JP2012119384A - Manufacturing method of laminated inductor component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a laminated inductor component capable of suppressing displacement between laminated conductor patterns and peeling between insulator green sheets.SOLUTION: A manufacturing method of a laminated inductor component comprises: a preparation step of preparing a plurality of insulator green sheets 23, 24 on which conductor patterns 25, 26 are formed; a lamination step of acquiring a laminate by laminating the plurality of insulator green sheets 23, 24; and a burning step of burning the laminate. Each time each of the plurality of insulator green sheets 23, 24 is laminated, each of the insulator green sheets 23, 24 is pressed via an elastic member 19 or 20 so that the elastic member 19 or 20 is deformed according to the thicknesses of the conductor patterns 25, 26.

Description

  The present invention relates to a method for manufacturing a multilayer inductor component.

  As a method for manufacturing a multilayer inductor component, when a plurality of insulator green sheets on which conductor patterns are formed is stacked, a method in which each insulator green sheet is pressed with a mold each time it is stacked is known (for example, Patent Document 1).

JP-A-6-231996

  In the said manufacturing method, since it presses with a metal mold | die whenever it laminates | stacks each insulator green sheet, the position shift of conductor patterns does not arise easily. However, in the same insulator green sheet, the pressure is less likely to act on the portion where the conductor pattern is not formed than the portion where the conductor pattern is formed due to the thickness of the conductor pattern. For this reason, compared with the part in which the conductor pattern is formed, in the part in which the conductor pattern is not formed, the insulator green sheets are hard to adhere | attach, and there existed a possibility that peeling might arise between insulator green sheets.

  Accordingly, an object of the present invention is to provide a method for manufacturing a multilayer inductor component capable of suppressing misalignment between stacked conductor patterns and suppressing separation between insulator green sheets.

  A manufacturing method of a multilayer inductor component according to the present invention includes a preparation step of preparing a plurality of insulator green sheets on which a conductor pattern is formed, a laminate step of stacking a plurality of insulator green sheets to obtain a laminate, and a laminate In the laminating step, each time a plurality of insulating green sheets are laminated, the elastic member is pressed through the elastic member so as to deform corresponding to the thickness of the conductor pattern. It is characterized by.

  In the method for manufacturing a multilayer inductor component according to the present invention, since the pressing is performed each time a plurality of insulator green sheets are stacked in the stacking step, the positional deviation between the conductor patterns is suppressed. Each insulator green sheet is pressed through the elastic member so that the elastic member is deformed corresponding to the thickness of the conductor pattern, so that pressure is easily applied to the portion where the conductor pattern is not formed. Peeling between green sheets is suppressed.

  In the laminating step, first, pressing is performed through the first elastic member, and the first elastic member is replaced with a second elastic member that is softer than the first elastic member, and then pressed through the second elastic member. Are preferably laminated. In this case, in the situation where the number of laminated insulator green sheets is increased and the thickness difference between the portion where the conductor pattern is formed and the portion where the conductor pattern is not formed is larger, the thickness of the conductor pattern is larger than that of the first elastic member. A second elastic member that is easily deformed is used. For this reason, even in a situation where the thickness difference between the portion where the conductor pattern is formed and the portion where the conductor pattern is not formed is large, pressure is easily applied to the portion where the conductor pattern is not formed, and between the insulator green sheets. Is further suppressed.

  In the preparation step, an insulator green sheet without a conductor pattern is prepared, and in the lamination step, a plurality of insulator green sheets with a conductor pattern are stacked, and then an insulator green sheet without a conductor pattern is formed. From the elastic member used when laminating a plurality of insulator green sheets on which conductor patterns are formed when laminating sheets and laminating insulator green sheets on which conductor patterns are not formed It is preferable to press through a soft elastic member. In this case, the conductor pattern is formed in a situation where the plurality of insulator green sheets on which the conductor pattern is formed are all laminated, and the thickness difference between the portion where the conductor pattern is formed and the portion where the conductor pattern is not formed is maximized. Compared to the elastic member used to press the insulating green sheet, an elastic member that is easily deformed corresponding to the thickness of the conductor pattern is used. For this reason, even in a situation where the thickness difference between the portion where the conductor pattern is formed and the portion where the conductor pattern is not formed becomes maximum, the pressure is easily applied to the portion where the conductor pattern is not formed, and between the insulator green sheets Is further suppressed.

  It is preferable to further include a pressure-bonding step for pressing the laminated body before the firing step. In this case, the pressure-bonding state between the insulator green sheets is made uniform in the pressure-bonding step, and peeling between the insulator green sheets is further suppressed.

  ADVANTAGE OF THE INVENTION According to this invention, while suppressing the position shift of the laminated conductor patterns, the manufacturing method of the multilayer inductor component which can suppress peeling between insulator green sheets can be provided.

It is a perspective view which shows the multilayer inductor component which concerns on this embodiment. FIG. 2 is an exploded perspective view of elements included in the multilayer inductor component shown in FIG. 1. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment. It is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description, the same reference numerals are used for the same elements or elements having the same function, and redundant description is omitted.

  First, based on FIG.1 and FIG.2, the structure of the multilayer inductor component which concerns on this embodiment is demonstrated. FIG. 1 is a perspective view showing a multilayer inductor component according to the present embodiment. FIG. 2 is an exploded perspective view of elements included in the multilayer inductor component shown in FIG.

  As shown in FIG. 1, the multilayer inductor component 1 includes a rectangular parallelepiped element 2 and a pair of terminal electrodes 3 formed at both ends of the element 2. The element 2 has a coil 4 inside. Both ends of the coil 4 are electrically connected to the terminal electrode 3 respectively.

  As shown in FIG. 2, the element 2 is formed by laminating three types of insulator layers 5, 6, and 7. Hereinafter, the stacking direction is the vertical direction of the element 2. The coil 4 is configured by laminating a plurality (for example, several tens) of insulating layers 7. A U-shaped conductor 9 is formed on each insulator layer 7. The conductor 9 constitutes approximately ½ turn of the coil 4. A penetrating conductor 11 that penetrates the insulator layer 7 is formed at one end of the conductor 9. The plurality of insulator layers 7 are laminated such that one end of the conductor 9 and the other end of another conductor 9 adjacent in the lamination direction are electrically connected by the through conductor 11. A plurality of conductors 9 are connected in a coil shape to constitute the coil 4.

  Insulator layers 6 are respectively disposed above and below the plurality of stacked insulator layers 7. A linear conductor 8 is formed on each insulator layer 6. A through conductor 10 that penetrates the insulator layer 6 is formed at one end of the conductor 8. The upper insulator layer 6 is laminated so that one end of the conductor 8 and the other end of the conductor 9 under the conductor 8 are electrically connected by the through conductor 10. The lower insulator layer 6 is laminated so that one end of the conductor 8 and the one end of the conductor 9 on the conductor 8 are electrically connected by the through conductor 11. The other end of the upper conductor 8 is exposed on one side of the element 2 and the other end of the lower conductor 8 is exposed on the other side opposite to the one side. The pair of terminal electrodes 3 are formed on one side and the other side of the element 2, respectively. The terminal electrode 3 formed on one side surface of the element 2 is electrically connected to the upper conductor 8. The terminal electrode 3 formed on the other side surface of the element 2 is electrically connected to the lower conductor 8. Both ends of the coil 4 are electrically connected to the terminal electrode 3 via conductors 8 respectively.

  One or a plurality of (for example, three) insulator layers 5 are disposed above the upper insulator layer 6 and below the lower insulator layer 6, respectively. A conductor is not formed on the insulator layer 5.

  Next, a manufacturing process of the multilayer inductor component 1 according to this embodiment will be described with reference to FIGS. 3-8 is a figure for demonstrating the manufacturing process of the multilayer inductor component which concerns on this embodiment.

First, as shown in FIGS. 3 and 4, a plurality of insulator green sheets (so-called ceramic green sheets) 22 to 24 corresponding to the plurality of insulator layers 5 to 7 are prepared (preparation step). The insulator green sheets 22 to 24 are made of a magnetic material (for example, Ni—Cu—Zn ferrite, Ni—Cu—Zn—Mg ferrite, Cu—Zn ferrite, Ni—Cu ferrite, etc.) or a nonmagnetic material. It is produced by a known method using a glass-based ceramic (for example, Sr, Ca, Al ₂ O ₃ , SiO ₂ or the like). For example, the insulator green sheets 22 to 24 are prepared by adding a binder resin (for example, an organic binder resin) and a solvent to Ni—Cu—Zn ferrite powder and kneading the slurry, using a doctor blade method. It is produced by applying onto the PET film 12 and drying.

  As shown in FIG. 4, a plurality of conductor patterns 26 and through conductor patterns 28 are formed on the insulator green sheet 24 corresponding to the insulator layer 7. Through holes 13 are formed by laser processing or the like at a plurality of positions where the through conductor patterns 28 are to be formed. Each conductor pattern 26 is formed, for example, by screen-printing a conductor material and drying it. The through conductor pattern 28 is formed by filling the through hole 13 with the conductor material when the conductor pattern 26 is formed by screen printing the conductor material. The conductive material is a paste-like composition obtained by mixing a conductive metal material, a binder resin (for example, an organic binder resin) and a solvent. As the metal material, for example, Ag powder can be used.

  On the insulator green sheet 23 corresponding to the insulator layer 6, a plurality of conductor patterns 25 and penetrating conductor patterns 27 are formed by the same material and the same method as the conductor patterns 26 and penetrating conductor patterns 28.

  Next, as shown in FIGS. 5 to 8, the insulator green sheets 22 to 24 are laminated to obtain a laminate 14 (see FIG. 8) (lamination step). Here, a lower mold 15 and an upper mold 16 which are a pair of molds are used. The lower mold 15 is a mold that serves as a base of the stack, and has a suction means 17 that sucks what is installed on the upper part with a negative pressure. A plurality of suction holes of the suction means 17 are opened on the upper surface of the lower mold 15. A ventilation paper 18 is disposed on the upper part of the lower mold 15. The ventilation paper 18 prevents the suction hole of the lower mold 15 from being transferred to the lower surface of the laminated body 14. The upper mold 16 is a mold that compresses what is installed on the lower mold 15 from above. A plate-like elastic member 19 is attached to the lower part of the upper mold 16. The elastic member 19 is a first elastic member. As the elastic member 19, for example, silicone rubber can be used.

  As shown in FIGS. 5 and 6, the insulator green sheets 22 to 24 are sequentially laminated on the ventilation paper 18. Each insulator green sheet 22-24 is arrange | positioned in the lamination position in the state which faced the PET film 12, and is pressed by the upper metal mold | die 16 with the PET film 12. FIG. That is, each insulator green sheet 22-24 is pressed every time it is laminated. Since the elastic member 19 is attached to the lower part of the upper mold 16, the insulator green sheets 22 to 24 are pressed via the elastic member 19. The insulator green sheets 23 and 24 are pressed so that the elastic member 19 is deformed corresponding to the thickness of the conductor patterns 25 and 26. When the newly laminated insulator green sheets 22 to 24 are pressed against the lower insulator green sheets 22 to 24 by pressing, the PET film 12 is peeled off and the next insulator green sheets 22 to 24 are laminated. The

  As shown in FIG. 7, when the insulator green sheets 22 to 24 are stacked and a predetermined number of insulator green sheets 24 are stacked, the elastic member 19 is replaced with an elastic member 20 that is softer than the elastic member 19. . The elastic member 20 is a second elastic member. Thereafter, the insulator green sheets 23 and 24 are pressed via the elastic member 20. As the elastic member 20, for example, silicone rubber can be used.

  As shown in FIG. 8, when all of the insulator green sheets 23 and 24 are laminated, the elastic member 20 is replaced with an elastic member 21 that is softer than the elastic member 20. The insulator green sheet 22 laminated on the insulator green sheet 23 is pressed via the elastic member 21. For example, silicone rubber can be used as the elastic member 21.

  Next, the laminate 14 is further pressed (crimping step). Here, for example, the laminate 14 is pressed by an isostatic pressing method. Subsequently, the laminated body 14 is cut between the plurality of conductor patterns 25 and 26 formed on each of the insulator green sheets 23 and 24, and separated into a plurality of laminated bodies (cutting step).

  Next, the laminated body 14 separated into a plurality of laminated bodies is fired (firing step). The plurality of laminated bodies become the elements 2 by firing. The insulator green sheets 22 to 24 are integrated as insulator layers 5 to 7. Conductor patterns 25 and 26 become conductors 8 and 9. The through conductor patterns 27 and 28 become the through conductors 10 and 11.

  Next, the terminal electrodes 3 are respectively formed on the one side surface and the other side surface of the element 2 (electrode forming step). The terminal electrode 3 is electrically connected to the other end of the conductor 8 exposed on the side surface of the element 2. The terminal electrode 3 is formed, for example, by applying a conductor paste containing Ag as a main component, baking it, and further performing electroplating. For electroplating, Cu and Ni and Sn, Ni and Sn, Ni and Au, Ni and Pd and Au, Ni, Pd and Ag, and the like can be used.

  Through these steps, the multilayer inductor component 1 having the configuration shown in FIGS. 1 and 2 is completed.

  As described above, in the manufacturing process of the multilayer inductor component 1 according to this embodiment, the insulating green sheets 23 and 24 are pressed each time they are stacked in the stacking process, so the stacked conductor patterns 25 and 26 are stacked. Misalignment between each other is suppressed. Each insulator green sheet 23, 24 is pressed through the elastic member 19 or the elastic member 20 so that the elastic member 19 or the elastic member 20 is deformed corresponding to the thickness of the conductor patterns 25, 26. Pressure is easily applied to portions where 25 and 26 are not formed, and separation between the insulator green sheets is suppressed.

  In the laminating step, first, the elastic member 19 is pressed and laminated, and the elastic member 19 is replaced with the elastic member 20 that is softer than the elastic member 19 in the middle, and the elastic member 20 is pressed and laminated. In a situation where the number of laminated insulator green sheets 23 and 24 is increased to a predetermined number, and the thickness difference between the portion where the conductor patterns 25 and 26 are formed and the portion where the conductor patterns 25 and 26 are not formed is increased. Compared with the elastic member 19, an elastic member 20 that is easily deformed in accordance with the thickness of the conductor patterns 25 and 26 is used. For this reason, even in a situation where the thickness difference between the portion where the conductor patterns 25 and 26 are formed and the portion where the conductor patterns 25 and 26 are not formed is large, pressure easily acts on the portion where the conductor patterns 25 and 26 are not formed. Peeling between the insulator green sheets is further suppressed.

  In the laminating step, after the insulating green sheets 23 and 24 are stacked, the insulating green sheet 22 is pressed via the elastic member 21 that is softer than the elastic members 19 and 20. In a situation where all the insulator green sheets 23 and 24 are laminated and the difference in thickness between the portion where the conductor patterns 25 and 26 are formed and the portion where the conductor patterns 25 and 26 are not formed is the maximum, the conductor is compared with the elastic members 19 and 20. An elastic member 21 that is easily deformed corresponding to the thickness of the patterns 25 and 26 is used. For this reason, even in a situation where the difference in thickness between the portion where the conductor patterns 25 and 26 are formed and the portion where the conductor patterns 25 and 26 are not formed is maximized, pressure easily acts on the portion where the conductor patterns 25 and 26 are not formed. Further, peeling between the insulator green sheets is further suppressed.

  Prior to the firing step, a pressure bonding step for pressing the laminate 14 is performed. For this reason, the crimping | compression-bonding state between the insulator green sheets 22-24 is equalized by the crimping | compression-bonding process, and peeling between insulator green sheets is further suppressed.

  In the present embodiment, the types of elastic members used in the process of laminating the insulator green sheets 23 and 24 are two types, that is, the elastic member 19 and the elastic member 20, but are not limited thereto. It is also possible to prepare elastic members having various hardnesses, use them in order from the hardest ones, and change the elastic members a plurality of times. Thereby, the pressure of the press in each lamination | stacking stage is optimized, and peeling between insulator green sheets is suppressed further.

  In the multilayer inductor component 1, the terminal electrode 3 is formed on the side surface of the element 2, that is, the surface parallel to the lamination direction of the insulator green sheets 22 to 24, but is not limited thereto. The terminal electrode 3 may be formed on the upper and lower surfaces of the element 2, that is, on the surface perpendicular to the stacking direction of the insulator green sheets 22 to 24.

  The coil 4 is configured such that a substantially U-shaped conductor 9 is connected in a coil shape. However, the present invention is not limited to this, and any other conductor may be used as long as the conductor 9 of each insulator layer 7 is connected in a coil shape. Any of these may be used. For example, the conductor 9 may have a substantially C shape, a substantially I shape, a substantially J shape, a substantially L shape, and the like, and may be connected in a coil shape.

  JP-A-8-279435 discloses a method for manufacturing a multilayer ceramic capacitor in which all ceramic green sheets on which internal electrodes are formed are stacked and then pressed through a rubber material. However, a method for manufacturing a multilayer inductor component is not disclosed or suggested. Moreover, in this manufacturing method, since it presses through a rubber material after all the ceramic green sheets are laminated | stacked, there exists a possibility that the position shift of internal electrodes cannot fully be suppressed.

  DESCRIPTION OF SYMBOLS 1 ... Laminated inductor component, 22, 23, 24 ... Insulator green sheet, 25, 26 ... Conductor pattern, 14 ... Laminated body, 19, 20, 21 ... Elastic member.

Claims (4)

A preparation step of preparing a plurality of insulator green sheets on which a conductor pattern is formed,
A laminating step of laminating the plurality of insulator green sheets to obtain a laminate;
A firing step of firing the laminate,
In the laminating step, each time the plurality of insulating green sheets are laminated, the elastic member is pressed through the elastic member so as to be deformed corresponding to the thickness of the conductor pattern. A manufacturing method for parts.   In the stacking step, first, the first elastic member is pressed and stacked, and the first elastic member is replaced with a second elastic member that is softer than the first elastic member, and the second elastic member is replaced with the second elastic member. The method of manufacturing a multilayer inductor component according to claim 1, wherein the multilayer inductor component is pressed and laminated. In the preparation step, an insulator green sheet in which the conductor pattern is not formed is prepared,
In the laminating step, after laminating the plurality of insulator green sheets on which the conductor pattern is formed, the insulator green sheet on which the conductor pattern is not formed is laminated to obtain the laminate.
When laminating the insulator green sheets on which the conductor pattern is not formed, via an elastic member that is softer than the elastic member used when laminating the plurality of insulator green sheets on which the conductor pattern is formed. The method of manufacturing a multilayer inductor component according to claim 1 or 2, wherein pressing is performed.   The method for manufacturing a multilayer inductor component according to any one of claims 1 to 3, further comprising a crimping step of pressing the multilayer body before the firing step.

Images