Stacked coil element and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-2016293322-A1
Application number	US-201615177381-A
Country	US
Kind code	A1
Filing date	Jun 9, 2016
Priority date	Mar 14, 2014
Publication date	Oct 6, 2016
Grant date	—

Abstract

A stacked coil element includes a stack including a plurality of insulating layers and a coil conductor structure with a winding axis in a thickness direction, and conductor patterns defining a portion of a coil provided on the insulating layers and electrically connected in the thickness direction. The stack includes a coil inner hole on an inner peripheral side of the coil conductor structure, the coil inner hole penetrating in the direction of the winding axis or having the direction of the winding axis as a depth direction. In at least one of the plurality of insulating layers, an end surface of the conductor pattern on the coil inner hole side is in the same plane as an end surface of the insulating layer on the coil inner hole side.

First claim

What is claimed is:

1 . A stacked coil element comprising:
a stack including a plurality of insulating layers and a coil conductor structure with a winding axis in a thickness direction, and conductor patterns defining a portion of a coil provided on the insulating layers and electrically connected in the thickness direction; wherein the stack includes a coil inner hole on an inner peripheral side of the coil conductor structure, the coil inner hole penetrating in the direction of the winding axis or having the direction of the winding axis as a depth direction; and in two or more of the plurality of insulating layers adjacent in the thickness direction, all of coil-inner-hole-side end surfaces of the conductor patterns on the two or more of the plurality of insulating layers and coil-inner-hole-side end surfaces of the two or more insulating layers are in a same plane perpendicular or substantially perpendicular to a main surface of the stack.

2 . The stacked coil element according to claim 1 , wherein in all of the plurality of insulating layers, all of the coil-inner-hole-side end surfaces of the conductor patterns and the coil-inner-hole-side end surfaces of the insulating layers are in a same plane.

3 . The stacked coil element according to claim 1 , wherein an insulating material is filled in the coil inner hole.

4 . The stacked coil element according to claim 3 , wherein the insulating material is a magnetic material.

5 . The stacked coil element according to claim 1 , wherein an end of the conductor pattern on the coil inner hole side has a thickness greater in the thickness direction of the stack than a thickness of an end of the conductor pattern on an opposite side of the coil inner hole side.

6 . A stacked coil element comprising
a stack including a plurality of insulating layers and a coil conductor structure with a winding axis in a thickness direction, and conductor patterns defining a portion of a coil provided on the insulating layers and electrically connected in the thickness direction; wherein the stack includes a coil inner hole on an inner peripheral side of the coil conductor structure, the coil inner hole penetrating in the direction of the winding axis or having the direction of the winding axis as a depth direction; in at least one of the plurality of insulating layers, a coil-inner-hole-side end surface of the respective conductor pattern is in a same plane as a coil-inner-hole-side end surface of the insulating layer; and a plating film covers the coil-inner-hole-side end surface of the conductor pattern.

7 . The stacked coil element according to claim 6 , wherein a dimension of the plating film in the thickness direction of the stack is greater than a thickness of the conductor pattern.

8 . The stacked coil element according to claim 6 , wherein in two or more of the plurality of insulating layers adjacent in the thickness direction, all of the coil-inner-hole-side end surfaces of the conductor patterns on the two or more of the plurality of insulating layers and the coil-inner-hole-side end surfaces of the two or more insulating layers are in a same plane.

9 . The stacked coil element according to claim 6 , wherein in all of the plurality of insulating layers, all of the coil-inner-hole-side end surfaces of the conductor patterns and the coil-inner-hole-side end surfaces of the insulating layers are in a same plane.

10 . The stacked coil element according to claim 6 , wherein an insulating material is filled in the coil inner hole.

11 . The stacked coil element according to claim 10 , wherein the insulating material is a magnetic material.

12 . The stacked coil element according to claim 6 , wherein an end of the conductor pattern on the coil inner hole side has a thickness greater in the thickness direction of the stack than a thickness of an end of the conductor pattern on an opposite side of the coil inner hole side.

13 . A method for manufacturing a stacked coil element including a stack of a plurality of insulating layers and a coil conductor structure with a winding axis in a thickness direction, and conductor patterns defining a portion of a coil provided on the insulating layers and electrically connected in the thickness direction, the method comprising:
forming, on each of the plurality of insulating layers, the respective conductor pattern defining a portion of the coil; obtaining a stack by stacking the plurality of insulating layers having the conductor patterns formed thereon; and in two or more of the plurality of insulating layers adjacent in the thickness direction, boring a hole in a portion corresponding to an inner peripheral side of the coil conductor structure, such that ends of the conductor patterns are removed, and all of hole-side end surfaces of the two or more of the plurality of insulating layers and hole-side end surfaces of the conductor patterns formed on the two or more of the plurality of insulating layers are in a same plane perpendicular or substantially perpendicular to a main surface of the stack.

14 . The method for manufacturing a stacked coil element according to claim 13 , wherein the hole boring is performed to the stack after obtaining the stack.

15 . The method for manufacturing a stacked coil element according to claim 14 , wherein in the hole boring, in all of the plurality of insulating layers, the hole is bored at a time in a portion corresponding to an inner side of the coil conductor structure, such that the ends of the conductor patterns are removed in all of the plurality of insulating layers.

16 . The method for manufacturing a stacked coil element according to claim 13 , further comprising filling an insulating material in an internal space of the hole after the hole boring.

17 . The method for manufacturing a stacked coil element according to claim 16 , wherein the insulating material is a magnetic material.

18 . A method for manufacturing a stacked coil element including a stack of a plurality of insulating layers and a coil conductor structure with a winding axis in a thickness direction, and conductor patterns defining a portion of a coil provided on the insulating layers and electrically connected in the thickness direction, the method comprising:
forming, on each of the plurality of insulating layers, the conductor pattern defining a portion of the coil; obtaining a stack by stacking the plurality of insulating layers having the conductor patterns formed thereon; in at least one of the plurality of insulating layers, boring a hole in a portion corresponding to an inner peripheral side of the coil conductor structure, such that an end of the respective conductor pattern is removed, and a hole-side end surface of the insulating layer and a hole-side end surface of the conductor pattern are in a same plane; and plating the hole-side end surface of the conductor pattern after the hole boring.

19 . The method for manufacturing a stacked coil element according to claim 18 , wherein the hole boring is performed to the stack after obtaining the stack.

20 . The method for manufacturing a stacked coil element according to claim 19 , wherein in the hole boring, in all of the plurality of insulating layers, the hole is bored at a time in a portion corresponding to an inner side of the coil conductor structure, such that the ends of the conductor patterns are removed in all of the plurality of insulating layers.

21 . The method for manufacturing a stacked coil element according

Assignees

• Murata Manufacturing Co

Inventors

• Yosui Kuniaki

Classifications

• H01F27/24

  Magnetic cores · CPC title

• H01F27/2804 Primary

  Printed windings · CPC title

• H01F17/0033

  with the coil helically wound around a magnetic core · CPC title

• H01F5/00

  Coils (superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00) · CPC title

• H01F41/042

  by thin film techniques · CPC title