JPWO2010150602A1 - 電子部品及びその製造方法 - Google Patents
電子部品及びその製造方法 Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 41
- 239000012212 insulator Substances 0.000 claims abstract description 177
- 239000004020 conductor Substances 0.000 claims abstract description 134
- 238000000034 method Methods 0.000 claims abstract description 37
- 238000010304 firing Methods 0.000 claims abstract description 11
- 238000010030 laminating Methods 0.000 claims description 8
- 230000004907 flux Effects 0.000 abstract description 32
- 239000000919 ceramic Substances 0.000 description 85
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 35
- 238000012986 modification Methods 0.000 description 13
- 230000004048 modification Effects 0.000 description 13
- 239000000463 material Substances 0.000 description 12
- 239000000843 powder Substances 0.000 description 12
- 229910000859 α-Fe Inorganic materials 0.000 description 9
- 238000010586 diagram Methods 0.000 description 6
- 229910052709 silver Inorganic materials 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 238000000206 photolithography Methods 0.000 description 5
- 238000007639 printing Methods 0.000 description 5
- 238000007650 screen-printing Methods 0.000 description 5
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical group [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 4
- 229910000480 nickel oxide Inorganic materials 0.000 description 4
- 239000004332 silver Substances 0.000 description 4
- 239000002002 slurry Substances 0.000 description 4
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 3
- 229910017518 Cu Zn Inorganic materials 0.000 description 3
- 229910017752 Cu-Zn Inorganic materials 0.000 description 3
- 229910017943 Cu—Zn Inorganic materials 0.000 description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 3
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- 239000002270 dispersing agent Substances 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 239000000696 magnetic material Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 3
- 239000004014 plasticizer Substances 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 238000004088 simulation Methods 0.000 description 3
- 238000009736 wetting Methods 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000007606 doctor blade method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- TVZPLCNGKSPOJA-UHFFFAOYSA-N copper zinc Chemical compound [Cu].[Zn] TVZPLCNGKSPOJA-UHFFFAOYSA-N 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000002003 electrode paste Substances 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
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- H01F17/00—Fixed inductances of the signal type
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- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
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- H01F2027/2809—Printed windings on stacked layers
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- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
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- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/003—Printed circuit coils
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
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- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
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Abstract
Description
以下に、本発明の一実施形態に係る電子部品について図面を参照しながら説明する。図1は、実施形態に係る電子部品10a〜10dの斜視図である。図2は、一実施形態に係る電子部品10aの積層体12aの分解斜視図である。図3は、図1のA−Aにおける電子部品10aの断面構造図である。図2に示す積層体12aは、焼成前の状態を示している。一方、図3に示す電子部品10aは、焼成後の状態を示している。以下、電子部品10aの積層方向をz軸方向と定義し、電子部品10aの長辺に沿った方向をx軸方向と定義し、電子部品10aの短辺に沿った方向をy軸方向と定義する。x軸、y軸及びz軸は互いに直交している。
以下に、電子部品10aの製造方法について図面を参照しながら説明する。なお、以下では、複数の電子部品10aを同時に作成する際の電子部品10aの製造方法について説明する。
電子部品10a及びその製造方法では、以下に説明するように、各コイル導体18a〜18fの周囲を周回する磁束による磁気飽和の発生を抑制できる。より詳細には、電子部品10aのコイルLに電流が流れると、図3に示すようなコイル導体18a〜18fの全体の周囲を周回する相対的に長い磁路を有する磁束φ1が発生すると共に、各コイル導体18a〜18fの周囲を周回する相対的に短い磁束を有する磁束φ2(図3では、コイル導体18dの周囲に発生する磁束φ2のみ記載)が発生する。そして、磁束φ2は、磁束φ1と同様に、電子部品10aにおいて磁気飽和を発生させる原因となりうる。
電子部品のサイズ:2.5mm×2.0mm×1.0mm
絶縁体層19a〜19gの厚み:10μm
以下に、第1の変形例に係る電子部品10b及びその製造方法について図面を参照しながら説明する。図5は、第1の変形例に係る電子部品10bの断面構造図である。図5では、図面が煩雑になることを避けるために、図3と同じ構成の参照符号については一部省略してある。
以下に、第2の変形例に係る電子部品10c及びその製造方法について図面を参照しながら説明する。図6は、第2の変形例に係る電子部品10cの断面構造図である。図6では、図面が煩雑になることを避けるために、図3と同じ構成の参照符号については一部省略してある。
以下に、第3の変形例に係る電子部品10d及びその製造方法について図面を参照しながら説明する。図7は、第3の変形例に係る電子部品10dの断面構造図である。図7では、図面が煩雑になることを避けるために、図7と同じ構成の参照符号については一部省略してある。
b1〜b6 ビアホール導体
10a〜10d 電子部品
12a〜12d 積層体
14a,14b 外部電極
15a〜15e,16a〜16g,19a〜19g,24d,28b,28f,30b,30f,34b,36b 絶縁体層
17a〜17g,26d,32b,32f,38b 単位層
18a〜18g コイル導体
20a〜20f 第1の部分
22a〜22g 第2の部分
Claims (10)
- 複数のコイル導体が積層方向から平面視したときに互いに重なった状態で接続されてなる螺旋状のコイルを内蔵している積層体であって、第1のNi含有率をなす第1の絶縁体層と、該第1の絶縁体層上に設けられている前記コイル導体と、前記第1のNi含有率よりも高い第2のNi含有率をなす第2の絶縁体層であって、該第1の絶縁体層上の該コイル導体以外の部分に設けられている第2の絶縁体層と、からなる第1の単位層が複数連続して積層されてなる積層体を形成する工程と、
前記積層体を焼成する工程と、
を備えていること、
を特徴とする電子部品の製造方法。 - 前記積層体を形成する工程は、前記第1の単位層を形成する工程として、
シート状の前記第1の絶縁体層を準備する工程と、
前記第1の絶縁体層上に前記コイル導体を形成する工程と、
前記第1の絶縁体層上に前記第2の絶縁体層を形成する工程と、
を含んでいること、
を特徴とする請求項1に記載の電子部品の製造方法。 - 前記積層体を形成する工程は、
前記第1の単位層を積層方向に連続して積層することにより、前記コイルを形成する工程を、
更に含んでいること、
を特徴とする請求項2に記載の電子部品の製造方法。 - 前記積層体を形成する工程は、第2の単位層を形成する工程として、
シート状の前記第1の絶縁体層を準備する工程と、
前記第1の絶縁体層上に前記コイル導体を形成する工程と、
前記第1のNi含有率をなす第3の絶縁体層を、前記第1の絶縁体層上の前記コイル導体以外の部分に形成する工程と、
を更に含み、
前記積層体を形成する工程は、
前記第1の単位層及び前記第2の単位層を積層する工程を、
更に含んでいること、
を特徴とする請求項2に記載の電子部品の製造方法。 - 前記積層体を形成する工程は、第3の単位層を形成する工程として、
シート状の前記第1の絶縁体層を準備する工程と、
前記第1の絶縁体層上に前記コイル導体を形成する工程と、
前記第1のNi含有率をなす第4の絶縁体層、及び、前記第2のNi含有率をなす第5の絶縁体層を、同一の前記第1の絶縁体層上の前記コイル導体以外の部分に形成する工程と、
を更に含み、
前記積層体を形成する工程は、
前記第1の単位層及び前記第3の単位層を積層する工程を、
更に含んでいること、
を特徴とする請求項2に記載の電子部品の製造方法。 - 前記第1の絶縁体層の厚みは、前記第2の絶縁体層の厚みよりも薄いこと、
を特徴とする請求項1ないし請求項5のいずれかに記載の電子部品の製造方法。 - 前記第1の絶縁体層の厚みは、5μm以上15μm以下であること、
を特徴とする請求項6に記載の電子部品の製造方法。 - 前記第1の絶縁体層は、Niを含有していない非磁性体層であること、
を特徴とする請求項1ないし請求項7のいずれかに記載の電子部品の製造方法。 - 前記積層体を焼成する工程の後には、前記第1の絶縁体層における前記コイル導体に積層方向の両側から挟まれている第1の部分でのNi含有率は、該第1の絶縁体層における該第1の部分以外の第2の部分でのNi含有率よりも低くなっていること、
を特徴とする請求項1ないし請求項8のいずれかに記載の電子部品の製造方法。 - 1枚のシート状の第1の絶縁体層と、前記第1の絶縁体層上に設けられているコイル導体と、該第1の絶縁体層上の該コイル導体以外の部分に設けられている第2の絶縁体層と、からなる単位層を複数備えた電子部品であって、
前記複数の単位層が連続して積層されることにより、複数の前記コイル導体が接続されて螺旋状のコイルが構成されており、
前記第1の絶縁体層における前記コイル導体に積層方向の両側から挟まれている第1の部分でのNi含有率は、該第1の絶縁体層における該第1の部分以外の第2の部分でのNi含有率よりも低くなっており、
前記第2の部分でのNi含有率は、前記第2の絶縁体層でのNi含有率よりも低くなっていること、
を特徴とする電子部品。
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