US-20260128212-A1 - INDUCTOR COMPONENT AND METHOD OF MANUFACTURING INDUCTOR COMPONENT

US20260128212A1US 20260128212 A1US20260128212 A1US 20260128212A1US-20260128212-A1

Abstract

An inductor component includes an element body, a coil in the element body, and a non-magnetic insulation layer covering at least part of the coil. The element body includes first and second magnetic layers laminated in order in a first direction. The coil includes a small-turn inductor wiring of 0.5 or less turns extending along a plane orthogonal to the first direction between the first and second magnetic layers. In a first cross-section orthogonal to an extending direction of the small-turn inductor wiring, the small-turn inductor wiring has a top surface facing in the first direction, a bottom surface facing in a second direction opposite from the first direction, a first side surface facing in a third direction orthogonal to the first direction, and a second side surface facing in a fourth direction opposite from the third direction.

Inventors

Yoshimasa YOSHIOKA
Ryuichiro Tominaga
Yayoi HISADA

Assignees

MURATA MANUFACTURING CO., LTD.

Dates

Publication Date: 20260507
Application Date: 20260106
Priority Date: 20211214

Claims (2)

1 . A method of manufacturing an inductor component, comprising: forming a small-turn inductor wiring of 0.5 or less turns including, in a first cross-section orthogonal to an extending direction, a top surface facing in a first direction, a bottom surface facing in a second direction opposite to the first direction, a first side surface facing in a third direction orthogonal to the first direction, and a second side surface facing in a fourth direction opposite to the third direction; forming an insulation layer to include, in the first cross-section, at least one portion of a top surface portion positioned further in the first direction with respect to the top surface or a bottom surface portion positioned further in the second direction with respect to the bottom surface, a first side surface portion covering the first side surface, a second side surface portion covering the second side surface, a first protrusion protruding from the at least one portion further in the third direction with respect to the first side surface portion, and a second protrusion protruding from the at least one portion further in the fourth direction with respect to the second side surface portion; and forming an element body by laminating a first magnetic layer and a second magnetic layer in the first direction to sandwich the small-turn inductor wiring and the insulation layer.
2 . The method of manufacturing an inductor component according to claim 1 , wherein the forming the small-turn inductor wiring further includes forming a dummy wiring at a position capable of overlapping the first protrusion or the second protrusion when viewed in the first direction, after forming the small-turn inductor wiring, the dummy wiring is removed, and the forming the element body further includes filling with the first magnetic layer or the second magnetic layer at a position where the dummy wiring is removed.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application is a Divisional of U.S. patent application Ser. No. 18/065,198, filed Dec. 13, 2022, which claims benefit of priority to Japanese Patent Application No. 2021-202782, filed Dec. 14, 2021, the entire content of which is incorporated herein by reference. BACKGROUND Technical Field The present disclosure relates to an inductor component and a method of manufacturing the inductor component. Background Art Japanese Unexamined Patent Application Publication No. 2017-11185 describes an inductor component of a related art. The inductor component includes an element body having a magnetic layer, a coil disposed in the element body, and a non-magnetic insulation layer covering the coil. The coil has layers of spiral wirings. Each spiral wiring has one or more turns. The insulation layer has a hole in a region corresponding to an inner magnetic path of the coil, and part of the element body is provided in the hole. SUMMARY It has been found that the following problems arise when a spiral wiring of 0.5 or less turns is used in an inductor component according to the related art. The spiral wiring of 0.5 or less turns has a curved portion that is shorter than that of a spiral wiring of one or more turns, and has a shape that is not completely wound. This makes the orientation of a contact surface between the insulation layer covering the spiral wiring and the element body uneven as compared with the spiral wiring of one or more turns, and there is a possibility that a degree of adhesion between the insulation layer and the element body in a specific direction decreases. Accordingly, when the element body and the insulation layer expand or contract because of, for example, a thermal load or the like, there is a possibility that a gap is generated between the insulation layer and the element body due to a difference in expansion coefficient and the low degree of adhesion in the specific direction, moisture enters the gap, and the deterioration of the inductor component is accelerated. Therefore, the present disclosure provides an inductor component and a method of manufacturing the inductor component capable of increasing a degree of adhesion between an element body and an insulation layer and increasing reliability. An inductor component as an aspect of the present disclosure includes an element body, a coil disposed in the element body, and an insulation layer that is a non-magnetic layer covering at least part of the coil. The element body includes a first magnetic layer and a second magnetic layer laminated in order in a first direction. The coil includes a small-turn inductor wiring of 0.5 or less turns extending along a plane orthogonal to the first direction between the first magnetic layer and the second magnetic layer. In a first cross-section orthogonal to an extending direction of the small-turn inductor wiring, the small-turn inductor wiring has a top surface facing in the first direction, a bottom surface facing in a second direction opposite from the first direction, a first side surface facing in a third direction orthogonal to the first direction, and a second side surface facing in a fourth direction opposite from the third direction. Also, the insulation layer has at least one portion of a top surface portion positioned further in the first direction relative to the top surface and a bottom surface portion positioned further in the second direction relative to the bottom surface, a first side surface portion covering the first side surface, a second side surface portion covering the second side surface, a first protrusion protruding from the at least one portion further in the third direction relative to the first side surface portion, and a second protrusion protruding from the at least one portion further in the fourth direction relative to the second side surface portion. Here, with respect to the number of turns of the small-turn inductor wiring, 0.5 or less turns refer to a state in which, when viewed in an axial direction of the coil, a center angle of lines connecting each center of both end portions of the small-turn inductor wiring and an axis of the coil is 180° or less, or a state, such as a linear shape or a meander shape, in which the coil is not wound into circles. According to the aspect, since the first protrusion and the second protrusion are provided, the contact area between the insulation layer and the element body may be increased by the first protrusion and the second protrusion, and the first protrusion and the second protrusion may be made to enter the element body. Thus, the degree of adhesion between the insulation layer and the element body is increased, and the reliability of the inductor component may be increased. Preferably, in an embodiment of the inductor component, multiple layers of the small-turn inductor wiring are present in the first direction, and in the first cross-section, a protrusion with a different length