Tdk Corporation

Fujitsu Takamisawa Component Limited

Chevron Oronite Company LLC

Chevron Japan Limited

Hitoshi Ohkubo

Masazumi Arata

Manabu Ohta

Hokuto Eda

Takahiro Kawahara

Yoshihiro Maeda

Kyohei Tonoyama

Shigeki Sato

Yuuya Kaname

Miyuki Asai

Tomokazu Ito

Masataro Saito

Kohei Takahashi

Makoto Morita

Takamasa Iwasaki

Shou Kawadahara

Kentaro Saito

Kenei Onuma

Ken Satoh

Hideto Itoh

Hajime Kuwajima

Hideharu Moro

Ryo Fukuoka

Hiroki Tsujiai

Hironori Kimata

Hiroyuki Matsumoto

Atsushi Sato

Takashi Nakagawa

Shinichi Sato

Kenichi Kawabata

Curtis Bay Campbell

Kazuhiro Yoshidome

Takashi Kudo

Takashi Terada

Junichi Maruyama

Kazutoshi Hayashi

Toshiyuki Anbo

Toshiaki Kikuchi

Atsuyuki Nakano

Masatoshi Shindoh

John Robert Miller

Koichi Kubo

Isao Tanaka

Jacob Daniel Ward

Brendan P Miller

An electronic component preventing peeling of an external terminal is provided. Since each of the external terminal electrodes on the upper face has a U-shaped outline, stress concentration is less likely to occur at an inner end portion than in the external terminal electrode having a corner at the inner end portion. Therefore, for example, even when an impact is applied, a situation in which the external terminal electrode peels off from the upper face due to stress concentration is prevented.

Electronic component

In the coil component, external stress applied when the upper coil structure, the lower coil structure, and the magnetic sheet are stacked is dispersed by the undulation of both main surfaces of the magnetic sheet. By dispersing the stress in this manner, a situation in which defects such as cracks occur in the coil structure is effectively suppressed.

Coil component

In a coil component and a method for manufacturing the same, a winding part of a coil is grown by plating so as to extend between resin walls of a resin body provided before the coil is grown by plating. The resin wall is interposed between adjacent turns of the winding part of the coil during the plating growth, and therefore contact between adjacent turns of the winding part of the coil cannot occur.

Method for manufacturing coil component having resin walls

In the coil component, the maximum reference surface height of the entire wall of the outermost wall and the innermost wall is the same as the reference surface height of the winding part of the coil, that is, equal to or less than the reference surface height of the winding part of the coil. In addition, in both the outermost wall and the innermost wall, the reference surface height of the second side surface is lower than the reference surface height of the winding part of the coil. In this case, in the vicinity of the upper surface of the outermost wall and the innermost wall, the magnetic flux toward the main surface side of the substrate is suppressed from being blocked by the outermost wall and the innermost wall, and the magnetic flux circulation is improved. Thus, the coil characteristics of the coil component are improved.

In an insulation layer of a coil component, a thickness of a second covering part and a third covering part located on the penetration hole side of a first covering part is thinner than that of the first covering part. A stray capacitance occurring between a flat coil pattern and external terminal electrodes is reduced by making the first covering part of the insulation layer thicker than the second covering part and the third covering part. Further, since the second covering part and the third covering part of the insulation layers are thinner than the first covering part, a magnetic volume is increased while external dimensions of the base body is maintained, and thus a high inductance is realized.

In a coil component, a main body portion is made of a metal magnetic powder-containing resin, and thus a resin component appears on end surfaces of the main body portion. In addition, since external terminal electrodes are made of a conductive resin, a resin component also appears on the surfaces of the external terminal electrodes. Accordingly, insulating coating layers are integrally covered with high adhesion with the end surfaces of the main body portion and the external terminal electrodes by the insulating coating layers coming into contact with the end surfaces of the main body portion so as to straddle the external terminal electrodes.

In a coil component, the pressure resistance is improved by main surfaces and of a main body portion being covered with an insulating layer. The main body portion has a surface part, the resin ratio of the surface part is higher than the internal resin ratio, and insulation is enhanced at the surface part. As a result, the pressure resistance on the surface of the main body portion is further improved and the pressure resistance of the entire coil component is further improved.

In a coil component, a shield layer is provided after the unevenness of the surface of an element body is smoothened by the surface being covered with an insulating layer. A Cu layer of the shield layer is provided on a smooth surface, and thus a thickness variation can be suppressed and the Cu layer can be formed with a substantially uniform thickness. In the coil component, a point where the shield layer is thin or a point lacking the shield layer is unlikely to be generated and a functional degradation of the shield layer is effectively suppressed.

In a coil component, a height hof a pedestal portion of a resin wall corresponds to the height position of a step portion. In addition, a height of a seed portion corresponds to the plating start position at a time when a winding portion of a coil is plated and grown. The plating start position and the step portion are designed to be close to each other by the height hof the pedestal portion and the height hof the seed portion satisfying 0.3≤h/h≤10. Accordingly, although the coil component has a configuration in which the resin wall has the step portion, the inside of the step portion is sufficiently filled with a coil conductor, and thus deterioration of characteristics is suppressed.

In a coil component, a second magnetic portion disposed in the vicinity of a coil is designed to have a higher proportion of Fe than a metal magnetic powder-containing resin constituting a first magnetic portion. Therefore, a magnetic flux of the coil flows smoothly. Although the second magnetic portion has a relatively lower withstand voltage than the first magnetic portion, since the second magnetic portion is surrounded by the first magnetic portion, it is not exposed on an outer surface of a magnetic body. For this reason, a situation in which the coil and external terminal electrodes are short-circuited with the second magnetic portion therebetween is effectively curbed, and short-circuiting between the coil and the external terminal electrodes can be curbed.

In a coil component, an uneven structure provided by an insulation layer and a resin wall contributes to extension of a contact area with respect to a magnetic body, so that an adhesive force with respect to the magnetic body is improved. In addition, the magnetic body protrudes downward toward an exposed region of the resin wall corresponding to a recessed portion in the uneven structure, a volume thereof is increased, and coil characteristics such as an inductance value are improved.

A coil component having high inductance while suppressing core loss is obtained. The coil component includes a coil and a magnetic core. The magnetic core has a laminated body in which soft magnetic layers are laminated. Micro gaps are formed in the soft magnetic layers. The soft magnetic layers are divided into at least two or more small pieces by the micro gaps. A structure made of Fe-based nano-crystals is observed in the soft magnetic layers.

A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 &#x3bc;m or more and 60 &#x3bc;m or less. A particle size of the intermediate size powder is 2.0 &#x3bc;m or more and less than 10 &#x3bc;m. A particle size of the small size powder is 0.1 &#x3bc;m or more and less than 2.0 &#x3bc;m. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1&#x2265;1.3, and A3/A2&#x2265;1.0.

Magnetic core and coil component

A magnetic core and a coil component with excellent permeability, core loss, DC superimposition property, and withstand voltage. A magnetic core has a metal magnetic powder containing resin including a metal magnetic powder. The metal magnetic powder includes a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 &#x3bc;m or more and 60 &#x3bc;m or less. A particle size of the intermediate size powder is 2.0 &#x3bc;m or more and less than 10 &#x3bc;m. A particle size of the small size powder is 0.1 &#x3bc;m or more and less than 2.0 &#x3bc;m. The large size powder includes a nano crystal. A ratio of the large size powder existing with respect to the metal magnetic powder is 39% or more and 91% or less in terms of an area ratio in a cross section of the magnetic core.

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Tokyo, Japan

Hitoshi Ohkubo