JP3433816B2 - Coil component and its manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is applied to a chip-shaped inductor, an impeller (which uses a coil conductor and its peripheral component as a circuit constituent element), a transformer, or a coil portion of a magnetic head. The present invention relates to a coil component or an LC composite component and a manufacturing method thereof.

[0002]

2. Description of the Related Art In order to meet the demands for miniaturization and thinning, these chip-shaped coil components are integrally laminated with a coil conductor in a magnetic body by a thick film forming technique by a printing method or a sheet method. Is produced. A laminated coil component manufactured by this thick film forming technique is disclosed in Japanese Patent Laid-Open No. 63-44286, Japanese Laid-Open Utility Model No. 59-14509, or Japanese Patent Laid-Open No. 3-5.
As disclosed in Japanese Patent No. 4808, etc.
It is formed by forming a coil conductor for a half turn or 3/4 turn of the coil on the upper surface of the coil by a printing method or the like and sequentially laminating the coil conductor. In this case, the starting ends and the terminating ends of the coil conductors of the vertically adjacent layers are connected to each other through a conductor filled in a through hole formed perpendicularly to the insulator sheet by punching or the like. To be done.

[0003]

However, in the case of the conventional structure in which the through-hole is formed vertically, it is not possible to form one turn of the coil in one laminating step. In the case of a print pattern for one turn, it was necessary to stack the coil conductors twice in order to form a coil for one turn.
Also, it is necessary to have two or more types of coil conductor printing patterns. For example, in the case of a coil conductor of 3/4 coil, four types of coil conductor printing patterns (printing patterns for the upper and lower extraction electrodes) are required. -Except).

For this reason, the number of times of lamination is increased in order to form the conductive coil having the specified number of turns, and the number of types of printing patterns of the coil conductor is increased, so that the management of the lamination process is complicated and the productivity is poor. There was a problem.

In view of the above situation, it is an object of the present invention to provide a coil component having a structure with good productivity and a manufacturing method thereof.

[0006]

In order to achieve the above-mentioned object, a coil component according to the present invention is a laminated coil component in which magnetic or non-magnetic insulating layers and coil conductors are alternately laminated . Coil conductor close to one coil
The same pattern is used, and the end of the coil conductor of one layer and the start of the coil conductor of the next layer are electrically connected to each other through the conductor filled in the obliquely formed through hole. Is characterized by.

Further, the method of manufacturing a coil component according to the present invention, a laser beam is attached to a magnetic or non-magnetic insulating sheet.
A through-hole is formed diagonally by means of a hole, and the insulator sheet is installed on the existing laminated body such that the lower opening of the through-hole is the terminal position of the coil conductor formed in the previous step. On the insulator sheet, close to one coil , and
A coil conductor having the same pattern in each layer is printed so that the starting end of the coil conductor is the upper opening of the through hole, so that the through hole is filled with the conductor and the coil conductor in the lower layer is covered with the through hole. It is characterized in that the laminated body is obtained by repeating the joining of the inner conductors once or more.

[0008]

As described above, the coil component of the present invention is close to one turn of the coil formed in the insulator sheet and is the same in each layer.
A through-hole in which the end of the pattern coil conductor is formed obliquely.
Since it is connected to the starting end of the adjacent coil conductor of the next layer via a hole, one coil winding is formed by one lamination of the coil conductor.

In the manufacture of the coil component according to the present invention, the conductor filled in the through hole at the same time as the coil conductor is printed is joined to the coil conductor in the lower layer having the same pattern as the upper layer. As in the case of stacking filled ones, connection failure due to contraction of the conductor in the through hole does not occur.

[0010]

1 (A) is a perspective view showing an embodiment of a coil component according to the present invention as seen through a coil inside a laminate, and FIG. 1 (B) is a sectional view taken along line EE of FIG. 1 (A). Is. Figure 1
In (A) and (B), the coil component 1 is an insulator sheet.
2 and a pattern close to one coil, and each layer
The coil conductors 5 having the same pattern are alternately laminated to form a laminated body, and the laminated body is fired. The coil conductor 5 of each layer is a through hole 6 obliquely formed on the insulator sheet 2 with the insulator sheet 2 interposed therebetween.
To form a coil 7 connected via a conductor filled in the coil. Here, 3 and 4 respectively indicate a lower extraction electrode and an upper extraction electrode which also serve as coil conductors.

FIG. 2 is a manufacturing process diagram showing a method for manufacturing a coil component according to the present invention for one chip. First,
In FIG. 2, for example, magnetic ferrite is replaced with, for example, butyler.
A plurality of insulating sheets 2 formed by forming a sheet with a suitable binder such as resin and extending it into a sheet to form a base of a laminated body until a required thickness is obtained. (A), the lower extraction electrode 3 is printed on it (b), and the insulating sheet 2a is formed by obliquely forming the through-hole 6 on the laser beam. Lower opening 6 of the through hole 6
The layers are laminated so that the position of a is the end on the lower extraction electrode 3 (c). Next, a coil conductor 5 having a pattern close to one coil is printed on the upper surface of the insulator sheet 2a such that the starting end X is located in the upper opening 6b of the through hole 6. (D).

Subsequently, the insulator sheet 2a having the through-hole 6 formed thereon is attached to the lower opening 6 of the through-hole 6.
The layers are laminated so that a is located at the terminal Y of the coil conductor 5 (e). After that, the steps (d) and (e) are repeated by the required number of coil turns, and the upper extraction electrode 4 is aligned with the starting end of the upper extraction electrode 4 in the upper opening 6b of the through hole 6 on the upper surface of the insulator sheet 2a. Is printed (f), and a plurality of insulating sheets 2 are laminated thereon until the required thickness is obtained (g). By firing the laminated body thus obtained at a predetermined temperature, the coil component 1 having the coil integrally built therein is manufactured.

Here, the coil conductor 5 and the extraction electrodes 3, 4
Is a powder of a metal conductor such as Ag, Ag-Pd, or Pd, which is made into a paste with an appropriate binder.

The insulating sheets 2 and 2a are lightly pressed by an appropriate pressure plate in each laminating process to press the upper and lower layers to each other so as to press the insulating sheets 2 and 2a and the insulating sheets 2 and 2a. It is preferable that the coil conductors 3 to 5 are brought into close contact with each other.

As described above, the paste-shaped coil conductor 5 is filled in the through-hole 6 at the same time as the printing, and the starting end X of the coil conductor 5 formed by the pattern close to one coil turns. -Since it is connected to the terminal end Y of the coil conductor 5 of the same pattern in the adjacent lower layer through the conductor filled in the hole 6, one lamination of the insulator sheet 2a and one coil formation. The printing of the conductor 5 forms a coil for one turn. Therefore, it is possible to reduce the number of laminations for the required number of turns of the coil as compared with the conventional example, and the productivity is improved. Further, since only one type of printing pattern for the coil conductor 5 is required, the control of the laminating process becomes easy and the productivity is improved.

By alternately laminating the insulator sheets 2a and printing the coil conductors 5, the coil conductors 5 are joined to the lower layer coil conductors 5 by the conductors filling the through holes 6 simultaneously with the printing of the coil conductors 5. Therefore, as in the case of stacking coil conductors 5 with through holes filled in advance,
The connection failure due to the contraction of the conductor in the through hole does not occur, and the quality can be improved.

In FIG. 1B, the distance W between the coil ends must be 50 μm or more in order to prevent a short circuit between them, and the thickness of the insulator sheet 2 must be large. The t1 is generally 30 to 35 μm, and the thickness t2 of the coil conductor 5 is 15 to 2 μm.
Considering the formation of 0 micron,
In order to sufficiently fill the hole 6 with a conductive paste normally used to eliminate disconnection defects, the diameter D of the through hole 6 is 80 to 100 μm and the angle θ is 10 ° to 10 °. It is preferably set to 25 degrees.

Further, the present invention relates to a chip-shaped inductor, an inductor or a transformer, a magnetic head, an LC composite component, or the like, in which a plurality of coils are vertically arranged or a plurality of coils are concentrically formed. It can also be applied to the coil portion. Moreover, as an insulator sheet,
Non-magnetic materials may be used to obtain the desired physical properties,
Also, it can be manufactured as a laminated body combined with a capacitor or a resistor.

[0019]

According to the first aspect of the present invention, since one coil can be formed by laminating the insulator sheet once and printing the coil conductor once, the number of laminations with respect to the required number of turns of the coil can be increased. Printing pattern of coil conductor can be reduced.
Since only one type is required, the stacking process can be easily controlled and the productivity is improved.

According to the second aspect of the present invention, since the lamination of the insulator sheets and the printing of the coil conductors are alternately performed, the conductors are filled in the through holes at the same time when the coil conductors are printed, and the conductors are vertically adjacent to each other. Since the coil conductor to be electrically connected is electrically connected, there is no connection failure due to contraction of the conductor in the through hole as in the case of stacking coil conductors filled in the through hole in advance, and quality is improved. You can

[Brief description of drawings]

1A is a perspective view showing an embodiment of a coil component according to the present invention as seen through a coil inside a laminated body, and FIG. 1B is a sectional view taken along line EE of FIG. 1A. .

FIG. 2 is a manufacturing process diagram showing a manufacturing method of an embodiment of a coil component according to the present invention.

[Explanation of symbols]

1 coil parts 2, 2a insulator sheet 3 Lower electrode 4 Upper extraction electrode 5 coil conductor 6 Through hole 6a Lower opening 6b Upper opening 7 coils

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Claims (2)

(57) [Claims] 1. A laminated coil component comprising magnetic or non-magnetic insulating layers and coil conductors alternately laminated,
The coil conductor of each layer was formed by the same pattern close to one coil, and the end of the coil conductor of one layer and the start of the coil conductor of the next layer were filled in a diagonally formed through hole. A coil component characterized by being electrically connected via a conductor. 2. A method for manufacturing a coil component according to claim 1 by a sheet method, wherein a through hole is formed obliquely by a laser beam on a magnetic or non-magnetic insulating sheet. In advance, the insulator sheet is stacked on the existing laminate so that the lower opening of the through hole is located at the end position of the coil conductor formed in the previous step, and the insulator sheet is attached to the coil sheet. By printing a coil conductor having a pattern that is close to the winding and is the same in each layer so that the starting end of the coil conductor is the upper opening of the through hole, the conductor is filled in the through hole to form a lower layer. A method for manufacturing a coil component, wherein a laminated body is obtained by repeating joining the conductor in the through hole to the coil conductor one or more times.