cross-sectional view from a direction intersecting the first reference line.

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