JP2018160610A - Coil component and method of manufacturing coil component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide: a coil component capable of preventing detachment of a magnetic filler; and a method of manufacturing the coil component.SOLUTION: A coil component 10 comprises: a coil part 12 provided with at least one layer of a flat coil C1 including a winding part 13 and an insulating layer 14 covering around the winding part 13; a coating part 7, covering the coil part 12, which is made of a mixture containing a magnetic filler F and resin R; and a conductor post 19A, provided in the coating part 7 in a penetrating manner, which extends along an axis A direction of the flat coil C1 from the winding part 13 to a top face 7a of the coating part 7. The conductor post 19A has: a post part 17A extending from the winding part 13 in the axis A direction of the flat coil C1; and a lid part 18A which is exposed from the coating part 7 and extends along the surface direction of the top face 7a from the end on the top face 7a side of the post part 17A.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a coil component and a method for manufacturing the coil component.

  As a conventional coil component, Patent Document 1 discloses a first magnetic substrate, a coil portion disposed on the first magnetic substrate in a state where the coil is electrically insulated by an insulating layer, and a coil. The coil component provided with the magnetic layer which covers the upper surface of a part, and the terminal electrode which conducts with the electrode extraction part of a coil is described.

JP 2003-133135 A

  By the way, as a material constituting the magnetic layer described in Patent Document 1, a magnetic resin in which a magnetic filler and a resin are mixed may be used. However, the magnetic filler may fall off the magnetic layer due to internal stress and external force of the coil component. In particular, since the magnetic layer and the electrode lead portion are made of different materials, the adhesion between the magnetic layer and the electrode lead portion is low. Therefore, the magnetic filler tends to fall off near the interface between the magnetic layer and the electrode lead portion.

  Then, an object of this invention is to provide the manufacturing method of the coil component which can suppress the drop-off | omission of a magnetic filler, and a coil component.

  A coil component according to an aspect of the present invention includes a coil portion having at least one planar coil including a winding portion and an insulating layer covering the periphery of the winding portion, and a covering portion that covers the coil portion and includes a magnetic filler and a resin. And a conductor post extending from the winding portion to the outer surface of the covering portion along the axial direction of the planar coil, and the conductor post extends from the winding portion in the axial direction of the planar coil. The post portion and a lid portion which is exposed from the covering portion and extends from the end portion on the outer surface side of the post portion along the surface direction of the outer surface.

  In the coil component, the covering portion around the post portion of the conductor post is covered with the lid portion of the conductor post. In the covering portion covered with the lid portion of the conductor post, it is possible to suppress the magnetic filler from dropping from the covering portion.

  In one form, the dimension of the cover part regarding the surface direction of an outer surface may be 10 times or more of the average particle diameter of a magnetic filler. By making the lid portion 10 times or more larger than the size of the magnetic filler, it is possible to more effectively suppress the magnetic filler from falling off the covering portion.

  In one form, the dimension of the cover part regarding the surface direction of an outer surface may be 1.1 times or more of the dimension of a post part. In this case, since the area of the covering portion covered by the lid portion can be increased, it is possible to more effectively suppress the magnetic filler from falling off the covering portion.

  In one form, the ratio of the magnetic filler contained in a coating | coated part may be 80 weight% or more. In order to increase the saturation magnetic flux density of the covering portion, it is preferable that the ratio of the magnetic filler contained in the covering portion is high. However, as the ratio of the magnetic fillers increases, the amount of the resin that functions as a binder that connects the magnetic fillers decreases, so that the magnetic fillers easily fall off. On the other hand, according to the coil component, since the covering portion around the conductor post is covered with the lid portion, even if the ratio of the magnetic filler is 80% by weight or more, which is likely to drop off, Dropping off of the magnetic filler can be suppressed while improving the saturation magnetic flux density.

  A manufacturing method of a coil component according to an aspect of the present invention includes a first step of forming a coil portion having at least one planar coil including a winding portion and an insulating layer covering the periphery of the winding portion, a magnetic filler, and a resin. A second step of forming a covering portion that covers the coil portion with a material including: a third step of forming a conductor post extending from the winding portion to the outer surface of the covering portion along the axial direction of the planar coil, In the third step, a post portion that extends from the winding portion along the axial direction of the planar coil, and a lid portion that is exposed from the covering portion and extends from the end portion on the outer surface side of the post portion along the surface direction of the outer surface. Forming a conductor post having

  In this method of manufacturing a coil component, in the third step, a lid portion extending along the outer surface from the end portion on the outer surface side of the post portion is formed. Thereby, in the periphery of a post part, it will be in the state where the coating | coated part was covered by the cover part. Therefore, by forming the conductor post in this way, it is possible to suppress the magnetic filler from falling off the covering portion. In addition, in the steps after the third step, the magnetic filler can be prevented from falling off due to handling or the like.

  In one form, you may form a cover part by grind | polishing the outer surface of a coating | coated part in a 3rd process. In this case, since the covering portion is polished in the third step, the magnetic filler is likely to fall off around the post portion. On the other hand, by performing the polishing so that the lid portion is formed, the lid portion is gradually formed during the polishing, so that the magnetic filler is prevented from falling off from the covering portion in the third step. Can do.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the coil components and coil components which can suppress the drop-off | omission of a magnetic filler are provided.

It is a perspective view which shows the power supply circuit unit provided with the coil components which concern on one Embodiment of this invention. It is a figure which shows the equivalent circuit of the power supply circuit unit of FIG. It is a perspective view which shows the coil components which concern on one Embodiment of this invention. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 3. FIG. 4 is an exploded perspective view of the coil component of FIG. 3. It is an enlarged view which shows roughly the structure of the connection part of a conductor post and an external terminal. It is a top view which shows a part of external terminal. It is a top view which shows a conductor post. It is a figure explaining the manufacturing process of coil components. It is a figure explaining the manufacturing process of coil components. It is a figure explaining the manufacturing process of coil components. It is a figure for demonstrating the effect | action of the conductor post of the coil components shown by FIG. It is a figure which shows schematically the conductor post which concerns on a comparative example. It is sectional drawing which shows the modification of the conductor post of FIG. It is a top view which shows another modification of the conductor post of FIG.

  Hereinafter, various embodiments will be described in detail with reference to the drawings. In addition, in each drawing, the same code | symbol is attached | subjected to the same or an equivalent part, and the overlapping description is abbreviate | omitted.

  First, with reference to FIG.1 and FIG.2, the whole structure of the power supply circuit unit 1 which concerns on one Embodiment of this invention is demonstrated. The power supply circuit unit described in the present embodiment is, for example, a switching power supply circuit unit that performs voltage conversion (step-down) of a DC voltage. As shown in FIGS. 1 and 2, the power supply circuit unit 1 includes a circuit board 2 and electronic components 3, 4, 5, 6, and 10. Specifically, the power supply IC 3, the diode 4, the capacitor 5, the switching element 6, and the coil component 10 are mounted on the circuit board 2.

  The configuration of the coil component 10 will be described with reference to FIGS. FIG. 3 is a perspective view of the coil component 10. 4 is a cross-sectional view taken along line IV-IV in FIG. FIG. 5 is an exploded perspective view of the coil component. In the exploded perspective view of FIG. 5, illustration of the coating | coated part 7 of FIG. 3 is abbreviate | omitted.

  As shown in FIG. 3, the coil component 10 includes a magnetic substrate 11, a coil portion 12, a covering portion 7, and conductor posts 19 </ b> A and 19 </ b> B.

  The coil part 12 is covered with the covering part 7, and the covering part 7 has a rectangular parallelepiped outer shape. The rectangular parallelepiped shape includes a rectangular parallelepiped shape in which corners and ridge lines are chamfered and a rectangular parallelepiped shape in which corners and ridge lines are rounded. The covering portion 7 has an upper surface (outer surface) 7a, and the upper surface 7a has a rectangular shape having a long side and a short side. The rectangular shape includes a rectangle with rounded corners. A cover insulating layer 30 is laminated on the upper surface 7a. External terminals 20 </ b> A and 20 </ b> B are provided on the insulating cover layer 30.

  The external terminal 20A is along one short side of the upper surface 7a, and the external terminal 20B is along the other short side of the upper surface 7a. The external terminals 20A and 20B are separated from each other in the direction along the long side of the upper surface 7a. The external terminals 20A and 20B are electrically connected to the conductor posts 19A and 19B, respectively.

  The magnetic substrate 11 is a substantially flat substrate made of a magnetic material such as ferrite (see FIG. 5). The magnetic substrate 11 is located on the side opposite to the upper surface 7 a of the covering portion 7.

  The covering portion 7 is formed on the magnetic substrate 11 and includes a coil portion 12 (see FIGS. 4 and 5) inside. The covering portion 7 is a mixture containing a magnetic filler and a binder resin (resin), and the constituent material of the magnetic filler is, for example, iron, carbonyl iron, silicon, chromium, nickel, or boron, and the constituent material of the binder resin is For example, epoxy resin. For example, 80% by weight or more of the entire covering portion 7 may be made of a magnetic filler. The average particle diameter of the magnetic filler can be, for example, 1 μm to 30 μm.

  The coil part 12 has a planar coil including an annular winding part 13 and an insulating layer 14 covering the winding part 13. The winding portions 13 are insulated from each other by an insulating layer 14. The coil unit 12 has at least one planar coil. In the present embodiment, the coil portion 12 has two layers of planar coils C1 and C2 and connecting portions 15 and 16.

  The planar coil C1 and the planar coil C2 have an axis (axis A in FIGS. 4 and 5) orthogonal to the magnetic substrate 11 and the upper surface 7a of the covering portion 7, and are stacked along the direction of the axis A. . The upper planar coil C2 is located closer to the upper surface 7a than the lower planar coil C1. Each of the planar coils C1 and C2 has substantially the same outer shape (specifically, a rectangular shape) in plan view. The planar coil C1 and the planar coil C2 have substantially the same dimensions. The planar coil C <b> 1 and the planar coil C <b> 2 have a rectangular ring shape with the same outer edge dimension and inner edge dimension in plan view, and the formation regions thereof are the same. The winding part 13 of the planar coil C1 and the winding part 13 of the planar coil C2 are each wound in a rectangular shape in the same layer. Each winding portion 13 is made of a metal material such as Cu, for example.

  The insulating layer 14 has an insulating property and is made of an insulating resin. Examples of the insulating resin used for the insulating layer 14 include polyimide and polyethylene terephthalate. The insulating layer 14 integrally covers the planar coils C <b> 1 and C <b> 2 of the coil portion 12 in the covering portion 7. The insulating layer 14 has a laminated structure, and in the present embodiment, the insulating layer 14 includes five insulating layers 14a, 14b, 14c, 14d, and 14e (see FIG. 5). The insulating layer 14a is located on the lower side (the magnetic substrate 11 side) of the lower planar coil C1, and is formed in substantially the same region as the formation region of the coil portion 12 in plan view. The insulating layer 14b fills the periphery and the space between the winding portion 13 and the winding portion of the planar coil C1, and a region corresponding to the inner diameter of the coil portion 12 is vacant. The insulating layer 14c is located between the lower planar coil C1 and the upper planar coil C2, and an area corresponding to the inner diameter of the coil portion 12 is open. The insulating layer 14d fills the periphery of the winding portion 13 of the planar coil C2 and the space between the winding portions, and an area corresponding to the inner diameter of the coil portion 12 is open. The insulating layer 14e is positioned on the upper side (upper surface 7a side) of the upper planar coil C2, and an area corresponding to the inner diameter of the coil portion 12 is open.

  The connecting portion 15 is interposed between the planar coil C1 and the planar coil C2, and the innermost winding portion of the winding portion 13 of the planar coil C1 and the innermost winding portion of the winding portion 13 of the planar coil C2. The part is connected. The connecting portion 16 extends from the planar coil C2 to the upper surface 7a side, and connects the winding portion 13 of the planar coil C2 and the conductor post 19B.

  The pair of conductor posts 19A, 19B are made of, for example, Cu, and are provided in the covering portion 7 so as to extend from both ends of the coil portion 12 along the direction of the axis A.

  The conductor post 19A is connected to one end of the coil portion 12 provided at the outermost winding portion of the upper planar coil C2. The conductor post 19A extends from the winding portion 13 of the planar coil C2 to the upper surface 7a so as to penetrate the covering portion 7, and is exposed on the upper surface 7a. An external terminal 20A is provided at a position corresponding to the exposed portion of the conductor post 19A. The conductor post 19 </ b> A is connected to the external terminal 20 </ b> A by the conductor portion 31 in the through hole (opening) 31 a of the cover insulating layer 30. Thus, one end of the coil portion 12 and the external terminal 20A are electrically connected via the conductor post 19A and the conductor portion 31.

  The conductor post 19B is connected to the other end of the coil portion 12 provided at the outermost winding portion of the planar coil C1. The conductor post 19B extends from the winding portion 13 of the planar coil C1 to the upper surface 7a so as to penetrate the covering portion 7, and is exposed on the upper surface 7a. An external terminal 20B is provided at a position corresponding to the exposed portion of the conductor post 19B. The conductor post 19 </ b> B is connected to the external terminal 20 </ b> B by the conductor portion 32 in the through hole (opening) 32 a of the cover insulating layer 30. Thus, the other end of the coil portion 12 and the external terminal 20B are electrically connected via the conductor post 19B and the conductor portion 32.

  The pair of external terminals 20A and 20B provided on the upper surface 7a of the covering portion 7 are both film-like and have a substantially rectangular shape in plan view. The areas of the external terminals 20A and 20B are substantially the same. The external terminals 20A and 20B are made of a conductive material such as Cu, for example. The external terminals 20A and 20B are plating electrodes formed by plating, for example. The external terminals 20A and 20B may have a single layer structure or a multi-layer structure.

  The insulating cover layer 30 is provided on the upper surface 7a of the covering portion 7, and is sandwiched between the conductor posts 19A and 19B and the external terminals 20A and 20B in the direction along the axis A. The insulating cover layer 30 has through holes 31a and 32a at positions corresponding to the conductor posts 19A and 19B. Conductor portions 31 and 32 made of a conductive material such as Cu are provided in the through holes 31a and 32a. The insulating cover layer 30 is made of an insulating material, for example, an insulating resin such as polyimide or epoxy.

  Next, the structures of the conductor posts 19A and 19B, the external terminals 20A and 20B, and the insulating cover layer 30 will be described in detail with reference to FIGS. FIG. 6 is an enlarged view schematically showing the structure of the connection portion between the conductor post and the external terminal. FIG. 7 is a plan view showing a part of the external terminals. FIG. 8 is a plan view showing the conductor post. In addition, since the structure of the connection part of the conductor post 19A and the external terminal 20A and the structure of the connection part of the conductor post 19B and the external terminal 20B are substantially the same, in FIG. 6, FIG. 7, and FIG. Only the structure of the connection part of 19A and the external terminal 20A is shown, and the description of the structure of the connection part of the conductor post 19A and the external terminal 20A is omitted.

  As shown in FIGS. 6, 7, and 8, the conductor post 19 </ b> A includes a post portion 17 </ b> A that extends from the winding portion 13 in the direction of the axis A (see FIGS. 4 and 5) of the planar coils C <b> 1 and C <b> 2. 17A has a lid portion 18A extending from the end portion on the upper surface 7a side along the surface direction of the upper surface 7a. The lid portion 18A is exposed from the covering portion 7 on the upper surface 7a, and the top surface of the lid portion 18A is flush with the upper surface 7a of the covering portion 7. The post portion 17A extends straight along the direction of the axis A. The post portion 17A and the lid portion 18A are integrally provided and are made of the same conductive material. In the present embodiment, the corner portion defined by the post portion 17A and the lid portion 18A is substantially perpendicular, but the corner portion may be formed of a curved surface. The conductor portion 31 is connected to the lid portion 18A of the conductor post 19A.

  In plan view, the shape of the post portion 17A, the lid portion 18A, and the through hole 31a of the cover insulating layer 30 is substantially circular. Further, the center positions of the post portion 17, the lid portion 18A, and the through hole 31a are substantially the same in plan view. The dimension D1 of the lid portion 18A in the direction along the surface direction of the upper surface 7a is larger than the dimension D2 of the post portion 17A. In the present embodiment, the dimension D1 of the lid part 18A in the direction along the surface direction of the upper surface 7a is 1.1 times or more the dimension D2 of the post part 17A. The dimension D3 of the through hole 31a of the cover insulating layer 30 is larger than the dimension D2 of the post portion 17A and smaller than the dimension D1 of the lid portion 18A. As a result, the insulating cover layer 30 is sandwiched between the lid portion 18A and the external terminal 20A. As an example, the dimension D1 of the lid part 18A can be about 150 μm to 550 μm, the dimension D2 of the post part 17A can be about 50 μm to 500 μm, and the dimension D3 of the through hole 31a can be about 100 μm to 400 μm. The center positions of the post portion 17, the lid portion 18A, and the through hole 31a do not have to be substantially the same, and there may be a deviation of about 5 μm to 50 μm due to a manufacturing error or the like.

  Next, a method for manufacturing the coil component 10 will be described with reference to FIGS. 9-11 is a figure explaining the manufacturing process of the coil component 10. FIG.

  First, the coil part 12 is formed on the magnetic substrate 11 (first step). Specifically, as shown in FIG. 9A, an insulating paste pattern is applied on the magnetic substrate 11 to form an insulating layer 14a. Subsequently, as shown in FIG. 9B, a seed portion 22 for plating the winding portion 13 of the planar coil C1 is formed on the insulating layer 14a. The seed portion 22 can be formed by plating, sputtering, or the like using a predetermined mask. Subsequently, as shown in FIG. 9C, an insulating layer 14b is formed. The insulating layer 14 b can be obtained by applying an insulating resin paste to the entire surface of the magnetic substrate 11 and then removing a portion corresponding to the seed portion 22. That is, the insulating layer 14b has a function of exposing the seed portion 22. The insulating layer 14b is a wall-like portion standing on the magnetic substrate 11, and defines a region where the winding portion 13 of the planar coil C1 is formed. Subsequently, as shown in FIG. 9D, a plating layer 24 is formed using the seed portion 22 between the insulating layers 14b. At this time, the plating that grows so as to fill the region defined between the insulating layers 14b becomes the winding portion 13 of the planar coil C1. As a result, the winding portion of the planar coil C1 is positioned between the adjacent insulating layers 14b.

  Subsequently, as shown in FIG. 10A, an insulating layer 14c is formed by applying an insulating resin paste pattern on the planar coil C1. At this time, openings 15 ′ and 16 ′ for forming the connecting portions 15 and 16 are formed in the insulating layer 14 c. Subsequently, as shown in FIG. 10B, the connecting portions 15 and 16 are formed by plating in the openings 15 'and 16' of the insulating layer 14c.

  Subsequently, as shown in FIG. 10C, the winding portion 13 of the planar coil C2 and the insulating layers 14d and 14e are formed on the insulating layer 14c in the same manner as described above. Specifically, similarly to the procedure shown in FIGS. 9B to 9D, a seed portion for plating the winding portion 13 of the planar coil C2 is formed, and the winding portion of the planar coil C2 is formed. An insulating layer 14d that defines a region where 13 is to be formed is formed, and the winding portion 13 of the planar coil C2 is formed by plating between the insulating layers 14d.

  And the insulating layer 14e is formed by apply | coating the insulating resin paste pattern on the winding part 13 of the planar coil C2. At this time, openings 19A 'and 19B' for forming the conductor posts 19A and 19B are formed in the insulating layer 14e. Thus, the insulating layer 14 has a laminated structure including a plurality of insulating layers 14a to 14e, and the winding portions 13 of the planar coils C1 and C2 are surrounded by the insulating layers 14a to 14e. . Through the above steps, the coil portion 12 is formed.

  Subsequently, as shown in FIG. 10D, portions of the plating layer 24 that do not constitute the winding portions 13 of the planar coils C1 and C2 (corresponding to the inner and outer peripheral portions of the planar coils C1 and C2). Part) is removed by etching or the like. In other words, the plating layer 24 not covered with the insulating layer 14 in FIG. 10C is removed.

  Subsequently, lead conductors 17A 'and 17B' to be the post portions 17A and 17B of the conductor posts 19A and 19B are formed. First, as shown in FIG. 11A, the lead conductor 17A ′ to be the post portion 17A of the conductor post 19A is formed at a position corresponding to the opening portion 19A ′ of the insulating layer 14e, and also corresponds to the opening portion 19B ′. The lead conductor 17B ′ to be the post portion 17B of the conductor post 19B is formed at the position to be formed. Specifically, seed portions for the lead conductors 17A ′ and 17B ′ are formed on the openings 19A ′ and 19B ′ by plating or sputtering using a predetermined mask, and the lead conductor is formed using the seed portions. 17A ′ and 17B ′ are formed by plating. When the lead conductors 17A 'and 17B' are formed by plating, for example, an insulating sacrificial layer (portion indicated by a two-dot chain line) can be used.

  Subsequently, as shown in FIG. 11B, a magnetic resin containing a magnetic filler and a resin is applied to the entire surface of the magnetic substrate 11 and a predetermined curing process is performed to form a covering portion 7 (second step). . As a result, the periphery of the lead conductors 17 </ b> A ′ and 17 </ b> B ′ is covered with the covering portion 7. At this time, the coating portion 7 is filled in the inner diameter portion of the coil portion 12. Subsequently, as shown in FIG. 11C, conductor posts 19A and 19B are formed (third step). Specifically, the covering portion 7 and the lead conductors 17A ′ and 17B ′ are polished. As a result, the lead conductors 17A 'and 17B' are exposed from the covering portion 7, and the lead conductors 17A 'and 17B' are extended by continuing the polishing. Thus, the conductor posts 19A and 19B having the post portions 17A and 17B and the cover portions 18A and 18B are formed from the lead conductors 17A 'and 17B'. Moreover, it will be in the state in which the upper surface 7a of the coating | coated part 7 was formed. The dimension D1 of the lid portions 18A and 18B can be adjusted by changing the polishing time. For example, the dimension D1 of the lid portions 18A and 18B increases as the polishing time increases. The shapes of the lid portions 18A and 18B can be adjusted, for example, by changing the polishing direction.

  Subsequently, as shown in FIG. 11D, before the external terminals 20A and 20B are formed by plating, an insulating material such as an insulating resin paste is applied on the upper surface 7a, so that the cover insulating layer 30 is formed. Form. When the insulating cover layer 30 is formed, the entire upper surface 7a is covered, and through holes 31a and 32a are formed at positions corresponding to the pair of conductor posts 19A and 19B, and the pair of conductor posts 19A and 19B are formed from the cover insulating layer 30. To expose. Specifically, an insulating material is once applied to the entire area of the upper surface 7a, and thereafter, the cover insulating layer 30 at portions corresponding to the conductor posts 19A and 19B is removed.

  Then, a seed portion (not shown) is formed on the cover insulating layer 30 in a region corresponding to the external terminals 20A and 20B by plating, sputtering, or the like using a predetermined mask. The seed portion is also formed on the lid portions 18A and 18B of the conductor posts 19A and 19B exposed from the through holes 31a and 32a of the insulating cover layer 30. Subsequently, the external terminals 20A and 20B are formed by electroless plating using the seed portion. At this time, the plating grows so as to fill the through holes 31a and 32a of the insulating cover layer 30 to form the conductor portions 31 and 32, and the external terminals 20A and 20B on the insulating cover layer 30 are formed. The coil component 10 is formed by the above process.

  Next, with reference to FIG.12 and FIG.13, the effect of the conductor posts 19A and 19B is demonstrated. FIG. 12 is a view for explaining the operation of the conductor post of the coil component shown in FIG. FIG. 13 is a diagram schematically showing a conductor post according to a comparative example. As shown in FIGS. 12 and 13, the covering portion 7 includes a magnetic filler F and a resin R for connecting the magnetic fillers F to each other.

  As shown in FIG. 13, the conductor post 40 according to the comparative example does not have a lid portion extending along the upper surface 7 a. In this case, since the conductor post 40 and the magnetic filler are made of different materials, the adhesion is low, and the magnetic filler is likely to fall off around the conductor post 40. On the other hand, as shown in FIG. 12, the conductor post 19A (conductor post 19B) of the coil component 10 according to the present embodiment includes the lid portion 18A (lid portion 18B). In the vicinity of the conductor post 19B), the covering portion is covered with the lid portion. Therefore, even if the adhesiveness between the magnetic filler and the conductor post 19A (conductor post 19B) is low, the magnetic filler is held by the lid portion 18A (lid portion 18B), and the magnetic filler is prevented from dropping from the covering portion. .

  As described above, the conductor posts 19A and 19B of the coil component 10 are formed on the side of the upper surface 7a of the post portions 17A and 17B extending from the winding portion 13 in the direction of the axis A of the planar coils C1 and C2. And lid portions 18A and 18B extending from the end portions along the surface direction of the upper surface 7a. By thus providing the lid portions 18A and 18B, the covering portion 7 around the post portions 17A and 17B is covered with the lid portions 18A and 18B of the conductor posts 19A and 19B. Therefore, in the covering part 7 covered with the cover parts 18A and 18B of the conductor posts 19A and 19B, it is possible to suppress the magnetic filler F from dropping from the covering part 7.

  Further, the dimension D1 of the lid portions 18A and 18B in the direction along the surface direction of the upper surface 7a is 10 times or more the average particle diameter of the magnetic filler F. Thereby, it can suppress more effectively that the magnetic filler F falls off from the coating | coated part 7 by enlarging cover part 18A, 18B 10 times or more with respect to the magnitude | size of the magnetic filler F. FIG.

  Further, the dimension D1 of the lid portions 18A and 18B with respect to the direction along the surface direction of the upper surface 7a is twice or more the dimension D2 of the post portions 17A and 17B. Thereby, since the area of the coating | coated part 7 covered with the cover parts 18A and 18B can be enlarged, it can suppress more effectively that the magnetic filler F falls off from the coating | coated part 7. FIG.

  Moreover, the ratio of the magnetic filler F contained in the coating | coated part 7 is 80 weight% or more. In order to increase the saturation magnetic flux density of the covering portion 7, it is preferable that the ratio of the magnetic filler F contained in the covering portion 7 is high. However, as the ratio of the magnetic filler F increases, the amount of the resin R that functions as a binder that connects the magnetic fillers F decreases, so that the magnetic filler F easily falls off. On the other hand, according to the coil component 10, since the covering portion 7 around the conductor posts 19A and 19B is covered with the lid portions 18A and 18B, the ratio of the magnetic filler F is 80% by weight or more that is likely to drop off. Even so, dropping of the magnetic filler F can be suppressed while improving the saturation magnetic flux density of the covering portion 7.

  Moreover, according to the manufacturing method of the coil component 10 which concerns on this embodiment, the cover parts 18A and 18B extended along the upper surface 7a from the edge part by the side of the upper surface 7a of the post parts 17A and 17B are formed in a 3rd process. As a result, the covering portion 7 is covered with the lid portions 18A and 18B around the post portions 17A and 17B. Therefore, by forming the conductor posts 19 </ b> A and 19 </ b> B in this way, it is possible to suppress the magnetic filler F from dropping from the covering portion 7. In addition, in the processes after the third process, it is possible to suppress the magnetic filler F from falling off due to handling or the like.

  In the third step, the lid portions 18A and 18B are formed by polishing the upper surface 7a of the covering portion 7. As described above, when the covering portion 7 is polished, the magnetic filler F is likely to fall off around the post portions 17A and 17B. On the other hand, by performing polishing so that the lid portions 18A and 18B are formed, the lid portions 18A and 18B are gradually formed during the polishing, so that the magnetic filler F is coated with the coating portion 7 in the third step. Can be prevented from falling off. At this time, the joint portion between the post portions 17A and 17B and the lid portions 18A and 18B may have a structure having a gently curved cross section.

  As mentioned above, although one Embodiment of this invention was described, this invention is not limited to the said embodiment, You may change in the range which does not change the summary described in each claim, or may apply to others. In the above-described embodiment, the lid portions 18A and 18B extend along the upper surface 7a with the post portions 17A and 17B as the center. However, the lid portions 18A and 18B should not have the post portions 17A and 17B as the center. Also good. For example, as shown in FIG. 14, the lid portion 18A (lid portion 18B) may extend from the post portion 17A to only one side along the upper surface 7a. In this case, the shape of the post portion 17A and the lid portion 18A in a plan view is, for example, a semicircular shape. As shown in FIG. 14, when the conductor post 19 </ b> A and the external terminal 20 </ b> A are located at the end of the coil component 10, the conductor post 19 </ b> A and the external terminal 20 </ b> A are cut off on the insulating cover layer 30. It is connected via the notch 33.

  In the above embodiment, the case where the post portions 17A and 17B and the lid portions 18A and 18B in the plan view are circular has been described. However, the post portions 17A and 17B and the lid portions 18A and 18B in the plan view are described. The shape of is not particularly limited. For example, as illustrated in FIG. 15, the shape of the post portion 17 </ b> A and the lid portion 18 </ b> A in a plan view may be a rectangular shape.

  In addition, the shape of the through holes 31a and 32a of the insulating cover layer 30 is not particularly limited and can be arbitrarily changed. For example, in the above embodiment, the case where the through holes 31a and 32a are circular has been described, but the through holes 31a and 32a may be rectangular. Further, the dimension D3 of the through holes 31a and 32a may be smaller than the dimension D2 of the post portions 17A and 17B, or may be larger than the dimension D1 of the lid portions 18A and 18B.

  DESCRIPTION OF SYMBOLS 1 ... Power supply circuit unit, 2 ... Circuit board, 3 ... Electronic component, 4 ... Diode, 5 ... Capacitor, 6 ... Switching element, 7 ... Cover part, 7a ... Upper surface (outer surface), 10 ... Coil component, 11 ... Magnetic Substrate, 12 ... Coil, 13 ... Winding, 14 ... Insulating layer, 15, 16 ... Connection, 17A, 17B ... Post, 18A, 18B ... Lid, 19A, 19B ... Conductor post, 20A, 20B ... External terminal, 30 ... cover insulating layer, 31a, 32a ... through hole (opening), A ... axis, C1, C2 ... planar coil, D1, D2, D3 ... dimensions, F ... magnetic filler, R ... resin.

Claims (6)

A coil portion having at least one planar coil including a winding portion and an insulating layer covering the periphery of the winding portion;
Covering the coil part, and a covering part made of a mixture containing a magnetic filler and a resin;
A conductor post penetrating in the covering portion and extending from the winding portion to the outer surface of the covering portion along the axial direction of the planar coil,
The conductor post extends from the winding portion in the axial direction of the planar coil, and is exposed from the covering portion and extends from the end on the outer surface side of the post portion along the surface direction of the outer surface. A coil component having a lid portion extending.   The dimension of the said cover part regarding the surface direction of the said outer surface is a coil component of Claim 1 which is 10 times or more of the average particle diameter of the said magnetic filler.   3. The coil component according to claim 1, wherein a dimension of the lid part with respect to a surface direction of the outer surface is 1.1 times or more a dimension of the post part.   The ratio of the said magnetic filler contained in the said coating | coated part is a coil component as described in any one of Claims 1-3 which is 80 weight% or more. A first step of forming a coil portion having at least one planar coil including a winding portion and an insulating layer covering the periphery of the winding portion;
A second step of forming a covering portion covering the coil portion with a material including a magnetic filler and a resin;
Forming a conductor post extending from the winding portion to the outer surface of the covering portion along the axial direction of the planar coil,
In the third step, a post portion extending along the axial direction of the planar coil from the winding portion, a surface direction of the outer surface from the end portion on the outer surface side of the post portion exposed from the covering portion A method of manufacturing a coil component, wherein the conductor post having a lid portion extending along the line is formed.   The method for manufacturing a coil component according to claim 5, wherein in the third step, the lid portion is formed by polishing the outer surface of the covering portion.

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