JP7351441B2 - Coil parts and method for manufacturing coil parts - Google Patents

Description

The present invention relates to a coil component including a coil.

As an invention related to a conventional coil component, for example, a multilayer board described in Patent Document 1 is known. This multilayer board includes a laminate and a coil. The laminate has a structure in which a plurality of base material layers are laminated. The material of the plurality of base layers is thermoplastic resin. The coil is provided within the laminate. The coil has a structure in which a plurality of coil conductor patterns stacked together with a plurality of base material layers are connected by an interlayer connection conductor. Such a multilayer board is produced by integrating a plurality of base material layers made of thermoplastic resin by thermocompression bonding.

Patent Application No. 2020-72163

By the way, in the multilayer board described in Patent Document 1, there is a desire to suppress deviation of the positions of the plurality of coil conductor patterns from design values and to reduce the DC resistance value of the coils.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a coil component and a method for manufacturing a coil component that can suppress the position of a plurality of coil conductors from deviating from a designed value and can reduce the DC resistance value of the coil.

A coil component according to one embodiment of the present invention includes:
One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
It is equipped with
The first coil conductor is located furthest in the first direction among the plurality of coil conductors,
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the second coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the second top portion in the line width direction. 2 is smaller than the second ratio obtained by dividing by the width of the bottom portion in the line width direction.

A method for manufacturing a coil component according to one embodiment of the present invention includes:
One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
Equipped with
A method for manufacturing a coil component,
a second coil conductor forming step of forming the second coil conductor on the resin layer;
a thermocompression bonding step of thermocompression bonding the plurality of resin layers after the second coil conductor forming step;
After the thermocompression bonding step, the vertical thickness of the first coil conductor located in the resin layer located in the first direction among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A first coil conductor forming step;
After the thermocompression bonding step, the thickness in the vertical direction of the third coil conductor located in the resin layer located in the second direction most among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A third coil conductor forming step,
It is equipped with
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the second coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the first bottom portion in the line width direction. 2 is smaller than the second ratio obtained by dividing by the width of the bottom portion in the line width direction.

A method for manufacturing a coil component according to one embodiment of the present invention includes:
One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
Equipped with
A method for manufacturing a coil component,
a second coil conductor forming step of forming the second coil conductor on the resin layer;
a third coil conductor forming step of forming the third coil conductor on the resin layer;
After the second coil conductor forming step and the third coil conductor forming step, heat-bonding the plurality of resin layers by thermocompression so that the second coil conductor and the third coil conductor are lined up in this order in the second direction. crimping process,
After the thermocompression bonding step, the vertical thickness of the first coil conductor located in the resin layer located in the first direction among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A first coil conductor forming step;
It is equipped with
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the second coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the second top portion in the line width direction. 2 is smaller than the second ratio obtained by dividing by the width of the bottom portion in the line width direction.

According to the coil component according to the present invention, it is possible to prevent the plurality of coil conductors from deviating from the designed value, and it is also possible to reduce the DC resistance value of the coil.

FIG. 1 is a cross-sectional view of a drive module 10 with a coil component 11. FIG. FIG. 2 is an exploded perspective view of the coil component 11. FIG. 3 is a cross-sectional view showing the manufacturing process of the coil component 11. FIG. 4 is a cross-sectional view showing the manufacturing process of the coil component 11. FIG. 5 is a cross-sectional view showing the manufacturing process of the coil component 11. FIG. 6 is a cross-sectional view of the coil component 11a. FIG. 7 is an exploded perspective view of the coil component 11a. FIG. 8 is a cross-sectional view of the coil component 11b. FIG. 9 is an exploded perspective view of the coil component 11b. FIG. 10 is a cross-sectional view of the coil component 11c. FIG. 11 is a cross-sectional view of the coil component 11d. FIG. 12 is a cross-sectional view showing the manufacturing process of the coil component 11d. FIG. 13 is a cross-sectional view showing the manufacturing process of the coil component 11d. FIG. 14 is a cross-sectional view showing the manufacturing process of the coil component 11d. FIG. 15 is a cross-sectional view of the coil component 11e. FIG. 16 is a cross-sectional view of the coil component 11f. FIG. 17 is a cross-sectional view showing the manufacturing process of the coil component 11f. FIG. 18 is a cross-sectional view showing the manufacturing process of the coil component 11f. FIG. 19 is a cross-sectional view showing the manufacturing process of the coil component 11f. FIG. 20 is a cross-sectional view of the coil component 11g.

(Embodiment)
[Structure of drive module]
Below, the structure of the drive module 10 according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view of a drive module 10 with a coil component 11. FIG. FIG. 2 is an exploded perspective view of the coil component 11.

In this specification, direction is defined as follows. The stacking direction of the stacked body 12 of the coil component 11 is defined as the vertical direction. The upper direction, which is one of the upper and lower directions, is the first direction DIR1. The downward direction, which is the other vertical direction, is the second direction DIR2. Further, the left-right direction and the front-back direction are perpendicular to the up-down direction. The left-right direction is perpendicular to the front-back direction. In addition, the up-down direction, the front-back direction, and the left-right direction in this embodiment do not need to correspond to the up-down direction, the front-back direction, and the left-right direction when the drive module 10 is used.

In the following, X is a part or member of the drive module 10. In this specification, unless otherwise specified, each part of X is defined as follows. The front part of the X means the front half of the X. The rear part of the X means the rear half of the X. The left part of X means the left half of X. The right side of X means the right half of X. The upper part of X means the upper half of X. The lower part of X means the lower half of X. The front end of X means the front end of X. The rear end of X means the end of X in the rear direction. The left end of X means the left end of X. The right end of X means the right end of X. The upper end of X means the upper end of X. The lower end of X means the lower end of X. The front end of X means the front end of X and its vicinity. The rear end of X means the rear end of X and its vicinity. The left end of X means the left end of X and its vicinity. The right end of X means the right end of X and its vicinity. The upper end of X means the upper end of X and its vicinity. The lower end of X means the lower end of X and its vicinity.

First, the structures of the drive module 10 and the coil component 11 will be described with reference to FIG. The drive module 10 is used, for example, in a wireless communication terminal such as a smartphone.

The drive module 10 includes a coil component 11 and a magnet 50, as shown in FIGS. 1 and 2. The coil component 11 includes a laminate 12, a coil L, and lead conductors 20a and 20b. The laminate 12 has a structure in which resin layers 15a to 15f are stacked vertically. In this embodiment, the laminate 12 includes resin layers 15a to 15f and protective layers 16a and 16b. The protective layer 16a, the resin layers 15a to 15f, and the protective layer 16b are arranged in this order from top to bottom.

As shown in FIG. 2, each of the resin layers 15a to 15f has an upper main surface and a lower main surface that are arranged in the vertical direction. The material of the resin layers 15a to 15f is thermoplastic resin. The thermoplastic resin is, for example, a liquid crystal polymer, PTFE (polytetrafluoroethylene), or the like. The material of the resin layers 15a to 15f may be polyimide. Therefore, the material of the laminate 12 is a non-magnetic material.

The protective layers 16a and 16b are resist layers. The protective layer 16a is located on the upper main surface of the resin layer 15a. The protective layer 16a protects the coil conductor 18a located on the upper main surface of the resin layer 15a. The protective layer 16b is located on the lower main surface of the resin layer 15f. The protective layer 16b protects the coil conductor 18f located on the lower main surface of the resin layer 15f. Each of the protective layers 16a and 16b may be formed by attaching an insulating sheet to the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15f, or by applying an insulating resin paste to the resin layer 15f. It may be formed by printing on the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15b.

The coil L is provided in the laminated body 12. The coil L is, as shown in FIGS. 1 and 2,
It has a spiral shape that revolves around a central axis Ax1 extending in the vertical direction. In this embodiment, the coil L has a spiral shape that moves upward while rotating clockwise. The coil L includes a plurality of coil conductors having a linear shape when viewed in the vertical direction. The plurality of coil conductors include a coil conductor 18a (first coil conductor), coil conductors 18b to 18e (second coil conductor), and a coil conductor 18f (third coil conductor) arranged in this order in the downward direction (second direction DIR2). Contains. In this embodiment, the coil L includes coil conductors 18a to 18f and interlayer connection conductors v1 to v6, as shown in FIG.

The coil conductors 18a to 18f are stacked vertically together with the resin layers 15a to 15f. More specifically, each of the coil conductors 18a to 18e is located on the upper main surface of the resin layers 15a to 15e. The coil conductor 18f is located on the lower main surface of the resin layer 15f. Thereby, the coil conductors 18a to 18f are arranged in this order from top to bottom. Further, the coil conductor 18a (first coil conductor) is located at the top (first direction DIR1) among the coil conductors 18a to 18f. The coil conductor 18f (third coil conductor) is located at the lowest position (second direction DIR2) among the coil conductors 18a to 18f.

Each of the coil conductors 18a to 18f (first coil conductor, second coil conductor, and third coil conductor) has a spiral shape that revolves around the central axis Ax1 for one or more turns when viewed in the vertical direction. . In this embodiment, the coil conductors 18a, 18c, and 18e have a spiral shape that approaches the center while rotating counterclockwise when viewed downward. The coil conductors 18b, 18d, and 18f have a spiral shape that approaches the center while rotating clockwise when viewed downward. Hereinafter, the outer circumferential ends of the coil conductors 18a to 18f will be referred to as outer circumferential ends. The ends on the inner circumferential side of the coil conductors 18a to 18f are called inner circumferential ends.

Each of the interlayer connection conductors v1 to v6 vertically penetrates the resin layers 15a to 15f. The interlayer connection conductor v1 electrically connects the inner peripheral end of the coil conductor 18a and the inner peripheral end of the coil conductor 18b. The interlayer connection conductor v2 electrically connects the outer peripheral end of the coil conductor 18b and the outer peripheral end of the coil conductor 18c. The interlayer connection conductor v3 electrically connects the inner peripheral end of the coil conductor 18c and the inner peripheral end of the coil conductor 18d. The interlayer connection conductor v4 electrically connects the outer peripheral end of the coil conductor 18d and the outer peripheral end of the coil conductor 18e. The interlayer connection conductor v5 and the interlayer connection conductor v6 are connected in series. Interlayer connection conductors v5 and v6 electrically connect the inner peripheral end of the coil conductor 18e and the inner peripheral end of the coil conductor 18f.

The lead conductor 20a is located on the upper main surface of the resin layer 15a. The lead conductor 20a is connected to the outer peripheral end of the coil conductor 18a. Further, the lead-out conductor 20a extends rightward from the outer peripheral end of the coil conductor 18a. As a result, the extraction conductor 20a is separated from the coil L by leaving the orbit of the coil conductors 18a to 18f.

The lead conductor 20b is located on the lower main surface of the resin layer 15f. The lead conductor 20b is connected to the outer peripheral end of the coil conductor 18f. Further, the lead-out conductor 20b extends rightward from the outer peripheral end of the coil conductor 18f. As a result, the extraction conductor 20b is separated from the coil L by leaving the orbit of the coil conductors 18a to 18f.

Each of the coil conductors 18b to 18e as described above is a conductor layer formed by etching a metal foil attached to the upper main surface of the resin layers 15b to 15e. The metal foil is, for example, copper foil. Each of the coil conductors 18a and 18f is a conductor layer formed by plating the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15b. The plating is, for example, copper plating. Further, the interlayer connection conductors v1 to v6 are formed by filling conductive paste into through holes formed in the resin layers 15a to 15e and solidifying the conductive paste by heating. The conductive paste is, for example, a mixture of metal powder and resin. Note that the interlayer connection conductors v1 to v6 may be formed by plating the inner peripheral surfaces of through holes formed in the resin layers 15a to 15e.

Here, as shown in FIG. 1, the vertical thickness T1 of the coil conductor 18a (first coil conductor) is larger (longer) than the vertical thickness T2 of the coil conductors 18b to 18e (second coil conductor). Relationship 1). The thickness T1 is the shortest distance between a first top portion S2 and a first bottom portion S1, which will be described later. Thickness T2 is the shortest distance between second top portion S4 and second bottom portion S3, which will be described later. Further, the vertical thickness T3 of the coil conductor 18f (third coil conductor) is larger (longer) than the vertical thickness T2 of the coil conductors 18b to 18e (second coil conductor) (Relationship 2). The thickness T3 is the shortest distance between the third top portion S6 and the third bottom portion S5, which will be described later. The coil conductors 18b to 18e (second coil conductors) refer to the coil conductors 18a to 18f excluding the uppermost coil conductor 18a and the lowermost coil conductor 18f.

Moreover, the above relationships 1 and 2 may be satisfied in all cross sections of the plurality of cross sections of the coil component 11 parallel to the vertical direction, or may be satisfied in all the cross sections of the coil component 11 parallel to the vertical direction. It may be established in at least one cross section within. Further, the vertical thickness T1 of the coil conductor 18a is an average value of the vertical thickness T1 of the coil conductor 18a. Note that the definitions of the thicknesses T2 and T3 are also the same as the definition of the thickness T1.

By the way, when viewed in the vertical direction, the direction perpendicular to the direction in which each of the coil conductors 18a to 18f (first coil conductor, second coil conductor, and third coil conductor) extends is the line width direction. The outer edge of the coil conductor 18a (first coil conductor) includes a first bottom portion S1, which is a plane located at the lowest position (in the second direction) on the outer edge of the coil conductor 18a (first coil conductor), and a first bottom portion S1 ( It has a first top part S2 which is a plane located at the uppermost position (in the first direction) at the outer edge of the first coil conductor. The first top portion S2 is located above the first bottom portion S1 (in the first direction DIR1) and has a normal line parallel to the first bottom portion S1. In this embodiment, the first top portion S2 is a flat surface. The first bottom portion S1 is fixed to the upper main surface of the resin layer 15a. Further, the surface roughness of the first bottom portion S1 is greater than the surface roughness of the first top portion S2. The width W2 of the first top portion S2 in the line width direction is smaller than the width W1 of the first bottom portion S1 in the line width direction.

Each of the outer edges of the coil conductors 18b to 18e (second coil conductors) includes a second bottom portion S3, which is a plane located at the lowest position (in the second direction) in the outer edges of the coil conductors 18b to 18e (second coil conductors); It also has a second top portion S4, which is a plane located at the uppermost position (in the first direction) at the outer edge of the coil conductors 18b to 18e (second coil conductors). The second top portion S4 is located above the second bottom portion S3 (in the first direction DIR1) and has a normal line parallel to the second bottom portion S3. The second bottom portions S3 of the coil conductors 18b to 18e are each fixed to the upper main surface of the resin layers 15b to 15e. Further, the surface roughness of the second bottom portion S3 is greater than the surface roughness of the second top portion S4. The width W4 of the second top portion S4 in the line width direction is smaller than the width W3 of the second bottom portion S3 in the line width direction. Further, in the present embodiment, the width W3 of the second bottom portion S3 in the line width direction is equal to the width W1 of the first bottom portion S1 in the line width direction. The width W4 of the second top portion S4 in the line width direction is larger than the width W2 of the first top portion S2 in the line width direction. Therefore, the first ratio P1 obtained by dividing the width W2 in the line width direction of the first top part S2 by the width W1 in the line width direction of the first bottom part S1 is the width W4 in the line width direction of the second top part S4. is smaller than the second ratio P2 obtained by dividing by the width W3 of the second bottom portion S3 in the line width direction (Relationship 3).

The outer edge of the coil conductor 18f (third coil conductor) includes a third bottom portion S5, which is a plane located at the lowest position (in the second direction) on the outer edge of the coil conductor 18f (third coil conductor), and a third bottom portion S5 ( It has a third top part S6 which is a plane located at the uppermost position (in the first direction) at the outer edge of the third coil conductor. The third top portion S6 is located above the third bottom portion S5 (in the first direction DIR1) and has a normal line parallel to the third bottom portion S5. The third bottom portion S5 is fixed to the lower main surface of the resin layer 15f. Further, the surface roughness of the third bottom portion S5 is greater than the surface roughness of the third top portion S6. The width W6 of the third top portion S6 in the line width direction is smaller than the width W5 of the third bottom portion S5 in the line width direction. Further, in the present embodiment, the width W3 of the second bottom portion S3 in the line width direction is equal to the width W5 of the third bottom portion S5 in the line width direction. The width W4 of the second top portion S4 in the line width direction is larger than the width W6 of the third top portion S6 in the line width direction. Therefore, the third ratio P3 obtained by dividing the width W6 of the third top portion S6 in the line width direction by the width W5 of the third bottom portion S5 in the line width direction is smaller than the second ratio P2 (Relationship 4).

Incidentally, the above relationships 3 and 4 may be satisfied in all cross sections of the plurality of cross sections of the coil component 11 parallel to the vertical direction, or may be satisfied in a plurality of cross sections of the coil component 11 parallel to the vertical direction. It may be established in at least one cross section within. Further, the width W1 of the first bottom portion S1 in the line width direction may be an average value of the width W1 of the coil conductor 18a in the line width direction. The definitions of the widths W2 to W6 are also the same as the definition of the width W1.

As shown in FIG. 1, the magnet 50 is located above the coil L (in the first direction DIR1). The magnet 50 overlaps the coil L when viewed in the vertical direction. The magnet 50 as described above extends in the left-right direction. The left side of the magnet 50 is the north pole. The right side of the magnet 50 is the south pole.

Further, the drive module 10 further includes a magnetic sensor (not shown). The magnetic sensor detects the magnetic force of the magnet 50. The magnetic sensor is mounted on the laminate 12, for example.

The drive module 10 as described above includes a control circuit (not shown). The magnetic sensor and coil L are electrically connected to a control circuit. The magnetic sensor generates an output signal according to the magnitude of the magnetic force detected by the magnetic sensor. The control circuit controls the magnitude of the current flowing through the coil L based on the output signal generated by the magnetic sensor. For example, when looking downward, when a clockwise current flows through the coil L, the current flows forward through the conductor located on the left side of the coil L, and the current flows backward through the conductor located on the right side of the coil L. Current flows in the direction. In the magnet 50, lines of magnetic force exit from the N pole and lines of magnetic force enter the S pole. Therefore, when a current flows forward through the conductor located on the left side of the coil L, the conductor located on the left side of the coil L receives a Lorentz force in the left direction. When a current flows backward through the conductor located on the right side of the coil L, the conductor located on the right side of the coil L receives a Lorentz force in the left direction. That is, the coil L receives force from the magnet 50 in the left direction. In other words, the magnet 50 receives force from the coil L in the right direction. As a result, the magnet 50 is displaced to the right with respect to the coil L. However, the coil L may be displaced to the left with respect to the magnet 50.

On the other hand, when looking downward, when a counterclockwise current flows through the coil L, the current flows backward through the conductor located on the left side of the coil L, and the current flows backward through the conductor located on the right side of the coil L. Current flows in the forward direction. When a current flows backward through the conductor located on the left side of the coil L, the conductor located on the left side of the coil L receives a Lorentz force in the right direction. When a current flows forward through the conductor located on the right side of the coil L, the conductor located on the right side of the coil L receives a Lorentz force in the right direction. That is, the coil L receives a force from the magnet 50 in the right direction. In other words, the magnet 50 receives force from the coil L in the left direction. As a result, the magnet 50 is displaced to the left with respect to the coil L. As described above, the position of the magnet 50 with respect to the coil L changes due to the magnetic force generated by the coil L. However, the coil L may be displaced to the right with respect to the magnet 50.

[Method for manufacturing coil component 11]
Below, a method for manufacturing the coil component 11 will be described with reference to the drawings. 3 to 5 are cross-sectional views showing the manufacturing process of the coil component 11.

First, as shown in FIG. 3, coil conductors 18b to 18e (second coil conductors) are formed on each of resin layers 15b to 15e (second coil conductor forming step). Specifically, metal foil is pasted on the upper main surfaces of the resin layers 15b to 15e. A mask is formed on this metal foil. Coil conductors 18b to 18e are then formed by etching through a mask. Moreover, metal films 200a and 200b are provided on the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15f. The metal films 200a and 200b are thinner than metal foil.

Furthermore, interlayer connection conductors v1 to v6 are formed in the resin layers 15a to 15f. Specifically, through holes are formed by irradiating each of the resin layers 15a to 15f with a laser beam. After that, the through holes are filled with conductive paste.

As shown in FIG. 4, after the second coil conductor forming step, the resin layers 15a to 15f are thermocompression bonded (thermocompression bonding step). This softens and fluidizes the resin layers 15a to 15f. Then, when the resin layers 15a to 15f are cooled, the resin layers 15a to 15f are integrated. Furthermore, the conductive paste in the through hole is solidified by thermocompression bonding.

As shown in FIG. 5, after the thermocompression bonding process, a coil conductor 18a is located in the uppermost resin layer 15a (in the first direction DIR1) among the plurality of resin layers 15a to 15f bonded by thermocompression in the thermocompression bonding process. The vertical thickness of the first coil conductor is increased (first coil conductor forming step). Furthermore, after the thermocompression bonding step, the coil conductor 18f (third coil conductor ) is increased in the vertical direction (third coil conductor forming step). Thereby, coil conductors 18a and 18f are completed. The coil conductors 18a and 18f are formed by, for example, MSAP (Modified Semi Additive Process). In MSAP, a mask is formed on the metal films 200a and 200b. Then, a plating layer is formed by plating the metal films 200a and 200b. Then remove the mask. Furthermore, unnecessary metal films 200a and 200b overlapping the mask are removed by etching.

Finally, a protective layer 16a is formed on the upper main surface of the resin layer 15a. A protective layer 16b is formed on the lower main surface of the resin layer 15f. Thereby, the coil component 11 is completed.

[effect]
According to the coil component 11, it is possible to prevent the positions of the coil conductors 18a to 18f from deviating from their designed values, and the DC resistance value of the coil L can be reduced. More specifically, in order to reduce the DC resistance value of the coil L, for example, the thickness of the coil conductors 18a to 18f in the vertical direction may be increased. This increases the cross-sectional area of the coil conductors 18a to 18f, and reduces the DC resistance value of the coil conductors 18a to 18f. However, when the thickness of the coil conductors 18a to 18f increases in the vertical direction, the coil conductors 18a to 18f move from the fluidized resin layers 15a to 15f in the front-rear direction and left-right direction during thermocompression bonding of the resin layers 15a to 15f. susceptible to large forces. As a result, the positions of the coil conductors 18a to 18f deviate from their designed values. As described above, it is difficult to simultaneously suppress the deviation of the positions of the coil conductors 18a to 18f from the designed values and reduce the DC resistance value of the coil L.

Therefore, as a result of ingenuity, the inventor of the present application came up with the idea of applying the following relationships 1 and 3 to the coil component 11.

Relationship 1: The vertical thickness T1 of the coil conductor 18a (first coil conductor) is greater than the vertical thickness T2 of the coil conductors 18b to 18e (second coil conductors).
Relationship 3: The first ratio P1 obtained by dividing the width W2 in the line width direction of the first top portion S2 by the width W1 in the line width direction of the first bottom portion S1 is the width in the line width direction of the second top portion S4. It is smaller than the second ratio P2 obtained by dividing W4 by the width W3 of the second bottom portion S3 in the line width direction.

When relationship 1 holds true, the cross-sectional area of the coil conductor 18a becomes larger, so the DC resistance value of the coil conductor 18a becomes smaller. Furthermore, by establishing relationships 1 and 3, the positions of the coil conductors 18b to 18e are prevented from deviating from their designed values. More specifically, the coil conductors 18b to 18e are located inside the resin layers 15a to 15f during thermocompression bonding. Therefore, when the resin layers 15a to 15f become fluidized, the positions of the coil conductors 18c to 18e tend to deviate from their designed values. Therefore, relations 1 and 3 are established. This improves the flatness of the coil conductor 18b. More specifically, when relationship 1 holds true, the vertical thickness T2 of the coil conductor 18b becomes smaller. Furthermore, since relationship 3 holds true, the second top portion S4 of the coil conductor 18b becomes wider. In this way, by establishing relationships 1 and 3, the coil conductor 18b has a flat cross-sectional shape. That is, the flatness of the coil conductor 18b is improved. For the same reason, the flatness of the coil conductors 18c to 18e is improved. When the flatness of the coil conductors 18b to 18e is improved in this way, the coil conductors 18b to 18e are less likely to receive force in the front-rear direction and left-right direction from the resin layers 15a to 15f fluidized during thermocompression bonding. As a result, the positions of the coil conductors 18a to 18f are prevented from deviating from their designed values.

Note that even when relations 2 and 4 hold, for the same reason as when relations 1 and 3 hold, it is possible to suppress the position of the coil conductors 18a to 18f from deviation from the design value, and to reduce the DC resistance of the coil L. value can be reduced.

The metal films 200a and 200b are thinner than metal foil. This makes it easy to remove unnecessary metal films 200a and 200b overlapping the mask by etching when forming coil conductors 18a and 18f using MSAP.

(First modification)
A coil component 11a according to a first modification will be described below with reference to the drawings. FIG. 6 is a cross-sectional view of the coil component 11a. FIG. 7 is an exploded perspective view of the coil component 11a.

The coil component 11a differs from the coil component 11 in that the width of the coil conductors 18a, 18f in the line width direction is larger than the width of the coil conductors 18b to 18e in the line width direction. As a result, the width W1 of the first bottom portion S1 in the line width direction is larger than the width W3 of the second bottom portion S3 in the line width direction. The width W5 of the third bottom portion S5 in the line width direction is larger than the width W3 of the second bottom portion S3 in the line width direction. The distance d1 between the coil conductors 18a (first coil conductors) adjacent to each other in the line width direction is smaller than the distance d2 between the coil conductors 18b to 18e (second coil conductors) adjacent to each other in the line width direction. Similarly, the distance d3 between the coil conductors 18f (third coil conductors) adjacent to each other in the line width direction is smaller than the distance d2 between the coil conductors 18b to 18e (second coil conductors) adjacent to each other in the line width direction. This makes it easier for the resin layers 15a to 15f to flow between the coil conductors 18b to 18e (second coil conductors) adjacent in the line width direction. As a result, formation of holes between the coil conductors 18b to 18e (second coil conductors) adjacent in the line width direction is suppressed. The other structure of the coil component 11a is the same as that of the coil component 11, so a description thereof will be omitted. The coil component 11a can have the same effects as the coil component 11.

(Second modification)
Below, a coil component 11b according to a second modification will be described with reference to the drawings. FIG. 8 is a cross-sectional view of the coil component 11b. FIG. 9 is an exploded perspective view of the coil component 11b.

Coil component 11b differs from coil component 11 in the shapes of coil conductors 18a and 18f. More specifically, the number of turns of each of the coil conductors 18a and 18f is greater than the number of turns of each of the coil conductors 18b to 18e. In this embodiment, the number of turns of each of the coil conductors 18a and 18f is approximately twice the number of turns of each of the coil conductors 18b to 18e. The widths of the coil conductors 18a and 18f in the line width direction are smaller than the widths of the coil conductors 18b to 18e in the line width direction. That is, the width W1 of the first bottom portion S1 in the line width direction is smaller than the width W3 of the second bottom portion S3 in the line width direction. The width W5 of the third bottom portion S5 in the line width direction is smaller than the width W3 of the second bottom portion S3 in the line width direction. When viewed in the vertical direction, substantially the entire coil conductor 18a overlaps with the coil conductors 18b to 18e. Similarly, substantially the entire coil conductor 18f overlaps with the coil conductors 18b to 18e.

Further, in the coil component 11b, the following formulas (1) and (2) hold true.

W1/T1×2<W3/T2...(1)
W5/T3×2<W3/T2...(2)
The other structure of the coil component 11b is the same as that of the coil component 11, so a description thereof will be omitted. The coil component 11b can have the same effects as the coil component 11.

Further, in the coil component 11b, the number of turns of each of the coil conductors 18a and 18f is greater than the number of turns of each of the coil conductors 18b to 18e. This increases the inductance value of the coil L.

(Third modification)
A coil component 11c according to a third modification will be described below with reference to the drawings. FIG. 10 is a cross-sectional view of the coil component 11c.

The coil component 11c differs from the coil component 11b in that the spacing between coil conductors 18a adjacent to each other in the line width direction is uniform, and that the spacing between coil conductors 18f adjacent to each other in the line width direction is uniform. The other structure of the coil component 11c is the same as that of the coil component 11b, so a description thereof will be omitted. The coil component 11c can have the same effects as the coil component 11b.

(Fourth modification)
A coil component 11d according to a fourth modification will be described below with reference to the drawings. FIG. 11 is a cross-sectional view of the coil component 11d.

The coil component 11d differs from the coil component 11 in that it does not include coil conductors 18d to 18f. The coil conductor 18b (second coil conductor) is located on the lower main surface of the resin layer 15a. Therefore, in the coil conductor 18b, the second bottom portion S3 is located above the second top portion S4. The second bottom portion S3 is fixed to the lower main surface of the resin layer 15a.

Further, the vertical thickness T1 of the coil conductor 18a (first coil conductor) is larger than the vertical thickness T3 of the coil conductor 18c (third coil conductor). The outer edge of the coil conductor 18c (third coil conductor) includes a third bottom portion S5, which is a plane located at the lowest position (in the second direction) in the outer edge of the coil conductor 18c (third coil conductor), and a third bottom portion S5 ( It has a third top part S6 which is a plane located at the uppermost position (in the first direction) at the outer edge of the third coil conductor. The third top portion S6 is located above the third bottom portion S5 (in the first direction DIR1) and has a normal line parallel to the third bottom portion S5. The width W6 of the third top portion S6 in the line width direction is smaller than the width W5 of the third bottom portion S5 in the line width direction. The first ratio P1 is smaller than the third ratio P3 obtained by dividing the width W6 of the third top portion S6 in the line width direction by the width W5 of the third bottom portion S5 in the line width direction.

The other structure of the coil component 11d is the same as that of the coil component 11, so a description thereof will be omitted. The coil component 11d can have the same effects as the coil component 11.

Below, a method for manufacturing the coil component 11d will be described with reference to the drawings. 12 to 14 are cross-sectional views showing the manufacturing process of the coil component 11d.

First, as shown in FIG. 12, a coil conductor 18b (second coil conductor) is formed on the resin layer 15a (second coil conductor forming step). A coil conductor 18c (third coil conductor) is formed on the resin layer 15b (third coil conductor forming step). Specifically, metal foil is attached to each of the upper main surface of the resin layer 15a and the upper main surface of the resin layer 15b. A mask is formed on this metal foil. Coil conductors 18b and 18c are then formed by etching through a mask. Further, a metal film 200a is provided on the upper main surface of the resin layer 15a. The metal film 200a is thinner than metal foil.

Furthermore, interlayer connection conductors v1 and v2 are formed on the resin layers 15a and 15b. Specifically, each of the resin layers 15a and 15b is irradiated with a laser beam to form a through hole. After that, the through holes are filled with conductive paste.

As shown in FIG. 13, after the second coil conductor forming step and the third coil conductor forming step, the coil conductor 18b (second coil conductor) and the coil conductor 18c (third coil conductor) are moved downward (in the second direction DIR2). ), the resin layers 15a to 15c are thermocompression bonded in this order (thermocompression bonding step). This softens and fluidizes the resin layers 15a to 15c. Then, when the resin layers 15a to 15c are cooled, the resin layers 15a to 15c are integrated. Furthermore, the conductive paste in the through hole is solidified by thermocompression bonding.

As shown in FIG. 14, after the thermocompression bonding step, a coil conductor 18a is located in the uppermost resin layer 15a (in the first direction DIR1) among the plurality of resin layers 15a to 15c bonded by thermocompression in the thermocompression bonding step. The vertical thickness of the first coil conductor is increased (first coil conductor forming step). The coil conductor 18a is formed of, for example, MSAP. In MSAP, a mask is formed on the metal film 200a. Then, a plating layer is formed by plating on the metal film 200a. Then remove the mask. Furthermore, unnecessary metal film 200a overlapping the mask is removed by etching.

Finally, a protective layer 16a is formed on the upper main surface of the resin layer 15a. Thereby, the coil component 11d is completed.

(Fifth modification)
A coil component 11e according to a fifth modification will be described below with reference to the drawings. FIG. 15 is a cross-sectional view of the coil component 11e.

The coil component 11e differs from the coil component 11d in that it further includes a resin layer 15g and an interlayer connection conductor v11, and that the positions of the coil conductors 18b and 18c are different. More specifically, the resin layer 15g is located between the resin layer 15a and the resin layer 15b. The coil conductor 18b is located on the lower main surface of the resin layer 15g. Coil conductor 18c is located on the lower main surface of resin layer 15b. Therefore, in the coil conductor 18b, the third bottom portion S5 is located above the third top portion S6. The third bottom portion S5 is fixed to the lower main surface of the resin layer 15g. The interlayer connection conductor v11 is connected in series with the interlayer connection conductor v1. The interlayer connection conductors v1 and v11 electrically connect the inner circumferential end of the coil conductor 18a and the inner circumferential end of the coil conductor 18b. The other structure of the coil component 11e is the same as that of the coil component 11d, so a description thereof will be omitted. The coil component 11e can have the same effect as the coil component 11d.

(Sixth variation)
A coil component 11f according to a sixth modification will be described below with reference to the drawings. FIG. 16 is a cross-sectional view of the coil component 11f.

The coil component 11f differs from the coil component 11 in the structure of coil conductors 18a and 18f. More specifically, in the coil component 11f, the coil conductor 18a includes a base conductor 181a and a plating layer 182a. The base conductor 181a is made of metal foil. Plating layer 182a covers base conductor 181a. The coil conductor 18f includes a base conductor 181f and a plating layer 182f. The base conductor 181f is made of metal foil. The plating layer 182f covers the base conductor 181f. The other structure of the coil component 11f is the same as that of the coil component 11, so a description thereof will be omitted. The coil component 11f can have the same effects as the coil component 11.

Further, in the coil component 11f, substantially the entire coil conductor 18a overlaps with the coil conductors 18b to 18e when viewed in the vertical direction. Similarly, substantially the entire coil conductor 18f overlaps with the coil conductors 18b to 18e. This makes it easier to apply force in the vertical direction to the coil conductors 18a to 18f during thermocompression bonding of the resin layers 15a to 15f, and makes it difficult to apply force in the front-back and left-right directions to the coil conductors 18a to 18f. As a result, the positions of the coil conductors 18a to 18f are prevented from deviating from their designed values.

Next, a method for manufacturing the coil component 11f will be described with reference to the drawings. 17 to 19 are cross-sectional views showing the manufacturing process of the coil component 11f.

First, as shown in FIG. 17, coil conductors 18b to 18e (second coil conductors) are formed on each of resin layers 15b to 15e (second coil conductor forming step). Specifically, metal foil is pasted on the upper main surfaces of the resin layers 15a to 15f. A mask is formed on this metal foil. Coil conductors 18b to 18e are then formed by etching through a mask.

Further, base conductors 181a and 181f are formed on the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15f, respectively. Specifically, metal foil is pasted on each of the upper main surface of the resin layer 15a and the lower main surface of the resin layer 15f. A mask is formed on this metal foil. Then, base conductors 181a and 181f are formed by etching through a mask.

Further, interlayer connection conductors v1 to v6 are formed in the resin layers 15b to 15e. Specifically, each of the resin layers 15b to 15e is irradiated with a laser beam to form a through hole. After that, the through holes are filled with conductive paste.

As shown in FIG. 18, the resin layers 15a to 15f are thermocompression bonded (thermocompression bonding step). This softens and fluidizes the resin layers 15a to 15f. Then, when the resin layers 15a to 15f are cooled, the resin layers 15a to 15f are integrated. Furthermore, the conductive paste in the through hole is solidified by thermocompression bonding.

As shown in FIG. 19, a coil conductor 18a (first coil conductor) located in the uppermost resin layer 15a (in the first direction DIR1) among the plurality of resin layers 15a to 15f bonded by thermocompression in the thermocompression bonding process (first coil conductor forming step). Furthermore, after the thermocompression bonding step, the coil conductor 18f (third coil conductor ) (third coil conductor forming step). Specifically, plating layers 182a and 182f are completed by plating base conductors 181a and 181f, respectively.

Finally, a protective layer 16a is formed on the upper main surface of the resin layer 15a. A protective layer 16b is formed on the lower main surface of the resin layer 15f. Thereby, the coil component 11f is completed.

(Seventh modification)
Below, a coil component 11g according to a seventh modification will be described with reference to the drawings. FIG. 20 is a cross-sectional view of the coil component 11g.

The coil component 11g includes coil components 11h and 11i. Each of the coil components 11h and 11i has the same structure as the coil component 11. The coil component 11h is mounted on the upper main surface of the coil component 11i. Thereby, the coil conductor 18f of the coil component 11h and the coil conductor 18a of the coil component 11i are electrically connected by solder.

Thereby, the coil component 11g has a structure in which the coil L1 of the coil component 11h and the coil L2 of the coil component 11i are connected in series. As a result, in the coil component 11g, the inductance value of the coil L increases.

(Other embodiments)
The coil components according to the present invention are not limited to the coil components 11, 11a to 11g, and can be modified within the scope of the gist. Note that the configurations of the coil components 11, 11a to 11g may be arbitrarily combined.

Note that the coil L has a structure in which a plurality of spiral coil conductors are connected. However, as long as the coil L has a spiral shape, the number of turns of the plurality of coil conductors may be one turn or less.

In addition, in the drive module 10, the left part of the magnet 50 may be the south pole, and the right part of the magnet 50 may be the north pole. Note that the magnet 50 may be a permanent magnet or an electromagnet.

Note that the material of the resin layers 15a to 15f may be a magnetic material.

Note that the material of the resin layers 15a to 15f may be a resin other than thermoplastic resin.

Note that a resin layer may be further laminated on the resin layer 15a. A resin layer may be further laminated below the resin layer 15f.

Note that the downward direction may be the first direction DIR1, and the upward direction may be the second direction DIR2.

Note that the width W1 of the first bottom portion S1 in the line width direction may be greater than or equal to the width W3 of the second bottom portion S3 in the line width direction.

Note that the distance between the coil conductors 18a (first coil conductors) adjacent to each other in the line width direction may be greater than or equal to the distance between the coil conductors 18b to 18e (second coil conductors) adjacent to each other in the line width direction.

Note that in the coil components 11, 11a to 11c, 11f, and 11g, the third proportion P3 may be equal to or greater than the second proportion P2.

Note that in the coil components 11, 11a to 11c, 11f, and 11g, the width W5 of the third bottom portion S5 in the line width direction may be greater than or equal to the width W3 of the second bottom portion S3 in the line width direction.

In the coil components 11, 11a to 11c, 11f, and 11g, the spacing between the coil conductors 18f (third coil conductors) adjacent to each other in the line width direction is the same as that of the coil conductors 18b to 18e (second coil conductor) adjacent to each other in the line width direction. The distance between the conductors) may be greater than the distance between the conductors.

Note that in the coil components 11d and 11e, the first ratio P1 may be equal to or greater than the third ratio P3.

Note that the coil components 11, 11a to 11f are applied to a drive module. However, the coil components 11, 11a to 11f may be used for purposes other than drive modules. The coil components 11, 11a to 11f may be used as antenna elements, for example. In this case, the coil L functions as a communication antenna or a wireless power feeding antenna.

10: Drive module 11, 11a to 11i: Coil component 12: Laminated body 15a to 15f: Resin layer 16a, 16b: Protective layer 18a to 18f: Coil conductor 20a, 20b: Extraction conductor 50: Magnet 181a, 181f: Base conductor 182a , 182f: Plated layer Ax1: Central axis L: Coil L1: Coil L2: Coil S1: First bottom part S2: First top part S3: Second bottom part S4: Second top part S5: Third bottom part S6: Third top part v1 to v6: interlayer connection conductor

Claims (11)

One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
It is equipped with
The first coil conductor is located furthest in the first direction among the plurality of coil conductors,
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the second top portion in the line width direction. 2 smaller than a second ratio obtained by dividing by the width in the line width direction of the bottom portion;
coil parts. The width of the first bottom portion in the line width direction is smaller than the width of the second bottom portion in the line width direction.
The coil component according to claim 1. The width of the first bottom portion in the line width direction is larger than the width of the second bottom portion in the line width direction.
The coil component according to claim 1. Each of the first coil conductor, the second coil conductor, and the third coil conductor has a spiral shape that revolves around the central axis for one or more turns when viewed in the vertical direction,
The distance between the first coil conductors adjacent to each other in the line width direction is smaller than the distance between the second coil conductors adjacent to each other in the line width direction.
The coil component according to any one of claims 1 to 3. The third coil conductor is located furthest in the second direction among the plurality of coil conductors,
The outer edge of the third coil conductor includes a third bottom portion which is a plane located furthest in the second direction at the outer edge of the third coil conductor, and a third bottom portion which is a plane located furthest in the first direction at the outer edge of the third coil conductor. It has a third top part that is a flat surface,
The width of the third top portion in the line width direction is smaller than the width of the third bottom portion in the line width direction,
The shortest distance between the third top part and the third bottom part is longer than the shortest distance between the second top part and the second bottom part,
A third ratio obtained by dividing the width of the third top portion in the line width direction by the width of the third bottom portion in the line width direction is smaller than the second ratio.
The coil component according to any one of claims 1 to 3 . The width of the third bottom portion in the line width direction is smaller than the width of the second bottom portion in the line width direction.
The coil component according to claim 5. The width of the third bottom portion in the line width direction is larger than the width of the second bottom portion in the line width direction.
The coil component according to claim 5. The first coil conductor, the second coil conductor, and the third coil conductor have a spiral shape that revolves around the central axis for one or more turns when viewed in the vertical direction,
The distance between the third coil conductors adjacent to each other in the line width direction is smaller than the distance between the second coil conductors adjacent to each other in the line width direction.
The coil component according to claim 5. The outer edge of the third coil conductor includes a third bottom portion which is a plane located furthest in the second direction at the outer edge of the third coil conductor, and a third bottom portion which is a plane located furthest in the first direction at the outer edge of the third coil conductor. It has a third top part that is a flat surface,
The width of the third top portion in the line width direction is smaller than the width of the third bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the third top part and the third bottom part,
The first ratio is smaller than a third ratio obtained by dividing the width of the third top part in the line width direction by the width of the third bottom part in the line width direction.
The coil component according to any one of claims 1 to 3 . One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
Equipped with
A method for manufacturing a coil component,
a second coil conductor forming step of forming the second coil conductor on the resin layer;
a thermocompression bonding step of thermocompression bonding the plurality of resin layers after the second coil conductor forming step;
After the thermocompression bonding step, the vertical thickness of the first coil conductor located in the resin layer located in the first direction among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A first coil conductor forming step;
After the thermocompression bonding step, the thickness in the vertical direction of the third coil conductor located in the resin layer located in the second direction most among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A third coil conductor forming step,
It is equipped with
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the second coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the second top portion in the line width direction. 2 smaller than a second ratio obtained by dividing by the width in the line width direction of the bottom portion;
Method of manufacturing coil parts. One direction in the vertical direction is a first direction, the other direction in the vertical direction is a second direction,
A laminate having a structure in which a plurality of resin layers are stacked in the vertical direction;
A coil including a plurality of coil conductors having a linear shape when viewed in the vertical direction, the coil having a spiral shape circulating around a central axis extending in the vertical direction, the plurality of coil conductors a coil including a first coil conductor, a second coil conductor, and a third coil conductor arranged in this order in the second direction;
Equipped with
A method for manufacturing a coil component,
a second coil conductor forming step of forming the second coil conductor on the resin layer;
a third coil conductor forming step of forming the third coil conductor on the resin layer;
After the second coil conductor forming step and the third coil conductor forming step, heat-bonding the plurality of resin layers by thermocompression so that the second coil conductor and the third coil conductor are lined up in this order in the second direction. crimping process,
After the thermocompression bonding step, the vertical thickness of the first coil conductor located in the resin layer located in the first direction among the plurality of resin layers thermocompression bonded in the thermocompression bonding step is increased. A first coil conductor forming step;
It is equipped with
When viewed in the vertical direction, the direction perpendicular to the direction in which each of the first coil conductor, the second coil conductor, and the third coil conductor extends is a line width direction,
The outer edge of the first coil conductor includes a first bottom portion which is a plane located furthest in the second direction at the outer edge of the first coil conductor, and a first bottom portion which is a plane located furthest in the first direction at the outer edge of the first coil conductor. has a first top portion that is a flat surface,
The width of the first top portion in the line width direction is smaller than the width of the first bottom portion in the line width direction,
The outer edge of the second coil conductor includes a second bottom portion which is a plane located furthest in the second direction at the outer edge of the second coil conductor, and a second bottom portion which is a plane located furthest in the first direction at the outer edge of the second coil conductor. It has a second top part that is a flat surface,
The width of the second top portion in the line width direction is smaller than the width of the second bottom portion in the line width direction,
The shortest distance between the first top part and the first bottom part is longer than the shortest distance between the second top part and the second bottom part,
A first ratio obtained by dividing the width of the first top portion in the line width direction by the width of the first bottom portion in the line width direction is calculated by dividing the width of the second top portion in the line width direction by the width of the first bottom portion in the line width direction. 2 smaller than a second ratio obtained by dividing by the width in the line width direction of the bottom portion;
Method of manufacturing coil parts.

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