CN208400649U - Coil component - Google Patents
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- CN208400649U CN208400649U CN201820567286.5U CN201820567286U CN208400649U CN 208400649 U CN208400649 U CN 208400649U CN 201820567286 U CN201820567286 U CN 201820567286U CN 208400649 U CN208400649 U CN 208400649U
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Abstract
The utility model provides the coil component that a kind of magnetic substance portion made of containing metallic and resin material is embedded with coil-conductor, and it includes the coil-conductors for using thinner conducting wire.Above-mentioned coil component is included containing magnetic substance portion made of metallic and resin material；It is embedded in the coil-conductor in above-mentioned magnetic substance portion；And the external electrode being electrically connected with above-mentioned coil-conductor, and, above-mentioned magnetic substance portion includes magnetic substance pedestal and magnetic substance sheath with protrusion, above-mentioned coil-conductor is configured to be located at the core of coil-conductor in above-mentioned magnetic substance pedestal upper convex portion, above-mentioned magnetic substance sheath is set as covering coil-conductor, and above-mentioned coil-conductor with a thickness of the flat wire of 0.02mm~0.14mm by constituting.
Description
Technical field
The utility model relates to a kind of coil components, have magnetic substance portion in particular to one kind, are embedded in the magnetism
Coil component made of the coil-conductor in body portion and the external electrode for the outside for being set to the magnetic substance portion.
Background technique
As the coil component for being embedded with coil-conductor in magnetic substance portion, it is known that contain metallic in the use of magnetic substance portion
With the coil component (patent document 1) of the composite material of resin material.
Existing technical literature
Patent document
Patent document 1: Japanese Unexamined Patent Publication 2016-201466 bulletin
Utility model content
Coil component requires big inductance, but inductance big in order to obtain is, it is preferable to use the more coil-conductors of the number of turns.For
Obtain the more coil-conductors of the number of turns, the thickness for preferably comprising the conducting wire of coil-conductor is smaller, but if reducing the thickness of conducting wire
, then there is the strength reduction of coil-conductor in degree.Especially as described above contain clipped wire in the use of magnetic substance portion
The coil component of the composite material of son and resin material is by the piece containing metallic and the composite material of resin material
Material clamping coil-conductor simultaneously carries out compression forming and manufactures, therefore in order to maintain the strong of briquetting pressure when tolerance compression forming
Degree, the reduction for constituting the thickness of the conducting wire of coil-conductor are restricted.
The purpose of this utility model is to provide one kind magnetic substance portions made of containing metallic and resin material to bury
Coil component equipped with coil-conductor, it includes the coil-conductors for using thinner conducting wire.
The present inventor has made intensive studies to solve the problem above-mentioned, as a result, it has been found that by by magnetic body portion at setting
It is equipped with the magnetic substance pedestal and magnetic substance sheath of the protrusion of the core of insertion coil, to line when can reduce manufacture coil component
The load of conductor is enclosed, so as to complete the utility model.
Main idea according to the present utility model provides a kind of coil component, comprising: form containing metallic and resin material
Magnetic substance portion；It is embedded in the coil-conductor in above-mentioned magnetic substance portion；And the external electrode being electrically connected with above-mentioned coil-conductor,
In, above-mentioned magnetic substance portion includes magnetic substance pedestal and magnetic substance sheath with protrusion, and above-mentioned coil-conductor is configured to above-mentioned
Magnetic substance pedestal upper convex portion is located at the core of coil-conductor, and above-mentioned magnetic substance sheath is set as covering coil-conductor, above-mentioned line
Conductor is enclosed by constituting with a thickness of the flat wire of 0.02mm~0.14mm.
According to the utility model, a kind of coil component is provided, comprising: contain magnetism made of metallic and resin material
Body portion；It is embedded in the coil-conductor in above-mentioned magnetic substance portion；And the external electrode being electrically connected with above-mentioned coil-conductor, wherein by
The small conducting wire of thickness, which constitutes coil-conductor, can assign high inductance thereby, it is possible to increase the number of turns of coil-conductor.
Detailed description of the invention
Fig. 1 is the perspective view for showing schematically an embodiment of coil component of the utility model.
Fig. 2 is the cross-sectional view for indicating the section of x-x of the coil component along Fig. 1.
Fig. 3 is the perspective view in the magnetic substance portion 2 for being embedded with coil-conductor 3 of the coil component of Fig. 1.
Fig. 4 is the plan view of the magnetic substance pedestal 8 configured with coil-conductor 3 of the coil component of Fig. 1.
Fig. 5 is the perspective view of the magnetic substance pedestal 8 of the coil component of Fig. 1.
Fig. 6 is the cross-sectional view for indicating the section of y-y of the magnetic substance pedestal 8 along Fig. 5.
Fig. 7 is the plan view of the magnetic substance pedestal 8 of Fig. 5.
Fig. 8 is the cross-sectional view of the magnetic substance pedestal in another form.
Fig. 9 is the cross-sectional view of the magnetic substance pedestal in another form.
Figure 10 is the cross-sectional view of the magnetic substance pedestal 8 configured with coil-conductor 3 of the coil component of Fig. 1.
Figure 11 is the figure to locate for illustrating the filling rate for calculating the metallic in embodiment.
Figure 12 is the perspective view for showing schematically the coil component of comparative example 1.
Figure 13 is the figure to locate for illustrating the filling rate for calculating the metallic in comparative example 1.
Symbol description
1 ... coil component
2 ... magnetic substance portions
3 ... coil-conductors
4,5 ... external electrodes
6 ... protective layers
8 ... magnetic substance pedestals
9 ... magnetic substance sheaths
11 ... protrusions
12, the end of 13 ... coil-conductors
14,15 ... slots
16 ... base portions
Before 17 ... base portions
The back side of 18 ... base portions
The bottom surface of 19 ... base portions
The upper surface of 20 ... base portions
21 ... recess portions
The wall surface of 22 ... recess portions
The bottom surface of 23 ... recess portions
24, the lead division of 25 ... coil-conductors
26, the end end portion of 27 ... coil-conductors
28, the region between the end end portion of 29 ... coil-conductors and the end face in magnetic substance portion
The coil component of 101 ... comparative examples 1
102 ... magnetic substance portions
103 ... coil-conductors
104,105 ... external electrodes
106 ... protective layers
Specific embodiment
Hereinafter, being described in detail referring to coil component of the attached drawing to the utility model.But the coil of present embodiment
Component and the shape and configuration of each component etc. are not limited to example illustrated.
The perspective view of the coil component 1 of present embodiment is schematically illustrated in Fig. 1, schematically illustrates its cross-sectional view in Fig. 2.
The perspective view in the magnetic substance portion 2 for being embedded with coil-conductor 3 of coil component 1 is schematically illustrated in Fig. 3.Also, in Fig. 4 schematically
The plan view of the magnetic substance pedestal 8 configured with coil-conductor 3 of coil component 1 is shown.But the capacitor of following embodiments
Example illustrated is not limited to shape and configuration of each component etc..
As depicted in figs. 1 and 2, the coil component 1 of present embodiment has approximately cuboid shape.It, will in coil component 1
The face of the figure left and right sides of its Fig. 2 is known as " end face ", and the face of figure upside is known as " upper surface ", and the face of figure downside is known as " bottom
The face for scheming nearby side is known as " front " by face ", and the inboard face of figure is known as " back side ".Coil component 1 mainly has magnetic substance portion
2, inbuilt coil-conductor 3, a pair of external electrodes 4,5 wherein.As shown in Figures 2 and 3, magnetic substance portion 2 is by magnetic substance pedestal 8
It is constituted with magnetic substance sheath 9.In magnetic substance portion 2, magnetic substance pedestal 8 and magnetic substance sheath 9, by the figure left and right sides of its Fig. 2
Face be known as " end face ", the face of figure upside is known as " upper surface ", the face of figure downside is known as " bottom surface ", will figure nearby side face
The inboard face of figure is known as " back side " by referred to as " front ".As shown in Figure 2 to 4, magnetic substance pedestal 8 on it surface have it is convex
Portion 11.Magnetic substance pedestal 8 in front, bottom surface and the back side there is slot 14,15 to connect with both ends of the surface.On magnetic substance pedestal 8,
The protrusion 11 that coil-conductor 3 is configured to magnetic substance pedestal 8 is located at core.The lead division 24,25 of coil-conductor 3 is along magnetic substance base
The back side of seat 8 and the slot 14,15 of bottom surface are drawn out to bottom surface by the back side from the upper surface of magnetic substance pedestal 8.The end of coil-conductor 3
End 12,13 is drawn out to before magnetic substance pedestal 8 or close front.Magnetic substance pedestal 8 is equipped with magnetic substance sheath 9 to cover
Lid coil-conductor 3.Belong to the bottom surface of the end end portion 26,27 in magnetic substance portion 2 of a part of the lead division 24,25 of coil-conductor 3
Expose.Also, external electrode 4,5 is set to the bottom surface in magnetic substance portion 2, electric with the above-mentioned end end portion of coil-conductor 3 26,27 respectively
Connection.In addition, all protected seam 6 covers coil component 1 other than external electrode 4,5.
In this specification, the length of coil component 1 is known as " L ", width is known as " W ", thickness (height) is known as " T "
(referring to Fig.1).In this specification, the face parallel with front and the back side is known as " face LT ", the face parallel with end face is known as " WT
The face parallel with upper surface and bottom surface is known as " face LW " by face ".
As described above, above-mentioned magnetic substance portion 2 is made of magnetic substance pedestal 8 and magnetic substance sheath 9.
As shown in Fig. 5~Fig. 7, above-mentioned magnetic substance pedestal 8 is with base portion 16 and the protrusion 11 being formed in base portion 16.
Base portion 16 is integrally formed with protrusion 11.Base portion 16 both ends (region of the left and right in Fig. 6) have across front 17,
The slot 14,15 of bottom surface 19 and the back side 18.In addition, the edge part of the upper surface 20 of base portion 16 is higher than central portion, that is, on above-mentioned
Surface, compared with the position where the edge of protrusion 11, the marginal portion at both ends is located above (upside of Fig. 6).
As described above, the position in magnetic substance pedestal 8, where the upper surface of base portion 16 20, with the edge of protrusion 11
It compares, at least part of marginal portion is located above.That is, the t2 ratio t1 in Fig. 6 is big.The above-mentioned marginal portion being located above can
To be the marginal portion of both ends of the surface, it is also possible to the marginal portion at front and the back side.It is preferred that the position where with the edge of protrusion 11
It sets and compares, marginal portion is integrally located at top.So that the edge part of base portion 16 is higher than central portion in this way, is easy to carry out line
Enclose the positioning of conductor 3.In addition, by the position for improving edge part, to be present in bottom surface when configuring coil-conductor on it
Conductor becomes larger at a distance from coil-conductor, therefore reliability improves.Side of the position of the upper surface 20 of base portion 16 from protrusion 11
Edge can be and ramp to the edge of base portion 16, be also possible to curve rising.That is, the upper surface 20 of base portion 16 can be with
It is plane, can also be bent.It is preferred that the position of the upper surface 20 of base portion 16 is from the edge of protrusion 11 to the edge of base portion 16
Until ramp.
It should be noted that in the utility model, in the upper surface of base portion 16 20, preferably with the edge of protrusion 11 where position
It sets and compares, marginal portion is located above, but not limited to this.For example, can be the side of protrusion 11 in the upper surface of base portion 16 20
The height of position and marginal portion where edge is identical (i.e. above-mentioned t1 is identical as t2) (Fig. 9), is also possible to the side with protrusion 11
Position where edge is located below (can be that above-mentioned t1 is greater than t2) compared to marginal portion.
In one form, the difference (t2-t1) of above-mentioned t2 and t1 can be preferably 0.10mm~0.30mm, more preferably
0.15mm~0.25mm.
As described above, base portion 16 has slot 14,15 in magnetic substance pedestal 8.Slot 14,15 is respectively provided with guidance coil and leads
The effect of the lead division 24,25 of body 3.
The depth of above-mentioned slot is not particularly limited, and preferably the thickness of the conductor of composition coil-conductor 3 is hereinafter, for example can be with
Preferably 0.05mm~0.20mm, such as 0.10mm~0.15mm.
The width of above-mentioned slot is preferably to constitute the width of the conductor of coil-conductor 3 or more, and more preferably greater than composition coil is led
The width of the conductor of body 3.
It should be noted that magnetic substance pedestal not necessarily has slot in the utility model.
As described above, protrusion 11 is cylinder-shaped in magnetic substance pedestal 8.In above-mentioned form, the diameter of protrusion 11 can be preferred
For 0.1mm~2.0mm, more preferably 0.5mm~1.0mm.
It should be noted that the shape of the protrusion from the upper surface side of magnetic substance pedestal 8 is not particularly limited, circle can be
The polygons such as shape, ellipse, triangle, quadrangle.It can be preferably identical with the cross sectional shape of the core of coil-conductor
Shape.
It more than the length of the highly preferred core for coil-conductor of raised part 11, can be preferably 0.1mm or more,
More preferably 0.3mm or more, more preferably 0.5mm or more.The height of protrusion 11 can be preferably 1.5mm hereinafter, more preferably
0.8mm is hereinafter, more preferably 0.5mm or less.Wherein, " height of protrusion " refers to the upper surface of the base portion contacted from protrusion
To the height at the top of protrusion, " length of core " refers to core along the length of the central axis of coil.
It should be noted that, as long as magnetic substance pedestal has the structure of protrusion, being just not particularly limited in the utility model.
In preferred form, as shown in figure 8, magnetic substance pedestal can its bottom surface the position opposed with protrusion at least
A part has recess portion 21.Recess portion 21 is arranged in at least the one of the bottom surface of the magnetic substance pedestal opposed with protrusion 11 in this way
Part can greatly improve the filling rate of the metallic of protrusion 11 using compression forming.
The shape of recess portion 21 from the bottom surface side of magnetic substance pedestal 8, is not particularly limited, and can be round, oval
It is the polygons such as shape, triangle, quadrangle, band-like.
In one form, above-mentioned recess portion 21 is present between external electrode 4,5, preferably deposits on the whole between external electrode 4,5
?.By the way that recess portion is arranged between external electrode 4,5, the path length (distance along magnetic substance surface) between external electrode 4,5 becomes
Greatly, it can be improved the electrical insulating property between two external electrodes, improve reliability.Also, by being arranged recess portion 21 in external electrode
4, between 5 on the whole, so that whens being installed on substrate etc. the minimum range of substrate etc. with the bottom surface in magnetic substance portion can be expanded, therefore
Reliability is got higher.In addition, protective layer can be contained in recess portion, therefore compared with the case where not forming recess portion, line can be reduced
The thickness of coil component.
In one form, the part opposed with protrusion 11 that above-mentioned recess portion 21 is set to the bottom surface of magnetic substance pedestal is whole
On.The part opposed with protrusion 11 that recess portion 21 is set to the bottom surface of magnetic substance pedestal in this way on the whole, can utilize
Compression forming further increases the filling rate of the metallic of protrusion 11.
The depth of above-mentioned recess portion 21 is not particularly limited, and can be preferably 0.01mm~0.08mm, more preferably 0.02mm
~0.05mm.Wherein, " depth of recess portion " refers to the depth of most deep position.
The width (width in the direction L) of above-mentioned recess portion 21 is not particularly limited, and can be preferably 0.3mm~0.8mm, more excellent
It is selected as 0.4mm~0.7mm.Wherein, " width of recess portion " refers to the width of widest position.
Angle formed by the wall surface 22 of above-mentioned recess portion 21 and bottom surface 23 can be preferably 90 ° or more, and more preferably 100 ° or more,
Further preferably 110 ° or more.Angle formed by the wall surface 22 of recess portion 21 and bottom surface 23 can be preferably 130 ° hereinafter, more preferably
It is 120 ° or less.
Above-mentioned magnetic substance sheath 9 is set as the upper surface of covering magnetic substance pedestal 8 and the coil-conductor positioned at the upper surface
3, the two of the lead division 24,25 and magnetic substance pedestal 8 of the back side of magnetic substance pedestal 8 and the coil-conductor 3 on the back side
End face.That is, in present embodiment, before magnetic substance pedestal 8, the bottom surface of magnetic substance pedestal 8 and the line on the bottom surface
The end end portion 26,27 for enclosing conductor 3 exposes from magnetic substance sheath 9.
In one form, magnetic substance sheath 9 is covered other than at least one side of magnetic substance pedestal 8, i.e. 3 sides.It answers
Explanation is given, side is the general name in front, this 4 faces of the back side and both ends of the surface.That is, at least one side of magnetic substance pedestal 8 from
Magnetic substance sheath 9 exposes.
In one form, magnetic substance sheath 9 covers the extraction for the coil-conductor being present on the side of magnetic substance pedestal 8
Portion.
It should be noted that in the utility model, as long as the winding section of magnetic substance sheath covering coil-conductor 3, shape do not have
It is particularly limited to.
Above-mentioned magnetic substance portion 2 is made of the composite material containing metallic and resin material.
It is not particularly limited as above-mentioned resin material, such as epoxy resin can be enumerated, phenolic resin, polyester resin, gathered
The thermosetting resins such as imide resin, polyolefin resin.Resin material can be only a kind, be also possible to two or more.
As the metal material for constituting above-mentioned metallic, be not particularly limited, for example, can enumerate iron, cobalt, nickel or gadolinium or
Person a kind in them contains alloy of more than two kinds.It is preferred that above-mentioned metal material is iron or ferroalloy.Iron can be iron sheet
Body is also possible to iron derivative, such as complex.It as above-mentioned iron derivative, is not particularly limited, can enumerate and belong to iron and CO
Complex carbonyl iron, preferably enumerate iron pentacarbonyl.Particularly preferred onion bulb layer structure is (from being centrally formed with one heart for particle
The structure of spherical layer) hard grade (Hard grade) carbonyl iron (for example, hard grade carbonyl iron of BASF AG).It is closed as iron
Gold is not particularly limited, for example, Fe-Si system alloy, Fe-Si-Cr system alloy, Fe-Si-Al system alloy etc. can be enumerated.
Above-mentioned alloy further can be used as other accessory ingredients containing B, C etc..The content of accessory ingredient is not particularly limited, such as can be
0.1wt%~5.0wt%, preferably 0.5wt%~3.0wt%.Above-mentioned metal material can be only a kind, or 2 kinds with
On.In addition, the metal material in magnetic substance pedestal 8 may be the same or different with the metal material in magnetic substance sheath 9.
It is preferred each independently in magnetic substance pedestal 8 and magnetic substance sheath 9 for above-mentioned metallic in one form
With 0.5 μm~10 μm, more preferably with 1 μm~5 μm, further preferably with 1 μm~3 μm of average grain diameter.On making
The average grain diameter for stating metallic is 0.5 μm or more, and the operation of metallic becomes easy.In addition, by making above-mentioned clipped wire
The average grain diameter of son is 10 μm hereinafter, the filling rate of metallic can be further increased, and the magnetic characteristic in magnetic substance portion improves.It is excellent
In the form of choosing, above-mentioned metallic can have identical average grain diameter in magnetic substance pedestal and magnetic substance sheath.Change speech
It, the metallic contained in magnetic substance portion 2 on the whole preferably with 0.5 μm~10 μm, more preferably there are 1 μm~5 μm, into one
Step is preferably with 1 μm~3 μm of average grain diameter.It should be noted that peak can be one in the size distribution of metallic, it can also
To be 2 or more, or it can be 2 or more overlap of peaks.
Wherein, above-mentioned average grain diameter refers to the gold in SEM (scanning electron microscope) image in the section in magnetic substance portion
Belong to the average value of the equivalent circle diameter of particle.For example, above-mentioned average grain diameter can obtain as follows: with SEM to cutting coil component 1
Obtained from many places (such as the 5 positions) region (such as 100 μm of 130 μ ms) in section shot, it is soft using image analysis
Part is (for example, Asahi Kasei Engineering Corporation system, " A picture" (registered trademark)) to the SEM
Image is parsed, and is found out 500 or more metallic equivalent circle diameters, is calculated its average value.
In preferred form, above-mentioned metallic preferably has 50%~90%, more preferably with 70%~90% CV
Value.Metallic with such CV value has than wider size distribution, and relatively small particle is able to enter relatively large
Between particle, therefore the filling rate of the metallic in magnetic substance portion further increases.Its result can further increase magnetism
The magnetic conductivity in body portion.
Wherein, above-mentioned CV value is the value calculated using following formula.
CV value (%)=(σ/Ave) × 100
(in formula:
Ave is average grain diameter
σ is the standard deviation of partial size.)
In preferred form, above-mentioned metallic preferably has each independently in magnetic substance pedestal 8 and magnetic substance sheath 9
There are 0.5 μm~10 μm, more preferably there are 1 μm~5 μm, further preferably with 1 μm~3 μm of average grain diameter, also, preferably tool
Have 50%~90%, more preferably with 70%~90% CV value.And in preferred form, above-mentioned metallic is in magnetism
It can have identical average grain diameter in body pedestal and magnetic substance sheath.
Above-mentioned metallic can be the particle of the metal (or alloy) of crystalline (hereinafter, also referred to as " crystallization plasmid
Son "), it is also possible to the particle (hereinafter, also referred to as " amorphous particle ") of amorphous metal (or alloy), can also be and receive
The particle of the metal (or alloy) of rice crystal structure (hereinafter, also referred to as " nanocrystal ").It should be explained that, wherein it is nanocrystalline
Body structure is the structure being precipitated with instigating small crystal amorphous state.In one form, the metallic for constituting magnetic substance portion can
To be at least two kinds of mixtures in crystalline particle, amorphous particle and nanocrystal, preferably crystalline particle and
The mixture of amorphous particle or nanocrystal.In one form, the metallic for constituting magnetic substance portion can be crystallization plasmid
The mixture of son and amorphous particle.In one form, the metallic for constituting magnetic substance portion can be crystalline particle and receive
The mixture of rice crystal grain.
In the mixture of above-mentioned crystalline particle and amorphous particle or nanometer crystalline particle, crystalline particle and amorphous state
Mixing ratio (the crystalline particle: amorphous particle or nanometer crystalline particle (quality of the metallic of particle or nanocrystalline structure
Than)) be not particularly limited, can be preferably 10:90~90:10, more preferably 10:90~60:40, further preferably 15:
85~60:40.
In preferred form, in the mixture of crystalline particle and amorphous particle, the metallic of above-mentioned crystalline can
Think iron, preferably carbonyl iron (the preferably hard grade carbonyl iron of onion bulb layer structure).Above-mentioned amorphous metallic can be with
For ferroalloy, for example, Fe-Si system alloy, Fe-Si-Cr system alloy or Fe-Si-Al system alloy, preferably Fe-
Si-Cr system alloy.In preferred form, the metallic of above-mentioned crystalline can be iron, also, above-mentioned amorphous gold
Belonging to particle can be ferroalloy, for example, Fe-Si system alloy, Fe-Si-Cr system alloy or Fe-Si-Al system alloy, excellent
It is selected as Fe-Si-Cr system alloy.
In preferred form, in the mixture of crystalline particle and nanometer crystalline particle, the metallic of above-mentioned crystalline
It can be iron, preferably carbonyl iron (the preferably hard grade carbonyl iron of onion bulb layer structure).It, can by using said mixture
Magnetic conductivity is further increased, loss is reduced.
In preferred form, the metallic of above-mentioned amorphous metallic and nanocrystalline structure preferably has 20 μm
~50 μm, more preferably with 20 μm~40 μm of average grain diameter.In preferred form, the metallic of above-mentioned crystalline preferably has
There are 1 μm~5 μm, more preferably with 1 μm~3 μm of average grain diameter.In preferred form, above-mentioned amorphous metallic and
The metallic of nanocrystalline structure with 20 μm~50 μm, preferably with 20 μm~40 μm of average grain diameter, above-mentioned crystalline
Metallic with 1 μm~5 μm, preferably with 1 μm~3 μm of average grain diameter.In preferred form, above-mentioned amorphous gold
The metallic for belonging to particle and nanocrystalline structure has the average grain diameter bigger than the metallic of above-mentioned crystalline.It is non-by making
Average grain diameter of the average grain diameter of the metallic of the metallic and nanocrystalline structure of crystalline state than the metallic of crystalline
It greatly, being capable of contribution of the opposite metallic for increasing amorphous particle and nanocrystalline structure to magnetic conductivity.
In preferred form, when using Fe-Si-Cr system alloy, the content of the Si in Fe-Si-Cr system alloy is
1.5wt%~14.0wt%, for example, 3.0wt%~10.0wt%, the content of Cr are preferably 0.5wt%~6.0wt%, such as
For 1.0wt%~3.0wt%.Especially by the amount for keeping the content of Cr above-mentioned, the same of the reduction of electrical characteristics can inhibited
When, passive layer is formed on the surface of metallic, inhibits the excessive oxidation of metallic.
It the surface of above-mentioned metallic can be by envelope (hereinafter, also referred to as " insulating film ") covering of insulating materials.
By covering the surface of metallic using insulating film, the resistivity of the inside in magnetic substance portion can be improved.
The surface of above-mentioned metallic is covered with the degree that can be improved interparticle insulating properties by insulating film,
It can be covered with the only a part on the surface of metallic by insulating film.In addition, the shape of insulating film is not particularly limited, it can
To be mesh-shape, it is also possible to stratiform.In preferred form, can be the surface of above-mentioned metallic 30% or more, preferably
60% or more, more preferable 80% or more, further preferred 90% or more, particularly preferred 100% region is covered by insulating film.
In one form, the insulating film and knot of the metallic of above-mentioned amorphous metallic and nanocrystalline structure
The insulating film of the metallic of crystalloid is the insulating film formed by different insulating materials.By the insulating materials shape containing silicon
At insulating film intensity it is high, therefore by can be improved metallic with the insulating materials coated metal particle containing silicon
Intensity.
In one form, the surface of the metallic of above-mentioned crystalline can be covered by the insulating materials containing Si.As
Insulating materials containing Si, for example, silicon systems compound, such as SiO can be enumeratedx(x is 1.5~2.5, and representative is SiO2)。
In one form, the surface of the metallic of above-mentioned amorphous metallic and nanocrystalline structure can be contained
There is the covering of the insulating materials of phosphoric acid or phosphate moiety (specifically P=O yl).
It as above-mentioned phosphoric acid, is not particularly limited, can enumerate by (R2O) P (=O) (OH)2Or (R2O)2P (=O) OH table
The organic phosphoric acid shown.In formula, R2It is each independently alkyl.It is preferred that R2Chain length be preferably 5 atoms or more, more preferably 10
Group more than a atom, more than further preferably 20 atoms.It is preferred that R2Chain length be preferably 200 atoms or less, more
Below preferably 100 atoms, further preferably 50 atom groups below.
Above-mentioned alkyl is preferably substituted or unsubstituted alkylether radicals or phenyl ether.As substituent group, for example, can lift
Alkyl, phenyl, polyoxyalkylenes, polyoxyalkylenes styryl, polyoxyalkylenes alkyl, unsaturation are polyxyethylated out
Deng.
Above-mentioned organic phosphoric acid can be phosphatic form.As the cation in above-mentioned phosphate, it is not particularly limited,
For example, the ion of the alkali metal of Li, Na, K, Rb, Cs etc. can be enumerated, the ion of the alkaline-earth metal of Be, Mg, Ca, Sr, Ba etc., Cu,
The ion of other metals such as Zn, Al, Mn, Ag, Fe, Co, Ni, NH4 +, amine ion etc..It is preferred that counter cation is Li+、Na+、K+、
NH4 +Or amine ion.
In preferred form, above-mentioned organic phosphoric acid can be polyoxyalkylene styrylphenyl ether phosphoric acid, polyoxyalkylene alkane
Base ether phosphoric acid, polyoxyalkylene alkyl aryl ether phosphoric acid, alkyl ether phosphates or unsaturated polyoxyethylene alkyl phenyl ether phosphoric acid or
Its salt of person.
The method of the coating of above-mentioned insulating film is not particularly limited, and can be used that well known to a person skilled in the art coatings
Method, for example, sol-gel method, mechanochemical reaction, spray drying process, fluidized bed prilling method, atomization, tub sputter (Barrel
) etc. sputtering carry out.
In preferred form, the surface of the metallic of above-mentioned crystalline can be covered by the insulating materials containing Si, on
The surface for stating the metallic of amorphous metallic and nanocrystalline structure can be by containing phosphoric acid or phosphate moiety
Insulating materials covering.In preferred form, the metallic of above-mentioned crystalline is iron, also, above-mentioned amorphous clipped wire
Son can be ferroalloy, for example, Fe-Si system alloy, Fe-Si-Cr system alloy or Fe-Si-Al system alloy, preferably
Fe-Si-Cr system alloy.
The thickness of above-mentioned insulating film is not particularly limited, and can be preferably 1nm~100nm, and more preferably 3nm~
50nm, further preferably 5nm~30nm, such as 10nm~30nm or 5nm~20nm.By the thickness for increasing insulating film
Degree, can further increase the resistivity in magnetic substance portion.In addition, magnetic substance portion can be made by the thickness for reducing insulating film
In metal material amount it is more, the characteristic of the magnetic in magnetic substance portion is improved, the miniaturization in magnetic substance portion easy to accomplish.
In one form, the thickness ratio of the insulating film of the metallic of amorphous metallic and nanocrystalline structure
The thickness of the insulating film of the metallic of crystalline is thicker.
In above-mentioned form, the thickness of the insulating film of the metallic of amorphous metallic and nanocrystalline structure
And the difference of the thickness of the insulating film of the metallic of crystalline can be preferably 5nm~25nm, more preferably 5nm~20nm,
Further preferably 10nm~20nm.
In preferred form, the thickness of the insulating film of the metallic of amorphous metallic and nanocrystalline structure
For 10nm~30nm, the insulating film of the metallic of crystalline with a thickness of 5nm~20nm.
In preferred form, the average grain diameter of the metallic of amorphous metallic and nanocrystalline structure is opposite
Greatly, the average grain diameter of the metallic of crystalline is relatively small, covers the metal of amorphous metallic and nanocrystalline structure
The insulating materials of particle contains phosphoric acid, and the insulating materials for covering the metallic of crystalline contains Si.If compared with insulating properties
The low insulating materials containing phosphoric acid is coated the biggish particle of partial size (metallic of amorphous particle or nanocrystalline structure),
It is then electrically connected in compression forming with the metallic of other amorphous particles or nanocrystalline structure, will form the grain of electrical connection
The block of son.Thus the magnetic conductivity in magnetic substance portion is improved.In addition, by with the relatively high insulating materials containing Si of insulating properties
The coating lesser particle of partial size (Crystalline particles), can be improved the insulating properties of magnetic substance portion entirety.It is easy to get both as a result, high
Magnetic conductivity and high insulating properties.
In above-mentioned magnetic substance portion 2, the filling rate of the metallic in magnetic substance pedestal 8 is than the metal in magnetic substance sheath 9
The filling rate of particle is high.By improving the filling rate of the metallic in magnetic substance pedestal, especially by raising magnetic substance base
The filling rate of metallic in the protrusion of seat, the magnetic conductivity in magnetic substance portion are got higher, and can obtain higher inductance.
The filling rate of metallic in magnetic substance pedestal 8 can be preferably 65% or more, more preferably 75% or more, into
One step is preferably 85% or more.In addition, the upper limit of the filling rate of the metallic in magnetic substance pedestal 8 is not particularly limited, example
Such as, which can be for 98% hereinafter, 95% or less, 90% or less or 85% or less.In one form, magnetic substance pedestal
The filling rate of metallic in 8 can be 65%~98%, 65%~85%, 75%~98% or 85%~98%.
The filling rate of metallic in magnetic substance sheath 9 can be preferably 50% or more, more preferably 65% or more, into
One step is preferably 75% or more.In addition, the upper limit of the filling rate of the metallic in magnetic substance sheath 9 is not particularly limited, example
Such as, which can be 93% or less, 90% or less, 80% or less or 75% or less.In one form, magnetic substance sheath
The filling rate of metallic in 9 can be 50%~93%, 50%~75%, 65%~93% or 75%~93%.
In one form, the filling rate of the metallic in magnetic substance pedestal 8 is 65%~98%, 65%~85%,
75%~98% or 85%~98%, the filling rate of the metallic in magnetic substance sheath 9 can be 50%~93%, 50%
~75%, 65%~93% or 75%~93%.For example, the filling rate of the metallic in magnetic substance pedestal 8 can be
65%~98%, the filling rate of the metallic in magnetic substance sheath 9 can be 50%~93%, alternatively, in magnetic substance pedestal 8
The filling rate of metallic can be 85%~98%, the filling rate of the metallic in magnetic substance sheath 9 can be 75%
~93%.
Wherein, above-mentioned filling rate refers to the ratio of area shared by the metallic in the SEM image in the section in magnetic substance portion
Example.For example, above-mentioned average grain diameter can obtain as follows: by wire saw (the Meiwafosis Co. Ltd. system of coil component 1
DWS3032-4 it) is cut off near article center portion, exposes the substantially central portion in the face LT.Ion beam milling is carried out to obtained section
(HitachiHigh-Technologies Co. Ltd. system ion milling device IM4000) is cut, the turned-down edge caused by cutting off is removed
It goes, obtains the section of observation.With defined region (such as 130 μ ms of many places (such as 5 positions) in SEM shooting section
100 μm), using image analysis software (for example, Asahi KaseiEngineering Corporation system, " A picture
" (registered trademark)) SEM image is parsed, find out the ratio of area shared by metallic in region.
Other objects can also be contained in magnetic substance portion 2 (two sides or either one) in magnetic substance pedestal 8 and magnetic substance sheath 9
The particle of matter, such as silica (typically silica (SiO2)) particle.In preferred form, magnetic substance pedestal 8 can be with
Particle containing other materials.By the particle containing other materials, mobility when manufacture magnetic substance portion can be adjusted.
The particle of other materials can have the average grain diameter of preferred 30nm~50nm, more preferable 35nm~45nm.Pass through
The range for keeping the average grain diameter of the particle of other materials above-mentioned can be improved mobility when manufacture magnetic substance portion.
The grain of other materials in magnetic substance portion 2 (two sides or either one) in magnetic substance pedestal 8 and magnetic substance sheath 9
The filling rate of son can be preferably 0.01% or more, such as 0.05% or more, preferably 3.0% hereinafter, more preferably 1.0% with
Under, further preferably 0.5% hereinafter, be still more preferably 0.1% or less.By the filling rate for making the particle of other materials
For range as described above, mobility when manufacture magnetic substance portion can be further increased.
Wherein, the average grain diameter of the particle of other materials and filling rate can be with the average grain diameters and filling rate of metallic
Similarly find out.
In present embodiment, as shown in Figures 2 and 3, above-mentioned coil-conductor 3 is helically wound into 2 sections and is formed as it
Two ends are located at outside.That is, coil-conductor 3 is will to be formed containing the Wire-wound of conductive material at α volumes.Coil-conductor 3
By being wound with the winding section of coil-conductor, being constituted from the lead division that winding section is drawn.Also, lead division, which has, is present in magnetic substance
End end portion on the bottom surface in portion.Coil-conductor 3 is configured to raised part 11 and is present in core (to be present in the inside of coil-conductor
Blank part), the short transverse of the central axis of coil-conductor along coil component.The lead division 24,25 of coil-conductor 3 is from magnetic substance
The back side of pedestal 8 is drawn out to bottom surface.
In above-mentioned coil-conductor 3, compared with constituting the conducting wire of innermost layer of winding section, outermost conducting wire is constituted positioned at upper
Side.In other words, it is compared at a distance from the conducting wire of the bottom surface from coil component to the innermost layer for constituting winding section, from coil component
Bottom surface is bigger to the distance for constituting outermost conducting wire.That is, the T2 ratio T1 in Figure 10 is big.Make the outside of coil-conductor in this way
Layer position it is higher, coil-conductor can be further increased at a distance from external electrode, improve reliability.Further, it is possible to
Ensure bigger space under the layer in the outside of coil-conductor, therefore external electrode, line easy to accomplish can be formed in the part
The dwarfing of coil component.The position of the winding section of coil-conductor can be with ramping towards outside, be also possible on curve
It rises.That is, the side of winding section can be plane, it is also possible to curved.Can the side of winding section of preferably coil-conductor be
Shape along the upper surface of the base portion of magnetic substance pedestal.
In one form, the difference (T2-T1: that is, constituting the height of outermost coiling and constituting coiling of above-mentioned T2 and T1
The difference of the height of the coiling of the innermost layer in portion) it can be preferably 0.02mm~0.10mm, more preferably 0.04mm~0.10mm.
It as above-mentioned conductive material, is not particularly limited, for example, gold, silver, copper, palladium, nickel etc. can be enumerated.It is preferred that conductive
Property material be copper.Conductive material can be only a kind, be also possible to two or more.
The conducting wire for forming above-mentioned coil-conductor 3 can be round wires, be also possible to flat wire, preferably flat wire.By making
With flat wire, it is easy seamless unoccupied place coiled electrical conductor.
The thickness of above-mentioned flat wire can be 0.02mm~0.14mm, and more preferably 0.9mm is hereinafter, further preferably
0.8mm or less.In addition, the thickness of above-mentioned flat wire can also be preferably 0.03mm or more, more preferably 0.04mm or more.Pass through
Reduce the thickness of flat wire, even identical the number of turns, coil-conductor also becomes smaller, and is conducive to the miniaturization of coil component entirety.
In addition, the number of turns can be increased in the coil-conductor of identical size.By make flat wire with a thickness of 0.02mm or more, can
Reduce the resistance of conducting wire.
The width of above-mentioned flat wire can be preferably 2.0mm hereinafter, more preferably 1.5mm is hereinafter, further preferably
1.0mm following.By reducing the width of flat wire, coil-conductor can be reduced, the miniaturization of component entirety is conducive to.In addition,
The width of above-mentioned flat wire can be preferably 0.1mm or more, more preferably 0.3mm or more.By the width for making flat wire
0.1mm or more can reduce the resistance of conducting wire.
The ratio between thickness and width of above-mentioned flat wire (thickness/width) can be preferably 0.1 or more, more preferably 0.2 with
On, preferably 0.7 hereinafter, more preferably 0.65 hereinafter, further preferably 0.4 or less.
In one form, the conducting wire for forming above-mentioned coil-conductor 3 can be coated by insulating properties substance.By utilizing insulating properties
The coating conducting wire for forming coil-conductor 3 of substance, can make coil-conductor 3 and the insulation in magnetic substance portion 2 more reliable.It should be noted that
In the part of above-mentioned conducting wire being connect with external electrode 4,5, such as the bottom surface of magnetic substance pedestal 8 is drawn out in present embodiment
Insulating properties substance is not present in the end end portion of coil-conductor, and conducting wire exposes.
The thickness for being coated the insulating properties substance envelope of above-mentioned conducting wire can be preferably 1 μm~10 μm, more preferably 2 μm~8 μ
M, further preferably 4 μm~6 μm.
It as above-mentioned insulating properties substance, is not particularly limited, for example, polyurethane resin, polyester resin, asphalt mixtures modified by epoxy resin can be enumerated
Rouge, polyamide-imide resin, preferably polyamide-imide resin.
In one form, the region 28,29 between the end end portion of above-mentioned coil-conductor and the end face in magnetic substance portion exists magnetic
Body portion.Width between end end portion and the end face in magnetic substance portion of above-mentioned coil-conductor preferably forms the width of the conducting wire of coil-conductor
0.2 times~0.8 times, more preferably 0.4 times~0.6 times of degree.
Said external electrode 4,5 is respectively set to the end of the bottom surface of coil component 1.External electrode 4,5 is respectively set to
It is drawn out in the end end portion 26,27 of the coil-conductor 3 of the bottom surface of magnetic substance pedestal 8.That is, external electrode 4,5 is led with coil respectively
The end end portion 26,27 of body 3 is electrically connected.
In one form, external electrode 4,5 not only can be in the coil-conductor 3 for being drawn out to the bottom surface of magnetic substance pedestal 8
End exists in end portion 26,27, can also exceed the end end portion of coil-conductor and extend to the other parts of the bottom surface of coil component
And exist.
In one form, external electrode 4,5 is set to that there is no the regions of protective layer 6, i.e. magnetic substance portion 2 and coil-conductor
In 3 region entireties exposed.
In one form, external electrode 4,5 extends to the end face of coil component.
In one form, external electrode 4,5 can the end end portion beyond coil-conductor and extend to the bottom surface of coil component
Other parts, and then extend to the end face of coil component.
External electrode 4,5 other than being formed in the end end portion of coil-conductor can be formed in magnetic substance portion 2, can also be with
It is formed on following protective layers 6.
In one form, external electrode 4,5 is more than the boundary of the exposed area of protective layer and magnetic substance portion and coil-conductor
And it is mounted on protective layer 6.In preferred form, the carrying distance of external electrode on the protection layer can be preferably 10 μm~80
μm, more preferably 10 μm~50 μm.By carrying external electrode on the protection layer, the removing of protective layer can be prevented.
In one form, external electrode 4,5 is prominent from the surface of coil component 1, preferably 10 μm~50 μm prominent, more preferably
It is 20 μm~40 μm prominent.
The thickness of said external electrode is not particularly limited, for example, can be 1 μm~100 μm, preferably 5 μm~50 μm,
More preferably 5 μm~20 μm.
The conductive material of said external electrode is preferably by a kind or a kind in Au, Ag, Pd, Ni, Sn and Cu
Above metal material is constituted.
Said external electrode can be single layer, be also possible to multilayer.It is external when external electrode is multilayer in one form
Electrode may include the layer containing Ag or Pd, the layer containing Ni or the layer containing Sn.In preferred form, said external electrode
It is made of the layer containing Ag or Pd, the layer containing Ni and the layer containing Sn.It is preferred that above-mentioned each layer since coil-conductor side by
Layer containing Ag or Pd, the layer containing Ni, the layer containing Sn sequence set gradually.It is preferred that the above-mentioned layer containing Ag or Pd is to burn
The layer (that is, layer of heat cure) of Ag cream or Pd cream is tied, the above-mentioned layer containing Ni and the layer containing Sn can be coating.
In addition to external electrode 4,5, the covering of 1 protected seam 6 of coil component.
The thickness of above-mentioned protective layer 6 is not particularly limited, and can be preferably 3 μm~20 μm, and more preferably 3 μm~10 μm,
Further preferably 3 μm~8 μm.By make protective layer with a thickness of above-mentioned range, can be in the size of suppression coil component 1
Increase while, it is ensured that the insulating properties on the surface of coil component 1.
As the insulating material of above-mentioned protective layer 6 is constituted, for example, it is sub- to enumerate acrylic resin, epoxy resin, polyamides
The high resin material of the electrical insulating properties such as amine.
In preferred form, above-mentioned protective layer 6 is in addition to that can also contain Ti containing above-mentioned insulating material.By making to protect
Contain Ti in layer, in plating when forming external electrode, coating is not easy to extend into protective layer, can adjust external electrode and exist
The carrying of protective layer.
The content of above-mentioned Ti is not particularly limited, and integrally can be preferably the 5 mass % of mass %~50 relative to protective layer,
More preferably 10 mass of mass %~30 %.
And in preferred form, above-mentioned protective layer 6 can also contain Al in addition to containing above-mentioned insulating material and Ti
With the one side or both in Si.By making containing Al or Si in protective layer, the heat that can reduce magnetic substance portion and protective layer is swollen
The difference of swollen coefficient.By reducing the difference of the thermal expansion coefficient in magnetic substance portion and protective layer, even if adding hot and cold because of coil component
But lead to the expansion and contraction that generate coil component, be also able to suppress protective layer and removed from magnetic substance portion.In addition, by making to protect
Contain Ti in sheath, to be able to suppress coating in the plating when forming external electrode and protrude into protective layer.
The content of above-mentioned A and Si is not particularly limited, and integrally respectively can be preferably 5 mass %~50 relative to protective layer
Quality %, more preferably 10 mass of mass %~30 %.
Relative to protective layer entirety, the total of above-mentioned Ti, Al and Si can be preferably 5 mass of mass %~50 %, more excellent
It is selected as 10 mass of mass %~30 %.
It should be noted that protective layer 6 is not required in the utility model, can be not present.
The coil component of the utility model can realize miniaturization while keeping electrical characteristics.In one form, this reality
It is preferably 0.9mm~2.2mm with the length (L) of novel coil component, more preferably 0.9mm~1.8mm.In one form,
The width (W) of the coil component of the utility model is preferably 0.6mm~1.8mm, more preferably 0.6mm~1.0mm.Preferred shape
In state, the length (L) of the coil component of the utility model is 0.9mm~2.2mm, and width (W) is 0.6mm~1.8mm, preferably long
Degree (L) is 0.9mm~1.8mm, width (W) is 0.6mm~1.0mm.In addition, in a form, the coil part of the utility model
The height (or thickness (T)) of part is preferably 0.8mm hereinafter, more preferably 0.7mm or less.
Next, being illustrated to the manufacturing method of coil component 1.
Magnetic substance pedestal is made
Magnetic substance pedestal 8 is manufactured first.
Metallic and resin material and other materials as needed are mixed, the mixture metal mold that will be obtained
It is press-formed.Then, the formed body of extrusion forming is heat-treated and solidifies resin material, thus obtain magnetic substance
Pedestal.
The amorphous metallic used preferably has 20 μm~50 μm, more preferably with 20 μm~40 μm of intermediate value grain
Diameter (50% equivalent diameter of Cumulative logit model of volume reference).In preferred form, the metallic of above-mentioned crystalline preferably has
There are 1 μm~5 μm, more preferably with 1 μm~3 μm of median particle diameter.In preferred form, above-mentioned amorphous metallic tool
Have 20 μm~50 μm, preferably with 20 μm~40 μm of median particle diameter, the metallic of above-mentioned crystalline have 1 μm~5 μm, it is excellent
Select the median particle diameter with 1 μm~3 μm.
The pressure of extrusion forming can be preferably 100MPa~5000MPa, more preferably 500MPa~3000MPa, into one
Step is preferably 800MPa~1500MPa.Coil-conductor is not configured when making magnetic substance pedestal, there is no deformations of coil-conductor etc.
The problem of, therefore can be press-formed with high pressure.By being press-formed with high pressure, magnetism can be improved
The filling rate of metallic in body pedestal.
The temperature of extrusion forming can be properly selected according to the resin used, for example, can for 50 DEG C~200 DEG C with
Under, preferably 80 DEG C~150 DEG C.
The temperature of heat treatment can be properly selected according to the resin used, such as can be 150 DEG C~400 DEG C, excellent
It is selected as 200 DEG C~300 DEG C.
The configuration of coil-conductor
Next, making the protrusion of magnetic substance pedestal be located at line on magnetic substance pedestal obtained above coil-conductor configuration
The core for enclosing conductor obtains the magnetic substance pedestal configured with coil-conductor.At this moment, two end end portions of coil-conductor are drawn
To the bottom surface of magnetic substance pedestal.
As the configuration method of coil-conductor, can will separately coil-conductor configuration obtained from coiled electrical conductor in magnetic substance
On pedestal, or can also in the protrusion coiled electrical conductor of magnetic substance pedestal, directly on magnetic substance pedestal make coil-conductor and
It is configured.It separately makes coil-conductor and configures when on magnetic substance pedestal, it is advantageous at manufacturing process's transfiguration easily aspect.Separately
Outside, when the protrusion coiled electrical conductor of magnetic substance pedestal makes coil-conductor, coil-conductor and magnetic substance base can further be made
Seat is closely sealed, therefore can reduce the diameter of coil-conductor, in this regard favorably.
The production of magnetic substance sheath
Metallic and resin material and other materials as needed are mixed.It is added in obtained mixture molten
Agent and be adjusted to viscosity appropriate, obtain the material of magnetic substance sheath formation.
Magnetic substance pedestal obtained above configured with coil-conductor is configured at mold.Then, by material obtained above
In material injection mold, extrusion forming.Then, the formed body obtained to extrusion forming is heat-treated and solidifies resin material,
To form magnetic substance sheath, obtain being embedded with the magnetic substance portion (green body) of coil-conductor in inside as a result,.
In one form, when magnetic substance pedestal is configured at mold, it can preferably make at least one side of magnetic substance pedestal
Face is sealed at the wall surface of mold.It is preferred that magnetic substance pedestal (is in the present embodiment magnetism with the side where coil-conductor
The back side of body pedestal) opposed side (in the present embodiment for magnetic substance pedestal before) is closely sealed with the wall surface of metal mold.
Thereby, it is possible to more reliably be present in the coil-conductor of side with the covering of magnetic substance sheath.
It as above-mentioned solvent, is not particularly limited, for example, propylene glycol monomethyl ether (PGM), methyl ethyl ketone can be enumerated
(MEK), N, dinethylformamide (DMF), propylene glycol methyl ether acetate (PMA), dipropylene glycol monomethyl ether (DPM), dipropyl
Glycol monomethylether acetate (DPMA), gamma-butyrolacton etc. are, it is preferable to use PGM.
The pressure of extrusion forming can be preferably 1MPa~100MPa, more preferably 5MPa~50MPa, further preferably
5MPa~15MPa.By being formed with such pressure, it is able to suppress the influence to internal coil-conductor.
The temperature of extrusion forming can be properly selected according to the resin used, such as can be 50 DEG C~200 DEG C, excellent
It is selected as 80 DEG C~150 DEG C.
The temperature of heat treatment can be properly selected according to the resin used, such as can be 150 DEG C~400 DEG C, excellent
It is selected as 150 DEG C~200 DEG C.
The production of protective layer
It can according to need addition Ti, Al, Si etc. in insulating material and organic solvent mixed, coated
Material.Obtained coating material is coated on above-mentioned green body, its solidification is made to obtain protective layer.
It as coating method, is not particularly limited, such as can be formed by spraying, impregnating.
The production of external electrode
The protective layer that the position of external electrode will be formed removes.By the removing, make the bottom surface for being drawn out to magnetic substance pedestal
Coil-conductor end end portion at least part exposing.Then, external electrode is formed in the exposing position of coil-conductor.Separately
Outside, when being coated coil-conductor using insulating properties substance, the substance of the insulating envelope can be removed while removing protective layer
It goes.
It as the removing method of above-mentioned protective layer, is not particularly limited, such as can enumerate at the physics such as laser irradiation, sandblasting
Reason and chemical treatment etc..It is preferred that protective layer is removed by laser irradiation.
It as the forming method of said external electrode, is not particularly limited, such as can enumerate using CVD, plating, chemistry
Plating, vapor deposition, sputtering, sintering of conductive paste etc. or their combination.In preferred form, external electrode is conductive by carrying out
Property cream sintering after, carry out plating (preferably electroplating processes) and formed.
The coil component 1 of the utility model manufactured as above.
Therefore, the utility model provides a kind of manufacturing method of coil component, wherein
Above-mentioned coil component is included containing magnetic substance portion made of metallic and resin material；It is embedded in above-mentioned magnetism
The coil-conductor in body portion；And the external electrode being electrically connected with above-mentioned coil-conductor,
Above-mentioned magnetic substance portion by with protrusion magnetic substance pedestal and magnetic substance sheath constitute,
Above-mentioned coil-conductor is configured to be located at the core of coil-conductor in above-mentioned magnetic substance pedestal upper convex portion, also, will
Above-mentioned magnetic substance sheath is set as covering coil-conductor,
The manufacturing method of above-mentioned coil component includes following process:
(i) process of magnetic substance pedestal is made；
(ii) process of coil-conductor is configured on magnetic substance pedestal；
(iii) the magnetic substance pedestal configured with coil-conductor is configured at mold, injects the material of magnetic substance sheath formation
Material is formed, and magnetic substance sheath, the process for obtaining the magnetic substance portion for being embedded with coil-conductor are formed；
(iv) process for forming protective layer in the magnetic substance portion for being embedded with coil-conductor；And
(v) protective layer of defined position is removed, forms the process of external electrode at this.
More than, the coil component and its manufacturing method of the utility model are illustrated, but the utility model is not limited to
Above-mentioned embodiment can be designed change in the range for the main idea for not departing from the utility model.
[embodiment]
(Examples 1 to 3)
The production of metallic
As metallic, prepare amorphous particle (Si content 7wt%, the Cr content of Fe-Si-Cr system alloy
3wt%, B content 3wt%, C content 0.8wt%；50 μm of median particle diameter (D50)) and Fe crystalline particle (median particle diameter
(D50)2μm).It should be noted that, using X-ray diffraction, confirmation indicates amorphous dizzy and identifies about amorphous state and crystalline
For amorphous state, confirms the diffraction maximum as caused by crystal phase and be accredited as crystalline.
Then, (thickness 20nm) Fe- is coated with phosphoric acid using machinery coating method (Mechanofusion (registered trademark))
The amorphous particle of Si-Cr system alloy.In addition, using use tetraethyl orthosilicate (TEOS) as the gel-of metal alkoxide
Sol method silica (SiO2) coating (thickness 10nm) Fe crystalline particle.
The production of magnetic substance pedestal
100 matter of mixed-powder relative to 80 mass % and Fe particle of above-mentioned Fe-Si-Cr system alloy particle, 20 mass %
Part is measured, the heat-curing resin of 3 mass parts epoxies is added, 0.08 mass parts median particle diameter (D50) is the SiO of 40nm2Pearl is used
Planetary stirring machine mixes 30 minutes, prepares the material of magnetic substance pedestal.Obtained material is press-formed with mold
(1000MPa, 100 DEG C), from mold taking-up after, 250 DEG C heat cure 30 minutes, obtain the magnetic substance of the protrusion with rail-like
Pedestal.It should be noted that angle formed by the wall surface of recess portion and bottom surface is 120 °.By magnetic substance pedestal 5 obtained average-sizes
It is shown in following table 1.
[table 1]
The production of coil-conductor
Prepare 3 kinds of different flat wires of thickness and width size shown in table 2, is made α volumes and makes coil-conductor.It uses
Flat wire be copper, it is coating with 4 μm of thickness of polyamidoimides.In addition, all 5 circles of the number of turns.
[table 2]
The preparation of the material of magnetic substance sheath
100 matter of mixed-powder relative to 80 mass % and Fe particle of above-mentioned Fe-Si-Cr system alloy particle, 20 mass %
Part is measured, the thermosetting resin of 3 mass parts epoxies is added, then using viscosity appropriate addition as the propylene glycol monomethyl ether of solvent
(PGM), it is mixed 30 minutes with planetary stirring machine, prepares the material of magnetic substance sheath.
The production of magnetic substance sheath
It is fitted into the core of coil-conductor in the protrusion of magnetic substance pedestal obtained above, by the both ends of coil-conductor along slot
The back side across magnetic substance pedestal is drawn out to bottom surface.The magnetic substance pedestal for being equipped with coil-conductor is set to mold.At this moment, make it
It is biased to contact before magnetic substance pedestal with the wall surface of mold.Then, in the mold for being equipped with magnetic substance pedestal in injection
The material for the magnetic substance sheath stated.Then, it is pressurizeed at 100 DEG C with 10MPa, magnetic substance sheath is formed, from mould
It is taken out in tool.Thereafter, by obtained formed body in 180 DEG C of progress heat cure in 30 minutes.After solidification, ZrO is used2The ceramic powder of matter
End is used as medium, carries out the grinding of dry type roller, the green body of coil component is made.
The formation of resinous coat (protective layer)
The Ti of specified amount (20wt%) is added in the epoxy resin of insulating properties, adds organic solvent, prepares coating material.
Green body obtained above is impregnated in obtained coating material, forms protective layer in billet surface.
The formation of external electrode
A part that protective layer obtained above is removed using laser leads the coil for the bottom surface for being drawn out to magnetic substance pedestal
A part of the end end portion of body and the bottom surface of the magnetic substance pedestal adjacent with end end portion is exposed.Contain Ag powder in exposed division coating
With the conductive paste of thermosetting epoxy resin, heat cure and form basal electrode, thereafter, Ni, Sn film are formed with plating, thus shape
At external electrode.
According to the above, the sample (coil component) of production Examples 1 to 3.
Evaluation
(1) magnetic permeability μ
Each 5 samples are made to each embodiment, with impedance analyzer (Agilent Technologies corporation,
E4991A；Condition: 1MHz, 1Vrms, 20 ± 3 DEG C of ambient temperature) measurement inductance, it calculates magnetic conductivity (μ).5 are found out to be averaged
Value, the magnetic conductivity as each embodiment.Show the result in following table 4.
(2) filling rate of the metallic of magnetic substance pedestal
By the sample of each embodiment with wire saw (Meiwafosis Co. Ltd. system DWS3032-4) in article center portion
It is nearby cut off, exposes the substantially central portion in the face LT.Ion milling (Hitachi High- is carried out to obtained section
Technologies Co. Ltd. system ion milling device IM4000), the turned-down edge caused by cutting off is removed, observation is obtained
Section.Filling rate in magnetic substance pedestal is to use base portion in the position (5 positions △ shown in Figure 11) of six equal part of the direction L
SEM shoots (regions of 130 100 μm of μ ms), and the filling rate of magnetic substance sheath is by the top of core in six equal part of the direction L
Position (0 5 positions shown in Figure 11) shoots (regions of 130 100 μm of μ ms) with SEM, uses image analysis software (Asahi
Kasei Engineering Corporation system；" A picture" (registered trademark)) SEM photograph is parsed, find out metal
Area shared by particle finds out ratio shared by the metallic relative to the whole area of measurement, by being averaged for 5 positions
Value is used as filling rate.Show the result in following Table 3.
(3) size distribution of metallic
Image analysis is carried out to the SEM photograph of 5 positions △ shown in Figure 11 in the section of sample in the same manner as (2),
The metallic equivalent circle diameter for finding out arbitrary 500, using the average value of 5 positions as average grain diameter (Ave).In addition,
Find out the standard deviation (σ) of partial size.In addition, finding out CV value ((σ/Ave) × 100) by these results.Show the result in following tables
3。
(4) thickness of resinous coat (protective layer)
Image is carried out to the SEM photograph of 5 arbitrarily located the position of the protective layer in the section of sample in the same manner as (2)
Parsing, measures the thickness of protective layer, using the average value of 5 positions as the thickness of protective layer.Show the result in following table 4.
(5) the carrying distance of external electrode on the protection layer
The boundary of protective layer and external electrode in the same manner as (2) to the bottom surface side of the magnetic substance pedestal in the section of sample
The SEM photographs of arbitrary 2 positions carry out image analysis, measurement external electrode (electrode plating) carrying on the protection layer away from
From using the average value of 2 positions as carrying distance.Show the result in following table 4.
(6) the insulating film thickness of metallic
The processing sample in the same manner as (2) exposes section.Pair cross-section uses scanning transmission electron microscope (Scanning
Transmission electron microscope；Model JEM-2200FS；Jeol Ltd.'s system) analysis coil
The composition of the metallic of the substantially central portion (position of the of Figure 11) of the core of component, identification be amorphous particle or
Crystalline particle.3 each to the particle identified shoot photo with 300k times, measure insulation-coated thickness.3 are found out to be averaged
Value, as the thickness of insulating film.Show the result in following table 4.
[table 3]
[table 4]
(embodiment 4 and 5)
Make size shown in the size following table 5 of magnetic substance pedestal, makes the production of magnetic substance pedestal and magnetic substance sheath
Used in epoxy resin additive amount be 2 mass parts, in addition to this, similarly to Example 1 make embodiment 4 and 5 examination
Sample (coil component).
[table 5]
Evaluation
It is carried out similarly evaluation with Examples 1 to 3, by the outer dimension of coil component, filling rate and metallic
The result of size distribution is shown in table 6, and the result of magnetic conductivity, the thickness of protective layer, carrying distance and coating thickness is shown in table
7。
[table 6]
[table 7]
Visual inspection
Each 10 appearances of sample obtained above are observed with optical microscopy.As a result, conducting wire is not in whole samples
Expose from the surface of coil component.
Comparative example 1
As metallic, prepare the amorphous particle of Fe-Si-Cr system alloy same as Example 1 and the knot of Fe
Crystalloid particle.It is coating that surface is carried out to these particles similarly to Example 1.
100 matter of mixed-powder relative to 80 mass % and Fe particle of above-mentioned Fe-Si-Cr system alloy particle, 20 mass %
Part is measured, 3 mass parts epoxy system resins, then the propylene glycol monomethyl ether (PGM) using viscosity appropriate addition as solvent, wet type is added
Mixing, obtains slurry.Using obtained slurry, magnetic substance piece is made with scraper method.
Using flat wire same as Example 1, α volumes of the coil-conductor that the number of turns is 5 is made.Wherein, in this comparative example 1
Coil-conductor T2-T1 be 0.
Coil-conductor is clamped between 2 magnetic substance sheet materials, is pressurizeed at 100 DEG C with 1000MPa.Obtained laminated body is used
Slicer is cut off, and after singualtion, is kept for 30 minutes at 180 DEG C, is made its heat cure.It should be noted that coil-conductor is from the end of green body
Draw (referring to Fig.1 2) in face.
It is carried out similarly the formation of roller grinding and protective layer with Examples 1 to 3, then, will be formed using laser external
The protective layer of the position of electrode removes, and exposes 4 face of end face and surrounding in magnetic substance portion.Contain Ag powder and heat in exposed division coating
The conductive paste of thermoset epoxy resin, heat cure and form basal electrode, thereafter, Ni, Sn film, thus shape are formed with electrolytic coating
At external electrode.
According to the above, the sample (coil component) of comparison example 1.
Evaluation
Visual inspection
10, sample appearances obtained above are observed with optical microscopy.As a result, coil is led in 10 sample wholes
Body deforms, so that conducting wire exposes from the surface of coil component.
Industrial availability
The coil component of the utility model can be used as inductor etc. and be widely used for various uses.
Claims (8)
1. a kind of coil component, there is magnetic substance portion, coil-conductor and external electrode, the magnetic substance portion contain metallic and
Resin material, the coil-conductor are embedded in the magnetic substance portion, and the external electrode is electrically connected with the coil-conductor,
The magnetic substance portion includes the magnetic substance pedestal and magnetic substance sheath with protrusion,
The coil-conductor is configured to be located at the core of coil-conductor in the magnetic substance pedestal upper convex portion,
The magnetic substance sheath is set as covering coil-conductor,
The coil-conductor with a thickness of the flat wire of 0.02mm~0.14mm by constituting.
2. coil component according to claim 1, wherein the flat wire with a thickness of 0.02mm~0.08mm.
3. coil component according to claim 1 or 2, wherein the ratio between thickness and width of the flat wire be 0.1~
0.7。
4. coil component according to claim 1 or 2, wherein the ratio between thickness and width of the flat wire be 0.1~
0.4。
5. coil component according to claim 1 or 2, wherein the flat wire is coated by insulating properties substance.
6. coil component according to claim 1 or 2, wherein the end end portion of the coil-conductor is drawn out to magnetic substance
The bottom surface of pedestal, external electrode are set to the bottom surface of coil component.
7. coil component according to claim 1 or 2, the length is 0.9mm~2.2mm, width is 0.6mm~1.8mm.
8. coil component according to claim 1 or 2, the length is 0.9mm~1.8mm, width is 0.6mm~1.0mm.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2017-083126 | 2017-04-19 | ||
| JP2017083126A JP2018182205A (en) | 2017-04-19 | 2017-04-19 | Coil component |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN208400649U true CN208400649U (en) | 2019-01-18 |
Family
ID=64276206
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201820567286.5U Active CN208400649U (en) | 2017-04-19 | 2018-04-19 | Coil component |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP2018182205A (en) |
| CN (1) | CN208400649U (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7103787B2 (en) * | 2017-12-27 | 2022-07-20 | 太陽誘電株式会社 | Coil parts and electronic devices |
| KR102130677B1 (en) | 2019-01-09 | 2020-07-06 | 삼성전기주식회사 | Coil component |
| KR102472930B1 (en) * | 2019-01-09 | 2022-12-01 | 삼성전기주식회사 | Coil component |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006165429A (en) * | 2004-12-10 | 2006-06-22 | Toko Inc | Winding inductor |
| JP5974283B2 (en) * | 2012-07-06 | 2016-08-23 | パナソニックＩｐマネジメント株式会社 | Inductor manufacturing method |
| US9087634B2 (en) * | 2013-03-14 | 2015-07-21 | Sumida Corporation | Method for manufacturing electronic component with coil |
-
2017
- 2017-04-19 JP JP2017083126A patent/JP2018182205A/en active Pending
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2018
- 2018-04-19 CN CN201820567286.5U patent/CN208400649U/en active Active
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|---|---|
| JP2018182205A (en) | 2018-11-15 |
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