WO2014068613A1 - コイル素子の製造方法 - Google Patents
コイル素子の製造方法 Download PDFInfo
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- WO2014068613A1 WO2014068613A1 PCT/JP2012/006961 JP2012006961W WO2014068613A1 WO 2014068613 A1 WO2014068613 A1 WO 2014068613A1 JP 2012006961 W JP2012006961 W JP 2012006961W WO 2014068613 A1 WO2014068613 A1 WO 2014068613A1
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- WIPO (PCT)
- Prior art keywords
- coil element
- conductor film
- coil
- transfer mold
- film
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 15
- 230000001681 protective effect Effects 0.000 claims abstract description 19
- 238000009713 electroplating Methods 0.000 claims abstract description 7
- 238000000227 grinding Methods 0.000 claims abstract description 5
- 239000002184 metal Substances 0.000 claims abstract description 5
- 229910052751 metal Inorganic materials 0.000 claims abstract description 5
- 238000005498 polishing Methods 0.000 claims abstract description 5
- 239000004020 conductor Substances 0.000 claims description 45
- 238000000034 method Methods 0.000 claims description 19
- 238000005530 etching Methods 0.000 claims description 7
- 229910021578 Iron(III) chloride Inorganic materials 0.000 claims description 3
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 3
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 claims description 3
- 238000004544 sputter deposition Methods 0.000 claims description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 238000000429 assembly Methods 0.000 description 8
- 230000000712 assembly Effects 0.000 description 8
- 239000010949 copper Substances 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 238000005323 electroforming Methods 0.000 description 3
- 238000000605 extraction Methods 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 229910000679 solder Inorganic materials 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000013518 transcription Methods 0.000 description 1
- 230000035897 transcription Effects 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—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
- 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
- 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
- H01F41/041—Printed circuit coils
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
- H01F17/0013—Printed inductances with stacked layers
Definitions
- the present invention relates to a method of manufacturing a coil element, and more particularly to a method of manufacturing a coil element that can make the plating height of a coil element peeled and transferred using a transfer mold uniform.
- Patent Document 1 describes a method for manufacturing an electronic component by electroforming (also referred to as electroplating). In this method, first, a mother mold is produced from a master mold, and then a transfer sun mold is produced on the surface of the mother mold by nickel electroforming. Then, the transfer sun mold is peeled from the mother mold, and the sun mold is used as a work mold to manufacture parts.
- the coil extraction electrode When producing a coil element by using a transfer mold, the coil extraction electrode has a coil pattern height (H) higher than that of the other part, and is connected to the upper coil element in a multilayer connection. It may be necessary to produce a coil component. In that case, it is necessary to make the depth of the pattern of the coil element imprinted in the transfer mold partially deep at the electrode extraction portion.
- the present invention has been made to solve the above-mentioned problems, and by removing the conductive film after electroforming by a predetermined thickness from the surface by polishing or grinding, the conductive film surface has no irregularities, and after the removal, It is an object of the present invention to provide a method of manufacturing a coil element that does not hinder the use of the coil element pattern.
- the means of the present invention is a method of manufacturing a coil element using a transfer mold, comprising the steps of preparing a transfer mold in which a reverse coil element pattern is engraved on the surface and at least the surface portion is made of metal, and the transfer Forming a central conductor film having a thickness exceeding the thickness of the region where the reversal coil element pattern is engraved on the entire surface of the mold by first electroplating;
- the step of flattening the surface of the center conductor film by polishing or grinding, the step of peeling the flattened center conductor film from the transfer mold, and the coil of the peeled center conductor film A step of depositing a protective film on the entire surface on the side where the element pattern is formed, and etching from the flattened side of the central conductor film until the central conductive film reaches the protective film And having a step of removing grayed, and a step of taking out the center conductor film is removed the protective film.
- a coil element comprising the center conductor film and the surface conductor film is formed by forming a surface conductor film that covers the center conductor film by second electroplating with the extracted center conductor film as a base.
- the method further comprising the step of: Further, the surface portion of the transfer mold is Ni, and NiO is formed on the surface of Ni.
- the protective film is SiO 2 , SOG, or a resist. Further, the protective film is formed by CVD or sputtering. Further, the etching of the central conductor film is performed using a ferric chloride solution.
- coil element patterns having different thicknesses can be formed from the flattened surface, there is an advantage that it is easy to manufacture a multilayered coil component.
- the figure which shows the preparation processes of the coil element by this invention The top view of the coil element assembly produced using the transcription
- FIG. 1 is a diagram showing a manufacturing process of a coil element according to the present invention.
- a metallic transfer mold 100 made of nickel (Ni) or the like with reverse coil element patterns 102a and 102b engraved on the surface thereof is prepared.
- the metallic transfer mold 100 need only be metallic at least on the surface, and need not be metallic as a whole.
- the surface portion of the transfer mold 100 is Ni, if the surface is oxidized to form NiO, the central conductor film can be easily peeled off in subsequent steps.
- the inverted coil element patterns 102a and 102b may have portions having different depths.
- the central conductor film 104 is formed on the entire surface of the transfer mold 100 by electroplating such as copper (Cu) so as to exceed the thickness of the region where the reverse coil element patterns 102a and 102b are engraved. At this time, irregularities corresponding to the depths of the inverted coil element patterns 102a and 102b are directly reflected on the surface of the central conductor film 104.
- electroplating such as copper (Cu) so as to exceed the thickness of the region where the reverse coil element patterns 102a and 102b are engraved.
- the central conductor film 104 is removed from the surface by a predetermined thickness by polishing or grinding, and is flattened without the unevenness existing on the surface. As a result, the central conductor film 106 having a flat surface is formed.
- the central conductor film 106 whose surface is flattened is peeled from the transfer mold 100.
- a protective film 108 is deposited on the entire surface of the peeled central conductor film 106 where the coil element patterns 102a and 102b are formed.
- the protective film 108 SiO 2 , SOG, or a resist can be used, and the protective film 108 may be formed by a method such as CVD or sputtering.
- the central conductor film 106 is removed by etching until it reaches the protective film 108 from the flattened side. The etching of the central conductor film 106 is preferably performed using a ferric chloride solution.
- FIG. 1f the protective film 108 is removed, and the central conductor films 106a and 106b are taken out.
- the central conductor films 106a and 106b thus taken out are used as coil elements having different thicknesses.
- the gap between the central conductor films 106a and 106b is reduced to increase the density, as shown in FIG.
- the surface conductor films 110a and 110b that thicken the surface may be formed.
- FIG. 2 is a plan view of a coil element assembly 1000 manufactured using a transfer mold substrate.
- the transfer mold substrate for producing the coil element assembly 1000 has the same shape as this shape.
- a rib 502, a gate 504, and a runner 506 are provided.
- Holes 508 are provided at the four corners of the rib 502, and the positions of the conductor patterns of the coil elements 500m and n formed in each layer of the plurality of coil element assemblies 1000 using the pins 510 penetrating the holes 508. Align.
- a plurality of coil element assemblies 1000-1, 1000-2,... 1000-N are aligned via pins 510 so that corresponding coil elements in each coil element assembly are aligned with each other.
- the tin plating constituting the bonding film is melted and acts as solder to join the coil elements of the respective layers.
- FIG. 4 is a diagram for explaining that a plurality of coil element assemblies are stacked and the coil elements of each layer are connected to form a coil.
- the embodiment shown in FIG. 4 shows a case where six layers of coil element assemblies are stacked and the coil elements in each layer are connected to produce one coil.
- Corresponding coil elements in the plurality of coil element assemblies can be configured to include different coil patterns.
- the first layer (Layer 1), the third layer (Layer 3), and the sixth layer (Layer 6) have different coil patterns, respectively, and the second layer (Layer 2) and The fourth layer (Layer 4) has the same coil pattern, and the third layer (Layer 3) and the fifth layer (Layer 5) have the same coil pattern.
- (B) and (C) six layers of coil element assemblies were laminated, joined so that corresponding coil elements in each layer were aligned, and the coil elements were connected to form one coil. It shows the state.
- the height (H) of the central conductor layer constituting the coil element is different in height at the connecting portion of each layer as shown in FIG. ing.
- the height (H) is 100 ⁇ m in the normal coil element pattern, but the height (H) is 150 ⁇ m in the connection portion between the layers.
- the upper core of the magnetic body having the protruding portion 604 penetrating the central portion of the coil as shown in FIG. Using 600 and the lower core 602, the electrode lead-out portion 606 is exposed to the outside to seal the coil.
- the upper core 600 and the lower core 602 are attached so as to avoid the gate 504 for pattern reinforcement shown in FIG.
- the upper core 600 and the lower core 602 are cut along the dicing line 608 in a subsequent dicing process.
- an insulating material 612 is filled from a gap (not shown) between the upper core 600 and the lower core 602, and the coil is fixed.
- the laminated coil element assemblies are cut using a cutter 700 in units of coils.
- (A) shows a coil element assembly
- (B) shows one coil component
- the electrode lead-out portion 606 is formed as a part of the first layer (Layer 1).
- the external electrode 610 is attached to the electrode lead-out portion 606 by a method such as a solder dipping method, and soldering is performed as a pretreatment for subsequent soldering to complete the coil component 3000. .
Abstract
Description
このようなコイル部品の製造方法として転写用金型を用いるものが知られている。特許文献1には、電気鋳造(電気めっきともいう)による電子部品の製造方法が記載されている。この方法ではまず、マスター金型からマザー金型を作製し、次にマザー金型の表面にニッケル電鋳法により転写用サン金型を作製する。そして、マザー金型から、この転写用サン金型を剥離し、このサン金型をワーク金型として使用し、部品の製造が行なわれる。
本発明は、上記課題を解決するためになされたもので、電気鋳造後の導体膜を表面から所定の厚さだけ研磨又は研削により除去することにより、導体膜表面の凹凸を無くし、取出し後のコイル素子パターンの使用に障害の無いコイル素子の製造方法を提供することを目的とする。
また、前記保護膜をCVD又はスパッタにより形成することを特徴とする。
さらに、前記中心導体膜の前記エッチングは、塩化第二鉄溶液を用いて行われることを特徴とする。
図1は、本発明によるコイル素子の作製工程を示す図である。
まず、図1aに示すように、表面に反転コイル素子パターン102a、102bが刻印されたニッケル(Ni)などで作製された金属性転写金型100を準備する。なお、金属性転写金型100は、少なくとも表面部が金属性であれば足り、全体が金属性である必要はない。なお、転写金型100の表面部がNiである場合には表面を酸化してNiOを形成しておくと後続の工程での中心導体膜剥離が容易となる。また、反転コイル素子パターン102a、102bは異なる深さの部分があっても良い。
保護膜108としては、SiO2、SOG又はレジストを使用することができ、CVD又はスパッタ等の方法により成膜しても良い。
ついで図1eに示すように、中心導体膜106を平坦化された側から保護膜108に到達するまでエッチングして除去する。この中心導体膜106のエッチングは塩化第2鉄溶液を用いて行なうと良い。次いで、図1fに示すように、保護膜108を除去し、中心導体膜106a、106bを取出す。
次に、このように作製されたコイル素子集合体を用いてコイル部品を作製する方法について説明する。後述するように、コイル部品はコイル素子集合体を複数枚積層して作製される。
そこで、各層のコイル素子同士を接合して接続するために、予めコイル素子の周囲に接合膜を形成しておく必要がある。
最後に、図8に示すように、電極引出し部606にはんだディップ法などの方法により、外部電極610を取付け、その後のはんだ付けのための前処理としてはんだ上げを行い、コイル部品3000を完成する。
102a、102b:反転コイル素子パターン
104:中心導体膜
106:剥離された中心導体膜
108:保護膜
110a、110b:表面導体膜
Claims (6)
- 転写金型を用いてコイル素子を製造する方法であって、
表面に反転コイル素子パターンが刻印され、少なくとも表面部が金属からなる転写金型を準備するステップと、
前記転写金型の全面に、第1の電気めっきにより前記反転コイル素子パターンが刻印されている領域の厚さを越える厚さの中心導体膜を形成するステップと、
前記中心導体膜を表面から所定の厚さだけ研磨又は研削により除去し、前記中心導体膜の表面を平坦化するステップと、
平坦化された前記中心導体膜を前記転写金型から剥離するステップと、
剥離された前記中心導体膜のコイル素子パターンが形成されている側の表面全面に保護膜を被着させるステップと、
前記中心導体膜の平坦化された側から前記中心導体膜を前記保護膜に到達するまでエッチングして除去するステップと、
前記保護膜を除去し前記中心導体膜を取出すステップと、を有することを特徴とする方法。 - 請求項1に記載の方法において、
取出された前記中心導体膜を下地として第2の電気めっきにより前記中心導体膜を被覆する表面導体膜を形成し、前記中心導体膜と前記表面導体膜とからなるコイル素子を形成するステップを更に有することを特徴とする方法。 - 請求項1に記載の方法において、
前記転写金型の前記表面部はNiで、Niの表面にNiOが形成されていることを特徴とする方法。 - 請求項1に記載の方法において、
前記保護膜がSiO2、SOG又はレジストであることを特徴とする方法。 - 請求項1に記載の方法において、
前記保護膜をCVD又はスパッタにより形成することを特徴とする方法。 - 請求項1に記載の方法において、
前記中心導体膜の前記エッチングは、塩化第二鉄溶液を用いて行われることを特徴とする方法。
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KR1020157014409A KR20150079934A (ko) | 2012-10-30 | 2012-10-30 | 코일 소자의 제조 방법 |
CN201280076682.3A CN104756209A (zh) | 2012-10-30 | 2012-10-30 | 线圈元件的制造方法 |
JP2013513445A JP5294287B1 (ja) | 2012-10-30 | 2012-10-30 | コイル素子の製造方法 |
US14/438,952 US20150287531A1 (en) | 2012-10-30 | 2012-10-30 | Coil element production method |
EP12887637.2A EP2916335A1 (en) | 2012-10-30 | 2012-10-30 | Coil element production method |
PCT/JP2012/006961 WO2014068613A1 (ja) | 2012-10-30 | 2012-10-30 | コイル素子の製造方法 |
TW102132141A TW201432745A (zh) | 2012-10-30 | 2013-09-06 | 線圈元件的製造方法 |
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EP (1) | EP2916335A1 (ja) |
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EP3397978A1 (en) | 2015-12-31 | 2018-11-07 | Koninklijke Philips N.V. | Magnetic field gradient coils with closely packed windings and methods of manufacturing same |
TWI651740B (zh) * | 2017-11-02 | 2019-02-21 | 弘鄴科技有限公司 | 應用於電子元件之線材導體成型方法 |
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- 2012-10-30 EP EP12887637.2A patent/EP2916335A1/en not_active Withdrawn
- 2012-10-30 CN CN201280076682.3A patent/CN104756209A/zh active Pending
- 2012-10-30 US US14/438,952 patent/US20150287531A1/en not_active Abandoned
- 2012-10-30 WO PCT/JP2012/006961 patent/WO2014068613A1/ja active Application Filing
- 2012-10-30 KR KR1020157014409A patent/KR20150079934A/ko not_active Application Discontinuation
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2013
- 2013-09-06 TW TW102132141A patent/TW201432745A/zh unknown
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Also Published As
Publication number | Publication date |
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JP5294287B1 (ja) | 2013-09-18 |
EP2916335A1 (en) | 2015-09-09 |
JPWO2014068613A1 (ja) | 2016-09-08 |
US20150287531A1 (en) | 2015-10-08 |
KR20150079934A (ko) | 2015-07-08 |
TW201432745A (zh) | 2014-08-16 |
CN104756209A (zh) | 2015-07-01 |
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