JPH11251152A - Composite part and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite part, being excellent in productivity, and method for manufacturing it wherein various types of filters are obtained with less modification as possible. SOLUTION: The composite part comprises a varistor 2 or a coil 1 wherein an electrode layer 7 and a varistor layer 6, or, a conductor layer 4 and an insulating body layer 3 are laminated. Varistor elements 2a and 2b, or, coil elements 1a and 1b, are formed in plural numbers in the same lamination plane while a plurality of varistors 2 or coils 1 are laminated in lamination direction to constitute a composite part. with this configuration, a composite part comprising such structure as various types of composite parts are easily manufactured is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite component used for various electronic devices and communication devices, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Composite components are widely used in various electronic devices and communication devices. In recent years, small or thin composite components have been increasingly required. Composite parts as countermeasures are also becoming increasingly important.

Conventionally, a composite component satisfying these demands is a laminated coil component obtained by alternately laminating a ferrite magnetic layer and a coil conductor layer (for example, Japanese Patent Publication No. 57-39).
No. 521) and a composite component (for example, Japanese Patent No. 2504230, Japanese Patent No.
No. 626143).

[0004] In the case of a composite component comprising a coil and a varistor, various composite components (for example, Japanese Patent No. 26261) are used depending on how the coils and the varistors constituting these components are arranged three-dimensionally.
No. 43, Japanese Unexamined Patent Publication No. 4-257110-2). In particular, a composite component used as a noise suppression component generally uses a plurality of coils and varistors to form an L-type, T-type, or π-type filter. An arrangement that facilitates the construction of such a filter is desirable. However, various composite parts have been proposed so far, but the configuration is a configuration specialized for any filter. For example, the one disclosed in Japanese Patent No. 2626143 is a composite component limited to a T-type filter.

[0005]

As described above, a composite component composed of a plurality of coils and varistors is
It was common to embody what is limited to any of the type, T type or π type. There has been a problem in realizing various types of L-type, T-type, π-type, and L-type multistage filters with a slight change.

SUMMARY OF THE INVENTION The present invention eliminates the above-mentioned drawbacks of the prior art, and provides a composite component having excellent productivity and a structure capable of realizing each type of filter with a minimum of changes of various types of filters and a method of manufacturing the same. The purpose is to do.

[0007]

Means for Solving the Problems To solve the above-mentioned problems, a composite component according to the present invention is a composite component comprising a varistor comprising an electrode layer and a varistor layer and a coil comprising a conductor layer and an insulator layer laminated. The varistor and the coil each have a configuration in which a plurality of varistor elements and coil elements are formed on the same laminated surface.

According to the present invention, there is provided a composite part which is excellent in productivity and can easily produce various types of filters.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention according to claim 1 of the present invention is directed to a composite component comprising a varistor comprising an electrode layer and a varistor layer and a coil comprising a conductor layer and an insulator layer, wherein the varistor and the coil A plurality of varistor elements and coil elements are formed on the same laminated surface, respectively.
The structure is such that it is easy to produce, and various types of filters such as various types such as L-type, T-type, π-type or multi-stage type can be easily formed.

[0010] The second aspect of the present invention has two varistor elements or two coil elements in the same lamination plane, so that various types of filters can be easily produced and manufactured easily. A structure that can be used.

According to a third aspect of the present invention, the coil elements in the same lamination are connected in series, the remaining terminals of each coil element are electrically connected to the end face electrodes formed on the surface, respectively. Varistor elements are connected in parallel, and one terminal of the varistor element is connected to the terminals of the two coil elements, and the other varistor element is a composite part connected to the end face electrode formed on the end face. A T-type filter can be configured.

According to a fourth aspect of the present invention, the coil elements in the same lamination are connected in series, and the other terminals of the coil elements are respectively connected to the end face electrodes formed on the end faces. One terminal of each varistor element is connected to one end face electrode formed on the end face, and the other respective terminal of each varistor element is connected to two end face electrodes formed on the end face connected to the terminal of each coil element. The π-type filter can be easily constituted by the composite parts connected to each other.

According to a fifth aspect of the present invention, the coil elements in the same lamination are connected in series, and the other terminals of the coil elements are respectively connected to the end face electrodes formed on the end faces. One terminal of each varistor element is connected to one end face electrode formed on the end face, and one of the other terminals of each varistor element is connected to terminals between coil elements connected in series, and another one The terminal of the varistor element is a composite component connected to one of the two end face electrodes connected to the terminal of the coil element, and can easily constitute an L-shaped two-stage filter.

According to a sixth aspect of the present invention, there is provided a method of forming an insulator layer, a step of forming a varistor layer, and a step of forming a conductor layer for a plurality of coil elements on a surface of the insulator layer.
A step of forming a plurality of varistor element electrode layers on the surface of the varistor layer, a step of forming holes or openings in the insulator layer and the varistor layer, and a varistor layer or electrode layer in which the varistor element electrode layer is formed Laminating a varistor layer without forming a layer, a step of laminating an insulator layer on which a conductor layer for a coil element is formed or an insulator layer on which a conductor layer is not formed, and a laminate obtained by lamination. And a step of forming an end surface electrode on the surface of the composite component, whereby composite components to be various types of filters can be easily formed.

According to a seventh aspect of the present invention, there is provided a method for forming an insulating layer, a step for forming a varistor layer, a step for forming a conductor layer for a plurality of coil elements on a surface of the insulating layer,
Forming a plurality of varistor element electrode layers on the surface of the varistor layer, forming holes or openings in the insulator layer, and forming a varistor layer or electrode layer on which the varistor element electrode layer is formed; Laminating a varistor layer that does not have the above, a step of laminating an insulator layer having a conductor layer for the coil element or an insulator layer having no conductor layer formed thereon, and A method of manufacturing a composite component comprising a step of forming an end face electrode, wherein composite components to be various types of filters can be easily formed.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. First, FIG. 1 shows a schematic lamination diagram of a typical example of the composite component of the present invention. FIG. 1 schematically shows a laminated state of a chip-shaped composite component of the present invention, and has a configuration in which a coil 1 and a varistor 2 are laminated as shown in FIG. The composite component has a configuration having three end electrodes 8 on the surface.

The coil 1 has a configuration in which an insulator layer 3 and a conductor layer 4 are laminated. The conductor layer 4 is a conductor 5 penetrating the insulator layer 3.
Are electrically connected. In FIG. 1, one coil element 1a, 1b is formed on each of the left and right sides, and this one coil element 1a is formed of two conductor layers 4 and a conductor 5 connecting them in the laminating direction. The varistor 2 has a configuration in which a varistor layer 6 and an electrode layer 7 are similarly laminated.
In FIG. 1, one varistor element 2a, 2b is also formed on each of the left and right varistors 2, and one varistor element 2a is formed by two electrode layers 7 in the stacking direction. FIG. 1 further includes a conductor 5 for electrically connecting the conductor layer 4 forming the coil 1 and a part of the electrode layer 7 forming the varistor 2. The three end face electrodes 8 are electrically connected to the electrode layer 7 constituting the varistor 2 and the conductor layer 4 constituting the coil 1, respectively, as shown in FIG.

The example shown in FIG. 1 is an example of a T-type filter. Similarly, FIGS. 2 and 3 show configuration examples of a π-type filter and an L-type two-stage filter.

FIGS. 1 to 3 show the minimum required structure. The number of insulator layers 3 and conductor layers 4 constituting the coil 1 may be increased to increase coil characteristics, that is, inductance. The varistor layer 6 and the electrode layer 7 constituting the varistor 2 may be similarly increased to improve the capacity. Further, there is no problem in a laminated structure in which the insulator layer 3 or the varistor layer 6 or the third layer is formed in the portion between the coil 1 and the varistor 2 or the portion on the opposite side.

In a composite component as a noise suppression component, one of the important electrical characteristics of a T-type or π-type filter is a cutoff frequency as a filter. This is generally defined as a frequency at which a predetermined amount of attenuation is obtained as a low-pass filter, and this frequency is substantially determined by the respective capacitance values of the coil 1 and the varistor 2 constituting the filter, that is, the L value or the C value.
As shown in FIG. 1, even with the same configuration, it is possible to change the C value by partially cutting the electrode layer 7 constituting the varistor 2 or change the C value by changing the thickness of the varistor layer 6. Easy. With these, filters having various cutoff frequencies can be realized. Further, as a method of changing the L value, one method is to change the magnetic permeability of the insulator layer 3 as described later.

As described above, the insulator layer 3 shown in FIG.
May be a non-magnetic material or a magnetic material. Any non-magnetic material may be used as long as it is electrically insulating, such as an organic insulating material such as glass epoxy or polyimide, or an inorganic insulating material such as glass, glass ceramics, or ceramics.

As the magnetic material, NiZn or NiZnC
Any ferrite material having a generally high magnetic permeability, such as a u-based material, may be used.

When the insulator layer 3 is made of a magnetic material, the inductance value of the coil 1 composed of the conductor layer 4 can be increased. The resonance frequency increases. As described above, the cutoff frequency of the filter can be changed.

As the material of the conductor layer 4 or the electrode layer 7, any material may be used as long as it is an electrically good conductor, but copper, silver and a palladium alloy or silver is desirable.

The end face electrode 8 may be made of a conductive material. However, it is generally preferable that the end face electrode 8 be composed of a plurality of layers instead of a single layer. Mounting strength or solder wettability during mounting,
It is necessary to consider solder cracks, etc. Specifically, the lowermost layer uses the same conductive material as the conductive layer 4 or the electrode layer 7,
For the intermediate layer, use nickel that has resistance to solder,
For the outermost layer, solder or tin having good wettability to solder is used.

However, this is an example, and it is not always necessary to adopt this configuration, and a conductive resin material may be included in addition to a material having excellent conductivity such as a metal.

Further, a predetermined wiring pattern is formed on a ceramic substrate such as alumina or ferrite, a window is provided on the ceramic substrate, a composite component is inserted, and the wiring pattern and the end face electrode 8 of the composite component are brought into contact with each other to form a thick film forming process. It is also conceivable that a structure corresponding to this thick film forming process can be provided by increasing the heat resistance because it is electrically connected by sintering.

As described in the above example, in a composite component including the varistor 2 or the coil 1 in which the electrode layer 7 and the varistor layer 6 or the conductor layer 4 and the insulator layer 3 are laminated, the varistor element By using a composite part having a structure in which a plurality of coil elements 2a, 2b or coil elements 1a, 1b are formed, unlike the conventional laminated type, it is easy to produce, and various types of composite parts can be separately produced with slight changes. It is possible to obtain a composite part having a structure capable of performing the above.

In the above-described embodiment, only the surface mounting type in which the end electrodes 8 are provided at both ends and the like has been described. However, a terminal in which a pin terminal is implanted in an insulator or a terminal instead of the end surface electrode 8 is used. A lead-type composite component in which the cap-shaped electrode having the above-mentioned shape is fitted and coupled to both ends of the insulator can also be used.

Next, a method of manufacturing a composite part according to the present invention will be described. One method of manufacturing a composite component according to the present invention includes a step of forming an insulator layer 3, a step of forming a varistor layer 6, and a step of forming a conductor layer 4 for coil elements 1a and 1b on the surface of the insulator layer 3. A step of forming, a step of forming electrode layers 7 for the varistor elements 2a and 2b on the surface of the varistor layer 6, a step of forming holes or openings in the insulator layer 3 or the varistor layer 6, and a step of forming the varistor element 2a. Laminating the varistor layer 6 on which the electrode layers 7 for the first and second electrodes 2b are formed or the varistor layer 6 on which the electrode layers 7 are not formed;
laminating the insulator layer 3 on which the conductor layers 4 for a and 1b are formed or the insulator layer 3 on which the conductor layer 4 is not formed;
Forming the end face electrodes 8 on the surface of the laminate obtained by lamination.

Next, a more detailed method of manufacturing a composite part according to the present invention will be described with reference to the drawings.

FIG. 1 is a schematic view showing the state of lamination of one composite part according to the present invention. The manufacturing method will be further described with reference to this figure. First, as shown in FIG. 1, an insulator layer 3 and a varistor layer 6 are formed in advance, and a hole or an opening is formed in the insulator layer 3 to form a conductor 5 as shown in FIG. Further, the insulating layer 3 and the varistor layer 6 are formed as shown in FIG.
The conductor layer 4 or the electrode layer 7 having a predetermined pattern as shown in FIG. The varistor layer 6 on which the insulator layer 3 and the electrode layer 7 are formed is sequentially laminated according to the lamination order as shown in FIG. An end face electrode 8 as shown in FIG. 1 is formed on the side surface of the laminate obtained by lamination. Although the end face electrode 8 is shown only in the minimum size in FIG.
There is of course no problem with a larger area than that shown in FIG.

The composite part of the present invention can be obtained by the above method. The firing may be performed without forming the end face electrodes 8. In other words, this is a method in which the electrode without the end face electrode 8 is fired, and the end face electrode 8 is formed after firing. An example of a forming method in this case will be described. A conductor is formed in the same shape as the end face electrode 8 and is fired once. Thereafter, nickel plating and solder or tin plating are performed using this conductor as an electrode. Finally, the end face electrode 8 has a three-layer structure of a conductor as a base of the end face electrode formed by firing and nickel and solder or tin formed by electroplating. Further, the firing may be performed separately for the coil 1 and the varistor 2, and the fired one may be laminated so as to have the structure shown in FIG.

The above-mentioned insulator layer 3 or varistor layer 6 is generally formed by a generally known green sheet molding method or printing method, but can also be formed by a dipping method, a powder molding method or a spin coating method. The conductor layer 4, the electrode layer 7, or the end face electrode 8 is generally printed by a printing method, such as pattern formation using a laser, a method of transferring a conductor formed in a predetermined shape by a mold or plating, dropping, potting, or the like. A method such as a thermal spraying method may be used.

The composite part obtained by the production method of the present invention comprises:
Since it is a composite part having excellent heat resistance, it can be easily modularized. For example, a predetermined wiring layer is formed on a ceramic substrate such as an alumina substrate or a ferrite substrate, and the wiring of the substrate and the end surface electrode 8 of the composite component are simultaneously connected to be integrated or assembled. In this case, since a window can be opened at a predetermined position on the substrate and the end surface electrode 8 on the side surface of the composite component can be connected to the wiring on the ceramic substrate, a thin module can be obtained. In this case, an ordinary thick film forming process using a generally known ceramic substrate can be applied. End electrode 8 of composite part
Is not premised on soldering, but may be fired and electrically connected.

The pastes or slurries for forming each of the above-mentioned layers include powders and solvents such as butyl carbitol, terpineol and alcohol, binders such as ethyl cellulose, polyvinyl butyral, polyvinyl alcohol, polyethylene oxide and ethylene-vinyl acetate.
Further, a sintering aid such as various oxides or glasses may be added, and a plasticizer or a dispersant such as butylbenzyl phthalate, dibutyl phthalate, or glycerin may be added. Each layer is formed using a kneaded material obtained by mixing these. These are laminated in a predetermined structure as described above and fired to obtain a composite part. As the slurry for producing the green sheet, various solvents having excellent evaporability, such as butyl acetate, methyl ethyl ketone, toluene, and alcohol, are preferable instead of the above-mentioned solvents.

The firing temperature range is from about 800 ° C. to 13
It is in the range of 00 ° C. In particular, it depends on the conductor material. For example, when silver is used as the conductor material, it is necessary to be around 900 ° C., and at 950 ° C. for an alloy of silver and palladium, and nickel or palladium is used as the conductor material for firing at a higher temperature. .

Next, more specific embodiments of the present invention will be described. (Example 1) NiZnCu-based ferrite as a magnetic material was selected as an insulator. Therefore, the insulator layer 3 becomes a ferrite layer as shown below.

8 g of butyral resin, 4 g of butylbenzyl phthalate, 24 g of methyl ethyl ketone and 24 g of butyl acetate were mixed with 100 g of NiZnCu-based ferrite powder and kneaded using a pot mill to prepare a ferrite slurry.

Using this slurry, a ferrite green sheet having a thickness of 0.2 mm was formed after drying using a coater. The green sheet was formed on a PET film.

Similarly, a varistor green sheet was formed in order to form a varistor using zinc oxide powder as a main component.

Using these ferrite green sheets and varistor green sheets, each green sheet was perforated in order to obtain a laminate as shown in FIG. Further, the conductor layer 4 or the electrode layer 7 was formed. Conductor layer 4
Alternatively, the electrode layer 7 was formed using a commercially available conductor paste and a printing machine. The conductor paste is a silver paste. The holes were made in a ferrite green sheet using a commercially available puncher.

These ferrite green sheets and varistor green sheets were laminated in a state as shown in FIG. A hot press is used for lamination, and the platen temperature of the hot press is 1
The temperature was set at 00 ° C. and the pressure was 500 kg / cm ² .

Next, as shown in FIG. 1, the end face electrode 8 was formed using a commercially available silver paste, and was baked at 900 ° C. for 2 hours.

No defects such as peeling, cracking and warping were observed in the composite part of the present invention obtained by the above method.

Next, the baked product was analyzed using an impedance analyzer or a network analyzer.
When various electric characteristics were measured, it was a composite part having excellent characteristics.

In the same manner, the π-type filter shown in FIG. 2 and the L-type two-stage filter shown in FIG. 3 were produced by sharing most of the green sheets previously produced. That is, FIG.
As shown in FIGS. 2 and 3, most of the conductor layer 4 and the electrode layer 7 can be used in common, and the type of each type can be changed by changing a part of the pattern of the conductor layer 4 or the electrode layer 7, Alternatively, it becomes possible by changing the stacking order.

Further, when the composite part obtained by firing in the same manner as described above was measured for various electric characteristics using an impedance analyzer or a network analyzer, it was found that the composite part also showed excellent electric characteristics. .

As described above, in order to obtain the varistor 2, a varistor sheet was formed using zinc oxide. A varistor sheet was similarly formed using barium titanate instead of zinc oxide, and a composite part was formed in the same manner. Excellent composite parts having the same electrical characteristics were obtained.

[0050]

As is apparent from the above description, the composite component of the present invention can easily be used to easily form various types of composite components by changing the pattern of a part of the conductor layer or the electrode layer or by slightly changing the holes or openings. It is of great industrial value that can be made separately and exhibits excellent electrical characteristics.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing a laminate showing an embodiment of a composite part according to the present invention.

FIG. 2 is a schematic lamination diagram showing still another embodiment of the composite component of the present invention.

FIG. 3 is a schematic lamination diagram showing still another embodiment of the composite component of the present invention.

[Explanation of symbols]

 Reference Signs List 1 coil 1a, 1b coil element 2 varistor 2a, 2b varistor element 3 insulator layer 4 conductor layer 5 conductor 6 varistor layer 7 electrode layer 8 end face electrode

Claims (7)

[Claims] 1. A composite component comprising a varistor comprising an electrode layer and a varistor layer and a coil comprising a conductor layer and an insulator layer, wherein a plurality of varistor elements and coil elements are provided on the same laminated surface as the varistor and the coil. Composite parts using the formed one. 2. The composite component according to claim 1, wherein two varistor elements or two coil elements are provided in the same lamination plane. 3. The coil elements in the same lamination are connected in series, the remaining terminals of each coil element are electrically connected to end face electrodes formed on the surface, respectively, and the varistor elements in the same lamination are connected in parallel. 3. The composite component according to claim 2, wherein one terminal of the varistor element is connected to terminals of two coil elements, and another terminal of the varistor element is connected to an end face electrode formed on an end face. 4. A coil element in the same stack is connected in series, and the other terminal of each coil element is connected to an end face electrode formed on an end face, and one terminal of each varistor element in the same stack. 3. An end face electrode formed on an end face of the varistor element, and the other terminal of each varistor element is connected to two end face electrodes formed on an end face connected to a terminal of each coil element. Composite parts. 5. A coil element in the same stack is connected in series, and the other terminal of each coil element is connected to an end face electrode formed on an end face, and one terminal of each of the varistor elements in the same stack. Is connected to one end face electrode formed on the end face, and one of the other terminals of each varistor element is connected to terminals of coil elements connected in series,
The composite component according to claim 2, wherein a terminal of another varistor element is connected to one of two end face electrodes connected to a terminal of the coil element. 6. A step of forming an insulator layer, a step of forming a varistor layer, a step of forming a conductor layer for a plurality of coil elements on a surface of the insulator layer, and a step of forming a plurality of varistors on a surface of the varistor layer A step of forming an electrode layer for an element, a step of forming a hole or an opening in an insulator layer and a varistor layer, and a step of forming a varistor layer having an electrode layer for a varistor element or a varistor layer having no electrode layer formed thereon. Laminating, laminating an insulator layer on which a conductor layer for a coil element is formed or an insulator layer on which a conductor layer is not formed, and forming an end face electrode on a surface of the laminated body obtained by lamination. A method of manufacturing a composite part comprising the steps of: 7. A step of forming an insulator layer, a step of forming a varistor layer, a step of forming a conductor layer for a plurality of coil elements on a surface of the insulator layer, and a step of forming a plurality of varistors on a surface of the varistor layer A step of forming an electrode layer for an element, a step of forming a hole or an opening in an insulator layer, and a step of laminating a varistor layer having an electrode layer for a varistor element or a varistor layer having no electrode layer formed thereon And a step of laminating an insulator layer having a conductor layer for a coil element or an insulator layer having no conductor layer formed thereon, and a step of forming an end face electrode on the surface of the laminated body obtained by lamination. Manufacturing method of composite parts.