This application claims priority to Japanese Patent Application No. JP 2009-089646, filed Apr. 2, 2009, the entire contents of which are incorporated herein by reference in their entirety.
1. Field of the Invention
The invention relates to an electronic component and a method of manufacturing the same and, in particular, an electronic component incorporating a coil and a method of manufacturing the same.
2. Description of the Related Art
One known traditional electronic component is a multilayer chip inductor described in Japanese Unexamined Patent Application Publication No. 2005-191191. The multilayer chip inductor described in this patent document is explained below with reference to the drawings.
As illustrated in
The multilayer structure 502 further incorporates lead-out conductors 506a and 506b. The lead-out conductors 506a and 506b are extended out to side faces of the multilayer structure 502 and connected to external electrodes (not illustrated) and also connected to the coil L.
The coil L in the multilayer chip inductor 500 illustrated in
However, the multilayer chip inductor 500 illustrated in
For a multilayer chip inductor 600 illustrated in
The length of each of the short sides L1 and L2 is smaller than the length of each of the long sides L3 and L4. Hence, the amount of reduction in the area inside the coil L in the multilayer chip inductor 600 illustrated in
However, the multilayer chip inductor 600 illustrated in
To overcome the problems described above, embodiments in accordance with the claimed invention provide an electronic component capable of obtaining a large inductance value and a high Q value and a method of manufacturing the electronic component.
According to one aspect, an electronic component includes a multilayer structure, a coil, an external electrode, and a lead-out conductor. The multilayer structure includes a plurality of insulator layers. The coil includes a plurality of coil conductors incorporated in the multilayer structure, a plurality of lands provided at the plurality of coil conductors, and a via-hole conductor connecting the plurality of lands. The external electrode is provided on a surface of the multilayer structure. The lead-out conductor is incorporated in the multilayer structure and connects the coil and the external electrode. The plurality of coil conductors form a substantially rectangular loop path by overlapping each other in plan view from a direction in which a coil axis extends. In plan view from the direction in which the coil axis extends, the plurality of lands protrude toward outside the path at a short side of the path and do not overlap the lead-out conductor.
According to another aspect, a method of manufacturing the electronic component includes forming, by a photolithography process, the insulator layers each having a via hole provided at a location where the via-hole conductor is to be provided and forming the coil conductors, the lands, and the via-hole conductor on the insulator layers.
Embodiments of the present invention can provide an electronic component having a large inductance value and a high Q value.
Other features, elements, characteristics and advantages of the present invention will become more apparent from the following detailed description with reference to the attached drawings.
An electronic component and a method of manufacturing the same according to exemplary embodiments are described below with reference to the drawings.
Configuration of Electronic Component
A configuration of an electronic component according to an exemplary embodiment is described below with reference to the drawings.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
The lead-out conductor 24b is extended out to a side face in the negative x-axis direction and thus connects the external electrode 14b and the coil L. In addition, the lead-out conductor 24b is provided at a downstream end in the counterclockwise direction of the coil conductor 20b, so the lead-out conductor 24b overlaps the path R at an end in the negative y-axis direction of the short side L2, as illustrated in
Method of Manufacturing Electronic Component
An exemplary method of manufacturing an electronic component 10 is described below with reference to the drawings. In the following description, a method of manufacturing an electronic component 10 for use in producing a plurality of electronic components 10 at a time is described.
First, a paste insulating material of ceramic made of glass and aluminum oxide is applied onto a film base (not illustrated in
Then, an insulator layer 16b having a via hole formed at a location where a via-hole conductor b1 is to be provided is formed by a photolithography process. Specifically, a paste insulating material is applied onto the insulator layer 16c, internal conductor 18b, and the lead-out conductor 24b. In addition, exposure and development are carried out to form the insulator layer 16b having a via hole formed at a location where the via-hole conductor b1 is to be provided.
Then, an internal conductor 18a, a lead-out conductor 24a, and the via-hole conductor b1 are formed on the insulator layer 16b by a photolithography process. A paste conductive material is applied onto the insulator layer 16b and then exposed and developed to form the internal conductor 18a, lead-out conductor 24a, and via-hole conductor b1.
Then, a paste insulating material is applied onto the insulator layer 16b, internal conductor 18a, and lead-out conductor 24a, and the entire surface is exposed to ultraviolet radiation to form the insulator layer 16a. In this way, a mother multilayer structure including a plurality of multilayer structures 12 is produced.
Then, the mother multilayer structure is divided into individual multilayer structures 12 by cutting the mother multilayer structure while pressing it down. After that, each of the multilayer structures 12 is fired with a specific temperature for a specific period of time.
Then, the multilayer structure 12 is abraded by the use of a barrel, thus rounding edges and removing burrs and also exposing the lead-out conductors 24a and 24b from the multilayer structure 12.
Then, side faces of the multilayer structure 12 are dipped into silver paste and baked to form a silver electrode. Lastly, a coating of nickel, copper, zinc, or other metallic materials is deposited onto the silver electrode to form external electrodes 14a and 14b. Through the above-described steps, the electronic component 10 is completed.
With the above electronic component 10, a larger inductance value is obtainable as described below. More specifically, for the multilayer chip inductor 500 illustrated in
In contrast, for the electronic component 10, the land 22 projects toward outside the path R at the short side L1, as illustrated in
However, the length of the short side L1 is smaller than the length of each of the long sides L3 and L4. Hence, the amount of reduction in the area inside the coil L in the electronic component 10 is smaller than that in the multilayer chip inductor 500. Accordingly, the reduction in the area inside the coil L in the electronic component 10 is suppressed more than that in the multilayer chip inductor 500. In other words, the reduction in the value of inductance of the coil L in the electronic component 10 is suppressed more than that in the multilayer chip inductor 500.
Additionally, with the electronic component 10, a high Q-value is obtainable, as described below. More specifically, as illustrated in
In contrast, for the electronic component 10, the land 22 does not overlap the lead-out conductor 24, as illustrated in
In particular, for the electronic component 10, the land 22 is provided at a first end of the short side L1, whereas the lead-out conductor 24a is provided at a second end of the short side L1, as illustrated in
For the electronic component 10, the diameter of each of the land 22 and the via-hole conductor b1 is larger than the line width of the coil conductor 20. Hence, the land 22 and the via-hole conductor b1 are in contact with each other through a relatively large area. As a result, the occurrence of poor connection between the via-hole conductor b1 and each of the coil conductors 20a and 20b can be reduced.
With the method of manufacturing the electronic component 10 described herein, the via-hole conductor b1 having a relatively large diameter can be easily formed. More specifically, if a laser beam is used to form a via hole, it is difficult for the via hole to have a relatively large diameter. In contrast, with the method of manufacturing the electronic component 10 described herein, the insulator layer 16b is produced by a photolithography process. With the photolithography process, a via hole with a relatively large diameter can be easily formed. Hence, with the method of manufacturing the electronic component 10, the via-hole conductor b1 having a relatively large diameter can be easily formed.
The inventors conducted an experiment and simulation described below in order to further clarify advantageous effects provided by the electronic component 10. More specifically, samples and analysis models of three different kinds of electronic components described below were produced. Then, an experiment for examining the incidence of breaks in wiring for the samples of the electronic components was carried out. The relationship between a frequency and a Q value was also examined by the use of the analysis models for the electronic components.
First, experimental results are described. The incidences of breaks in wiring for the electronic components 10, 110, and 210 are 0%, 25%, and 0%, respectively. These experimental results reveal that the incidences of breaks in wiring between the via-hole conductor and the coil conductor for the electronic components 10 and 210, each of which has the via-hole conductor with a relatively large diameter, are relatively low, whereas the incidence of breaks in wiring between the via-hole conductor and the coil conductor for the electronic component 110, which has the via-hole conductor with a relatively small diameter is relatively high. Accordingly, it has been found that, with the electronic component 10, the occurrence of breaks between the coil conductor 20 and the via-hole conductor b1 can be suppressed.
Next, simulation results are described.
The land 122 of the electronic component 110 is smaller than the land 222 of the electronic component 210. Therefore, the area inside the coil L of the electronic component 110 is larger than that of the electronic component 210. As a result, the value of inductance of the coil L of the electronic component 110 is larger than that of the electronic component 210. Accordingly, the Q value of the electronic component 110 is larger than that of the electronic component 210. The diameter of the via-hole conductor of the electronic component 10 is larger than that of the via-hole conductor of the electronic component 110. Therefore, the value of direct-current resistance of the coil L of the electronic component 10 is smaller than that of the electronic component 110. Accordingly, the Q value of the electronic component 10 is larger than that of the electronic component 110. For the above reasons, with the electronic component 10, a high Q value is obtainable.
Modifications
The electronic component 10a according to a first exemplary modification is described below with reference to the drawings.
The electronic component 10a differs from the electronic component 10 in that the electronic component 10a includes lands 22c and 22d, a wiring conductor 26, and a via-hole conductor b2. Specifically, the wiring conductor 26 extends from the land 22b toward the negative x-axis direction and overlaps the coil conductor 20a in plan view from the z-axis direction. The lands 22c and 22d are provided at an end in the positive y-axis direction of the short side L2 and overlap each other in plan view from the z-axis direction. In addition, the lands 22c and 22d do not overlap the lead-out conductor 24b in plan view from the z-axis direction. The lands 22c and 22d protrude toward the negative x-axis direction so as to protrude toward outside the path R. The via-hole conductor b2 connects the lands 22c and 22d.
For the electronic component 10a described above, the wiring conductor 26 is connected substantially in parallel to the coil conductor 20a in a section between the via-hole conductors b1 and b2. As a result, the value of direct-current resistance of the coil L of the electronic component 10a is smaller than that of the electronic component 10.
Next, the electronic component 10b according to a second exemplary modification and the electronic component 10c according to a third exemplary modification are described with reference to the drawings.
The electronic component 10b illustrated in
Embodiments of the present invention are useful for an electronic component and a method of manufacturing the electronic component and, in particular, are advantageous in that a larger inductance value and a high Q value are obtainable.
While exemplary embodiments of the invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the invention. The scope of the invention, therefore, is to be determined solely by the following claims.
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