JP2011035147A - Method of manufacturing coil component, and coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a coil component which prevents plating from being brought into a state peeled from a drum core basis material or damaged, and a coil component manufactured by the same. <P>SOLUTION: In a coil component body preparation process in this manufacturing method, a coil component body 1' having a nearly-quadrangular prism-shaped prismatic body having two end faces and four side faces connecting the two end faces is manufactured. In the next polishing process, polishing is performed by bringing a circumferential surface 1001A of a polishing blade 1001 into contact with a main surface 1'A and a pair of facing surfaces 1'C by the polishing blade 1001 arranged on a dicer and forming a nearly-cylindrical shape. Then, a plating process of forming a Ni layer on a lower base electrode by a plating process by electrolytic plating, and forming an upper base electrode by forming a Sn-plated layer on a surface of the Ni layer by applying a Sn plating process by electrolytic plating onto it is executed. This coil component is manufactured by passing through the above processes. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a coil component manufacturing method and a coil component, and more particularly to a coil component manufacturing method and a coil component that require a predetermined inductance characteristic.

  As a coil component, one having a configuration including a drum core having a pair of flange portions and a core portion connecting the pair of flange portions is known. A winding made of an insulation-coated copper wire is wound around the core portion of the drum core, and from above, a resin is filled and fixed so as to fill a space between the pair of flange portions. Each of the pair of flanges has a substantially rectangular parallelepiped shape, and one side surface of each of the flanges is disposed to face the substrate, and the coil component is mounted on the substrate. One end or the other end of the winding is electrically connected to a terminal electrode provided on the flange. The terminal electrode is mainly provided on the entire surface of the one side surface of the pair of flange portions having a substantially rectangular parallelepiped shape. A solder fillet is formed on the terminal electrode, and the coil component is mounted and fixed on the substrate.

  A closed magnetic circuit is formed around the coil component so as to exit from one flange of the drum core and enter the other flange. Along with this, a counter electromotive force of a closed magnetic circuit is generated in the terminal electrode formed in the collar portion. Then, a current that surrounds the peripheral surface of the flange flows in the terminal electrode. This current generates a reverse magnetic field that cancels the magnetic field of the closed magnetic circuit, and deteriorates the inductance characteristics of the coil component.

  Japanese Patent Laying-Open No. 2007-273532 (Patent Document 1) describes a coil component that prevents deterioration of inductance characteristics. A chamfered portion by polishing is applied to a side portion of the flange portion of the coil part, which has a substantially rectangular parallelepiped shape, where two adjacent side surfaces are connected. The coil component is manufactured as follows. First, a drum core having a winding core and a pair of flanges is prepared. Next, an Ag paste is attached to the end face of the collar part and the side surface of the collar part in the axial direction of the core part by dipping (immersion), and then dried to form a first Ag film that forms a base electrode.

  Next, the winding is wound around the winding core, and the end of the winding is thermocompression-bonded on the first Ag film on the circumferential surface of the flange. Next, a resin is formed by a mold or the like so as to cover the winding wound around the winding core portion between the flange portions. Next, an Ag paste is deposited on the first Ag film including the thermocompression bonding part at the end of the winding, thereby forming a second Ag film that forms a base electrode. Then, using electroplating, a Cu film, a Ni film, and a Sn film are sequentially formed on the second Ag film and plated. Then, with sandpaper, a file, etc., the part of the side where the two adjacent side surfaces of the buttock are connected is polished (chamfered) until the drum core substrate is exposed, and the underlying electrode and plating at this part are removed. To do. Thus, the coil component is manufactured.

JP 2007-273532 A

  However, in the method of manufacturing a coil component described in the above publication, the portion that is not removed and the portion pulled when the plating is removed by the polishing process is in a state of peeling from the drum core substrate, There was a problem of getting scratched.

  Therefore, the present invention provides a coil component manufacturing method for preventing plating from being peeled off from the drum core substrate or scratching, and a coil component manufactured by the coil component manufacturing method. With the goal.

  In order to achieve the above object, the present invention provides a coil conductor, at least the coil conductor is sheathed with an exterior body, the end surfaces of both ends in the axial direction of a prismatic body that forms a part of the outer shell, and the Coil components in which a base electrode is provided at both end portions in the axial direction of the side surface of the prismatic body, and the base electrode provided at one side surface portion is a connecting portion to which the coil conductor is electrically connected. A coil component main body preparation step for preparing a main body, and polishing the base electrode and a part of the exterior body on the entire side surface of the coil component main body corresponding to all side surfaces other than the one side surface of the prismatic body. Thus, there is provided a method for manufacturing a coil component, which includes a polishing step for removing all the base electrodes on all side surfaces other than the one side surface, and a plating step for performing plating on the base electrode.

  A ground electrode is provided on the end surfaces of both end portions in the axial direction of the prismatic body and at the both end portions in the axial direction of the side surface of the prismatic body, the coil conductor having at least a coil conductor and an exterior body forming a part of the outer shell. And a base electrode provided on one side portion is a coil component body preparation step for preparing a coil component body that forms a connecting portion to which a coil conductor is electrically connected, and one side surface of a prismatic body. A polishing step for removing all base electrodes on all side surfaces except one side surface by polishing the base electrode and a part of the exterior body on the entire side surface of the coil component body corresponding to all side surfaces other than Since it has a plating process that performs plating on the electrode, the plating is not pulled by the polishing process, and a part of the plating is prevented from being peeled off or scratched from the drum core substrate. Door can be. In addition, since all the base electrodes on all the side surfaces other than the one side surface are removed, it is possible to suppress the occurrence of the counter electromotive force of the closed magnetic circuit in the terminal electrode as much as possible, and a predetermined inductor characteristic can be obtained. Coil parts can be manufactured.

  Here, the side surface of the coil component body corresponding to one of the side surfaces other than the one side surface of the prismatic body has a main surface, and the side surface on the opposite side of the coil component body with respect to the main surface is An anti-main surface is formed, and in the polishing step, the main surface is preferably polished in a state where the anti-main surface is brought into contact with the upper surface of the support member and the coil component main body is placed on the support member. .

  The side surface of the coil component body corresponding to one of the side surfaces other than one side surface of the prismatic body has a main surface, and the side surface on the opposite side of the coil component body has an anti-main surface with respect to the main surface. Then, since the main surface is polished in a state where the anti-main surface is brought into contact with the upper surface of the support member and the coil component body is placed on the support member, the surface can be stably polished on the upper surface. Therefore, it can polish reliably.

  Further, in the polishing step, the polishing blade is maintained in a state where the axis of the polishing blade having a substantially cylindrical shape and rotatable about the axis is maintained perpendicular to the longitudinal direction of the main surface and parallel to the main surface. And rotating the peripheral surface of the polishing blade from one end side to the other end side in the longitudinal direction of the main surface to polish the main surface, and the polishing blade in the axial direction of the polishing blade It is preferable that the length of the peripheral surface is longer than the width of the main surface.

  Since the length of the peripheral surface of the polishing blade in the axial direction of the polishing blade is longer than the width of the main surface, the main surface is polished by sliding once from one end side to the other end side in the longitudinal direction of the main surface. be able to. Therefore, the polishing blade does not need to touch the main surface over and over, and the finish and reliability of the main surface can be improved.

  Further, the side surface of the coil component main body has a pair of opposing surfaces in addition to the anti-main surface and the main surface. In the polishing step, a pair of opposing polishing blades are brought into contact with the pair of opposing surfaces. It is preferable to perform polishing on the pair of facing surfaces simultaneously.

  The side surface of the coil component main body has a pair of opposing surfaces in addition to the anti-main surface and the main surface. In the polishing process, a pair of opposing polishing blades are brought into contact with the pair of opposing surfaces and simultaneously polished on the pair of opposing surfaces. For this reason, the width of the pair of polishing blades is fixed and polishing is performed between the pair of polishing blades, so that variations in the width of the coil component can be suppressed.

  The coil corresponding to the side surface of the coil component body corresponding to the side surface other than the one side surface of the prismatic body and the end surface of the prismatic body after the polishing step and before the plating step It is preferable to chamfer at least one of the side portions connecting the end surfaces of the component main body.

  The side connecting the side surface of the coil component body corresponding to the side surface other than one side surface of the prismatic body and the end surface of the coil component body corresponding to the end surface of the prismatic body after the polishing step and before the plating step In order to chamfer at least one side of the part, the plating formed by the plating process is prevented from projecting in a direction perpendicular to the side surface of the coil component body polished by the polishing process. can do. For this reason, when a coil component is mounted on the mounting substrate, it is possible to prevent the plating from coming into contact with other components or the like disposed adjacent to the side surface other than the one side surface, thereby achieving higher density mounting. be able to.

  In addition, the coil conductor is made of a conductive wire, and in the coil component body preparation step, the core part connection surface, four side surfaces connected to the core part connection surface, and the core part connection surface connected to the four side surfaces. And a pair of substantially rectangular parallelepiped ridges each having an end surface facing each other, and a core portion in which both end portions in the axial direction are respectively connected to the core portion connection surfaces of the pair of ridge portions. A step of preparing a core in which the four side surfaces of one of the collar portions are in a substantially parallel relationship with the four side surfaces of the other collar portion, and the end surface and the four side surfaces of the collar portion. A step of providing a base electrode, winding the conductive wire around the core, and connecting one end and the other end of the conductive wire to the base electrode on the first side surface of the four side surfaces of the pair of flanges. A step of electrically connecting each one, and the core portion in which the conductive wire is wound by filling a resin between the pair of flange portions It is preferable to produce a coil component body having angular pillar shape of a substantially rectangular prism shape by then molded into a substantially rectangular prism shape performing a step of molding the outer package made of a resin mold to cover.

  In the coil component body preparation step, a pair of substantially rectangular parallelepiped shapes each having a winding core connecting surface, four side faces connected to the winding core connecting face, and end faces connected to the four side faces and facing the winding core connecting face And a core part in which both axial ends are respectively connected to the core part connection surfaces of the pair of collar parts, and the four side surfaces of one collar part are of the other collar part. A step of preparing a core having a substantially parallel positional relationship with each of the four side surfaces, a step of providing a base electrode on the end surface and the four side surfaces of the flange portion, winding a conducting wire around the core portion, The step of electrically connecting one end and the other end of the conducting wire to the underlying electrode on the first side surface among the four side surfaces, respectively, and filling the resin between the pair of flanges and winding the conducting wire Molding into a substantially quadrangular prism shape so as to cover the wound core, and forming an exterior body made of resin mold In order to manufacture a coil component body having a substantially quadrangular prism-shaped body by performing the steps, plating is pulled by polishing at the side of the heel part where the side face and end face of the buttock are connected Therefore, it is possible to prevent a part of the plating from being peeled off from the drum core substrate or from being scratched. In addition, since the base electrodes on the side surfaces other than the first side surface among the four side surfaces of the collar portion are all removed, it is possible to suppress the occurrence of a counter electromotive force of the closed magnetic circuit as much as possible in the terminal electrode, Thus, it is possible to manufacture a coil component capable of obtaining the inductor characteristics.

  The resin mold preferably has a mark portion for recognizing the position of the connecting portion. Since the resin mold has the mark portion, it is possible to recognize the position of the connecting portion and identify the electrical connection location between the conducting wire and the base electrode.

  Moreover, it is preferable that this mark part is arrange | positioned in the part of this resin mold of the side surface of this coil component main body corresponding to side surfaces other than this 1st side surface.

  Since the mark portion is disposed in the resin mold portion on the side surface of the coil component body corresponding to the side surface other than the first side surface, the mark portion can be removed by a polishing process, and the mark portion is formed on the surface of the coil component. When it is unnecessary, the mark portion does not have to remain on the coil component surface.

  Further, the axial center position of the core portion in the coil component main body is the thickness by which the side surface of the coil component main body corresponding to the second side surface facing the first side surface is polished in the polishing step. It is preferable that the first side surface is biased.

  The axis of the winding core portion of the coil component body is biased toward the first side surface by the thickness of the side surface of the coil component body corresponding to the second side surface facing the first side surface, which is polished in the polishing process. Therefore, the thickness of the second side surface of the resin mold covering the core portion in the coil component can be made the same as the thickness of the first side surface, and the first side surface side is also the first side. Similarly to the side surface side, a resin mold having a sufficient thickness can be obtained.

  In addition, the present invention provides a coil component that is manufactured by the above-described method for manufacturing a coil component, and the entire base electrode is plated so that the base electrode is not exposed to the outside.

  The coil component is manufactured by the above-described method for manufacturing a coil component, and the entire base electrode is plated so that the base electrode is not exposed to the outside. Therefore, the base electrode can be protected by plating. Further, it is possible to prevent a part of the plating from being peeled off from the drum core substrate or from being scratched. In addition, since all the base electrodes on all the side surfaces other than the one side surface are removed, it is possible to suppress the occurrence of the counter electromotive force of the closed magnetic circuit in the terminal electrode as much as possible, and a predetermined inductor characteristic can be obtained. It can be a coil component.

  As described above, the present invention provides a coil component manufacturing method for preventing plating from being peeled off from the drum core substrate or scratching, and a coil component manufactured by the coil component manufacturing method. Can do.

The perspective view which shows the coil components by the 1st Embodiment of this invention. Sectional drawing which shows the coil components by 1st Embodiment of this invention. It is a figure which shows the manufacturing method of the coil components by embodiment of this invention, (a) is a perspective view which shows the state which started grinding | polishing the main surface in a grinding | polishing process, (b) grind | polished the main surface in a grinding | polishing process. The perspective view which shows the state which started and finished, (c) is a perspective view which shows the state of the main surface after grinding | polishing. (D) is a perspective view showing a state in which the side surface adjacent to the main surface is started to be polished in the polishing step, (e) is a perspective view showing a state in which polishing of the side surface adjacent to the main surface is finished in the polishing step, (f) ) Is a perspective view showing a state of a side surface adjacent to the main surface after polishing. It is a figure which shows the coil components by 2nd Embodiment of this invention, (a) is a disassembled perspective view, (b) is a perspective view. The perspective view which shows the modification of the coil components by the 1st Embodiment of this invention.

  A method for manufacturing a coil component and a coil component according to a first embodiment of the present invention will be described. First, the coil component manufactured by the manufacturing method of a coil component is demonstrated based on FIG. 1, FIG. Specifically, the coil component is an inductor component used in a portable small electronic device or the like. As shown in FIG. 2, the coil component 1 includes a core 10, a winding 30, a terminal electrode 40, The resin part 60 is provided. The coil component 1 has a substantially rectangular parallelepiped shape as a whole, and dimensions corresponding to the X-axis direction, the Y-axis direction, and the Z-axis direction described later are about 2.5 mm, 1.5 mm, and 1.2 mm, respectively.

  The core 10 is made of a magnetic material (for example, ferrite). The core 10 is a so-called drum core having a winding core portion 11 and a pair of flange portions 15 and 15. Hereinafter, the axial direction of the core part 11 is the X-axis direction, the directions orthogonal to the axial direction of the core part 11 and from the front side to the back side of the paper surface of FIG. 2 are the Y-axis direction, the X-axis direction, and the Y-axis direction. A direction orthogonal to the axial direction will be described as the Z-axis direction. In addition, the coil component 1 has a symmetrical shape in the X-axis direction around the center position in the X-axis direction of the winding core portion 11, and unless otherwise specified, the pair of flange portions 15, 15 is one of the flange portions 15. The description about the other flange 15 is omitted.

  The winding core 11 has a substantially quadrangular prism shape whose axis extends in the X-axis direction. One end and the other end of the core part 11 are respectively connected to inner surfaces 21 described later of the pair of flange parts 15 and 15, and connect the pair of flange parts 15 and 15 to each other. One winding 30 is wound around the core part 11. As the winding 30, for example, a copper wire with a surrounding insulation coating can be used. The copper wire constituting the winding 30 corresponds to a coil conductor.

  The pair of flange portions 15 and 15 are provided at both ends of the core portion 11 in the X-axis direction, and the flange portion 15 is formed integrally with the core portion 11. The collar portion 15 has a substantially rectangular parallelepiped shape, and has first to fourth side surfaces 16 to 19, an outer surface 20, and an inner surface 21 as shown in FIG. 1. The outer surface 20 corresponds to an end surface, and the inner surface 21 corresponds to a winding core connecting surface. The first side surface 16 and the second side surface 17 of the flange portion 15 face each other in the Z-axis direction. The third side surface 18 and the fourth side surface 19 of the flange portion 15 face each other in the Y-axis direction. Further, the outer surface 20 and the inner surface 21 of the flange portion 15 face each other in the X-axis direction. The first to fourth side surfaces 16 to 19, the outer surface 20, and the inner surface 21 constitute an outer surface that defines the contour of the flange 15. Further, the four side surfaces 16 to 19 of the one flange portion 15 are flush with the four side surfaces 16 to 19 of the other flange portion 15, respectively.

  The outer surface 20 forms an end surface of each of the pair of flange portions 15 in the X-axis direction. When the coil component 1 is mounted on a circuit board (not shown), the first side surface 16 forms a mounting surface facing the electrode pattern on the surface of the circuit board (not shown) and is parallel to the surface of the circuit board (not shown). It is comprised so that it may make.

  The terminal electrode 40 has an end face facing portion 41 provided so as to face the outer surface 20 over the entire surface of the outer surface 20 and a mounting provided so as to face the first side surface 16 over the entire surface of the first side surface 16. It is comprised only with the surface opposing part 42. FIG. The end surface facing portion 41 has a base electrode 41A and an upper electrode 41B, and the mounting surface facing portion 42 has a base electrode 42A and an upper electrode 42B. At the side where the first side surface 16 and the outer surface 20 are connected, the base electrode 41A and the base electrode 42A are connected, and the upper electrode 41B and the upper electrode 42B are connected to each other, so that the end surface facing portion 41 and the mounting surface facing portion 42 are connected. As described above, the terminal electrode 40 is provided on the entire outer surface 20, the entire first side surface 16, and a part of the bottom surface 60 </ b> A of the resin portion 60. It is provided only on the top and on the entire first side surface 16.

  The base electrode 41 </ b> A is provided on the outer surface 20 by baking Ag over the entire surface. In the upper electrode 41B, an Ag layer is formed over the entire surface of the base electrode 41A in this order by dipping, an Ni layer is formed on the entire surface of the Ag layer by plating, and Sn is plated on the entire surface of the Ni layer. Is provided. A part of the base electrode 41A and the edge in the positive direction of the Z-axis are covered with the top electrode 41B and are not exposed to the outside. Similarly, the edge of the base electrode 41A in the Y-axis plus direction and the minus direction is covered with the upper electrode 41B and is not exposed to the outside. Accordingly, the entire base electrode 41A is plated.

  The base electrode 42A is provided by baking Ag over the entire surface of the first side surface 16 and a part of the bottom surface 60A of the resin portion 60 described later. In the upper electrode 42B, an Ag layer is formed in this order by dipping over the entire surface of the base electrode 42A and a part of a bottom surface 60A of the resin portion 60 described later, and an Ni layer is formed on the entire surface of the Ag layer by plating. In addition, Sn is plated on the entire surface of the Ni layer. A part of the base electrode 42A and the edge portions in the Y-axis plus direction and the minus direction are covered with the top electrode 42B and are not exposed to the outside. Therefore, the upper electrode 42B is processed on the entire lower electrode 42A.

  The base electrode 42A that forms a part of the mounting surface facing portion 42 on the one flange 15 is connected to one end 30A (FIG. 2) of the winding 30 before the Ag layer and the Ni layer of the top electrode 42B are formed. A copper wire, which will be described later, is fixed by thermocompression bonding and electrically connected to each other to form a connecting portion. The copper wire constituting one end 30A of the winding 30 is covered with the upper electrode 42B at the connecting portion, is not exposed to the outside, and is sandwiched between the upper electrode 42B and the lower electrode 42A It has become a relationship. Similarly to the base electrode 42A, the base electrode 42A that forms part of the mounting surface facing portion 42 of the other flange 15 is also electrically connected with a later-described copper wire constituting the other end 30B of the winding 30. The connecting portion is an area connected to and connected to.

  As shown in FIGS. 1 and 2, the resin portion 60 wraps around the core portion 11 around which the winding 30 is wound so as to be filled between the inner surfaces 21 of the pair of flange portions 15 and 15. It is provided to cover. The resin part 60 is configured by mixing ferrite powder with resin.

  The surface of the resin part 60 has a bottom surface 60A, an upper surface 60B, a first side surface 60C, and a second side surface (not shown). The upper surface 60B is located between the second side surface 17 of the one flange portion 15 and the second side surface 17 of the other flange portion 15, and is connected to the second second side surfaces 17 and 17 so as to connect the second side surfaces 17 and 17. The side surfaces 17 and 17 are flush with each other. 60 C of 1st side surfaces are located between the 3rd side surface 18 of the one collar part 15, and the 3rd side surface 18 of the other collar part 15, and connect these two 3rd side surfaces 18 and 18. The third side surfaces 18 and 18 are configured to be flush with each other. The second side surface (not shown) is located between the fourth side surface 19 of the one flange portion 15 and the fourth side surface 19 of the other flange portion 15, and connects these two fourth side surfaces 19, 19. Thus, the fourth side surfaces 19 and 19 are configured to be flush with each other.

  As described above, the coil component 1 is provided with the upper electrodes 41B and 42B by plating the entire lower electrodes 41A and 42A so that the lower electrodes 41A and 42A are not exposed to the outside. The base electrodes 41A and 42A can be protected by the electrodes 41B and 42B. In addition, since the base electrode is not present on the outer surface of the collar other than the fourth side face 19 and the first side face 16, it is possible to generate a counter electromotive force of the closed magnetic circuit in the terminal electrode 40 as much as possible. The coil component 1 can be suppressed and can obtain predetermined inductor characteristics.

  The manufacturing method of the coil component is as follows. First, a coil component body preparation process is performed. In the coil component body preparation step, first, the core 10 including the core portion 11 and the pair of flange portions 15 and 15 is prepared. Next, an Ag paste is applied to the entire outer surface 20 and side surfaces 16 to 19 of the flange 15 by dipping (dipping) and then dried to form an Ag film that partially becomes the base electrodes 41A and 42A. Next, the winding wire 30 is wound around the winding core portion 11, and the copper wire constituting one end 30 </ b> A and the other end 30 </ b> B of the winding wire 30 is connected to the base electrode 42 </ b> A on the first side surfaces 16, 16 of the flange portions 15, 15. Thermocompression bonded onto 42A.

  Next, a resin portion 60 made of a resin mold having a quadrangular prism shape is formed. The resin part 60 corresponds to an exterior body. The resin portion 60 is formed by a pair of flange portions 15, 15 using a mold by transfer molding so as to cover and cover the winding 30 wound around the core portion 11 between the pair of flange portions 15, 15. It is carried out by filling the resin between. The coil component main body 1 ′ (FIG. 3) having a substantially quadrangular prism-shaped prism body having two end surfaces and four side surfaces connecting the two end surfaces is manufactured by the above process. Here, the prismatic body has a winding 30 as a coil conductor, and the winding 30 is packaged with a resin mold constituting the resin portion 60, and the resin mold forms a part of the outer shell. It refers to what constitutes the component main body 1 ′, and refers to a state where the base electrodes 41 </ b> A and 42 </ b> A are not yet formed. Next, an Ag layer is formed by dipping on the base electrodes 41A and 42A so as to cover the thermocompressed portions of the copper wires constituting the one end 30A and the other end 30B of the winding 30. The above is the coil component body preparation step.

  Next, a polishing process is performed. In the polishing step, as shown in FIGS. 3A and 3B, a second side surface of the four side surfaces of the coil component main body 1 ′ is obtained by a polishing blade 1001 having a substantially cylindrical shape provided on the dicer. 17 and the side surface 1′A (upper surface in FIG. 3A) to be the upper surface 60B of the resin portion 60 are polished. The side surface 1′A corresponds to the main surface, and the surface 1′B opposite to the main surface 1′A corresponds to the anti-main surface. The length of the peripheral surface 1001A of the polishing blade 1001 in the axial direction of the polishing blade 1001 is longer than the width of the main surface 1′A in the longitudinal direction.

  At the time of polishing, the main blade 1′A is placed on the support member with the anti-main surface 1′B in contact with the upper surface of the support member (not shown), and the polishing blade 1001 is placed on the main surface 1′A. Polishing is performed by contacting the peripheral surface 1001A. At this time, a plurality of coil component bodies 1 ′ are arranged in a positional relationship in which the longitudinal directions thereof are parallel to each other, and adjacent coil component bodies 1 ′ are separated from each other at a predetermined interval. Polishing is performed on each main surface 1′A of the coil component main bodies 1 ′ arranged in this way. Since the coil parts main body 1 ′ is disposed at a predetermined interval in this way, the main surface 1 ′ A is polished from one end side to the other end side in the longitudinal direction of the main surface 1 ′ A. In addition, the main surface 1′A of the other coil component main body 1 ′ arranged next to the one coil component main body 1 ′ is not polished. By this polishing, as shown in FIG. 3C, a part of the resin mold and the base electrode on the main surface 1′A are all removed to form the upper surface 60B of the resin portion 60, and the second The entire side surface 17 is exposed.

  In this way, the main surface 1'A is polished with the anti-main surface 1'B in contact with the upper surface of the support member (not shown) and the coil component body 1 'is placed on the support member. Thus, polishing can be performed stably, and therefore polishing can be performed reliably. Also, since the length of the peripheral surface 1001A of the polishing blade 1001 in the axial direction of the polishing blade 1001 is longer than the width of the main surface 1′A in the longitudinal direction, one end of the main surface 1′A in the longitudinal direction is formed. The main surface 1'A can be polished by sliding once from the side to the other end side. Therefore, the polishing blade 1001 does not need to touch the main surface 1′A many times, and the finish and reliability of the main surface 1′A can be improved.

  Next, the coil component main body 1 ′ is rotated by 90 ° about its axis, and becomes the fourth side surface 19 of the four side surfaces of the coil component main body 1 ′ and the second side surface (not shown) of the resin portion 60. The side surface 1′C is placed on a support member (not shown) so as to be the upper surface as shown in FIGS. 3 (d) and 3 (e). The side surface 1′C corresponds to one of a pair of opposed surfaces. Then, the side surface 1′C is polished by bringing the peripheral surface 1001A of the polishing blade 1001 having a substantially cylindrical shape into contact with the side surface 1′C. As a result, as shown in FIG. 3 (f), a part of the resin mold on the side surface and all of the base electrode are removed, and a second side surface (not shown) of the resin portion 60 is formed. The entire side surface 19 is exposed.

  Next, the coil component main body 1 ′ is rotated by 180 ° about the axis thereof, and the side surfaces that become the third side surface 18 and the first side surface 60C of the resin portion 60 among the four side surfaces of the coil component main body 1 ′ are set. It mounts on the support member which is not illustrated so that it may become an upper surface. The side surface corresponds to the other of the pair of opposed surfaces. Then, the side surface is polished by bringing the peripheral surface 1001A of the polishing blade 1001 having a substantially cylindrical shape into contact with the side surface 1′C. As a result, a part of the resin mold on the side surface and the entire base electrode are removed, the first side surface 60C of the resin portion 60 is formed, and the entire third side surface 18 is exposed. The above is the polishing process.

  Next, barrel polishing is performed to remove the edge generated at the edge of the coil component body 1 ′ that has undergone the polishing process. Next, a Ni layer is formed on the base electrodes 41A and 42A by a plating process by electrolytic plating, and a Sn plating process by electrolytic plating is further formed thereon to form a Sn plating layer on the surface of the Ni layer. A plating step for forming the upper electrodes 41B and 42B is performed. The coil component 1 is manufactured through the above steps.

  As described above, since the coil component manufacturing method includes the coil component body preparation step, the polishing step, and the plating step, the upper electrodes 41B and 42B to be plated by the polishing process are not pulled, and the upper electrode It can prevent that 41B and a part of 42B will be in the state peeled from the drum core base | substrate which comprises the collar part 15, or a crack.

  Next, a coil component according to a second embodiment will be described with reference to FIG. The coil component 101 according to the second embodiment is a multilayer electronic component in which a plurality of insulating layer forming green sheets 1a to 1m are stacked and fired. The coil component 101 has a quadrangular prism shape having a pair of end faces 101A and 101A and four side faces 101B to 101E connecting the pair of end faces 101A and 101A. The coil component 101 includes a laminated component main body portion 111 and a terminal electrode 140 having a substantially rectangular parallelepiped shape whose outer shape is a quadrangular prism shape.

  The terminal electrode 140 is provided on the entire surface of both end surfaces 111A and 111A of the multilayer component main body 111 and a part of the lower surface 111B and closer to both end surfaces. The terminal electrode 140 includes a base electrode formed by applying and baking a conductive paste made of silver paste by dipping or the like, and electroplating on the base electrode so as to cover the entire base electrode so that the base electrode is not exposed to the outside. It is comprised by the plating 140A formed by giving. As electroplating, copper and nickel and tin, nickel and gold, nickel and palladium and gold, nickel and palladium and silver, nickel and silver, or the like is used.

  As shown in FIG. 4A, the laminated component body 111 is a sheet for forming an insulating layer in which, for example, magnetic powder or non-magnetic powder having a low dielectric constant is mixed with a binder or a plasticizer to form a sheet. Sheets 1a to 1m are laminated and fired. Insulating layer forming green sheets 1c to 1d are provided with coil conductors 2, 2a and 2b, and the coil conductors 2, 2a and 2b have a U-shape (3/4 turn) as shown in FIG. ) And the like. Conductor filled through holes 4 are provided at the ends of the coil conductors 2, 2a, 2b. The insulating layer forming green sheets 1a, 1b, 1k, and 1m are provided with a conductor-filled through hole 4 at the center and an extraction electrode 5A so as to cover the through hole 4.

  The coil conductors 2, 2a, 2b and the extraction electrode 5A on the insulating layer forming green sheets 1a to 1m are provided by printing a conductor paste containing metal powder such as silver or an alloy thereof. Similarly, the conductor constituting the through hole 4 is formed by filling a through hole formed in the insulating layer forming green sheet 1a or the like with a conductive paste containing metal powder such as silver or an alloy thereof.

  In the coil component main body preparation step of the coil component manufacturing method, first, the laminated component main body 111 is manufactured as follows. In the actual manufacturing process, a large insulating layer-forming green sheet is used and cut before baking, which will be described later, to simultaneously manufacture a multilayer body portion 111 of a large number of multilayer electronic components. A process for manufacturing the body main body 111 will be described. First, as shown in FIG. 4A, a plurality of insulating layer forming green sheets 1c to 1j are laminated. At this time, the coil conductors 2, 2a and 2b of the insulating layer forming green sheets 1c to 1j adjacent to each other in the stacking direction are electrically connected through the through holes 4, and the coil conductors 2, 2a and 2b are spiraled as a whole. To be in a state of being shaped.

  At the same time, the insulating layer forming green sheets 1c to 1j are further laminated with insulating layer forming green sheets 1a and 1b on the left side in the stacking direction shown in FIG. Green sheets 1k and 1m are further laminated. Further, from the left side in the laminating direction, the transfer is performed by the film 6 to which the conductive paste serving as the lead electrode 5A covering the central portion of the left surface of the insulating layer forming green sheet 1a is applied, and the lead electrode 5A is transferred to the insulating layer forming green. It is provided in the central portion of the left surface of the sheet 1a. These laminated green sheets 1a to 1m for forming an insulating layer are pressure-bonded, cut into a predetermined shape and fired. The laminated component body 111 is manufactured through the above steps.

  Next, a conductive paste is deposited by dipping or the like on the entire surface of both end surfaces 111A and 111A of the multilayer component main body 111 and both end surfaces 111A and 111A of the four side surfaces 111B to 111E to form a base electrode. Thus, the coil component body is manufactured. The above is the coil component body preparation step.

  Next, a polishing process is performed as in the first embodiment. In the polishing step, the surface that becomes the side surfaces 101C, 101D, and 101E other than the end surface and the lower surface of the coil component body corresponding to the both end surfaces 101A and 101A and the lower surface 101B of the coil component 101 shown in FIG. 4B by the polishing blade 1001. To polish. As a result, the terminal electrode 140 is provided on the entire surface of both end surfaces 111A and 111A of the multilayer component main body 111 and a portion of the lower surface 111B shown in FIG. 4B and in the vicinity of both end surfaces 111A and 111A. It is assumed that Next, a plating process is performed in which electroplating is performed on the base electrode to provide plating 140A as the top electrode. The coil component 101 is manufactured through the above steps.

  The coil component and the method for manufacturing the coil component according to the present invention are not limited to the above-described embodiments, and various modifications and improvements can be made within the scope described in the claims. For example, after the polishing step and before the plating step, connect the side surface of the coil component body corresponding to the side surface other than one side surface of the prismatic body and the end surface of the coil component body corresponding to the end surface of the prismatic body. You may chamfer the part of at least 1 side of the part of the side to perform.

  Specifically, for example, after the polishing process and before the plating process, as shown in FIG. 5, chamfer the side portion that forms the connection position between the main surface 1 ′ A and the end surface of the coil component body. A chamfered portion 201a is provided. Thus, even if the upper end of the upper electrode 41B formed by the plating process after chamfering is formed in a state where it slightly extends upward from the chamfered portion 201a, the upper end of the upper electrode 41B is It is possible to prevent the coil component 201 from protruding upward from the upper surface. For this reason, when the coil component 201 is mounted on a mounting substrate (not shown), the upper end of the upper electrode 41B is in contact with a sheet (not shown) or other components that are disposed adjacent to the upper surface of the coil component 201. This can be prevented, and higher-density mounting can be achieved.

  In this embodiment, one polishing blade 1001 is used. However, a pair of polishing blades arranged to face each other may be used. For example, the distance between the pair of polishing blades is fixed to be substantially the same as the width of the coil component 1 in the Y-axis direction, and is brought into contact with the pair of opposed surfaces of the coil component body 1 ′ in the Y-axis direction. Polishing may be performed at the same time. By doing in this way, the dispersion | variation in the width | variety of the coil component 1 in a Y-axis direction can be suppressed.

  Moreover, the resin mold which comprises the resin part 60 may have the mark part for recognizing the position of a connection part. For example, the mark portion is formed on the surface of the resin portion 60 that is polished in the polishing step, that is, the upper surface 60B, the first side surface 60C, or the second side surface (not shown) of the resin portion 60.

  With this configuration, the position of the connecting portion can be recognized, and the electrical connection location between the winding 30 and the base electrodes 41A and 42A can be identified. Further, the mark portion can be removed by the polishing process, and when the mark portion is unnecessary on the surface of the coil component 1, it is not necessary to leave the mark portion on the surface of the coil component 1.

  Further, the axis of the core part 11 in the coil component main body 1 ′ may be arranged so as to be biased toward the bottom surface 60 </ b> A of the resin part 60 by the thickness by which the main surface is polished in the polishing process. Accordingly, the thickness of the upper surface 60B side of the resin portion 60 covering the core portion 11 in the coil component can be made the same as the thickness of the bottom surface 60A side, and the thickness on the upper surface 60B side is also sufficient as the bottom surface 60A side. It can be set as the resin part 60 in which is secured.

  In the polishing step, the polishing blade 1001 having a substantially cylindrical shape provided in the dicer is used, but the means for polishing is not limited to this.

  Moreover, although the core 10 was comprised from the magnetic body (for example, ferrite etc.), it is not limited to this. For example, the core may be made of a nonmagnetic material such as ceramic.

  Moreover, although the resin part 60 was comprised from the insulator material formed by mixing a ferrite powder with an epoxy resin, it is not limited to this, For example, the ferrite powder does not need to be mixed.

  Moreover, although the conductor was comprised with the copper wire which comprises the coil | winding 30, it is not limited to this, What is necessary is just a conductor arrange | positioned at the core part corresponded at least to the core part 11, and having one end and the other end. Therefore, the conductor does not have to be wound around the core. Further, the number of windings 30 is not limited to one and may be a plurality.

  The present invention is particularly useful in the field of inductor components used particularly in small portable electronic devices and the like.

DESCRIPTION OF SYMBOLS 1, 101, 201 Coil component 1 'Coil component main body 1'A Main surface 1'B Anti-main surface 1'C, 1'D A pair of opposing surface 11 Core part 15 Collar part 16 First side surface 17 2nd Side surface 18 Third side surface 19 Fourth side surface 20 Bottom surface 21 Upper surface 30 Winding 30A One end 30B Other end 41A, 42A Base electrode 41B, 42B Top electrode 60 Resin portion 201a Chamfered portion 1001 Polishing blade

Claims (10)

End portions of both end portions in the axial direction of the prismatic body and at least both end portions in the axial direction of the side surfaces of the prismatic body having a coil conductor and at least the coil conductor being sheathed by the exterior body. A coil part body preparation step of preparing a coil part body that forms a connecting portion to which the coil conductor is electrically connected;
By polishing the base electrode and a part of the exterior body over the entire side surface of the coil component body corresponding to all the side surfaces other than the one side surface of the prismatic body, all the surfaces other than the one side surface are polished. A polishing step of removing all the underlying electrodes on the side surfaces;
And a plating step of performing a plating process on the base electrode. The side surface of the coil component body corresponding to one of the side surfaces other than the one side surface of the prismatic body forms a main surface, and the side surface on the opposite side of the coil component body with respect to the main surface is the anti-main surface. ,
2. The polishing step according to claim 1, wherein the main surface is polished in a state where the anti-main surface is brought into contact with the upper surface of the support member and the coil component main body is placed on the support member. Manufacturing method of coil parts. In the polishing step, the polishing blade is rotated in a state in which the axis of the polishing blade having a substantially cylindrical shape and rotatable about the axis is maintained perpendicular to the longitudinal direction of the main surface and parallel to the main surface. The main surface is polished by sliding the peripheral surface of the polishing blade from one end side to the other end side in the longitudinal direction of the main surface,
The method of manufacturing a coil component according to claim 2, wherein the length of the peripheral surface of the polishing blade in the axial direction of the polishing blade is longer than the width of the main surface. The side surface of the coil component body has a pair of opposing surfaces in addition to the anti-main surface and the main surface,
3. The method of manufacturing a coil component according to claim 2, wherein in the polishing step, a pair of polishing blades arranged opposite to each other are brought into contact with the pair of opposing surfaces, and the pair of opposing surfaces are simultaneously polished.   After the polishing step and before the plating step, the side surface of the coil component body corresponding to the side surface other than the one side surface of the prismatic body and the coil component body corresponding to the end surface of the prismatic body 5. The method of manufacturing a coil component according to claim 1, wherein at least one of the side portions connecting the end surfaces of the coil parts is chamfered. The coil conductor is made of a conductive wire,
In the coil component main body preparation step, a pair of core portions connecting surfaces, four side surfaces connected to the core portion connecting surfaces, and end surfaces connected to the four side surfaces and facing the core portion connecting surfaces, respectively. A hook portion having a substantially rectangular parallelepiped shape, and a core portion having both axial ends connected to the core portion connecting surfaces of the pair of hook portions, respectively, A step of preparing a core whose side surface has a substantially parallel positional relationship with the four side surfaces of the other flange portion;
Providing a base electrode on the end surface and the four side surfaces of the flange;
The conductive wire is wound around the core portion, and one end and the other end of the conductive wire are electrically connected to the base electrode on the first side surface of the four side surfaces of the pair of flange portions, respectively. Connecting, and
Performing a step of filling the resin between the pair of collars and molding the exterior body made of a resin mold by molding into a substantially quadrangular prism shape so as to cover the core portion around which the conductive wire is wound. The method of manufacturing a coil component according to any one of claims 1 to 5, wherein a coil component main body having the substantially rectangular column-shaped body is manufactured by the method described above.   7. The method of manufacturing a coil component according to claim 6, wherein the resin mold has a mark portion for recognizing the position of the connecting portion.   8. The method of manufacturing a coil component according to claim 7, wherein the mark portion is disposed in the resin mold portion on a side surface of the coil component body corresponding to a side surface other than the first side surface.   The axial center of the winding core portion of the coil component body has the first thickness corresponding to the thickness at which the side surface of the coil component body corresponding to the second side surface facing the first side surface is polished in the polishing step. The method of manufacturing a coil component according to any one of claims 6 to 8, wherein the coil component is arranged so as to be biased toward a side surface of the coil component.   A coil component manufactured by the method for manufacturing a coil component according to claim 1, wherein the entire base electrode is plated so that the base electrode is not exposed to the outside.

Images