Manufacture method of coil component, and coil component

Patent metadata

Field	Value
Publication number	US-2016379750-A1
Application number	US-201615180743-A
Country	US
Kind code	A1
Filing date	Jun 13, 2016
Priority date	Jun 24, 2015
Publication date	Dec 29, 2016
Grant date	—

Abstract

The manufacture method of a coil component includes the steps of bonding a dummy metal layer onto one face of a mounting base, stacking a base insulating resin on the dummy metal layer, stacking a first spiral wiring and a first insulating resin in this order on the base insulating resin to cover the first spiral wiring with the first insulating resin and stacking a second spiral wiring and a second insulating resin in this order on the first insulating resin to cover the second spiral wiring with the second insulating resin to thereby form a coil substrate, detaching the mounting base from the dummy metal layer in a bonding face between the one face of the mounting base and the dummy metal layer, removing the dummy metal layer from the coil substrate, and covering the coil substrate with a magnetic resin.

First claim

1 . A manufacture method of a coil component, comprising the steps of:
bonding a dummy metal layer onto a mounting base; stacking a base insulating resin on the dummy metal layer; stacking a first spiral wiring and a first insulating resin in this order on the base insulating resin to cover the first spiral wiring with the first insulating resin and stacking a second spiral wiring and a second insulating resin in this order on the first insulating resin to cover the second spiral wiring with the second insulating resin, to form a coil substrate; detaching the mounting base from the dummy metal layer at a bonding face between the mounting base and the dummy metal layer; removing the dummy metal layer from the coil substrate; and covering the coil substrate with a magnetic resin.

2 . The manufacture method of a coil component according to claim 1 , wherein
the mounting base includes an insulating substrate and a base metal layer disposed on the insulating substrate and bonded to the dummy metal layer.

3 . The manufacture method of a coil component according to claim 1 , wherein
the step of forming the coil substrate includes the steps of: disposing an opening in the base insulating resin to expose the dummy metal layer; disposing the first spiral wiring on the base insulating resin and disposing a first sacrificial electric conductor that corresponds to an inner flux path, on the dummy metal layer in the opening of the base insulating resin; thickening the first spiral wiring using plating by directly or indirectly energizing the first spiral wiring and thickening the first sacrificial electric conductor connected to the dummy metal layer using plating by energizing the dummy metal layer; covering the first spiral wiring and the first sacrificial electric conductor with the first insulating resin; disposing an opening in the first insulating resin to expose the first sacrificial electric conductor; disposing the second spiral wiring on the first insulating resin and disposing a second sacrificial electric conductor that corresponds to an inner flux path, on the first sacrificial electric conductor in the opening of the first insulating resin; thickening the second spiral wiring using plating by directly or indirectly energizing the second spiral wiring and thickening the second sacrificial electric conductor using plating through the first sacrificial electric conductor by energizing the dummy metal layer; covering the second spiral wiring and the second sacrificial electric conductor with the second insulating resin; disposing an opening in the second insulating resin to expose the second sacrificial electric conductor; and removing the first sacrificial electric conductor and the second sacrificial electric conductor to form a hole that corresponds to an inner flux path, wherein at the step of covering the coil substrate with the magnetic resin, the hole is filled with the magnetic resin to configure the inner flux path using the magnetic resin.

4 . A coil component comprising:
a base insulating resin; a first spiral wiring stacked on the base insulating resin; a first insulating resin that is stacked on the first spiral wiring, the first insulating resin covering the first spiral wiring; a second spiral wiring that is stacked on the first insulating resin, the second spiral wiring being connected to the first spiral wiring through a via wiring extending in a layer stacking direction; a second insulating resin that is stacked on the second spiral wiring, the second insulating resin covering the second spiral wiring; and a magnetic resin that covers the base insulating resin, the first insulating resin, and the second insulating resin.

5 . The coil component according to claim 4 , wherein
the base insulating resin, the first insulating resin, and the second insulating resin include a same material.

6 . The coil component according to claim 4 , wherein
cross-sectional shapes in the layer stacking direction of the first spiral wiring and the second spiral wiring are each a convex shape that protrudes in a same direction of the layer stacking direction and that has a curved side face.

Assignees

• Murata Manufacturing Co

Inventors

• Hamada Akinori
• Nishiyama Kenji
• Yasuda Shinji

Classifications

• H01F2017/0073

  with a special conductive pattern, e.g. flat spiral · CPC title

• H01F17/04

  with magnetic core · CPC title

• H01F27/29

  Terminals; Tapping arrangements {for signal inductances} · CPC title

• H01F7/06

  Electromagnets; Actuators including electromagnets {(electric coils H01F5/00; devices for holding workpieces using electric force B23Q3/15; load-engaging elements for lifting articles electromagnetically B66C1/06; electromagnetic couplings F16D27/00; magnetic brakes F16D63/002; electromagnetically operated valves F16K11/24, F16K31/00; analysing materials by magnetic means G01N27/72, G01N27/80; electromagnets for winding mechanical clocks G04C1/02; electromagnetic relays H01H51/00; windings for salient poles of dynamo-electric machines H02K3/18; electromagnets for telegraphic communication H04L; for arc lamps H05B31/28)} · CPC title

• H01F27/02

  Casings · CPC title