Inductor component and method of manufacturing same
An inductor component comprising an element body having first and second magnetic layers laminated in order along a first direction; an inductor wire on a plane orthogonal to the first direction between the first and second magnetic layers and including side surfaces facing a direction orthogonal to the first direction; and a side surface insulating part made of a non-magnetic material covering only a part of the side surfaces. The first and second magnetic layers each include a flat magnetic powder and a resin containing the magnetic powder. The first magnetic layer exists in a direction opposite to the first direction with respect to the inductor wire. The second magnetic layer exists in the first direction and in a direction orthogonal to the first direction. The side surface insulating part is made of a material that is the same as that of the resin of the second magnetic layer.
1 . An inductor component comprising:
an element body having a first magnetic layer and a second magnetic layer that are laminated in order along a first direction;
an inductor wire arranged on a plane orthogonal to the first direction between the first magnetic layer and the second magnetic layer, the inductor wire including side surfaces facing a direction orthogonal to the first direction;
a bottom surface insulating part that extends into the second magnetic layer and is on a portion of a surface of the first magnetic layer that contacts the second magnetic layer; and
a side surface insulating part made of a non-magnetic material covering only a part of the side surfaces of the inductor wire,
the first magnetic layer and the second magnetic layer each including a flat magnetic powder and a resin containing the magnetic powder,
the first magnetic layer existing in a direction opposite to the first direction with respect to the inductor wire,
the second magnetic layer existing in the first direction and in a direction orthogonal to the first direction,
the side surface insulating part being made of a material that is the same as that of the resin of the second magnetic layer,
the side surface insulating part is in contact with material in the second magnetic layer and is in contact with the part of the side surfaces of the inductor wire, and
a portion of the side surfaces of the inductor wire other than the part of the side surfaces of the inductor wire that is covered by the side surface insulating part is in direct contact with the second magnetic layer.
2 . The inductor component of claim 1 , wherein
a part of the inductor wire is in contact with the magnetic powder.
3 . The inductor component of claim 1 , wherein
the inductor wire includes a bottom surface facing the direction opposite to the first direction, and
the bottom surface insulating part is in contact with the bottom surface.
4 . The inductor component of claim 3 , wherein
in a section orthogonal to a direction where the inductor wire extends,
an angle defined by a longitudinal axis of the flat magnetic powder included in the first magnetic layer with respect to the bottom surface is 45° or less.
5 . The inductor component of claim 4 , wherein
the side surface insulating part is in contact with the bottom surface insulating part.
6 . The inductor component of claim 3 , wherein
the side surface insulating part differs in composition from the bottom surface insulating part.
7 . The inductor component of claim 3 , wherein
the inductor wire includes a top surface facing the first direction, the inductor component further comprising:
a peripheral surface insulating part that is in contact with the side surface and the top surface, wherein
the peripheral surface insulating part differs in composition from the side surface insulating part and from the bottom surface insulating part, and wherein
the side surface insulating part has a thickness that is greater than that of the peripheral surface insulating part.
8 . The inductor component of claim 1 , wherein
the side surface insulating part has a height in the first direction that is one-half or less of that of the inductor wire.
9 . The inductor component of claim 1 , wherein
in a section orthogonal to a direction where the inductor wire extends,
the second magnetic layer has a side surface vicinity region defined by the side surface of the inductor wire and a position apart a predetermined distance from the side surface in a direction orthogonal to the first direction, and
an angle defined by a longitudinal axis of the flat magnetic powder included in the side surface vicinity region with respect to the side surface is 45° or less.
10 . The inductor component of claim 1 , wherein
in a section orthogonal to a direction where the inductor wire extends,
an angle defined by a longitudinal axis of the flat magnetic powder included in the second magnetic layer with respect to the side surface increases according as moving away from the side surface of the inductor wire in a direction orthogonal to the first direction.
11 . The inductor component of claim 1 , wherein
when a main surface of the second magnetic layer in the first direction is viewed from a direction orthogonal to the main surface of the second magnetic layer,
the second magnetic layer has an overlapping region overlapping with the inductor wire and a non-overlapping region not overlapping with the inductor wire, and wherein
at least a part of the non-overlapping region is lower in brightness than the overlapping region.
12 . The inductor component of claim 1 , wherein
in a section orthogonal to a direction where the inductor wire extends at a center of the inductor wire in the direction where the inductor wire extends,
when a maximum ferrite length of the magnetic powder is LF and a thickness orthogonal to the maximum ferrite length of the magnetic powder is TF, LF/TF≥10 holds, D90 of the maximum ferrite length being 100 μm or less.
13 . The inductor component of claim 1 , wherein
the first magnetic layer and the second magnetic layer each have a void ratio of from 1 vol % to 10 vol %.
14 . The inductor component of claim 2 , wherein
the inductor wire includes a bottom surface facing the direction opposite to the first direction, and
the bottom surface insulating part is in contact with the bottom surface.
15 . The inductor component of claim 4 , wherein
the side surface insulating part differs in composition from the bottom surface insulating part.
16 . The inductor component of claim 4 , wherein
the inductor wire includes a top surface facing the first direction, the inductor component further comprising:
a peripheral surface insulating part that is in contact with the side surface and the top surface, wherein
the peripheral surface insulating part differs in composition from the side surface insulating part and from the bottom surface insulating part, and wherein
the side surface insulating part has a thickness that is greater than that of the peripheral surface insulating part.
17 . The inductor component of claim 2 , wherein
the side surface insulating part has a height in the first direction that is one-half or less of that of the inductor wire.
18 . The inductor component of claim 2 , wherein
in a section orthogonal to a direction where the inductor wire extends,
the second magnetic layer has a side surface vicinity region defined by the side surface of the inductor wire and a position apart a predetermined distance from the side surface in a direction orthogonal to the first direction, and
an angle defined by a longitudinal axis of the flat magnetic powder included in the side surface vicinity region with respect to the side surface is 45° or less.