JP2018046117A - Coil component and coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an easy-to-transport and easy-to-handle coil component having sufficient strength, in which short-circuit fault is less likely to occur, and to provide a coil device having the coil component.SOLUTION: A coil component 6 includes a first conductivity plate piece 6a having a two-dimensional first prescribed pattern 7a, a second conductivity plate piece 6b having a two-dimensional second prescribed pattern 7b, and at least an intermediate insulation base material 16m out of a surface layer base material 16s and the intermediate insulation base material 16m. The first conductivity plate piece 6a and the second conductivity plate piece 6b are arranged in the lamination direction. At a first inside end 8a, a first inside convex part 9a is formed to project in the lamination direction from the two-dimensional plane of the first prescribed pattern 7a. The first inside convex part 9a is connected electrically with a second inside end 8b. The first conductivity plate piece 6a and the second conductivity plate piece 6b are integrated via the intermediate insulation base material 16m.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a coil device used as an inductor, for example, and a coil component disposed inside the coil device.

  Various electronic devices are equipped with many coil devices used as inductors. As an example of such a coil device, for example, a coil device shown in Patent Document 1 has been developed. In the coil device shown in Patent Document 1, a pair of spiral conductive metal pieces are laminated, and the inner ends of the metal pieces are welded to each other and connected.

  However, in the conventional coil device, since each metal piece is thin and flat, it is difficult to sufficiently secure the strength of the coil component in which the inner ends of each metal piece are connected. If the strength of the coil component is insufficient, when the coil component is transported, or when the coil component is placed inside the mold and a granule containing magnetic powder is compressed to form a powder magnetic core Then, displacement and deformation occur in each metal piece. Further, when the above-mentioned granule contains metal alloy particles, the metal alloy particles may enter into the gaps between the metal pieces, which may cause problems such as short circuit failure.

JP 2004-327622 A

  The present invention has been made in view of such a situation, and an object of the present invention is to provide a coil component that has sufficient strength, is less likely to cause a short-circuit failure, is easy to transport and is easy to handle, and a coil device having the coil component. Is to provide.

In order to achieve the above object, the coil component according to the present invention comprises:
A first conductive plate having a first inner end and a first outer end and having a two-dimensional first predetermined pattern;
A second conductive plate piece having a second inner end and a second outer end and having a two-dimensional second predetermined pattern;
Of the plate surfaces of the first conductive plate piece and the second conductive plate piece, an insulating base material that covers at least the plate surface on the side where the first conductive plate piece and the second conductive plate piece face each other A coil component having
The first conductive plate piece and the second conductive plate piece are arranged in the stacking direction,
The first conductive plate piece and the second conductive plate piece are integrated via the insulating base material.

  In the coil component according to the present invention, among the plate surfaces of the first conductive plate piece and the second conductive plate piece, at least the plate surface on the side where the first conductive plate piece and the second conductive plate piece face each other is It is covered with an insulating substrate. Furthermore, the first conductive plate piece and the second conductive plate piece are integrated via an insulating base material.

  Thus, since the first conductive plate piece and the second conductive plate piece are integrated through the insulating base material to constitute the coil component, the first conductive plate piece and the second conductive plate piece. Becomes difficult to peel off, the strength is improved, and it is easy to carry and handle. Furthermore, when a coil part is placed inside a mold and a powder magnetic core is formed by compression molding of a granule containing magnetic powder or the like, it is difficult for each metal piece to be displaced or deformed. The sex plate pieces are kept horizontal to each other. For this reason, the dispersion | variation in the characteristic (inductance characteristic etc.) of a coil apparatus can be suppressed.

  Further, even when the above-mentioned granule contains metal alloy particles, the insulating base material functions as a protective layer, so that the metal alloy particles enter between the first conductive plate piece and the second conductive plate piece. Hateful.

  Further, among the plate surfaces of each conductive plate piece, the plate surface opposite to the side where the first conductive plate piece and the second conductive plate piece face each other is also covered with an insulating base material, so that each insulating group The conductive plate pieces can be more firmly integrated through the material. Moreover, the protection function of the coil component by an insulating base material also increases.

  Preferably, the first inner end is formed with a first inner protrusion that protrudes in the stacking direction from the two-dimensional plane of the first predetermined pattern, and the first inner protrusion is the second inner end. It is electrically connected to the part. With this configuration, the first inner convex portion and the second inner end portion are three-dimensionally connected between the first predetermined pattern and the second predetermined pattern. For this reason, a gap is formed between the predetermined patterns, and the conductive plate pieces can be integrated by interposing the insulating base material in the gap.

  Preferably, at least one of the first predetermined pattern and the second predetermined pattern is a spiral pattern. With this configuration, the number of turns of the coil component can be increased.

  Preferably, the first inner end portion and the second inner end portion are arranged at positions spaced radially outward from the center of the spiral pattern. By comprising in this way, when a 1st electroconductive board piece and a 2nd electroconductive board piece are laminated | stacked, a hollow part is formed in a coil component and a core can be arrange | positioned in this hollow part. Thereby, the inductance of the coil device can be further increased, and the saturation current characteristic can be improved (the saturation current is increased). From the viewpoint of increasing the number of turns of the coil, the first inner end and the second inner end may be arranged at the center of the spiral pattern.

  Preferably, the insulating base material includes a resin, and the first conductive plate piece and the second conductive plate piece are integrated with the insulating base material via the resin. With such a configuration, the resin oozes out from the insulating base material and adheres to the first conductive plate piece and the second conductive plate piece and hardens. Therefore, each conductive plate piece is interposed through the resin. Can be firmly integrated. Moreover, since each electroconductive board piece hardens | cures and is covered with resin with which hardness was raised, the intensity | strength of coil components can further be raised. In addition, it is possible to effectively prevent each conductive plate piece from being peeled off from a compression molded body (core) such as a magnetic powder filled in the coil device.

  Preferably, the resin fills a pattern gap formed in either the first predetermined pattern or the second predetermined pattern. That is, the resin that has oozed out of the insulating base material is filled in a pattern gap formed in at least one of the first predetermined pattern and the second predetermined pattern. When the resin is cured, the first conductive plate piece and the second conductive plate piece can be more firmly integrated through the resin. Moreover, since the resin functions as a protective layer, the above-described metal alloy particles can be effectively prevented from entering the pattern gap.

  An external terminal piece may be formed integrally with the first outer end. The external terminal piece is a portion exposed to the outside from a sealing portion in a coil device described later. Since this portion is integrally formed with the first outer end portion, it is not necessary to separately connect the terminal pieces.

The coil component of the present invention is
A third conductive plate piece having a third inner end portion and a third outer end portion, having a two-dimensional third predetermined pattern, and arranged so as to be laminated with the second conductive plate piece;
It may further include an insulating base material that covers at least a plate surface of the third conductive plate piece on a side where the second conductive plate piece and the third conductive plate piece are opposed to each other. Good.

Preferably, the second outer end portion is formed with a second outer convex portion protruding in a stacking direction from a two-dimensional plane of the second predetermined pattern,
The second outer convex portion is electrically connected to the third outer end;
The second conductive plate piece and the third conductive plate piece are integrated via an insulating base material that covers the plate surface of the third conductive plate piece.

  With this configuration, the number of turns of the coil component can be further increased.

The coil component of the present invention is
A fourth conductive plate piece having a fourth inner end portion and a fourth outer end portion, having a four-dimensional fourth predetermined pattern, and being arranged to be laminated with the third conductive plate piece;
An insulating base material that covers at least a plate surface of the fourth conductive plate piece that faces the third conductive plate piece and the fourth conductive plate piece may be further included. Good.

Preferably, the third inner end is formed with a third inner protrusion that protrudes in the stacking direction from the two-dimensional plane of the third predetermined pattern,
The third inner convex portion is electrically connected to the fourth inner end portion;
The third conductive plate piece and the fourth conductive plate piece are integrated via an insulating base material that covers the plate surface of the fourth conductive plate piece.

  With this configuration, the number of turns of the coil portion can be further increased.

  A fourth external terminal piece may be formed integrally with the fourth outer end portion. A 4th external terminal piece is a part exposed outside from the sealing part in the coil apparatus mentioned later. Since this portion is integrally formed with the fourth outer end portion, it is not necessary to separately connect the terminal pieces.

  A plurality of pairs of the second conductive plate piece and the third conductive plate piece may be repeatedly stacked between the first conductive plate piece and the fourth conductive plate piece. Good. With this configuration, the number of turns of the coil component can be further increased.

  Preferably, at least one of the third predetermined pattern and the fourth predetermined pattern is a spiral pattern. With this configuration, the number of turns of the coil component can be further increased.

  The insulating base material includes a resin, and the second conductive plate piece and the third conductive plate piece are integrated with the insulating base material covering the plate surface of the third conductive plate piece via the resin. The third conductive plate piece and the fourth conductive plate piece may be integrated with an insulating base material that covers the plate surface of the fourth conductive plate piece. Also in this case, the same effect as that obtained when the first conductive plate piece and the second conductive plate piece are integrated with the insulating base material through the resin described above can be obtained.

  A second external terminal piece may be formed integrally with the second outer end portion. A 2nd external terminal piece is a part exposed outside from the sealing part in the coil apparatus mentioned later. Since this portion is integrally formed with the second outer end portion, there is no need to separately connect the terminal pieces.

  A coil device according to the present invention includes the coil component according to any one of the above and a sealing portion that covers a main part of the coil component. The sealing portion may be made of a magnetic substance-containing resin. The coil component of the present invention can be easily embedded in the sealing portion.

FIG. 1 is a schematic perspective view of a coil device according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view taken along line II-II of the coil device shown in FIG. FIG. 3A is a perspective view showing a process of manufacturing a coil component of the coil device shown in FIG. FIG. 3B is a perspective view showing a step subsequent to FIG. 3A. FIG. 3C is a perspective view showing a step subsequent to FIG. 3B. FIG. 3D is a schematic cross-sectional view taken along line IIID-IIID of the coil device shown in FIG. 3C. FIG. 4A is a schematic perspective view of a coil device according to another embodiment of the present invention. 4B is a schematic cross-sectional view taken along line IVB-IVB of the coil device shown in FIG. 4A. FIG. 5 is an exploded perspective view of a coil component of the coil device shown in FIG. 4A. FIG. 6A is a schematic perspective view of a coil device according to another embodiment of the present invention. 6B is a schematic cross-sectional view taken along the line VIB-VIB of the coil device shown in FIG. 6A. FIG. 7 is an exploded perspective view of a coil component of the coil device shown in FIG. 6A. FIG. 8 is a schematic perspective view of a coil device according to another embodiment of the present invention. FIG. 9 is an exploded perspective view of a coil component of the coil device shown in FIG.

  Hereinafter, the present invention will be described based on embodiments shown in the drawings.

First Embodiment As shown in FIG. 1, an inductor element 2 as a coil device according to an embodiment of the present invention includes a core portion (sealing portion) 4 as a compression molded body, and a coil inside the core portion 4. And a coil component 6 to be configured. The main part of the coil component 6 is covered by the core part 4. The main part of the coil component 6 is a part excluding the lead parts 17a and 17b and the external terminal pieces 12a and 12b exposed from the core part 4.

  As shown in FIG. 2, the coil component 6 includes a plurality of conductive plate pieces 6a and 6b stacked in the Z-axis direction (stacking direction). In the following embodiments, two first and second conductive plate pieces 6a and 6b are described as being laminated in the Z-axis direction to constitute the coil component 6, but the present invention is not limited to this.

  The first conductive plate piece 6a has a spiral-shaped (spiral) first predetermined pattern 7a on a two-dimensional plane including the X axis and the Y axis. The first predetermined pattern 7a is formed by forming a spiral first predetermined pattern gap 7a1 in the first conductive plate piece 6a. In the present embodiment, the first predetermined pattern gap 7a1 constitutes a spiral groove.

  The number of turns of the spiral first predetermined pattern 7a is not particularly limited, but is preferably 1/2 to 10 turns, and more preferably 1 to 5 turns. A first inner end 8a is formed at the inner end of the spiral first predetermined pattern 7a, and a first outer end 10a is formed at the outer end of the spiral pattern 7a. “Helix” is not only a square (including rectangle) spiral as seen from the Z-axis direction shown in the figure, but also a circular helix, elliptical helix, other curved shape, or other polygonal helix. including.

  The first outer end portion 10a is a portion located at the outer end of the spiral first predetermined pattern 7a. In the present embodiment, a first lead portion 17a is formed integrally with the first outer end portion 10a. As shown in FIG. 3B, the first lead portion 17a protrudes from the first outer end portion 10a in the radially outward direction of the spiral (in this embodiment, the X-axis direction). As shown in FIGS. 1 and 2, the first lead portion 17 a is bent in the Z-axis direction along the outer surface of the core portion 4.

  An external terminal piece 12a is formed integrally with the lead portion 17a. The external terminal piece 12a is formed integrally with the lead frame 14a shown in FIG. 3B, and the lead frame 14a is removed in a subsequent process. As shown in FIG. 2, the external terminal piece 12a is arranged on the lower surface 4B of the core portion 4, and as shown in FIG. 1, protrudes in the radial inner side direction (X-axis direction in this embodiment) of the spiral. Has a shape.

  In the present embodiment, the distal end portion of the first lead portion 17a that protrudes from the core portion 4 and is bent in the Z-axis direction is bent in the X-axis direction along the outer surface of the core portion 4, and the bent distal end portion is externally connected. It functions as the terminal piece 12a. Thus, the external terminal piece 12a is integrally formed with the first lead portion 17a, so that it is not necessary to connect the external terminal piece 12a separately. The external terminal piece 12a may be retrofitted to the first lead portion 17a by welding or the like.

  As shown in FIG. 3B, in the present embodiment, the first inner end portion 8a is a portion having a width wider than the pattern width of the spiral pattern 7a, and has a substantially square shape. The first inner end 8a is integrally formed with a first inner protrusion 9a that protrudes in the stacking direction (Z-axis direction) from the two-dimensional plane of the spiral pattern. The shape of the first inner end portion 8a is not limited to the illustrated example, and may be appropriately changed such as a circular shape. Moreover, you may change a shape suitably also about the 1st inner side convex part 9a. Moreover, you may change suitably the position of the 1st inner side convex part 9a within the area | region of the 1st inner side edge part 8a. Further, the first inner convex portion 9a may be configured to be retrofitted to the first inner end portion 8a.

  As shown in FIG. 3C, the second conductive plate piece 6b has a second predetermined pattern 7b that is spiral in a two-dimensional plane including the X axis and the Y axis. The second predetermined pattern 7b is formed by forming a spiral second predetermined pattern gap 7b1 in the second conductive plate piece 6b. In the present embodiment, the second predetermined pattern gap 7b1 constitutes a spiral groove.

  The spiral second predetermined pattern 7b is the same as the spiral first predetermined pattern 7a except that the spiral predetermined pattern 7a is a reverse spiral pattern from the inside to the outside. That is, as shown in FIG. 3B, the first predetermined pattern 7a has a left-handed spiral shape, and as shown in FIG. 3C, the second predetermined pattern 7b has a right-handed spiral shape. A second inner end portion 8b is formed at the inner end of the spiral second predetermined pattern 7b, and a second outer end portion 10b is formed at the outer end of the spiral pattern 7b.

  A lead portion 17b is integrally formed with the second outer end portion 10b, and an external terminal piece 12b is integrally formed with the lead portion 17b. The external terminal piece 12b is formed opposite to the external terminal piece 12a in the X-axis direction, and is connected to a lead frame 14b to be removed in a later process.

  As shown in FIG. 2, the second inner end portion 8b is the same as the first inner end portion 8a except that a convex portion corresponding to the first inner convex portion 9a is not integrally formed. . Therefore, in the second inner end portion 8b, the plate surface on the side where the first conductive plate pieces 6a are arranged has a flat shape. The gap in the Z-axis direction between the first predetermined pattern 7a and the second predetermined pattern 7b is preferably 10 to 100 μm, more preferably 30 to 60 μm. In addition, the said clearance gap can be controlled by adjusting the height of the Z-axis direction of the 1st inner side convex part 9a.

  Of the plate surfaces of the first conductive plate piece 6a and the second conductive plate piece 6b, at least the plate surface on the side where the first conductive plate piece 6a and the second conductive plate piece 6b face each other is an insulating substrate. Covered with. In the present embodiment, the insulating base material that covers the lower surface of the first conductive plate piece 6a and the upper surface of the second conductive plate piece 6b is referred to as a surface layer insulating base material 16s, and the upper surface of the first conductive plate piece 6a and the second conductive plate piece 6a. The insulating base material that covers the lower surface of the conductive plate piece 6b is referred to as an intermediate insulating base material 16m.

  In the example shown in FIG. 2, each plate surface of each conductive plate piece 6a and 6b is covered with a surface insulating base material 16s and an intermediate insulating base material 16m, respectively, but the surface insulating base material 16s is not essential, It may be omitted. In the present embodiment, these insulating base materials 16s and 16m are formed of a single layer, but may be formed of a plurality of layers.

  As shown in FIG. 1, the surface insulating base material 16 s and the intermediate insulating base material 16 m have the same size of the XY plane as the plate surfaces of the first conductive plate piece 6 a and the second conductive plate piece 6 b. However, the size of each insulating base material 16m and 16s may be smaller or larger than this.

  However, as shown in FIG. 2, openings are formed in the central portions of the insulating base materials 16s and 16m, specifically, the portions corresponding to the first inner end portion 8a and the second inner end portion 8b. Preferably it is. This is to make it easy to form the joint portion 9ab between the first conductive plate piece 6a and the second conductive plate piece 6b after mounting the surface insulating base material 16s and the intermediate insulating base material 16m. In addition, when the surface insulating base material 16s is mounted after the joint portion 9ab between the first conductive plate piece 6a and the second conductive plate piece 6b is formed, the central opening portion may not be provided.

  Since it is difficult to attach the intermediate insulating base material 16m after forming the joint portion 9ab between the first conductive plate piece 6a and the second conductive plate piece 6b, before forming the joint portion 9ab. It is preferable to attach between the first conductive plate piece 6a and the second conductive plate piece 6b. By providing the coil component 6 with the intermediate insulating base material 16m, the conductive paths 15 of the conductive plate pieces 6a and 6b constituting the coil component 6 can be insulated from each other. In the present embodiment, the cross-sectional shape of the conductive path 15 is a rectangle.

  Although it does not specifically limit as a material of each electroconductive board piece 6a and 6b, For example, Cu, Al, Fe, Ag, Au, those alloys, etc. are illustrated.

  Insulating base materials 16s and 16m are each composed of a resin sheet alone, a laminated sheet in which an adhesive resin is laminated on one or both sides of the resin sheet, or an adhesive resin-containing base material. At least the insulating base material 16m and the first conductive plate piece 6a, and the insulating base material 16m and the second conductive plate piece 6b are integrated via a resin contained in the insulating base material 16m. In addition, the resin contained in the insulating base material 16m is filled in the first predetermined pattern gap 7a1 and the second predetermined pattern gap 7b1.

  When the insulating base material 16s is provided, the insulating base material 16s and the first conductive plate piece 6a or the second conductive plate piece 6b are integrated with each other through a resin contained in the insulating base material 16s. ing. Further, the resin contained in the insulating base 16s may enter the first predetermined pattern gap 7a1 and the second predetermined pattern gap 7b1.

  The resin contained in the insulating base materials 16s and 16m is not particularly limited, but is a thermosetting resin such as an epoxy resin or a urethane resin, a thermoplastic resin such as an acrylic resin or an olefin resin, an acrylate radical polymer, Examples include ultraviolet curable resins such as epoxy cationic polymers, thermoplastic polyamide resins, and the like. The insulating base materials 16s and 16m preferably include a base material sheet having a uniform thickness even after heat treatment. As the base material sheet, a mesh-like base material sheet, a porous base material sheet, a woven fabric sheet is used. Or a nonwoven fabric sheet or a substrate sheet having holes formed therein is preferred.

  In the present embodiment, as shown in FIG. 2, the first inner convex portion 9a is electrically connected to the second inner end portion 8b to form a joint portion 9ab. The joint 9ab is formed near the center of the spiral patterns 7a and 7b. As described above, since an opening is formed in the central portion of the intermediate insulating base material 16m, the electrical connection between the first inner convex portion 9a and the second inner end portion 8b is made by the intermediate insulating base material 16m. There is no hindrance. The joint portion 9ab can be formed by overlapping the first inner convex portion 9a and the second inner end portion 8b in the stacking direction and irradiating the portion with laser.

  In the present embodiment, as shown in FIG. 3C, the above-mentioned joining is performed in a state where the lead frames 14a and 14b are attached to the conductive plate pieces 6a and 6b, respectively, and then the core portion shown in FIG. 4 may be formed, and thereafter the lead frames 14a and 14b may be removed by cutting or the like. Alternatively, the lead frames 14a and 14b may be removed by cutting or the like before the core portion 4 is formed. As shown in FIG. 2, in the present embodiment, the core portion 4 is configured to integrally cover the inner peripheral portion, the outer peripheral portion, and both ends of the winding shaft of the coil component 6.

  The core part 4 is formed by compression molding or injection molding a granule containing magnetic powder and a binder. Although it does not specifically limit as magnetic powder, Sendust (Fe-Si-Al; Iron-silicon-aluminum), Fe-Si-Cr (iron-silicon-chromium), permalloy (Fe-Ni), carbonyl iron system, Metallic magnetic powders such as carbonyl Ni-based, amorphous powder, and nanocrystal powder are preferably used.

  The particle size of the magnetic powder is preferably 0.5 to 50 μm. In the present embodiment, the magnetic powder is a metal magnetic particle, and the outer periphery of the particle is preferably coated with an insulating film. Examples of the insulating film include a metal oxide film, a resin film, and a chemical film such as phosphorus or zinc.

  However, the magnetic powder may be a ferrite magnetic powder such as Mn—Zn and Ni—Cu—Zn. The binder resin is not particularly limited, and examples thereof include epoxy resins, phenol resins, acrylic resins, polyester resins, polyimides, polyamideimides, silicon resins, and combinations thereof.

  In the present embodiment, the external terminal pieces 12a and 12b are integrally formed with either of the conductive plate pieces 6a or 6b constituting the coil component 6, and are larger than the pattern widths of the spiral patterns 7a and 7b. It has a large Y-axis direction width. The Y-axis direction width of the external terminal pieces 12 a and 12 b is preferably 30% to 100% of the Y-axis direction width of the core portion 4.

  In the present embodiment, the lower surface 4B of the core portion 4 is a mounting-side outer surface connected to a circuit board or the like, and is formed substantially parallel to a plane passing through the X axis and Y axis perpendicular to each other. Is substantially parallel to a Z axis perpendicular to a plane passing through the X axis and the Y axis. In the present embodiment, the upper surface 4A of the core portion 4 is a non-mounting side outer surface that is substantially parallel to the lower surface 4B, and the four side surfaces 4C are substantially perpendicular to the upper surface and the lower surface. However, the shape of the core portion 4 is not particularly limited, and is not limited to a hexahedron, and may be a cylindrical shape, an elliptical column, a polygonal column, or the like.

  The size of the inductor element 2 of the present embodiment is not particularly limited. For example, the X-axis direction width X0 is 1.0 to 20 mm, the Y-axis direction width Y0 is 1.0 to 20 mm, and the height Z0 is 1.0 to 10 mm. It is. The inductor element 2 includes, for example, a transformer, a balun, a common mode filter (common mode choke), a circuit element such as a DC / DC converter, a choke coil in a power supply line, a decoupling element, an element for impedance matching, and a filter constituent element. It can be used as an antenna element.

  Next, a method for manufacturing the inductor element 2 shown in FIGS. 1 and 2 will be described. First, a conductive plate such as a metal plate (for example, Sn plating material) is punched into a shape as shown in FIG. 3A (stamping step). As shown in FIG. 3A, a plurality of conductive plate pieces 6a connected to the lead frame 14a via lead portions 17a (including the external terminal pieces 12a) are formed on the conductive plate pieces after punching. . Each first conductive plate piece 6a is integrally formed with a first inner convex portion 9a. Although the 1st inner side convex part 9a may be formed simultaneously at the time of a punching process, you may shape | mold in a process different from a punching process.

  Next, the first conductive plate pieces 6a shown in FIG. 3A are irradiated with cutting laser light in a predetermined pattern to form spiral first predetermined pattern gaps 7a1 as shown in FIG. 3B. A spiral first predetermined pattern 7a is formed on the conductive plate piece 6a (laser cutting step). A spiral first predetermined pattern gap 7a1 is formed in each first conductive plate piece 6a shown in FIG. 3A with a laser beam, so that each first conductive plate piece 6a has a first inner end 8a and The first outer end portion 10a is formed at the same time.

  Further, a wide portion 13 is formed in the middle of the pattern 7a in the vicinity of the first outer end portion 10a. By forming the wide portion 13, as shown in FIG. 3C, the outer peripheral shape of the first conductive plate piece 6a and the outer peripheral shape of the second conductive plate piece 6b can be made the same. When the 1 conductive plate piece 6a and the 2nd conductive plate piece 6b are laminated | stacked and it is set as the coil component 6, the intensity | strength of the coil component 6 can be improved.

  In the above-described process, the method for forming the first predetermined pattern 7a on the first conductive plate piece 6a has been described. However, the method for forming the second predetermined pattern 7b on the second conductive plate piece 6b is the same. Description is omitted. However, in order to form the second predetermined pattern 7b on the second conductive plate piece 6b, the same conductive plate piece as shown in FIG. 3C is used except that the first inner convex portion 9a shown in FIG. 3A is not provided. 2 The predetermined pattern gap 7b1 may be formed.

  Next, as shown in FIG. 3D, as shown in FIG. 3C, the first conductive plate piece 6a and the first inner convex portion 9a are abutted against the lower surface in the Z-axis direction of the second inner end portion 8b. The second conductive plate pieces 6b are laminated (lamination process). Before that, as shown in FIG. 3D, the intermediate insulating base material 16m is attached to the upper surface of each first conductive plate piece 6a or the lower surface of each second conductive plate piece 6b (intermediate insulating base material applying step). In the laminating step of the first conductive plate piece 6a and the second conductive plate piece 6b, the intermediate insulating base material 16m is sandwiched between them.

  If necessary, as shown in FIG. 3D, the surface insulating base material 16s is attached to the lower surface of each first conductive plate piece 6a and the upper surface of each second conductive plate piece 6b (surface layer insulating base material application) Process). Note that this step is not essential, and may be performed only when the strength of the first conductive plate piece 6a and the second conductive plate piece 6b is sufficiently increased or strong against deformation.

  Next, laser welding is performed on the joint portion between the first inner convex portion 9a and the second inner end portion 8b with the second inner end portion 8b butted against the first inner convex portion 9a (laser welding process). Thereby, as shown in FIG. 3D, the joint portion 9ab is formed in the portion.

  The method for forming the joint portion 9ab is not limited to laser welding, and other examples include resistance welding, arc welding, ultrasonic joining, solder joining, and joining with a conductive paste. . At the time of joining, the lead frames 14a and 14b are preferably attached to the conductive plate pieces 6a and 6b, respectively, but may be after being removed.

  Next, the resin impregnated in the surface insulating base material 16s and the intermediate insulating base material 16m is melt-cured (melt-curing step). In this step, the heating temperature is set to, for example, about 80 to 150 ° C., and the resin impregnated in each of the insulating base materials 16s and 16m is melted. The molten resin enters the first predetermined pattern gap 7a1 and the second predetermined pattern gap 7b1, and is filled there.

  Thereafter or simultaneously, the resin impregnated in the insulating base materials 16s and 16m and the resin filled in the pattern gaps 7a1 and 7b1 are fully cured. Thereby, the 1st conductive board piece 6a and the 2nd conductive board piece 6b are integrated via the surface layer insulation base material 16s and the intermediate | middle insulation base material 16m. In addition, you may implement a melt-hardening process prior to a laser cutting process.

  Next, the main part of the coil component 6 is inserted into the mold, the lead parts 17a and 17b are exposed from the mold, and the core part 4 is formed by compression molding in the mold (molding process). At the time of compression molding, an inductor element 2 shown in FIG. 1 is obtained by filling a mixture of magnetic powder and binder resin into a cavity of a mold and heating and compressing the whole.

  The heating temperature at the time of heat compression is preferably 50 to 300 ° C., and the compression pressure is preferably 1 to 400 Pa. As a method for compression molding, a mold may be used, or hydraulic pressure or water pressure may be used. At the time of compression molding, instead of the above-described mixture, only the resin may be filled in the cavity. Further, the molding process may be omitted, and the main part of the coil component 6 may be simply put in the exterior body (sealing part) and fixed.

  Next, the lead frames 14a and 14b shown in FIG. 3C are removed by cutting with a cutting tool. Further, as shown in FIG. 1, the lead portions 17a and 17b protruding from the core portion 4 are bent from the side surface 4C of the core portion 4 to the lower surface 4B along the outer surface of the core portion 4 (cut forming). Process). Thereby, the external terminal pieces 12 a and 12 b are arranged on the lower surface 4 </ b> B of the core portion 4. In the present embodiment, the lower surface 4B of the core portion 4 is a mounting surface, and the upper surface of the core portion 4 is an anti-mounting surface.

  In the coil component 6 according to the present embodiment, the first inner end 8a is formed with a first inner protrusion 9a that protrudes in the stacking direction from the two-dimensional plane of the first predetermined pattern 7a. Of the plate surfaces of the first conductive plate piece 6a and the second conductive plate piece 6b, at least the plate surface on the side where the first conductive plate piece 6a and the second conductive plate piece 6b face each other is intermediately insulated. It is covered with a base material 16m. Further, the first conductive plate piece 6a and the second conductive plate piece 6b are integrated via an intermediate insulating base material 16m.

  That is, since the first inner convex portion 9a and the second inner end portion 8b are three-dimensionally connected between the first predetermined pattern 7a and the second predetermined pattern 7b, a gap is formed between each predetermined pattern, By interposing the intermediate insulating base material 16m in the gap, the conductive plate pieces 6a and 6b can be integrated.

  As described above, the first conductive plate piece 6a and the second conductive plate piece 6b are integrated through the intermediate insulating base material 16m to form the coil component 6, so that the first conductive plate piece 6a and The second conductive plate pieces 6b are difficult to peel off, the strength is improved, and the conveyance is easy and easy to handle. Further, when the coil component 6 is disposed inside the mold and a granule containing magnetic powder or the like is compression-molded to form a powder magnetic core, the metal pieces 6a and 6b are unlikely to be displaced or deformed. Thus, the conductive plate pieces 6a and 6b are kept horizontal to each other. For this reason, it is possible to prevent the inductance value of the inductance element 2 and the variation of the DC superimposition characteristics, the insulation failure, and the like from occurring.

  In addition, since the intermediate insulating base material 16m is interposed between the first predetermined pattern 7a and the second predetermined pattern 7b, there is a low possibility of causing a short circuit failure between the conductive plate pieces 6a and 6b. Further, even when the metal alloy particles are included in the granule, the first predetermined pattern gap 7a1 and the second predetermined pattern gap 7b1 are filled with the resin contained in the insulating base material 16m and / or 16s. Therefore, there is little possibility that metal alloy particles enter these gaps.

  Further, since the lower surface of the first conductive plate piece 6a and the upper surface of the second conductive plate piece 6b are also covered with the surface insulating base material 16s, the strength of the coil component 6 can be further increased, and the coil component 6 is also improved. The protection function of the coil parts at the time of conveyance and compacting is also enhanced.

  In the present embodiment, the intermediate insulating base material 16m and the surface insulating base material 16s include a resin, and the first conductive plate piece 6a and the second conductive plate piece 6b are connected to the insulating base material 16m and the resin through the resin. It is integrated into 16s. With such a configuration, the resin oozes from the insulating base materials 16m and 16s and adheres to the conductive plate pieces 6a and 6b and is cured, so that each conductive plate piece 16m and 16s can be firmly integrated.

  In the present embodiment, the resin that has oozed from the insulating base materials 16m and 16s is filled in the first predetermined pattern gap 7a1 and the second predetermined pattern gap 7b1. Therefore, the conductive plate pieces 16m and 16s can be more firmly integrated through the resin. In addition, since the resin functions as a protective layer, it is possible to more effectively prevent the metal alloy particles described above from entering the pattern gaps 7a1 and 7b1.

  In the present embodiment, at least the insulating base material 16m is composed of a base material sheet having voids inside such as a nonwoven fabric, and the following advantages are obtained.

  First, in this type of base sheet, since various resins penetrate into the base sheet, the insulating base 16m and the conductive plate pieces 6a and 6b are strongly bonded to each other through the resin. The peel strength of the plate pieces 6a and 6b can be increased. Secondly, in this type of base material sheet, since the resin content changes depending on the degree of voids, a base material having an appropriate amount of voids depending on the thickness and shape of each conductive plate piece 6a and 6b. By selecting the sheet, the content of the resin impregnated in the base sheet can be optimized.

  Third, this type of substrate sheet can be impregnated with a large amount of resin. When the resin is cured, the total thickness of the base sheet changes. However, since the amount of change decreases as the resin content increases, the quality of the built-in sheet can be stabilized. Fourthly, with this type of substrate sheet, the resin can be easily immersed into both surfaces of the substrate. Note that when the resin is cured, the total thickness of the base sheet changes, but the uniformity of the thickness of the sheet is maintained.

  In addition, as an insulating base material, it is also possible to use what applied resin to the at least one surface of the flat tape-shaped base material. For example, what formed the layer of the modified | denatured epoxy resin on both surfaces of the polyester film as an example is mentioned. However, in order to produce such an insulating base material, an operation of applying a resin to at least one surface of the base material is required. However, if the above-described base material is used, the operation can be omitted. In addition, as an insulating base material, it is also possible to use the sheet | seat consisting only of a thermoplastic resin or a thermosetting resin.

  In this embodiment, you may use the sheet | seat (for example, prepreg) of the semi-hardened state which impregnated resin to the nonwoven fabric tape as an insulating base material. And this is affixed on the lower surface of the 1st electroconductive board piece 6a, and the upper surface of the 2nd electroconductive board piece 6b, and is utilized as the surface layer insulation base material 16s, and the upper surface of the 1st electroconductive board piece 6a or 2nd electroconductivity You may affix on the lower surface of the board piece 6b, and you may utilize as the intermediate insulation base material 16m. When pasting each insulating base material 16s and 16m, an adhesive layer made of an adhesive is formed on the surface layer of each conductive plate piece 6a and 6b, and each insulating base material 16s and 16m is placed on the adhesive layer. It may be adhered. The adhesive layer may be previously formed on the surfaces of the insulating base materials 16s and 16m.

  Moreover, in this embodiment, since all the electroconductive plate pieces 6a and 6b have the helical patterns 7a and 7b, respectively, the number of turns of the coil component 6 can be increased. Further, in the present embodiment, the external terminal piece 12a is integrally formed on the first outer end portion 10a via the lead portion 17a, and the second outer end portion 10b is formed on the first outer end portion 10b via the lead portion 17b. Two external terminal pieces 12b are integrally formed. The external terminal pieces 10 a and 10 b are portions exposed from the core portion (sealing portion) 4 to the outside. Since these portions are integrally formed on any of the conductive plate pieces, there is no need to separately connect the terminal pieces.

  Furthermore, in the above-described embodiment, the first lead portion 17a is integrally formed with the first outer end portion 10a, so that it is not necessary to separately connect the first lead portion 17a. The first lead portion 17a may be retrofitted to the first outer end portion 10a by welding or the like. Further, the shape of the first outer end portion 10a is not limited to the illustrated example, and may be changed as appropriate, such as a circular shape. The second lead portion 17b and the second outer end portion 10b are the same as the first lead portion 17a and the first outer end portion 10a.

  In the embodiment described above, the method for processing the metal plate (including the metal foil) constituting the conductive plate piece 6a (including 6b) shown in FIG. 3A is not limited to the punching process, but an etching process, Examples include wire cutting, laser processing, electric discharge processing, and drill processing. Further, the processing method for forming the predetermined pattern gaps 7a1 and 7b1 is not limited to laser processing, and examples thereof include punching processing, etching processing, wire cutting, electric discharge processing, and drill processing.

Second Embodiment As shown in FIGS. 4A, 4B and 5, the inductor element 102 according to the present embodiment is the same as the inductor element 2 according to the first embodiment except that the configuration of the coil component 106 is slightly different. is there. In the coil component 106 of the present embodiment, the positions of the first inner end portion 108a and the second inner end portion 108b respectively formed on the first conductive plate piece 106a and the second conductive plate piece 106b are the first implementation. It differs from the position of the 1st inner side edge part 8a and the 2nd inner side edge part 8b of a form. Further, in the surface insulating base material 116s and the intermediate insulating base material 116m of the present embodiment, the opening area of the opening formed in the central portion is the opening formed in each of the insulating base materials 16s and 16m of the first embodiment. Different from the opening area.

  Hereinafter, a different part from 1st Embodiment is demonstrated in detail, and description of a common part is abbreviate | omitted. Further, in the members shown in the drawings, common members are denoted by common reference numerals, and description thereof is partially omitted.

  In the present embodiment, the first inner end portion 108a is disposed at a position away from the center of the spiral first predetermined pattern 107a radially outward. Further, the second inner end portion 108b is disposed at a position away from the center of the spiral second predetermined pattern 107b radially outward. Therefore, no pattern is formed near the center of the first predetermined pattern 107a and the second predetermined pattern 107b. The first predetermined pattern 107a is formed by forming a first predetermined pattern gap 107a1 in the first conductive plate piece 106a. In the present embodiment, the first predetermined pattern gap 107a1 constitutes a spiral groove of the spiral pattern 107a.

  The second predetermined pattern 107b is formed by forming a second predetermined pattern gap 107b1 in the second conductive plate piece 106b. In the present embodiment, the second predetermined pattern gap 107b1 constitutes a spiral groove of the spiral pattern 107b. The joint 109ab shown in FIG. 4B is formed by performing laser welding or the like by abutting the first inner convex portion 109a and the second inner end portion 108b formed on the first inner end portion 108a.

  The surface insulating base material 116s and the intermediate insulating base material 116m are formed with openings larger than the openings formed in the surface layer insulating base material 116s and the intermediate insulating base material 116m. It is about the same as the area.

  The coil component 106 according to the present embodiment also has the same effects as the coil component 6 of the first embodiment. In addition, with the above configuration, when the first conductive plate piece 106a, the second conductive plate piece 106b, the surface insulating base material 116s, and the intermediate insulating base material 116m are stacked, the coil component 106 has FIG. 4A. And the hollow part as shown to FIG. 4B is formed, and the core part 4 can be arrange | positioned in this hollow part. Therefore, the inductance of the inductance element 102 can be increased, and the saturation current characteristic can be improved (the saturation current is increased). In addition, you may use the coil component 106 as an air-core coil, without arrange | positioning the core part 4 in a hollow part. As a core part, not only what was compacted with the coil component 106 but the toroidal type | mold core, EI type | mold core etc. which were shape | molded separately from the coil component 106 can be illustrated.

Third Embodiment As shown in FIGS. 6A, 6B, and 7, the inductor element 202 according to this embodiment is the same as the inductor element 102 according to the second embodiment except that the configuration of the coil component 206 is slightly different. is there. In the present embodiment, the shapes of the first inner end portion 208a and the second inner end portion 208b are different from the shapes of the first inner end portion 108a and the second inner end portion 108b in the second embodiment. Hereinafter, a different part from 2nd Embodiment is demonstrated in detail, and description of a common part is abbreviate | omitted. Further, in the members shown in the drawings, common members are denoted by common reference numerals, and description thereof is partially omitted.

  6B and 4B, the first inner end portion 208a and the second inner end portion 208b of the present embodiment have a protruding width in the Y direction that is the first inner end portion 108a and the second inner end portion. It is formed to be smaller than the protruding width of the portion 108b. Specifically, the first inner end portion 208a and the second inner end portion 208b have a point on the first inner convex portion 109a (in the illustrated example, the approximate center of the first inner convex portion 109a) on the XZ plane. It has a shape that cuts in parallel. That is, the first inner convex portion 209a is formed such that the protruding width in the Y-axis direction is smaller than the protruding width of the first inner convex portion 109a. Due to the above configuration, a region having no pattern is formed near the center of the first predetermined pattern 207a and the second predetermined pattern 207b, which is larger than the first predetermined pattern 107a and the second predetermined pattern 107b.

  The coil component 206 according to the present embodiment also has the same effects as the coil component 106 of the second embodiment. In addition, with the above configuration, when the first conductive plate piece 206a, the second conductive plate piece 206b, the surface insulating base material 116s and the intermediate insulating base material 116m are stacked, the coil component 206 has a coil part. A hollow portion larger than 106 is formed, and a core portion having a diameter larger than that of the core portion in the second embodiment can be disposed in the hollow portion.

Fourth Embodiment As shown in FIGS. 8 and 9, an inductor element 302 according to this embodiment is the same as the inductor element 202 according to the third embodiment except that the configuration of the coil component 306 is different. The coil component 306 of this embodiment has four conductive plate pieces. Hereinafter, parts different from the third embodiment will be described in detail, and description of common parts will be omitted. Further, in the members shown in the drawings, common members are denoted by common reference numerals, and description thereof is partially omitted.

  As shown in FIG. 9, the second conductive plate piece 306b has a second predetermined pattern 307b in a spiral (spiral) shape on a two-dimensional plane including the X axis and the Y axis, and the second conductive plate piece. It is arranged above 306b in the Z-axis direction. The second predetermined pattern 307b is formed by forming a second predetermined pattern gap 307b1 in the second conductive plate piece 306b. In the present embodiment, the second predetermined pattern gap 307b1 constitutes a spiral groove of the spiral pattern 307b. The second conductive plate piece 306b is formed in the second outer end portion 310b except that the lead portion 17b and the external terminal piece 12b are not formed and the second outer convex portion 311b is integrally formed. This is the same as the second conductive plate piece 206b of the third embodiment. The second outer protrusion 311b protrudes in the stacking direction (Z-axis direction) from the two-dimensional plane of the spiral pattern 307b.

  The third conductive plate piece 306c has a third predetermined pattern 307c that is a spiral (spiral) shape in a two-dimensional plane including the X-axis and the Y-axis, and is located above the third conductive plate piece 306c in the Z-axis direction. It is arranged in. The third predetermined pattern 307c is formed by forming a third predetermined pattern gap 307c1 in the third conductive plate piece 306c. In the present embodiment, the third predetermined pattern gap 307c1 constitutes a spiral groove of the spiral pattern 307c. The spiral third predetermined pattern 307c is the same as the spiral second predetermined pattern 307b except that the spiral predetermined pattern 307b is a reverse spiral pattern from the inside to the outside. However, a third inner end 308c is formed at the inner end of the spiral third predetermined pattern 307c, and a third outer end 310c is formed at the outer end of the spiral pattern 307c. .

  The third inner end 308c is integrally formed with a third inner protrusion 309c that protrudes in the stacking direction (Z-axis direction) from the two-dimensional plane of the spiral pattern. The second outer convex portion 311b is electrically connected to the third outer end portion 310c. An intermediate insulating base material 116m is attached to the upper surface of the second conductive plate piece 306b or the lower surface of the third conductive plate piece 306c. Therefore, the second conductive plate piece 306b and the third conductive plate piece 306c ooze out from the intermediate insulating base material 116m (more precisely, the intermediate insulating base material 116m covering the lower surface of the third conductive plate piece 306c. Resin).

  The fourth conductive plate piece 306d has a fourth predetermined pattern 307d that is a spiral (spiral) shape in a two-dimensional plane including the X-axis and the Y-axis, and is located above the fourth conductive plate piece 306d in the Z-axis direction. It is arranged in. The fourth predetermined pattern 307d is formed by forming a fourth predetermined pattern gap 307d1 in the fourth conductive plate piece 306d. In the present embodiment, the fourth predetermined pattern gap 307d1 constitutes a spiral groove of the spiral pattern 307d. The spiral fourth predetermined pattern 307d is the same as the spiral third predetermined pattern 307c except that the spiral predetermined pattern 307d is a reverse spiral pattern from the outside to the inside. However, a fourth inner end 308d is formed at the inner end of the spiral fourth predetermined pattern 307d, and a fourth outer end 10d is formed at the outer end of the spiral pattern 307d. .

  The fourth outer end portion 10d is integrally formed with a lead portion 17d and an external terminal piece 12d. The fourth outer end portion 10d is the same as the second outer end portion 10b, and the lead portion 17d and the external terminal piece 12d are the same as the lead portion 17b and the external terminal piece 12b. The third inner convex portion 309c is similar to the second inner convex portion 209a, and is electrically connected to the fourth inner end portion 308d. An intermediate insulating base material 116m is attached to the upper surface of the third conductive plate piece 306c or the lower surface of the fourth conductive plate piece 306d. Therefore, the third conductive plate piece 306c and the fourth conductive plate piece 306d ooze out from the intermediate insulating base material 116m (more precisely, the intermediate insulating base material 116m covering the lower surface of the fourth conductive plate piece 306d. Resin). Further, the fourth conductive plate piece 306d is integrated via a surface layer insulating base material 116s (more precisely, a resin leached from the surface layer insulating base material 116s) covering the upper surface of the fourth conductive plate piece 306d. ing.

  The coil component 306 according to the present embodiment also has the same effects as the coil component 206 of the third embodiment. In addition, in the present embodiment, the number of turns of the coil component 306 can be further increased.

  Between the first conductive plate piece 206a and the fourth conductive plate piece 306d, a plurality of pairs of the second conductive plate piece 306b and the third conductive plate piece 306c are repeatedly stacked. Also good. With this configuration, the number of turns of the coil component 306 can be further increased.

  The present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention.

  For example, in the embodiment shown in FIGS. 1, 2, and 3A to 3D, the first conductive plate piece 6a and the second conductive plate piece 6b are laminated in the Z-axis direction to form the coil component 6. However, the third to fourth conductive plate pieces or more conductive plate pieces are laminated on the second conductive plate piece 6b shown in FIG. 3C in the manner shown in FIG. Also good.

  In that case, a fourth external terminal piece may be formed integrally with the fourth outer end portion. A 4th external terminal piece is a part exposed outside from the sealing part in the coil apparatus mentioned later. Since this portion is integrally formed with the fourth outer end portion, it is not necessary to separately connect the terminal pieces. The fourth external terminal piece is the same as the external terminal piece 12b shown in FIG.

  Further, a plurality of pairs of the second conductive plate piece and the third conductive plate piece may be repeatedly stacked between the first conductive plate piece and the fourth conductive plate piece. . With this configuration, the number of turns of the coil component can be further increased.

2,102-302 ... Inductor element (coil device)
4 ... Core part (sealing part)
4A ... Upper surface 4B ... Lower surface 4C ... Side surfaces 6, 106 to 306 ... Coil parts 6a, 106a, 206a ... First conductive plate pieces 6b, 106b, 206b, 306b ... Second conductive plate pieces 306c ... Third conductive plate Piece 306d ... 4th electroconductive board piece 7a, 107a, 207a ... 1st predetermined pattern 7a1, 107a1, 207a1 ... 1st predetermined pattern clearance gap 7b, 107b, 207b, 307b ... 2nd predetermined pattern 7b1, 107b1, 207b1, 307b1 ... Second predetermined pattern gap 307c ... Third predetermined pattern 307c1 ... Third predetermined pattern gap 307d ... Fourth predetermined pattern 307d1 ... Fourth predetermined pattern gap 8a, 108a, 208a ... First inner end 8b, 108b, 208b ... Second Inner end 308c ... Third inner end 308d ... Fourth inner end 9a, 109a, 209a ... 1st inner side convex part 309c ... 3rd inner side convex part 9ab, 109ab, 209ab ... Joint part 10a ... 1st outer side edge part 10b, 310b ... 2nd outer side edge part 310c ... 3rd outer side edge part 10d ... 4th outer end 311b ... 2nd outside convex part 12a, 12b, 12d ... External terminal piece 13 ... Wide part 14a, 14b ... Lead frame 15 ... Conductive path 16s, 116s ... Surface layer insulation base material 16m, 116m ... Intermediate insulation Base material 17a, 17b, 17d ... Lead part

Claims (11)

A first conductive plate having a first inner end and a first outer end and having a two-dimensional first predetermined pattern;
A second conductive plate piece having a second inner end and a second outer end and having a two-dimensional second predetermined pattern;
Of the plate surfaces of the first conductive plate piece and the second conductive plate piece, an insulating base material that covers at least the plate surface on the side where the first conductive plate piece and the second conductive plate piece face each other A coil component having
The first conductive plate piece and the second conductive plate piece are arranged in a stacking direction, and the first conductive plate piece and the second conductive plate piece are integrated via the insulating base material. Coil parts. The first inner end is formed with a first inner protrusion that protrudes in the stacking direction from the two-dimensional plane of the first predetermined pattern,
The coil component according to claim 1, wherein the first inner convex portion is electrically connected to the second inner end portion.   The coil component according to claim 1 or 2, wherein at least one of the first predetermined pattern and the second predetermined pattern is a spiral pattern.   4. The coil component according to claim 3, wherein the first inner end and the second inner end are disposed at positions radially outward from a center of the spiral pattern.   The said insulating base material contains resin, The said 1st electroconductive board piece and the said 2nd electroconductive board piece are integrated with the said insulating base material through the said resin, The any one of Claims 1-4. Coil parts.   The coil component according to claim 5, wherein the resin fills a pattern gap formed in either the first predetermined pattern or the second predetermined pattern. A third conductive plate piece having a third inner end portion and a third outer end portion, having a two-dimensional third predetermined pattern, and arranged so as to be laminated with the second conductive plate piece;
An insulating base material that covers at least a plate surface of the third conductive plate piece on a side where the second conductive plate piece and the third conductive plate piece are opposed to each other;
The second outer end is formed with a second outer protrusion that protrudes in the stacking direction from the two-dimensional plane of the second predetermined pattern,
The second outer convex portion is electrically connected to the third outer end;
The second conductive plate piece and the third conductive plate piece are integrated via an insulating base material that covers a plate surface of the third conductive plate piece. Coil parts. A fourth conductive plate piece having a fourth inner end portion and a fourth outer end portion, having a four-dimensional fourth predetermined pattern, and being arranged to be laminated with the third conductive plate piece;
An insulating base material that covers at least the plate surface of the fourth conductive plate piece on the side where the third conductive plate piece and the fourth conductive plate piece face each other; and
The third inner end is formed with a third inner protrusion that protrudes in the stacking direction from the two-dimensional plane of the third predetermined pattern,
The third inner convex portion is electrically connected to the fourth inner end portion;
The coil component according to claim 7, wherein the third conductive plate piece and the fourth conductive plate piece are integrated via an insulating base material that covers a plate surface of the fourth conductive plate piece.   A plurality of pairs of the second conductive plate piece and the third conductive plate piece are repeatedly laminated between the first conductive plate piece and the fourth conductive plate piece. 8. The coil component according to 8. The coil component according to any one of claims 1 to 9,
And a sealing unit that covers a main part of the coil component.   The coil device according to claim 10, wherein the sealing portion is made of a magnetic substance-containing resin.

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