Patent Grant
11842842
This application claims benefit of priority to Japanese Patent Application No. 2020-030655, filed Feb. 26, 2020, the entire content of which is incorporated herein by reference.
The present disclosure relates to an inductor component and a manufacturing method of the inductor component.
In the inductor component described in Japanese Unexamined Patent Application Publication No. 2013-225718, an inductor wiring line is laminated on a surface of an insulation substrate. A face of the inductor wiring line on the side opposite to the insulation substrate is covered by an insulation layer. Then, the inductor wiring line, the insulation substrate, and the insulation layer are covered by a magnetic layer.
In the inductor component described in Japanese Unexamined Patent Application Publication No. 2013-225718, the thickness of the inductor component is increased by the amount of the insulation substrate. Therefore, it is conceivable to directly laminate the inductor wiring line on the magnetic layer by omitting the insulation substrate. However, depending on the material of the magnetic layer and the inductor wiring line, adhesion between the magnetic layer and the inductor wiring line may not be sufficiently ensured. Accordingly, it is not practical to directly laminate the inductor wiring line on the magnetic layer by simply omitting the insulation substrate in order to reduce the thickness of the inductor component.
Accordingly, an aspect of the present disclosure is an inductor component including a magnetic layer in which a magnetic metal powder is dispersedly present in a base material made of an insulation material; and an inductor wiring line laminated on a surface of the magnetic layer, in which the inductor wiring line includes an anchor portion extending from a main face in the inductor wiring line on a side of the magnetic layer and covering a surface of the magnetic metal powder in the magnetic layer.
According to the above-described configuration, the inductor wiring line includes the anchor portion, and thus, an anchor effect may be obtained between the inductor wiring line and the magnetic layer. Therefore, the necessary adhesion may be ensured even when the inductor wiring line and the magnetic layer have no other layers interposed therebetween, and are directly in contact with each other.
Also, an aspect of the present disclosure is a manufacturing method of an inductor component including covering, by a resist layer, part of a surface of a first magnetic layer in which a magnetic metal powder is dispersed in a base material made of an insulation material and part of the magnetic metal powder is exposed to the surface; laminating an inductor wiring line in a portion of the surface of the first magnetic layer being not covered by the resist layer by immersing the first magnetic layer after the covering in a plating solution; and removing, after the lamination, the resist layer, in which, in the laminating, the inductor wiring line is also formed on a surface of the magnetic metal powder exposed to the surface of the first magnetic layer.
According to the configuration described above, the inductor wiring line is also formed on the surface of the magnetic metal powder in the first magnetic layer, and thus, the anchor effect may be obtained between the inductor wiring line and the magnetic layer. Therefore, the necessary adhesion may be ensured even when the inductor wiring line and the magnetic layer have no other layers interposed therebetween, and are directly in contact with each other.
Other features, elements, characteristics and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments of the present disclosure with reference to the attached drawings.
Hereinafter, an inductor component and an embodiment of the inductor component will be described. Note that constituent elements may be illustrated in an enlarged manner in order to facilitate understanding of the drawings. The dimensional ratio of the constituent element may differ from the actual dimensional ratio or that in another drawing.
Hereinafter, a first embodiment of the inductor component will be described.
An inductor component 10 has, as a whole, a structure in which three thin plate-shape layers are laminated in a thickness direction as illustrated in
A first layer L1 has a substantially square shape when viewed in the up-down direction. The first layer L1 is constituted of only a first magnetic layer 21. Magnetic metal powders 20B are dispersed in a base material 20A made of an insulation material in the first magnetic layer 21 as illustrated in
A second layer L2 having the substantially square shape same as the first layer L1 when viewed in the up-down direction is laminated on the upper side face of the first layer L1 in the lamination direction as illustrated in
The inductor wiring line 30 is constituted of a wiring line main body 31, a first pad 32, and a second pad 33 in the second layer L2 as illustrated in
The number of turns of the inductor wiring line 30 is determined based on a virtual vector. The starting point of the virtual vector is placed on a virtual center line extending in the extending direction of the inductor wiring line 30 through the center of the wiring line width of the inductor wiring line 30. The direction of the virtual vector rotates in a normal direction view when the starting point of the inductor wiring line 30 is moved from one end to the other end of the virtual center line. The number of turns of the inductor wiring line 30 is defined as about 1.0 turn when the direction of the virtual vector rotates about 360 degrees. Thus, when the inductor wiring line 30 is wound about 180 degrees, the number of turns is about 0.5 turns, for example. The direction of the virtual vector virtually placed on the inductor wiring line rotates about 540 degrees in the embodiment. With this, the number of turns of the wound inductor wiring line 30 is about 1.5 turns in the embodiment.
The first pad 32 is connected to the outer peripheral end portion 31A of the wiring line main body 31. The first pad 32 has a substantially circular shape when viewed in the up-down direction. The diameter of the circle of the first pad 32 is larger than the wiring line width of the wiring line main body 31.
The first dummy wiring line 41 extends from the first pad 32 toward the outer edge side of the second layer L2. The first dummy wiring line 41 extends to the side face of the second layer L2, and is exposed to the outer face of the inductor component 10.
The second pad 33 is connected to the inner peripheral end portion 31B of the wiring line main body 31. The second pad 33 has a substantially circular shape when viewed in the up-down direction. The diameter of the circle of the second pad 33 is larger than the wiring line width of the wiring line main body 31.
The second dummy wiring line 42 extends from a portion wound by about 0.5 turns from the outer peripheral end portion 31A of winding in a region between the outer peripheral end portion 31A and the inner peripheral end portion 31B of the wiring line main body 31. The second dummy wiring line 42 extends to the side face of the second layer L2, and is exposed to the outer face of the inductor component 10.
The inductor wiring line 30 has a structure including a catalyst layer 30A, a first wiring line layer 30B, and a second wiring line layer 30C are laminated in order from the side of the first magnetic layer 21 constituting the first layer L1 as illustrated in
The first wiring line layer 30B is directly laminated on the upper face of the catalyst layer 30A. The material of the first wiring line layer 30B has a copper ratio equal to or less than about 99 wt % and a nickel ratio equal to or larger than about 0.1 wt %. A thickness TB of the first wiring line layer 30B is equal to or less than about one-tenth of the wiring line width of the inductor wiring line 30. The thickness TB of the first wiring line layer 30B is about 2.0 μm in the embodiment. Here, the thickness TB of the first wiring line layer 30B is determined as follows. The thickness from the upper end of the first magnetic layer 21 to the upper end of the first wiring line layer 30B is measured at three points in a cross section along the lamination direction in one observation field under a microscope of 1500 times magnification. The thickness TB of the first wiring line layer 30B is determined as the average value of the three measured values. The thickness TB of the first wiring line layer 30B is substantially constant in the embodiment. Note that the thickness of the catalyst layer 30A described above is exaggerated in
The second wiring line layer 30C is directly laminated on the upper face of the first wiring line layer 30B. The thickness TC of the second wiring line layer 30C is equal to or about five times larger than the thickness TB of the first wiring line layer 30B. The second wiring line layer 30C has the thickness TC of about 45 μm in the embodiment. An overall thickness TA of the inductor wiring line 30 is about 47 μm as illustrated in
An anchor portion 34 extends from the main face MF of the inductor wiring line 30. The anchor portion 34 covers the surfaces of the magnetic metal powders 20B in contact with the main face MF among the large number of magnetic metal powders 20B in the first magnetic layer 21. The anchor portion 34 extends from the main face MF so as to enter a gap between the base material 20A and the magnetic metal powder 20B in the first magnetic layer 21. Further, the magnetic metal powder 20B covered by the anchor portion 34 includes a section in which equal to or more than about one-third of the surface is covered by the anchor portion 34 when the magnetic metal powder 20B is viewed in a cross section. The cross section is orthogonal to the main face MF in the embodiment.
In the second layer L2, an inner side region relative to the inductor wiring line 30 is the inner magnetic path portion 22 as illustrated in
A third layer L3 having the substantially square shape same as the second layer L2 when viewed in the up-down direction is laminated on the upper face of the second layer L2. The third layer L3 is constituted of a first vertical wiring line 51, a second vertical wiring line 52, and a second magnetic layer 24.
The first vertical wiring line 51 is directly connected to the upper side face of the first pad 32 without any other layers interposed therebetween. The first vertical wiring line 51 has a substantially columnar shape, and an axis line direction of the column coincides with the up-down direction. The diameter of the substantially circular first vertical wiring line 51 is slightly smaller than the diameter of the first pad 32 when viewed from the upper side in the up-down direction. The material of the first vertical wiring line 51 is the same as that of the second wiring line layer 30C of the inductor wiring line 30.
The second vertical wiring line 52 is directly connected to the upper side face of the second pad 33 without any other layers interposed therebetween. The second vertical wiring line 52 has a substantially columnar shape, and an axis line direction of the column coincides with the up-down direction. The diameter of the substantially circular second vertical wiring line 52 is slightly smaller than the diameter of the second pad 33 when viewed from the upper side in the up-down direction. The material of the second vertical wiring line 52 is the same as that of the second wiring line layer 30C of the inductor wiring line 30. Note that the second wiring line layer 30C of the inductor wiring line 30, the first dummy wiring line 41, the second dummy wiring line 42, the first vertical wiring line 51, and the second vertical wiring line 52 are integrated with one another. Note that the first vertical wiring line 51 and the second vertical wiring line 52 are virtually illustrated by a dashed-and-double-dotted line in
In the third layer L3, a region other than the first vertical wiring line 51 and the second vertical wiring line 52 is the second magnetic layer 24. The outer shape of the second magnetic layer 24 is the substantially square shape same as the first magnetic layer 21 when viewed in the up-down direction. The material of the second magnetic layer 24 is the same as that of the first magnetic layer 21.
The upper side face of the third layer L3 is covered by a covering layer 60 with an insulation property as illustrated in
An outer electrode 70 is connected to the upper side face of the first vertical wiring line 51. The outer electrode 70 seems as if it seems penetrating through the covering layer 60, and the upper face of the outer electrode 70 is exposed from the covering layer 60. The outer electrode 70 has a three-layer structure, and is constituted of a copper layer 70A, a nickel layer 70B, and a gold layer 70C in order from the lower side in the lamination direction. In addition, the outer electrode 70 is also connected to the upper side face of the second vertical wiring line 52. Note that the covering layer 60 and the outer electrode 70 are not illustrated in
Next, a manufacturing method of the inductor component 10 in the first embodiment will be described.
The manufacturing method of the inductor component 10 includes a first magnetic layer processing step, a first covering step, an inductor wiring line processing step, a first resist layer removing step, a second covering step, a vertical wiring line processing step, a second resist layer removing step, a second magnetic layer processing step, a covering layer processing step, a base substrate removing step, and an outer electrode processing step as illustrated in
In manufacturing the inductor component 10, first, the first magnetic layer processing step is performed. A base substrate with a copper foil 80 is prepared as illustrated in
The first covering step is performed next to the first magnetic layer processing step. In the first covering step, a first resist layer 91 covering the portion of the upper side face of the first magnetic layer 21, on which the inductor wiring line 30, the first dummy wiring line 41, and the second dummy wiring line 42 are not formed, is patterned as illustrated in
An inductor wiring line processing step is performed next to the first covering step. In the inductor wiring line processing step, the inductor wiring line 30 configured of the catalyst layer 30A, the first wiring line layer 30B, and the second wiring line layer 30C is formed on the upper side face of the first magnetic layer 21 as illustrated in
Here, since the electroless copper plating solution enters a slight gap between the base material 20A described above and the magnetic metal powder 20B, the substitution of iron with copper occurs not only on the exposed face side of the magnetic metal powder 20B but also on the surface of the magnetic metal powder 20B on the inner side of the base material 20A. Then, copper deposited on the surface of the magnetic metal powder 20B on the inner side of the base material 20A functions as the anchor portion 34.
The covering amount is controlled such that copper deposited on the surface of the magnetic metal powder 20B on the inner side of the base material 20A covers equal to or more than about one-third of the surface area of the magnetic metal powder 20B. Specifically, the covering amount is controlled by such as the application duration of a voltage for the electroless copper plating, the amount of the electric current, the content of copper or the catalyst in the plating solution or the like.
An electrolytic copper plating is performed next to the electroless copper plating as illustrated in
The first resist layer removing step for removing the first resist layer 91 is performed next to the inductor wiring line processing step. In the first resist layer removing step, the first resist layer 91 is peeled off to remove from the first magnetic layer 21 as illustrated in
The second covering step is performed next to the first resist layer removing step. In the second covering step, patterned is a second resist layer 92 covering the portion of the upper side face of the first magnetic layer 21 and the upper side face of the second wiring line layer 30C, on which the first vertical wiring line 51 and the second vertical wiring line 52 are not formed as illustrated in
The vertical wiring line processing step for forming the first vertical wiring line 51 and the second vertical wiring line 52 is performed next to the second covering step. In the vertical wiring line processing step, electrolytic copper plating is performed, and the first vertical wiring line 51 and the second vertical wiring line 52 are formed in the portion of the upper side face of the second wiring line layer 30C not covered by the second resist layer 92. The first vertical wiring line 51 and the second vertical wiring line 52 have the copper ratio equal to or larger than about 99 wt %.
The second resist layer removing step for removing the second resist layer 92 is performed next to the vertical wiring line processing step. In the second resist layer removing step, the second resist layer 92 is peeled off to remove from the first magnetic layer 21, similarly to the first resist layer removing step.
The second magnetic layer processing step is performed next to the second resist layer removing step. In the second magnetic layer processing step, first, a magnetic material composed of the base material 20A and the magnetic metal powder 20B is filled from the upper side face of the first magnetic layer 21 toward the upper side in the lamination direction relative to the upper ends of the first vertical wiring line 51 and the second vertical wiring line 52 as illustrated in
The covering layer processing step is performed next to the second magnetic layer processing step. As illustrated in
The base substrate removing step is performed next to the covering layer processing step. In the base substrate removing step, the base substrate with the copper foil 80 is removed as illustrated in
The outer electrode processing step is performed next to the base substrate removing step. The outer electrode 70 is formed on the upper side face of the first vertical wiring line 51 as illustrated in
A dividing step is performed next to the outer electrode processing step. Specifically, the dividing is performed by cutting with a dicing machine at break lines DL as illustrated in
Next, effects of the first embodiment will be described.
(1) According to the inductor component 10 in the first embodiment, the anchor portion 34 extends from the lower side face of the catalyst layer 30A constituting the main face MF of the inductor wiring line 30. Then, the anchor portion 34 covers the surfaces of the magnetic metal powders 20B dispersed in the base material 20A of the first magnetic layer 21. Therefore, an anchor effect is obtained between the inductor wiring line 30 and the first magnetic layer 21 by the anchor portion 34. As a result, the adhesion between the inductor wiring line 30 and the first magnetic layer 21 is improved. Thus, in the inductor component 10, it is achieved that the inductor wiring line 30 is directly laminated on the first magnetic layer 21 while ensuring the required adhesion between the inductor wiring line 30 and the first magnetic layer 21.
(2) According to the inductor component 10 in the first embodiment, the magnetic metal powder 20B covered by the anchor portion 34 includes a cross section in which equal to or more than about one-third of the surface is covered by the anchor portion 34 when the magnetic metal powder 20B is viewed in a cross section. Therefore, the relatively large anchor portion 34 allows the reliable close contact between the inductor wiring line 30 and the first magnetic layer 21.
(3) According to the manufacturing method of the inductor component 10 in the first embodiment, the magnetic metal powder 20B is exposed on part of the surface of the first magnetic layer 21 in the inductor wiring line processing step, and the inductor wiring line 30 is formed on part of the surface of the first magnetic layer 21 by immersing the first magnetic layer 21 in a plating solution. Therefore, the plating liquid enters the gap between the base material 20A and the magnetic metal powder 20B in the first magnetic layer 21, and the anchor portion 34 may be formed on the surface of the magnetic metal powder 20B on the inner side of the base material 20A.
(4) According to the manufacturing method of the inductor component 10 in the first embodiment, the electroless copper plating is performed by performing immersion in the electroless copper plating solution, and the first wiring line layer 30B having a copper ratio equal to or less than about 99 wt % and a nickel ratio equal to or larger than about 0.1 wt % is formed on the upper side face of the catalyst layer 30A. Therefore, damage to the surface of the first magnetic layer 21, in a case where the first wiring line layer 30B is formed by for example, sputtering or the like, is made relatively small, and the first wiring line layer 30B may be formed without excessively reducing the amount of the magnetic metal powder 20B in the first magnetic layer 21.
(5) According to the inductor component 10 in the first embodiment, iron being a material of the magnetic metal powder 20B has a higher ionization tendency than copper being the material of the first wiring line layer 30B. Therefore, iron having a large ionization tendency becomes ions and copper having a small ionization tendency deposits between the copper salt in the electroless copper plating and the surface of the magnetic metal powder 20B. With this, it is possible for copper to deposit so as to cover the surface of the magnetic metal powder 20B even when the base material 20A and the magnetic metal powder 20B are relatively dense.
(6) According to the inductor component 10 in the first embodiment, the thickness TC of the second wiring line layer 30C is equal to or about five times larger than the thickness TB of the first wiring line layer 30B. Therefore, the thickness TA of the inductor wiring line 30 may be increased to some extent and the DC resistance may be reduced.
(7) According to the manufacturing method of the inductor component 10 in the first embodiment, the electrolytic copper plating is performed, and the second wiring line layer 30C is formed on the surface of the first wiring line layer 30B. The second wiring line layer 30C has the copper ratio equal to or larger than about 99 wt % and the nickel ratio equal to or less than the detection limit. Therefore, the second wiring line layer 30C having a large thickness may be efficiently formed compared with the electroless copper plating.
(8) According to the inductor component 10 in the first embodiment, the catalyst layer 30A is disposed on the first magnetic layer 21 side of the first wiring line layer 30B. The catalyst layer 30A activates the deposition of copper in the electroless copper plating. Therefore, since palladium as the catalyst is adsorbed in a layered manner on the entire surface of the first magnetic layer 21, copper is deposited on the entire surface of the first magnetic layer 21 when the electroless copper plating is performed. This makes it easy to form the first wiring line layer 30B having a uniform thickness.
(9) According to the inductor component 10 in the first embodiment, the base material 20A contains epoxy-based resin and an inorganic filler. Therefore, a physical defect such as a crack is unlikely to occur when the thickness of the first magnetic layer 21 is reduced to some extent, and sufficient strength may be maintained without an additive insulation substrate or the like.
(10) According to the inductor component 10 in the first embodiment, the covering layer 60 covers the upper face of the third layer L3. Therefore, the insulation property with the outside may easily be ensured.
(11) According to the inductor component 10 in the first embodiment, the average particle size of the magnetic metal powder 20B is equal to or less than about 5.0 μm. Further, the average particle size of the magnetic metal powder 20B is equal to or less than about one-tenth of the wiring line width of the wiring line main body 31 of the inductor wiring line 30. Therefore, the average particle size of the magnetic metal powder 20B is relatively small. With this, the surface area of the magnetic metal powder 20B in contact with the inductor wiring line 30 increases, and it is easy to provide a large number of anchor portions 34. As a result, it is easy to obtain a stable anchor effect.
Hereinafter, a second embodiment of the inductor component will be described.
An inductor component 110 has, as a whole, a structure in which six plate-shape layers are laminated in a thickness direction as illustrated in
A first layer L11 has a substantially rectangular shape when viewed in the up-down direction. The first layer L11 is constituted of only a first magnetic layer 121. Magnetic metal powders 120B are dispersed in a base material 120A made of an insulation material in the first magnetic layer 121 as illustrated in
A second layer L12 having the substantially rectangular shape same as the first layer L11 when viewed in the up-down direction is laminated on the upper side face of the first layer L11 in the lamination direction as illustrated in
In the second layer L12, when viewed from the upper side of the up-down direction, the first wiring line main body 131 of the first inductor wiring line 130 spirally extends around the vicinity of the center of the face on the side opposite to the main face MF2 of the second layer L12 having a substantially rectangular shape as illustrated in
An angle in which the first inductor wiring line 130 is wound is about 540 degrees in the embodiment. With this, the number of turns of the wound first inductor wiring line 130 is about 1.5 turns in the embodiment. When the second layer L12 is viewed from the upper side of the up-down direction, the side on which the first end of the first wiring line main body 131 is disposed is referred to as a first end side, and the side on which the second end of the first wiring line body 131 is disposed is referred to as a second end side in a long-side direction of the second layer L12 having a substantially rectangular shape in the embodiment.
The first pad 132 is connected to the first end on one side of the extending direction of the first wiring line main body 131. The first pad 132 has a substantially rectangular shape when viewed in the up-down direction. The first pad 132 constitutes a first end portion of the first inductor wiring line 130. The first pad 132 is disposed in the vicinity of the corner of the second layer L12 having a substantially rectangular shape when viewed in the up-down direction. The wiring line width of the first pad 132 is larger than the wiring line width of the first wiring line main body 131 connected to the first pad 132.
The second pad 133 is connected to the second end on the other side of the extending direction of the first wiring line main body 131. The second pad 133 has a substantially circular shape when viewed in the up-down direction. The second pad 133 constitutes a second end portion of the first inductor wiring line 130. The diameter of the circle of the second pad 133 is larger than the width of the first wiring line main body 131 connected to the second pad 133.
The first dummy wiring line 141 is connected to the first pad 132. The first dummy wiring line 141 extends from the portion of the first pad 132 on the side opposite to the first wiring line main body 131 toward the side face of the second layer L12, and is exposed to the outer face of the inductor component 110.
In the second layer L12, when viewed in the up-down direction, the first connection wiring line 146 is disposed on the side opposite to the first pad 132 in a short-side direction of the second layer L12 having a substantially rectangular shape and in the vicinity of the corner on the first end side in the long-side direction. The first connection wiring line 146 is line-symmetric with a straight line passing through the center of the second layer L12 in the short-side direction and extending in the long-side direction of the second layer L12 as a symmetric axis.
The first inductor wiring line 130 has a structure where a first wiring line layer 130B, and a second wiring line layer 130C are laminated in order from the side of the first magnetic layer 121 constituting the first layer L11 as illustrated in
The material of the first wiring line layer 130B has a copper ratio equal to or less than about 99 wt % and a nickel ratio equal to or larger than about 0.1 wt %. The thickness TB2 of the first wiring line layer 130B is equal to or less than about one-tenth of the wiring line width of the inductor wiring line 30. The thickness TB2 of the first wiring line layer 130B is about 2.0 μm in the embodiment. Here, the thickness TB2 of the first wiring line layer 130B is determined as follows. The thickness in the lamination direction from the upper end of the first magnetic layer 121 to the upper end of the first wiring line layer 130B is measured at three points in a cross section along the lamination direction in one observation field under a microscope of 1500 times magnification. The thickness TB2 of the first wiring line layer 130B is determined as the average value of the three measured values. The thickness TB2 of the first wiring line layer 130B is substantially constant in the embodiment. Note that the wiring line width of the first inductor wiring line 130 is determined as the average value of three points of the width dimension of the first inductor wiring line 130 in the vicinity of the center in the extending direction.
The second wiring line layer 130C is directly laminated on the upper face of the first wiring line layer 130B. Further, the second wiring line layer 130C covers an area slightly wider than the first wiring line layer 130B from the upper side in the lamination direction. That is, the side face of the surface of the first wiring line layer 130B facing the direction orthogonal to the lamination direction is covered by the second wiring line layer 130C. Then, part of the outer face of the second wiring line layer 130C constitutes part of the main face MF2 of the first inductor wiring line 130.
A thickness TC2 of the second wiring line layer 130C is equal to or about five times larger than the thickness TB2 of the first wiring line layer 130B. The thickness TC2 of the second wiring line layer 130C is about 45 μm in the embodiment. Thus, the thickness of the first inductor wiring line 130 constituted of the first wiring line layer 130B and the second wiring line layer 130C is about 47 μm as illustrated in
An anchor portion 134 extends from the main face MF2 of the first inductor wiring line 130. The anchor portion 134 extends from both of the first wiring line layer 130B and the second wiring line layer 130C constituting the main face MF2 of the first inductor wiring line 130 in the embodiment. The anchor portion 134 covers the surfaces of the magnetic metal powders 120B in contact with the main face MF2 among the large number of magnetic metal powders 120B in the first magnetic layer 121. Therefore, the anchor portion 134 extends from the main face MF2 so as to enter a gap between the base material 120A and the magnetic metal powder 120B in the first magnetic layer 121. Further, the magnetic metal powder 120B covered by the anchor portion 134 includes a cross section in which equal to or more than about one-third of the surface is covered by the anchor portion 134 when the magnetic metal powder 120B is viewed in a cross section.
In the second layer L12, the side face of the first inductor wiring line 130, the side face of the first dummy wiring line 141, and the side face of the first connection wiring line 146 are covered by the first insulation portion 181 as illustrated in
A third layer L13 having the substantially rectangular shape same as the second layer L12 when viewed in the up-down direction is laminated on the upper face of the second layer L12. The third layer L13 is constituted of a second insulation portion 182, a first via 191, a second via 192, a third via 193, and a third magnetic layer 123.
The first via 191 is disposed on the upper side of the first pad 132 of the second layer L12, and is connected to the first pad 132. The second via 192 is disposed on the upper side of the first connection wiring line 146 of the second layer L12, and is connected to the first connection wiring line 146. The third via 193 is disposed on the upper side of the second pad 133 of the second layer L12, and is connected to the second pad 133. The first via 191, the second via 192, and the third via 193 have a substantially columnar shape, and the axial direction thereof coincides with the lamination direction. The length of the first via 191, the second via 192, and the third via 193 in the lamination direction is the same as the thickness of the third layer L13 in the lamination direction. Thus, the first via 191, the second via 192, and the third via 193 penetrate through the third magnetic layer 123 in the lamination direction.
The second insulation portion 182 covers the first inductor wiring line 130, the first dummy wiring line 141, the first connection wiring line 146, and the first insulation portion 181 from the upper side. That is, the second insulation portion 182 covers all the face, of the upper face of the respective wiring lines disposed in the second layer L12, other than the portions where the first via 191, the second via 192, and the third via 193 are disposed. The second insulation portion 182 has a shape to cover an area slightly wider than the outer edges of the first inductor wiring line 130, the first dummy wiring line 141, and the first connection wiring line 146 when viewed in the up-down direction. The second insulation portion 182 is insulation resin with an insulation property similar to the first insulation portion 181. Note that in the embodiment, the first insulation portion 181 and the second insulation portion 182 constitute a first insulation layer.
In the third layer L13, the portion excluding the first via 191, the second via 192, the third via 193, and the second insulation portion 182 is the third magnetic layer 123. Therefore, the third magnetic layer 123 is disposed in the central portion of the third layer L13, the both end portions of the third layer L13 in the short-side direction, and the first end side portion of the third layer L13 in the long-side direction. The third magnetic layer 123 is made of the same magnetic material as the first magnetic layer 121 described above.
A fourth layer L14 having the substantially rectangular shape same as the third layer L13 when viewed in the up-down direction is laminated on the upper face of the third layer L13. The fourth layer L14 is constituted of a second inductor wiring line 135, a second dummy wiring line 142, a second connection wiring line 147, a third insulation portion 183, and a fourth magnetic layer 124. The second inductor wiring line 135 is constituted of a second wiring line main body 136 having a substantially constant wiring line width, a third pad 137 connected to a first end of the second wiring line main body 136, and a fourth pad 138 connected to a second end of the second wiring line main body 136. That is, the second inductor wiring line 135 is laminated on the first inductor wiring line 130 with an interval of the third layer L13 in the lamination direction. Further, the third pad 137 serves as a first end portion of the second inductor wiring line 135, and the fourth pad 138 serves as a second end portion of the second inductor wiring line 135 in the embodiment.
In the fourth layer L14, when viewed in the up-down direction, the second wiring line main body 136 of the second inductor wiring line 135 spirally extends around the vicinity of the center of the face of the fourth layer L14 having a substantially rectangular shape on the side opposite to a main face MF3. Specifically, the second wiring line main body 136 of the second inductor wiring line 135 is spirally wound in the counterclockwise direction from the first end in the outer side portion in the radial direction toward the second end in the inner side portion in the radial direction. That is, the winding direction of the second inductor wiring line 135 is opposite to the winding direction of the first inductor wiring line 130.
The angle in which the second inductor wiring line 135 is wound is about 540 degrees in the embodiment. With this, the number of turns of the wound second inductor wiring line 135 is about 1.5 turns in the embodiment.
The third pad 137 is connected to the first end on one side of the extending direction of the second wiring line main body 136. The third pad 137 has a substantially rectangular shape when viewed in the up-down direction. The third pad 137 constitutes a first end portion of the second inductor wiring line 135. The third pad 137 is disposed in the vicinity of the corner of the fourth layer L14 having a substantially rectangular shape when viewed in the up-down direction. The third pad 137 is wider than the second wiring line main body 136 connected to the third pad 137 in the wiring line width.
The fourth pad 138 is connected to a second end on the other side of the extending direction of the second wiring line main body 136. The fourth pad 138 has a substantially circular shape when viewed in the up-down direction. The fourth pad 138 is positioned on the upper side of the second pad 133 of the second layer L12, and is connected to the second pad 133 through the third via 193. The fourth pad 138 is wider than the second wiring line main body 136 connected to the fourth pad 138 in the wiring line width. The fourth pad 138 constitutes a second end portion of the second inductor wiring line 135.
The second dummy wiring line 142 is connected to the third pad 137. The second dummy wiring line 142 extends from the portion of the third pad 137 on the side opposite to the second wiring line main body 136 toward the side face of the fourth layer L14, and is exposed to the outer face of the second inductor wiring line 135.
In the fourth layer L14, when viewed in the up-down direction, the second connection wiring line 147 is disposed on the side opposite to the third pad 137 in the short-side direction of the fourth layer L14 having a substantially rectangular shape and in the vicinity of the corner of the first end side in the long-side direction. The second connection wiring line 147 is line-symmetric with a straight line passing through the center of the fourth layer L14 in the short-side direction and extending in the long-side direction of the fourth layer L14 as a symmetric axis. The second inductor wiring line 135 and the second connection wiring line 147 are illustrated by a broken line in
The third via 193 is integrated with the second inductor wiring line 135 as illustrated in
The fourth wiring line layer 200B is laminated on the upper face of the third wiring line layer 200A. The material of the fourth wiring line layer 200B has a copper ratio equal to or larger than about 99 wt %. The upper end of the fourth wiring line layer 200B is flush with the upper end of the fourth layer L14.
In the fourth layer L14, the gap between the side faces of the second inductor wiring line 135 is covered by the third insulation portion 183 as illustrated in
The portion other than the second inductor wiring line 135, the second dummy wiring line 142, the second connection wiring line 147, and the third insulation portion 183 is the fourth magnetic layer 124. Therefore, the fourth magnetic layer 124 is disposed in the central portion of the fourth layer L14, the both end portions of the fourth layer L14 in the short-side direction, and the first end side portion of the fourth layer L14 in the long-side direction. The material of the fourth magnetic layer 124 is the same as that of the first magnetic layer 121.
A fifth layer L15 having the substantially rectangular shape same as the fourth layer L14 when viewed in the up-down direction is laminated on the upper face of the fourth layer L14. The fifth layer L15 is constituted of a fifth magnetic layer 125, a fourth insulation portion 184, a first columnar wiring line 194, a second columnar wiring line 195, and a third columnar wiring line 196. The first columnar wiring line 194, the second columnar wiring line 195, and the third columnar wiring line 196 penetrate through the fifth layer L15 in the lamination direction.
The fourth insulation portion 184 covers all the upper face of the third insulation portion 183 and part of the upper face of the second inductor wiring line 135. Thus, the fourth insulation portion 184 covers the third insulation portion 183 from the upper side. The fourth insulation portion 184 is insulation resin with an insulation property similar to the third insulation portion 183, and the insulation performance thereof is higher than that of the second inductor wiring line 135. Note that the second insulation layer is constituted of the third insulation portion 183 and the fourth insulation portion 184 in the embodiment.
In the fifth layer L15, the portion excluding the first columnar wiring line 194, the second columnar wiring line 195, the third columnar wiring line 196, and the fourth insulation portion 184 is the fifth magnetic layer 125. The material of the fifth magnetic layer 125 is the same as that of the first magnetic layer 121 described above and is a magnetic material.
A sixth layer L16 having the substantially rectangular shape same as the fifth layer L15 when viewed in the up-down direction is laminated on the upper face of the fifth layer L15. The sixth layer L16 is constituted of a sixth magnetic layer 126, a fourth columnar wiring line 197, a fifth columnar wiring line 198, and a sixth columnar wiring line 199.
The fourth columnar wiring line 197 is disposed on the upper side of the second connection wiring line 147 in the fourth layer L14, and is connected to the second connection wiring line 147 through the second columnar wiring line 195. The sixth columnar wiring line 199 is disposed on the upper side of the third pad 137 of the fourth layer L14, and is connected to the third pad 137 through the first columnar wiring line 194. The fourth columnar wiring line 197 and the sixth columnar wiring line 199 have a substantially prismatic shape, and the axial direction thereof coincides with the lamination direction. The length of the fourth columnar wiring line 197 and the sixth columnar wiring line 199 in the lamination direction is identical with the thickness of the sixth layer L16 in the lamination direction. Thus, the fourth columnar wiring line 197 and the sixth columnar wiring line 199 penetrate through the sixth layer L16 in the lamination direction. That is, the first columnar wiring line 194 and the sixth columnar wiring line 199 constitute a first vertical wiring line in the embodiment. Further, the second columnar wiring line 195 and the fourth columnar wiring line 197 constitute a third vertical wiring line.
In addition, the fifth columnar wiring line 198 is disposed on the upper side of the fourth pad 138 of the second inductor wiring line 135 in the fourth layer L14, and is connected to the fourth pad 138 through the third columnar wiring line 196. That is, the third columnar wiring line 196 and the fifth columnar wiring line 198 constitute a second vertical wiring line in the embodiment. Note that the fourth columnar wiring line 197, the fifth columnar wiring line 198, and the sixth columnar wiring line 199 are illustrated by a dashed-and-double-dotted line in
In the sixth layer L16, the portion excluding the fourth columnar wiring line 197, the fifth columnar wiring line 198, and the sixth columnar wiring line 199 is the sixth magnetic layer 126 as illustrated in
The outer electrode 230 is laminated on the upper side face of the fifth columnar wiring line 198 as illustrated in
Next, a manufacturing method of the inductor component 110 in the second embodiment will be described.
As illustrated in
In manufacturing the inductor component 110, at first, the first magnetic layer processing step is performed. A base substrate with a copper foil 210 is prepared as illustrated in
The first covering step is performed next to the second magnetic layer processing step. In the first covering step, in the upper side face of the first magnetic layer 121, the first resist layer 221 covering the portion on which the first wiring line layer 130B is not formed is patterned as illustrated in
The first wiring line layer processing step is performed next to the first covering step. In the first wiring line layer processing step, the first wiring line layer 130B is formed on the upper side face of the first magnetic layer 121 as illustrated in
Here, Since the electroless copper plating solution enters a slight gap between the base material 120A and the magnetic metal powder 120B, the substitution of iron with copper occurs not only on the exposed face side of the magnetic metal powder 120B but also on the surface of the magnetic metal powder 120B on the inner side of the base material 120A. Copper deposited on the surface of the magnetic metal powder 120B on the inner side of the base material 120A functions as the anchor portion 134. Thus, the anchor portion 134 extending from the lower side face of the first wiring line layer 130B is formed with electroless copper plating.
The first resist layer removing step for removing the first resist layer 221 is performed next to the first wiring line processing step. In the first resist layer removing step, the first resist layer 221 is peeled off to remove from the first magnetic layer 121 as illustrated in
The second covering step is performed next to the first resist layer removing step. In the second covering step, in the upper side face of the first magnetic layer 121, the second resist layer 222 covering the portion on which the second wiring line layer 130C is not formed is patterned as illustrated in
The second wiring line layer processing step is performed next to the second covering step. In the second wiring line layer processing step, the second wiring line layer 130C is formed in the portion not covered by the second resist layer 222. Specifically, electrolytic copper plating is performed, and the second wiring line layer 130C having a copper ratio equal to or larger than about 99 wt % is formed on the surface not covered by the second resist layer 222. At this time, the end portion of the second wiring line layer 130C is in direct close contact with the first magnetic layer 121 not covered by the first wiring line layer 130B as illustrated in
The second resist layer removing step is performed next to the second wiring line layer processing step. In the second resist layer removing step, the second resist layer 222 is peeled off to remove from the first magnetic layer 121 as illustrated in
The first insulation layer processing step is performed next to the second resist layer removing step. The first inductor wiring line 130 is covered by an insulation material from the upper side in the lamination direction as illustrated in
The third wiring line processing step is performed next to the first insulation layer processing step. First, in the upper side face of the first inductor wiring line 130, a hole penetrating through the second insulation portion 182 is formed by laser at the portion on which the third via 193 is formed as illustrated in
The third covering step is performed next to the third wiring line processing step. In the third covering step, in the surface of the third wiring line layer 200A, the third resist layer 223 covering the portion on which the fourth wiring line layer 200B is not formed is patterned. Note that the aspect of the photolithography in the third covering step is the same as that in the first covering step and a detailed description thereof will be omitted.
The fourth wiring line layer processing step is performed next to the third covering step. In the fourth wiring line layer processing step, the electrolytic copper plating is performed, and in the surface of the third wiring line layer 200A, the fourth wiring line layer 200B having a copper ratio equal to or larger than about 99 wt % is formed on the portion not covered by the third resist layer 223.
The fourth covering step is performed next to the fourth wiring line processing step. In the fourth covering step, the fourth resist layer 224 covering the portion in which the vertical wiring line is not formed is patterned as illustrated in
The vertical wiring line processing step is performed next to the fourth covering step. In the vertical wiring line processing step, the electrolytic copper plating is performed, and in the surface of the second wiring line layer 130C, each vertical wiring line of a copper ratio equal to or larger than about 99 wt % is formed on the portion not covered by the fourth resist layer 224. That is, the third columnar wiring line 196 and the fifth columnar wiring line 198 are formed. Note that although not illustrated in the drawings, the first columnar wiring line 194, the second columnar wiring line 195, the fourth columnar wiring line 197, and the sixth columnar wiring line 199 are also formed.
The fourth resist layer removing step and the third resist layer removing step are performed at the same time next to the vertical wiring line processing step. Specifically, the third resist layer 223 and the fourth resist layer 224 are peeled off to remove from the first magnetic layer 121 as illustrated in
The second insulation layer processing step is performed next to the third resist layer removing step. In the second insulation layer processing step, an insulation resin is applied to the upper side face as illustrated in
The second magnetic layer processing step is performed next to the second insulation layer processing step. In the second magnetic layer processing step, a magnetic material is filled to the upper side in the lamination direction relative to the upper end of the fifth columnar wiring line 198 as illustrated in
The base substrate removing step is performed next to the second magnetic layer processing step. In the base substrate removing step, the base substrate with the copper foil 210 is removed as illustrated in
The outer electrode processing step is performed next to the base substrate removing step. Specifically, the outer electrode 230 is formed on the upper side faces of the respective vertical wiring lines, that is, the upper side faces of the fourth columnar wiring line 197, the fifth columnar wiring line 198, and the sixth columnar wiring line 199 by electroless plating, electrolytic plating, printing, sputtering, or the like. The outer electrode has a single-layer or a laminated structure including any of copper, nickel, gold, and tin.
The dividing step is performed next to the outer electrode processing step. Specifically, the dividing is performed by cutting with a dicing machine at break lines DL as illustrated in
Next, effects of the second embodiment will be described. According to the second embodiment, in addition to the effects of (1) to (7), (9), and (11) of the first embodiment, the following effects are achieved.
(12) According to the inductor component 110 in the second embodiment, not only the lower face of the first wiring line layer 130B but also the lower face of the second wiring line layer 130C constitutes part of the main face MF2 of the first inductor wiring line 130. Therefore, the anchor portion 134 also extends from the lower side face of the second wiring line layer 130C, and an anchor effect generated between the first inductor wiring line 130 and the first magnetic layer 121 may more largely be obtained.
(13) According to the inductor component 110 in the second embodiment, the anchor portion 134 extends from the main face MF2 of the first inductor wiring line 130, but an anchor portion does not extend from the main face MF3 of the second inductor wiring line 135. Further, the second inductor wiring line 135 is laminated on the first inductor wiring line 130 with an interval in the lamination direction. Therefore, the degree of freedom in design is improved when a plurality of inductor wiring lines is laminated.
Each of the embodiments may be implemented with the following modifications. Each of the embodiments and the following modifications can be implemented in combination within a scope not technically contradicting each other.
In each of the embodiments, the inductor wiring line is capable of imparting inductance to the inductor component by generating magnetic flux in the magnetic layer when an electric current flows.
In each of the embodiments, the shape of the inductor wiring line is not limited to the example in each embodiment. For example, the inductor wiring line may have a curved shape of less than about 1.0 turn or a linear shape of 0 turns. Further, part of a plurality of inductor wiring lines may have a shape different from that of other inductor wiring line. Furthermore, in each of the embodiments, the inductor wiring line may have a meander shape.
In the first embodiment, the plurality of inductor wiring lines 30 may be arranged in a direction parallel to the main face MF, or may be disposed in the same layer. In these cases, the provision of the plurality of inductor wiring lines 30 may suppress an excessive increase in the overall size in the lamination direction because the plurality of inductor wiring lines 30 is disposed in the same layer while an overall inductance is improved. Further, the inductor component 10 in which the plurality of inductor wiring lines 30 is provided in the same layer may be used by being divided into a plurality of inductor components.
In each of the embodiments, the wiring line structure of the inductor wiring line is not limited to the example in each embodiment. For example, in the inductor wiring line, the shapes of the first pad and the second pad may be changed, or the first pad and the second pad may be omitted.
In the first embodiment, the catalyst layer 30A and the second wiring line layer 30C may be omitted in the inductor wiring line 30, and the inductor wiring line 30 may be constituted of only the first wiring line layer 30B. Even in this case, the lower side face of the first wiring line layer 30B constitutes the main face MF of the inductor wiring line 30 and the anchor portion 34 needs to extend from the lower side face of the first wiring line layer 30B.
In each of the embodiments, the amount covered by the anchor portion is not limited to the example in each embodiment. For example, the anchor portion may not cover all of the surface of the magnetic metal powder in contact with, and may cover less than about one-third of the area thereof. In this case, the magnetic metal powder covered by the anchor portion may not include a cross section in which equal to or more than about one-third of the surface is covered by the anchor portion when the magnetic metal powder is viewed in a cross section. Further, the anchor portion may not cover the surfaces of all the magnetic metal powders in contact with the main face of the inductor wiring line.
In each of the embodiments, the formation of the anchor portion and the control of the amount to be covered by the anchor portion are not limited to the example in the embodiment. For example, in the first embodiment, an alkaline chemical solution that dissolves the base material 20A of the first magnetic layer 21 and does not dissolve the magnetic metal powder 20B is used at the time of surface treatment such as removing the resin residue of the first magnetic layer 21, and the interface state between the base material 20A and the magnetic metal powder 20B may be controlled with the duration of the processing time.
In the first embodiment, a slight gap is formed between the base material 20A and the magnetic metal powder 20B when the grinding is performed and an electroless copper plating solution is infused into the gap in the inductor wiring line processing step. However, any other known method may be used as long as the anchor portion 34 may be formed. In particular, even in a case where there is no clear gap at the interface between the base material 20A and the magnetic metal powder 20B, the electroless copper plating solution enters along the interface between the base material 20A and the magnetic metal powder 20B, and the substitution of iron with copper described above is generated. Therefore, a gap between the base material 20A and the magnetic metal powder 20B need not be formed at the time of the grinding.
In the second embodiment, the anchor portion 134 may not extend from the lower face of the first wiring line layer 130B, but may extend only from the lower face of the second wiring line layer 130C constituting part of the main face MF2 of the first inductor wiring line 130.
In each of the embodiments, the material of the first wiring line layer is not limited to the example in each embodiment. For example, the material of the first wiring line layer may have a nickel ratio equal to or less than about 99 wt % and a phosphorus ratio equal to or larger than about 0.5 wt % and equal to or less than about 10 wt % (i.e., from about 0.5 wt % to about 10 wt %). In this case, containing phosphorus allows the control of the stress existing in nickel, and the residual stress in the inductor component may be mitigated. Further, containing nickel in the first wiring line layer may suppress electromigration.
In each of the embodiments, the material of the magnetic metal powder is not limited to the example in each embodiment. For example, the material of the magnetic metal powder may contain a metal powder other than iron, and may not be a metal having a higher ionization tendency than that of the material of the first wiring line layer. In this case, when the grain boundaries between the magnetic metal powder and the base material are relatively large and the plating solution can be infused, the anchor portion may be formed, for example.
In each of the embodiments, the material of the second wiring line layer may be a metal other than copper. Note that the boundary face between the second wiring line layer and the first wiring line layer is not necessarily clear, and in some cases, a clear interface between the first wiring line layer and the second wiring line layer may not be observed.
In each of the embodiments, the thickness of the second wiring line layer may be less than about five times the thickness of the first wiring line layer.
In the first embodiment, the material of the catalyst layer 30A is not limited to the example in the embodiment. The material of the catalyst layer 30A needs to include at least one or more metals among palladium, platinum, silver, and gold.
In the first embodiment, the thickness TA of the inductor wiring line 30 is not limited to the example in the embodiment. When the thickness TA of the inductor wiring line 30 is equal to or larger than about 40 μm, the DC resistance may be made relatively small. When the thickness TA of the inductor wiring line 30 is equal to or less than about 120 μm, the wiring line width with respect to the thickness TA may not excessively be increased.
In the first embodiment, the thickness TB of the first wiring line layer 30B is not limited to the example in the embodiment. When the thickness TB of the first wiring line layer 30B is equal to or larger than about 0.3 μm and equal to or less than about 10 μm (i.e., from about 0.3 μm to about 10 μm), the first wiring line layer 30B may easily be formed by electroless copper plating.
In each of the embodiments, the material of the base material is not limited to the example in the embodiment. For example, when the material of the base material contains at least one resin among epoxy-based resin, phenol-based resin, and acrylic-based resin, and an inorganic filler having an average particle size equal to or less than about 1 μm, it is suitable for ensuring strength of the magnetic layer. Further, the material of the base material is not limited to the above, and may be only resin with an insulation property.
In each of the embodiments, the average particle size of the magnetic metal powder is not limited to the example in the embodiment. When the average particle size of the magnetic metal powder is equal to or less than 5.0 μm, the number of anchor portions may easily be increased. Further, the average particle size of the magnetic metal powder may be larger than about one-tenth of the wiring line width of the inductor wiring line 30.
In the embodiments, the boundaries of the magnetic layers in the respective layers may be integrated such that the interfaces cannot be confirmed, or may be separate bodies in which the interfaces can be confirmed.
While preferred embodiments of the disclosure 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 disclosure. The scope of the disclosure, therefore, is to be determined solely by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-030655 | Feb 2020 | JP | national |
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| 20050068148 | Yoshida | Mar 2005 | A1 |
| 20050140488 | Shimoyama | Jun 2005 | A1 |
| 20150270053 | Cha | Sep 2015 | A1 |
| 20170200554 | Kudo | Jul 2017 | A1 |
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| 1637963 | Jul 2005 | CN |
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| Number | Date | Country | |
|---|---|---|---|
| 20210265097 A1 | Aug 2021 | US |
