ELECTRONIC COMPONENT AND METHOD FOR FORMING RESIN LAYER ON ELECTRONIC COMPONENT

An electronic component includes a plurality of laminated insulating layers, one or more surface conductors formed on a surface of the insulating layer, and an internal conductor formed at a boundary portion between the adjacent insulating layers. A thickness of the surface conductor is larger than a thickness of a thinnest layer of the insulating layers and larger than a thickness of the internal conductor.

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The present disclosure relates to an electronic component in which an insulating layer is laminated, and a resin layer forming method for the electronic component.

Description of the Related Art

Conventionally, as this type of electronic component, for example, an electronic component described in Patent Document 1 (Japanese Patent No. 4821302) is known. In the electronic component described in Patent Document 1, ceramic insulating layers and conductive layers are alternately laminated. A conductor on which an inductor pattern and a land pattern are formed is provided in the uppermost conductive layer.Patent Document 1: Japanese Patent No. 4821302

BRIEF SUMMARY OF THE DISCLOSURE

In such an electronic component, electrical characteristics of an element or the like, for example, an electrical characteristic of an inductor formed by a wiring pattern provided in the electronic component changes according to at least a thickness and a width of a conductor forming the wiring pattern. Therefore, in the uppermost conductive layer, it is conceivable to change the thickness and width of the conductor by trimming to adjust the electrical characteristics of an element or the like. However, in the electronic component described in Patent Document 1, the conductor is thin because the conductor is formed by screen printing, photolithography, a thin film method, or the like. Therefore, it is difficult to trim the conductor. Even if the conductor can be trimmed, the trimmable thickness of the conductor is small. Therefore, the electrical characteristics of an element or the like cannot be sufficiently adjusted.

Therefore, a possible benefit of the present disclosure is to solve the above problems, and to provide an electronic component having a large trimmable thickness of a conductor and a large adjustment range of electrical characteristics of an element or the like.

In order to solve the problem, an electronic component according to the present disclosure includes: a plurality of laminated insulating layers; one or more surface conductors formed on a surface of the insulating layer; and an internal conductor formed at a boundary portion between the adjacent insulating layers, in which a thickness of the surface conductor is larger than a thickness of a thinnest layer of the insulating layers and larger than a thickness of the internal conductor.

According to the present disclosure, it is possible to provide an electronic component having a large trimmable thickness of a conductor and a large adjustment range of electrical characteristics of an element or the like.

DETAILED DESCRIPTION OF THE DISCLOSURE

An electronic component according to one aspect of the present disclosure includes: a plurality of laminated insulating layers; one or more surface conductors formed on a surface of the insulating layer; and an internal conductor formed at a boundary portion between the adjacent insulating layers, in which a thickness of the surface conductor is larger than a thickness of a thinnest layer of the insulating layers and larger than a thickness of the internal conductor.

According to this configuration, the surface conductor can be largely trimmed in the thickness direction. As a result, the electrical characteristics of an element or the like including the surface conductor can be adjusted in a wide range.

In the conventional electronic component, when a first conductor requiring trimming and a second conductor not requiring trimming are mixed on a surface of an insulating layer, the thicknesses of the first conductor and the second conductor are almost the same. For this reason, it is difficult to trim only the first conductor by a planar processing method such as etching or surface grinding. On the other hand, according to the above configuration, it is possible to realize an electronic component in which the first conductor which is a surface conductor is thicker than the second conductor. In such an electronic component, since there is a difference in thickness between the first conductor and the second conductor, it is easy to trim only the first conductor by a planar processing method. Therefore, the manufacturing efficiency of the electronic component can be improved.

The thickness of the surface conductor may be larger than twice the thickness of the thinnest layer of the insulating layers.

According to this configuration, the trimmable thickness of the surface conductor can be increased as compared with a configuration in which the thickness of the surface conductor is smaller than twice the thickness of the thinnest layer of the insulating layers. Therefore, it is possible to realize an electronic component having a large adjustment range of electrical characteristics of an element or the like including a surface conductor.

In addition, the thickness of the surface conductor may be larger than the thickness of the thickest layer of the insulating layers.

According to this configuration, the trimmable thickness of the surface conductor can be increased as compared with the configuration in which the thickness of the surface conductor is smaller than the thickness of the thickest layer of the insulating layers. Therefore, it is possible to realize an electronic component having a large adjustment range of electrical characteristics of an element or the like including a surface conductor.

A plating film may be formed on at least a part of the surface of the surface conductor.

According to this configuration, by forming the plating film on at least a part of the surface of the surface conductor, the thickness of the conductor in which the surface conductor and the plating film are integrated can be increased. That is, the conductor can be not only thinned by trimming or the like, but also thickened. Therefore, it is possible to realize an electronic component having a large adjustment range of electrical characteristics of an element or the like including a surface conductor.

Further, the electronic component may include a plurality of connection conductors formed inside the insulating layer or on the surface of the insulating layer and electrically connected to the surface conductors, respectively.

According to this configuration, the surface conductor can form a wiring through which a signal is input from one connection conductor and output to the other connection conductor. In the wiring formed of the surface conductor, since the surface conductor is thick, a large conductor cross section can be obtained. This makes it possible to realize wiring capable of applying a large current without increasing the width of the surface conductor. In addition, the width of the surface conductor can be reduced while maintaining the conductor cross-sectional area. That is, it is possible to reduce the area occupied by the surface conductor on the surface of the insulating layer while maintaining the allowable current value of the wiring. Therefore, the electronic component can be downsized, and wiring, components, and the like can be further arranged.

At least one of the plurality of connection conductors may be a via conductor penetrating one of the plurality of insulating layers in a lamination direction of the insulating layers.

According to this configuration, the via conductor of the plurality of connection conductors is not exposed to the surface of the insulating layer. Therefore, it is possible to reduce members for suppressing the influence of atmosphere, moisture, and the like on the surface conductor. Therefore, since the number of members of the electronic component is reduced, the manufacturing efficiency of the electronic component can be improved.

In addition, the electronic component may include an inductor conductor electrically connected to the surface conductor via the connection conductor, and the surface conductor may constitute at least a part of the inductor together with the connection conductor and the inductor conductor.

According to this configuration, since the surface conductor is thick in at least a part of the inductor, a larger conductor cross section can be obtained. This reduces the insertion loss of the inductor. In addition, since the trimmable thickness of the surface conductor is large, the adjustment range of the electrical characteristics of the inductor is large.

In addition, the surface conductor may include a first portion that is thicker than the thickness of the thinnest layer of the insulating layers and is thicker than the thickness of the internal conductor, and a second portion that is continuous with the first portion along the surface of the insulating layer and is thinner than the first portion.

According to this configuration, there is a difference in thickness at a boundary portion between the first portion and the second portion, and a shadow is generated at the boundary portion. This shadow can be used as a directional mark indicating the direction of the electronic component. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface of the insulating layer, it is possible to reduce the size of the electronic component and to further arrange wiring, components, and the like.

Further, the electronic component may have a rotationally symmetric outer shape in plan view, and a boundary portion between the first portion and the second portion in the surface conductor may be arranged in a non-rotationally symmetric manner with respect to a center point of the rotational symmetry of the electronic component.

According to this configuration, at least one shadow generated by the boundary portion between the first portion and the second portion in the surface conductor appears at a non-rotationally symmetric position with respect to the center point when the electronic component is viewed in plan view. Therefore, the shadow that can be used as a directional mark indicating the direction of the electronic component can be realized.

Further, the electronic component may have a rotationally symmetric outer shape in plan view, and the surface conductor may be arranged in a non-rotationally symmetric manner with respect to a center point of the rotational symmetry of the electronic component in plan view.

According to this configuration, the surface conductor can indicate the direction of the electronic component by its position and shape in plan view. That is, the surface conductor can also serve as a directional mark indicating the direction of the electronic component. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface of the insulating layer, it is possible to reduce the size of the electronic component and to further arrange wiring, components, and the like.

The electronic component may include a resin layer or a glass layer covering at least a part of the surface conductor.

According to this configuration, at least a part of the surface conductor can be protected by the resin layer or the glass layer from the influence of foreign matter, impact, or the like from the outside. In addition, the resin layer or the glass layer improves the mechanical strength of the electronic component. Furthermore, it is possible to arrange a shield that shields electromagnetic waves at a position facing the electronic component via the resin layer or the glass layer.

At least a part of the resin layer or at least a part of the glass layer may be thicker than a thickness of a thinnest layer of the insulating layers and thicker than a thickness of the internal conductor.

According to this configuration, it is possible to realize a resin layer or a glass layer capable of more reliably protecting the surface conductor from the influence of foreign matter, impact, or the like from the outside and further improving the mechanical strength of the electronic component.

The electronic component may further include a via conductor penetrating one of the plurality of insulating layers in the lamination direction of the insulating layers, and the thickness of the surface conductor may be larger than a length of the via conductor in the lamination direction.

According to this configuration, the surface conductor can be largely trimmed in the thickness direction. As a result, the electrical characteristics of an element or the like including the surface conductor can be adjusted in a wide range.

In the conventional electronic component, when a first conductor requiring trimming and a second conductor not requiring trimming are mixed on a surface of an insulating layer, the thicknesses of the first conductor and the second conductor are almost the same. For this reason, it is difficult to trim only the first conductor by a planar processing method such as etching or surface grinding. On the other hand, according to the above configuration, it is possible to realize an electronic component in which the first conductor which is a surface conductor is thicker than the second conductor. In such an electronic component, since there is a difference in thickness between the first conductor and the second conductor, it is easy to trim only the first conductor by a planar processing method. Therefore, the manufacturing efficiency of the electronic component can be improved.

In addition, the surface conductor may include a first portion that is thicker than the length of the via conductor in the lamination direction, and a second portion that is continuous with the first portion along a surface of the insulating layer and is thinner than the first portion.

According to this configuration, there is a difference in thickness at a boundary portion between the first portion and the second portion, and a shadow is generated at the boundary portion. This shadow can be used as a directional mark indicating the direction of the electronic component. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface of the insulating layer, it is possible to reduce the size of the electronic component and to further arrange wiring, components, and the like.

The surface conductor may constitute at least a part of the inductor.

According to this configuration, since the surface conductor is thick in at least a part of the inductor, a larger conductor cross section can be obtained. This reduces the insertion loss of the inductor. In addition, since the trimmable thickness of the surface conductor is large, the adjustment range of the electrical characteristics of the inductor is large.

A resin layer forming method for an electronic component according to an aspect of the present disclosure includes: an immersion step of immersing an electronic component not including a resin layer in a resin to attach the resin to an outer surface of the electronic component including a surface of the insulating layer; a curing step of curing the resin attached to at least a part of the surface conductor to form a resin layer; and a removal step of removing the uncured resin from the electronic component.

According to this method, the resin layer can be formed by attaching the resin to the entire electronic component and curing the resin only at a desired portion on the electronic component. Therefore, unlike the method for forming the resin layer by applying the resin only to a desired portion, it is not necessary to align the electronic components in order to attach the resin. Therefore, the manufacturing efficiency of the electronic component can be improved.

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the present disclosure is not limited to the following embodiments.

In the drawings, substantially the same elements are denoted by the same reference numerals, and description thereof is omitted.

Hereinafter, for convenience of description, terms indicating directions such as “upper surface”, “lower surface”, “upper side”, “right side”, and “left side” are used, but these terms are not intended to limit a usage state or the like of the electronic component according to the present disclosure.

First Embodiment

An electronic component according to a first embodiment of the present disclosure will be described with reference toFIGS.1to3.FIG.1is a plan view of an electronic component according to a first embodiment of the present disclosure, excluding a plating film.FIG.2is a cross-sectional view taken along line A1-A1of the electronic component inFIG.1.FIG.3is a cross-sectional view taken along line B1-B1of the electronic component inFIG.1.

As illustrated inFIGS.2and3, in the first embodiment, an electronic component1A includes five laminated insulating layers2. The five insulating layers2include a first surface layer21constituting the upper surface of the electronic component1A, a second surface layer22constituting the lower surface, and an intermediate layer23laminated between the first surface layer21and the second surface layer22. In addition, the electronic component1A includes via conductors3that penetrate one insulating layer2. As illustrated inFIG.1, a surface conductor4and a land conductor5are formed on a surface21aof the first surface layer21.

The insulating layer2illustrated inFIGS.2and3is formed, for example, by firing a sheet having a sinterable ceramic powder. The thickness of the insulating layer2is, for example, 1 to 150 μm. In the first embodiment and a second embodiment described later, the thicknesses of the five insulating layers2are the same.

The via conductor3is formed by firing a conductive paste having a conductive powder. The length of the via conductor3in the penetrating direction is the same as or substantially the same as the thickness of one insulating layer2. The via conductor3has, for example, a truncated cone shape having a diameter of 20 to 200 μm.

As illustrated inFIGS.1to3, the surface conductor4is formed on the surface21aof the first surface layer21. The surface conductor4is formed by firing a conductive paste having a conductive powder.

As illustrated inFIG.2, two via conductors3formed in the first surface layer21are connected to both end portions of the surface conductor4. These two via conductors3are an example of a “connection conductor” in the present disclosure. The via conductors3penetrate one of the laminated insulating layers2in the lamination direction of the insulating layers2(hereinafter, simply referred to as “lamination direction”). The electric signal applied to one via conductor3is transmitted to one end portion of the surface conductor4, transmitted to the other end portion of the surface conductor4, and output to the other via conductor3. In this manner, the surface conductor4can function as wiring.

As illustrated inFIGS.2and3, the thickness of the surface conductor4is larger than the length of the via conductor3in the penetrating direction. The thickness of the surface conductor4is, for example, 2 to 10 times the thickness of the insulating layer2. The surface conductor4has, for example, a width of 20 to 200 μm and a length of 50 to 3000 μm. In the present embodiment, the surface conductor4has an elongated shape in which both end portions are rounded in plan view illustrated inFIG.1.

As illustrated inFIG.1, the surface conductor4includes surface conductors4A having a constant or substantially constant thickness over the entire surface conductor4A, and a surface conductor4B having a partially different thickness.

As illustrated inFIG.2, the surface conductor4B includes a first portion41thicker than the length of the via conductor3in the penetrating direction, and a second portion42continuous with the first portion41along the surface21aof the first surface layer21and thinner than the first portion41. In such a surface conductor4B, as illustrated inFIG.1, shadows S1are generated by a difference in thickness between the first portion41and the second portion42. For example, the shadows S1illustrated inFIG.1indicate shadows generated when the electronic component1A is illuminated from slightly above both end portions of the surface conductor4.

The surface conductor4A and the first portion41of the surface conductor4B can be trimmed in the thickness direction by a planar processing method after formation. Examples of the planar processing method include etching and surface grinding.

As illustrated inFIGS.1and3, the land conductor5for connecting to another electronic component or the like is provided on the surface21aof the first surface layer21. In the present embodiment, the land conductor5is formed to be thinner than the second portion42of the surface conductor4B.

As illustrated inFIGS.2and3, a plating film6is formed on the surfaces of the surface conductor4and the land conductor5. The plating film6suppresses the influence of atmosphere, moisture, and the like on the surface conductor4and the land conductor5. The plating film6is, for example, a Ni—Sn plating film, a Ni-electroless Au plating film, or the like.

Note that the plating film6is formed as necessary, and may be formed only on a part of the surface conductor4or the land conductor5, or may not be formed, for example.

As illustrated inFIGS.2and3, an internal conductor7extending in a direction in which the insulating layer2extends is formed at a boundary portion between the plurality of insulating layers2. The thickness of the internal conductor7is, for example, 2 to 10 μm.

As illustrated inFIG.1, the electronic component1A has a rotationally symmetric outer shape with respect to a virtual center point P of the electronic component1A in plan view. Here, “rotationally symmetric” means that the relative position and the shape with respect to the virtual center point P coincide with those before rotation when the electronic component1A is rotated around the virtual center point P in plan view. In the present embodiment, the outer shape of the electronic component1A is rectangular. In this case, when the electronic component1A is rotated by 180 degrees around the virtual center point P in plan view, the relative position and the shape of the electronic component1A with respect to the virtual center point P coincide with those before the rotation. Therefore, the outer shape of the electronic component1A in the present embodiment is rotationally symmetric.

The surface conductor4and the land conductor5are arranged rotationally symmetrically with respect to the virtual center point P on the surface21aof the first surface layer21. Therefore, the direction of the electronic component1A cannot be determined from the outer shape of the electronic component1A in plan view and the shapes and positions of the surface conductor4and the land conductor5.

However, in the present embodiment, the direction of the electronic component1A can be determined in plan view by the shadows S1caused by the difference in thickness in the surface conductor4B. In the present embodiment, the surface conductor4B is arranged on the left side of the virtual center point P in the plan view illustrated inFIG.1. On the other hand, the surface conductor4B is not arranged on the right side of the virtual center point P in the plan view illustrated inFIG.1. Therefore, when the electronic component1A is viewed in plan view, the shadows S1are seen only on the left side of the virtual center point P. Therefore, the direction of the electronic component1A can be determined from the position of the shadow S1in plan view. That is, the shadow S1can be used as a directional mark indicating the direction of the electronic component1A depending on the position in the plan view. In addition, since the visibility of the shadow S1is improved by illuminating the electronic component1A, it is easier to determine the direction of the electronic component1A.

The shadow S1occurs at a boundary portion43between the first portion41and the second portion42of the surface conductor4B. As described above, in the present embodiment, the surface conductor4B having the boundary portion43is arranged only on the left side of the virtual center point P in the plan view illustrated inFIG.1. Therefore, when the boundary portion43is rotated around the virtual center point P in plan view, the relative position and the shape of the boundary portion43with respect to the virtual center point P do not coincide with those before and after the rotation. That is, the boundary portion43is arranged in a non-rotationally symmetric manner with respect to the virtual center point P. Therefore, the shadow S1can be used as a directional mark.

Note that the mode in which the boundary portion43is arranged in a non-rotationally symmetric manner with respect to the virtual center point P is not limited to the above-described mode. As long as the boundary portion43is arranged in a non-rotationally symmetric manner with respect to the virtual center point P, the shadow S1can be used as a directional mark regardless of the number of surface conductors4B and the number of boundary portions43formed on each surface conductor4B. For example, even when the electronic component1A has two boundary portions43arranged on both left and right sides of the virtual center point P in the plan view illustrated inFIG.1, at least one of the shapes of the two boundary portions43and the relative positions with respect to the virtual center point P only needs to be different from each other. In this case, when one boundary portion43is rotated around the virtual center point P, the one boundary portion43does not overlap the other boundary portion43so as to coincide with the other boundary portion43. That is, the two boundary portions43are arranged in a non-rotationally symmetric manner with respect to the virtual center point P.

According to the electronic component1A according to the present embodiment, the thickness of the surface conductor4is larger than the length of the via conductor3in the lamination direction. Therefore, the surface conductor4can be largely trimmed in the thickness direction. As a result, the electrical characteristics of an element or the like including the surface conductor4can be adjusted in a wide range.

In the conventional electronic component, when a first conductor requiring trimming and a second conductor not requiring trimming are mixed on a surface of an insulating layer, the thicknesses of the first conductor and the second conductor are almost the same. For this reason, it is difficult to trim only the first conductor by a planar processing method such as etching or surface grinding. On the other hand, according to the electronic component1A according to the present embodiment, it is possible to realize the electronic component1A in which the surface conductor4is thicker than the land conductor5. In such an electronic component1A, since there is a difference in thickness between the surface conductor4and the land conductor5, it is easy to trim only the surface conductor4by a planar processing method. Therefore, the manufacturing efficiency of the electronic component1A can be improved.

In addition, the electronic component1A according to the present embodiment includes a plurality of via conductors3each electrically connected to the surface conductor4. As a result, the surface conductor4can form a wiring through which a signal is input from one via conductor3and a signal is output to the other via conductor3. In the wiring formed of the surface conductor4, since the surface conductor4is thick, a large conductor cross section can be obtained. This makes it possible to realize wiring capable of applying a large current without increasing the width of the surface conductor4. In addition, the width of the surface conductor4can be reduced while maintaining the conductor cross-sectional area. That is, it is possible to reduce the area occupied by the surface conductor4on the surface21aof the insulating layer2while maintaining the allowable current value of the wiring. Therefore, the electronic component1A can be downsized, and wiring, components, and the like can be further arranged.

In addition, according to the electronic component1A according to the present embodiment, the via conductor3among the plurality of connection conductors is not exposed on the surface21aof the insulating layer2. Therefore, it is possible to reduce members for suppressing the influence of atmosphere, moisture, and the like on the surface conductor4. Therefore, since the number of members of the electronic component1A is reduced, the manufacturing efficiency of the electronic component1A can be improved.

In addition, according to the electronic component1A according to the present embodiment, the surface conductor4includes the first portion41thicker than the length of the via conductor3in the lamination direction, and the second portion42continuous with the first portion41along the surface21aof the insulating layer2and thinner than the first portion41. At this time, there is a difference in thickness at the boundary portion43between the first portion41and the second portion42, and the shadow S1is generated at the boundary portion43. The shadow S1can be used as a directional mark indicating the direction of the electronic component1A. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component1A can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface21aof the insulating layer2, it is possible to reduce the size of the electronic component1A and to further arrange wiring, components, and the like.

In addition, according to the electronic component1A according to the present embodiment, the boundary portion43between the first portion41and the second portion42in the surface conductor4is arranged in a non-rotationally symmetric manner with respect to the center point P of the rotational symmetry of the electronic component1A. As a result, at least one shadow S1generated by the boundary portion43appears at a non-rotationally symmetric position with respect to the center point P when the electronic component1A is viewed in plan view. Therefore, the shadow S1that can be used as a directional mark indicating the direction of the electronic component1A can be realized.

Second Embodiment

Next, an electronic component according to a second embodiment of the present disclosure will be described with reference toFIGS.4to6.FIG.4is a plan view of an electronic component according to the second embodiment of the present disclosure, excluding a resin layer.FIG.5is a cross-sectional view taken along line A2-A2of the electronic component inFIG.4.FIG.6is a cross-sectional view taken along line B2-B2of the electronic component inFIG.4.

An electronic component1B according to the second embodiment is different from the electronic component1A according to the first embodiment in that a surface conductor4constitutes a part of an inductor9. As illustrated inFIG.4, the surface conductor4is arranged in a non-rotationally symmetric manner with respect to a virtual center point P. As illustrated inFIGS.5and6, the surface conductor4is covered with a resin layer8. The land conductor5is formed on the surface22aof the second surface layer22.

In the second embodiment, as illustrated inFIG.4, three surface conductors4are arranged in parallel to each other on a surface21aof a first surface layer21.

As illustrated inFIG.4, the three surface conductors4are electrically connected via via conductors3connected to the end portions of the surface conductors4and two internal conductors7. The two internal conductors7connect the via conductors3arranged on the opposite sides of the adjacent surface conductors4. The via conductor3connected to the end portion of each surface conductor4is an example of a “connection conductor” in the present disclosure. The two internal conductors7are an example of an “inductor conductor” in the present disclosure.

As a result, the via conductors3, the surface conductors4, and the internal conductors7constitute the coil-shaped inductor9. In the present embodiment, the winding axis direction of the inductor9is a direction perpendicular to the direction in which the insulating layer2spreads and the direction in which the surface conductor4extends (left-right direction inFIG.4, and depth direction of the paper surface inFIG.5).

As illustrated inFIG.4, the electronic component1B has a rotationally symmetric outer shape in plan view, similarly to the electronic component1A. That is, when the electronic component1B is rotated around the virtual center point P in plan view, the relative position and the shape with respect to the virtual center point P coincide with those before the rotation. On the other hand, in the present embodiment, the three surface conductors4are arranged only on the right side of the virtual center point P and are not arranged on the left side in the plan view illustrated inFIG.4. Therefore, when the three surface conductors4are rotated around the virtual center point P in plan view, the relative positions and the shapes of the three surface conductors4with respect to the virtual center point P do not coincide with those before and after the rotation. That is, the surface conductors4are arranged in a non-rotationally symmetric manner with respect to the virtual center point P. Therefore, the direction of the electronic component1B can be determined from the positions of the surface conductors4in plan view. Therefore, the surface conductors4can be used as directional marks indicating the direction of the electronic component1B by their positions and shapes in plan view.

For example, as in the present embodiment, the surface conductors4can be used as directional marks when being arranged in a non-rotationally symmetric manner with respect to the virtual center point P in plan view. As long as such an arrangement is satisfied, one or a plurality of surface conductors4can indicate the direction of the electronic component1B in plan view. For example, even when the surface conductors4are arranged on both the left and right sides of the virtual center point P in the plan view illustrated inFIG.1, at least one of the shapes of the surface conductor4arranged on the right side and the surface conductor4arranged on the left side and the relative positions with respect to the virtual center point P only needs to be different. In this case, when the surface conductor4arranged on the right side is rotated around the virtual center point P, the surface conductor4arranged on the right side does not overlap the surface conductor4arranged on the left side so as to coincide with the surface conductor4arranged on the left side. That is, the surface conductors4arranged on the left and right sides are arranged in a non-rotationally symmetric manner with respect to the virtual center point P.

Further, since the surface conductor4is thick, when the electronic component1B is illuminated, a clear shadow S2is generated by the surface conductor4. The shadow S2occurs, for example, in a case where light can be transmitted through the resin layer8described later, in a case where the surface conductor4protrudes from the surface of the resin layer8, in a case where the electronic component1B does not include the resin layer8, or the like. The shadow S2illustrated inFIG.4indicates a shadow when the electronic component1B including the resin layer8through which light can be transmitted is illuminated from diagonally upper right of the electronic component1B. Note that such a shadow S2occurs in each of the surface conductors4, butFIG.4representatively illustrates only the shadow S2of the surface conductor4closest to the virtual center point P. According to such a shadow S2, since the visibility of the surface conductor4in plan view is good, it is easy to determine the direction of the electronic component1B.

As illustrated inFIGS.5and6, the resin layer8that covers the surface conductor4is formed on the surface21aof the first surface layer21. For the resin layer8, for example, an acrylic resin, a urethane resin, an epoxy resin, a phenol resin, a silicone resin, polyimide, or the like is used. In the present embodiment, the resin layer8is formed over the entire surface21aof the first surface layer21. In the present embodiment, the thickness of the resin layer8is larger than any of the length of the via conductor3in the penetrating direction, the thickness of each insulating layer2, and the thickness of each internal conductor7in a portion not overlapping the surface conductor4in plan view. In the present embodiment, since the five insulating layers2have the same thickness, it can be said that the thickness of the portion of the resin layer8is larger than the thickness of the thinnest layer of the five insulating layers2. Here, the thickness of the resin layer8refers to, for example, the thickness from the surface21aof the first surface layer21to an outer surface8aof the resin layer8in the lamination direction.

The resin layer8formed on the side of the surface conductor4prevents the surface conductor4from being peeled off from the surface21aof the first surface layer21or from being displaced on the surface21a. In addition, since the resin layer8is covered with the surface conductor4, the influence of atmosphere, moisture, and the like on the surface conductor4is suppressed. Further, by forming the resin layer8, the mechanical strength of the electronic component1B can be improved. Furthermore, a shield (not illustrated) that shields electromagnetic waves can be provided on the outer surface8aof the resin layer8. By interposing the resin layer8between the shield and the surface conductor4, it is possible to realize a shield that is not electrically connected to the surface conductor4.

According to the electronic component1B according to the present embodiment, the surface conductor4constitutes at least a part of the inductor9together with the via conductors3and the internal conductor7. In at least a part of such an inductor9, since the surface conductor4is thick, a larger conductor cross section can be obtained. This reduces the insertion loss of the inductor9. In addition, since the trimmable thickness of the surface conductor4is large, the adjustment range of the electrical characteristics of the inductor9is large.

In addition, according to the electronic component1B according to the present embodiment, the surface conductor4is arranged in a non-rotationally symmetric manner with respect to the center point P of the rotational symmetry of the electronic component1B. Therefore, the direction of the electronic component1B can be indicated by the position and shape of the surface conductor4in plan view. That is, the surface conductor4can also serve as a directional mark indicating the direction of the electronic component1B. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component1B can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface21aof the insulating layer2, it is possible to reduce the size of the electronic component1B and to further arrange wiring, components, and the like.

In addition, according to the electronic component1B according to the present embodiment, the electronic component1B includes the resin layer8that covers at least a part of the surface conductor4. The resin layer8can protect the surface conductor4from the influence of foreign matter, impact, or the like from the outside. In addition, the resin layer8improves the mechanical strength of the electronic component1B. Furthermore, a shield that shields electromagnetic waves can be arranged at a position facing the electronic component1B via the resin layer8.

In addition, according to the electronic component1B according to the present embodiment, a part of the resin layer8is thicker than the thickness of the thinnest layer of the insulating layers2and thicker than the thickness of the internal conductor7. As a result, it is possible to realize the resin layer8capable of more reliably protecting the surface conductor4from the influence of foreign matter, impact, or the like from the outside and further improving the mechanical strength of the electronic component1B.

Third Embodiment

Next, an electronic component according to a third embodiment of the present disclosure will be described with reference toFIGS.7to9.FIG.7is a plan view of the electronic component according to the third embodiment of the present disclosure.FIG.8is a cross-sectional view taken along line A3-A3of the electronic component inFIG.7.FIG.9is an enlarged view of a Z1region inFIG.8.

As illustrated inFIG.7, the electronic component1C according to the third embodiment has a substantially rectangular outer shape when viewed from the lamination direction.

As illustrated inFIG.8, the electronic component1C includes eleven laminated insulating layers2. The eleven insulating layers2include a first surface layer21constituting the upper surface of the electronic component1C, a second surface layer22constituting the lower surface, and nine intermediate layers23A to23I laminated between the first surface layer21and the second surface layer22.

The thicknesses of the insulating layers2in the lamination direction may be the same as or different from each other. In the example illustrated inFIG.8, the intermediate layer23A is the thinnest among the eleven insulating layers2. The thickness T2of the intermediate layer23A is, for example, 5 μm. The intermediate layer23D is the thickest among the eleven insulating layers2. The thickness T3of the intermediate layer23D is, for example, 40 μm.

As indicated by an alternate long and short dash line inFIG.7, one land conductor5A functioning as a ground electrode and two land conductors5B functioning as an input electrode or an output electrode are provided on a surface22a(seeFIG.8) of the second surface layer22. In the example illustrated inFIG.7, the land conductor5A is arranged at the center in the long-side direction (the left-right direction inFIG.7) of the outer shape of the electronic component1C when viewed from the lamination direction. The two land conductors5B are arranged so as to sandwich the land conductor5A in the long-side direction.

Four surface conductors4are arranged on the surface21aof the first surface layer21. The four surface conductors4include surface conductors4C to4E. Each of the surface conductors4extends in the short-side direction (up-down direction inFIG.7) of the outer shape of the electronic component1C when viewed from the lamination direction. As illustrated inFIG.8, a plating film6is formed on the surface of the surface conductor4.

In the example illustrated inFIG.8, similarly to the surface conductor4A in the first embodiment, the surface conductor4has a constant or substantially constant thickness over the entire surface conductor4. The thickness T1of the surface conductor4is larger than the thickness T2of the intermediate layer23A and larger than the thickness of an internal conductor7(described later). For example, the thickness T1of the surface conductor4is larger than the thickness of the thickest internal conductor7included in the electronic component1C. In the present embodiment, the thickness of the surface conductor4is larger than twice the thickness T2of the intermediate layer23A and larger than the thickness T3of the intermediate layer23D. In addition, the thickness of the surface conductor4may be larger than twice the thickness T3of the intermediate layer23D. Here, the “thickness of the surface conductor4” does not include the thickness of the plating film6formed on the surface of the surface conductor4. The thickness of the surface conductor4is, for example, 50 μm.

In the example illustrated inFIG.7, the plating film6is formed on the entire surface of each surface conductor4. The plating film6may be formed only on a part of the surface of the surface conductor4. The thickness of the plating film6is, for example, 5 to 20 μm.

The surface conductor4and the plating film6constitute an integrated conductor. Therefore, the current flowing through the surface conductor4also flows through the plating film6.

As indicated by a broken line inFIG.7, the electronic component1C includes five internal conductors7. The five internal conductors7include internal conductors7A to7E. The internal conductors7are formed at boundary portions between the adjacent insulating layers2. Each of the internal conductors7A and7D is electrically connected to each of the land conductors5B. As illustrated inFIG.8, the internal conductor7E is connected to the land conductor5A via the plurality of via conductors3. Since the land conductor5A is grounded, the internal conductor7E is grounded. Note that the internal conductor7E only needs to be electrically connected to the land conductor5A, and may be connected to the land conductor5A via a component other than the via conductors3.

As illustrated inFIG.7, the four internal conductors7A to7D are arranged so as not to face each other in the lamination direction. That is, the four internal conductors7A to7D do not overlap when viewed from the lamination direction. On the other hand, the internal conductor7E is arranged so as to face the internal conductors7A to7D with the insulating layer2interposed therebetween in the lamination direction (see, for example,FIG.8.). As a result, capacitors17A to17D are formed by the internal conductors7A to7D and the internal conductor7E, respectively. The internal conductor7A and the internal conductor7D face an internal conductor (not illustrated) via the insulating layer2to form capacitive coupling.

As illustrated inFIG.8, the internal conductor7C is connected to the surface conductor4E via eight via conductors3penetrating the first surface layer21and the seven intermediate layers23A to23G. The internal conductor7E is connected to the surface conductor4E via nine via conductors3penetrating the first surface layer21and the eight intermediate layers23A to23H. Note that the internal conductor7C and the surface conductor4E and the internal conductor7E and the surface conductor4E may be connected via one or a plurality of via conductors3.

In the example illustrated inFIG.8, the plurality of via conductors3connecting the internal conductors7C and7E and the surface conductor4E are continuously arranged in the lamination direction as so-called continuous vias. In the example illustrated inFIG.9, each via conductor3in the continuous vias has a tapered shape when viewed from a direction orthogonal to the lamination direction. In this case, each via conductor3has a truncated cone shape. Each via conductor3is not limited to the truncated cone shape, and may have, for example, a cylindrical shape.

Similarly to the surface conductor4E, each of the surface conductors4C,4D, and4F is connected to each of the internal conductors7A,7B, and7D via the via conductor3. Each of the surface conductors4C,4D, and4F is connected to the internal conductor7E via the via conductor3. Note that the surface conductors4C to4F and the internal conductors7A to7D or the internal conductor7E only need to be electrically connected, and may be connected via a component other than the via conductor3.

The surface conductor4E and the via conductor3connecting the surface conductor4E and each of the internal conductors7C and7E constitute an inductor9C. Similarly, the surface conductors4C,4D, and4F and the via conductor3connecting the surface conductors4C,4D, and4F and the internal conductors7A,7B,7D, and7E constitute inductors9A,9B, and9D, respectively. That is, each of the surface conductors4C to4F constitutes a part of each of the inductors9A to9D. The via conductor3connected to each of the surface conductors4C to4F is an example of a “connection conductor” in the present disclosure.

Each of the inductors9A to9D and each of the capacitors17A to17D form an LC parallel resonator in which one inductor and one capacitor are connected in parallel. That is, the electronic component1C includes four LC parallel resonators. The four LC parallel resonators are arranged along the long-side direction of the outer shape of the electronic component1C when viewed from the lamination direction. Therefore, when the adjacent LC parallel resonators are electromagnetically coupled, the electronic component1C functions as a band pass filter.

According to the electronic component1C according to the present embodiment, the thickness of the surface conductor4is larger than the thickness of the thinnest intermediate layer23A of the insulating layers2and larger than the thickness of the internal conductor7. Therefore, the surface conductor4can be largely trimmed in the thickness direction. As a result, the electrical characteristics of the inductors9A to9D including the surface conductor4can be adjusted in a wide range.

In the electronic component1C according to the present embodiment, the thickness of the surface conductor4is larger than twice the thickness of the thinnest intermediate layer23A of the insulating layers2. Therefore, the trimmable thickness of the surface conductor4can be increased as compared with a configuration in which the thickness of the surface conductor4is smaller than twice the thickness of the thinnest intermediate layer23A of the insulating layers2. Therefore, it is possible to realize the electronic component1C having a large adjustment range of the electrical characteristics of the inductors9A to9D including the surface conductor4.

In the electronic component1C according to the present embodiment, the thickness of the surface conductor4is larger than the thickness of the thickest intermediate layer23D of the insulating layers2. Therefore, the trimmable thickness of the surface conductor4can be increased as compared with the configuration in which the thickness of the surface conductor4is smaller than the thickness of the thickest intermediate layer23D of the insulating layers2. Therefore, it is possible to realize the electronic component1C having a large adjustment range of the electrical characteristics of the inductors9A to9D including the surface conductor4.

In addition, according to the electronic component1C according to the present embodiment, by forming the plating film6on at least a part of the surface of the surface conductor4, the thickness of the conductor in which the surface conductor4and the plating film6are integrated can be increased. That is, the conductor can be not only thinned by trimming or the like, but also thickened. Therefore, it is possible to realize the electronic component1C having a large adjustment range of the electrical characteristics of the inductors9A to9D including the surface conductor4.

In the present embodiment, when the surface conductor4is trimmed and thinned, the conductor cross-sectional area of the surface conductor4decreases. At this time, the inductance values of the inductors9A to9D increase. As a result, the resonance frequency of the LC parallel resonator including the inductors9A to9D and the capacitors17A to17D decreases. On the other hand, when the plating film6is formed on the surface of the surface conductor4, the conductor in which the surface conductor4and the plating film6are integrated becomes thick, so that the cross-sectional area of the conductor increases. Therefore, the inductance values of the inductors9A to9D are low contrary to the case where the surface conductor4becomes thin. As a result, the resonance frequency increases. In addition, the thickness of the conductor can be finely adjusted, for example, by changing the plating processing time. Therefore, the electrical characteristics of the inductor9including the surface conductor4can be adjusted with high accuracy.

Fourth Embodiment

Next, an electronic component according to a fourth embodiment of the present disclosure will be described with reference toFIGS.10and11.FIG.10is a plan view of the electronic component according to the fourth embodiment of the present disclosure.FIG.11is a cross-sectional view taken along line A4-A4of the electronic component inFIG.10.

The electronic component1D according to the fourth embodiment is different from the electronic component1C according to the third embodiment in that a surface conductor4G is further provided. In addition, the electronic component1D does not include the surface conductors4D and4E and the internal conductors7B and7C. The plating film6is not formed on the surface of the surface conductor4.

As illustrated inFIG.10, the electronic component1D includes three surface conductors4and three internal conductors7. The three surface conductors include surface conductors4C,4F, and4G. The three internal conductors7include internal conductors7A,7D, and7E.

As illustrated inFIG.11, the internal conductor7D is connected to a land conductor5B functioning as an input electrode or an output electrode via a via conductor3penetrating a second surface layer22. The internal conductor7E is connected to a land conductor5A (seeFIG.10) to be grounded via two via conductors (not illustrated) penetrating an intermediate layer23I and the second surface layer22.

As illustrated inFIG.11, the internal conductor7D and the grounded internal conductor7E are arranged so as to face each other in the lamination direction. Therefore, the internal conductors7D and7E function as a capacitor17D. The surface conductor4F is connected to the grounded internal conductor7E via nine via conductors3penetrating a first surface layer21and eight intermediate layers23A to23H. The surface conductor4F is connected to the internal conductor7D via ten via conductors3penetrating the first surface layer21and nine intermediate layers23A to23I. The surface conductor4F and the via conductor3connecting the surface conductor4F and each of the internal conductors7D and7E constitute an inductor9D. The inductor9D and the capacitor17D form an LC parallel resonator.

Similarly, the internal conductor7A and the internal conductor7E are arranged so as to face each other in the lamination direction, thereby functioning as the capacitor17A. The surface conductor4C is connected to each of the internal conductors7A and7E via the plurality of via conductors3. The surface conductor4C and the via conductor3connecting the surface conductor4C and each of the internal conductors7A and7E constitute an inductor9A. The inductor9A and the capacitor17A form an LC parallel resonator.

The via conductor3connected to each of the surface conductors4C and4F is an example of a “connection conductor” in the present disclosure.

As illustrated inFIG.10, the surface conductor4G is further provided on the surface21aof the first surface layer21. Both end portions of the surface conductor4G are connected to the surface conductors4C and4F. The surface conductor4G has a meander shape when viewed from the lamination direction. As a result, the surface conductor4G functions as an inductor9E. That is, the two LC parallel resonators are electromagnetically coupled and electrically connected by the inductor9E.

According to the electronic component1D according to the fourth embodiment, since the surface conductor4is thick in at least a part of the inductors9A,9D, and9E, a larger conductor cross section can be obtained. This reduces the insertion loss of the inductors9A,9D, and9E. In addition, since the trimmable thickness of the surface conductor4is large, the adjustment range of the electrical characteristics of the inductors9A,9D, and9E is large.

Fifth Embodiment

Next, an electronic component according to a fifth embodiment of the present disclosure will be described with reference toFIGS.12and13.FIG.12is a plan view of the electronic component according to the fifth embodiment of the present disclosure.FIG.13is a cross-sectional view of the electronic component taken along line A5-A5inFIG.12.

An electronic component1E according to the fifth embodiment is different from the electronic component1D according to the fourth embodiment in that a surface conductor4provided on a surface21aof a first surface layer21has a spiral shape when viewed from the lamination direction.

As illustrated inFIG.12, the electronic component1E includes one surface conductor4, an internal conductor7D, and a grounded internal conductor7E. Similarly to the electronic component1D according to the fourth embodiment, the internal conductor7D and the grounded internal conductor7E face each other in the lamination direction to constitute a capacitor17D.

The surface conductor4has a spiral shape when viewed from the lamination direction. That is, the surface conductor4is a coil whose winding axis direction is the lamination direction (the depth direction of the paper surface inFIG.12), and constitutes an inductor9F. As illustrated inFIG.13, the inner end portion of the spiral shape of the surface conductor4is connected to the internal conductor7E via the nine via conductors penetrating the first surface layer21and the eight intermediate layers23A to23H. The outer end portion of the spiral shape of the surface conductor4is connected to the internal conductor7D via the plurality of via conductors3(seeFIG.12).

The via conductor3connected to the surface conductor4is an example of a “connection conductor” in the present disclosure.

As illustrated inFIG.13, the surface conductor4includes a first portion41and a second portion42that is continuous with the first portion41along the surface21aof the first surface layer21and is thinner in the lamination direction than the first portion41. The thickness T4of the first portion41is larger than the thickness T2of the intermediate layer23A and larger than the thickness of the internal conductor7. For example, the thickness T4of the first portion41is larger than the thickness of the thickest internal conductor7of the electronic component1E. In the present embodiment, the thickness of the first portion41is larger than twice the thickness T2of the intermediate layer23A and larger than the thickness T3of the intermediate layer23D. In addition, the thickness of the first portion41may be thicker than twice the thickness T3of the intermediate layer23D.

In the present embodiment, as illustrated inFIG.12, the width of the first portion41when viewed from the lamination direction is smaller than the width of the second portion42when viewed from the lamination direction. The width of the first portion41may be thicker than the width of the second portion42or may be the same as the width of the second portion42.

Sixth Embodiment

Next, an electronic component according to a sixth embodiment of the present disclosure will be described with reference toFIGS.14to15.FIG.14is a plan view of the electronic component according to the sixth embodiment of the present disclosure.FIG.15is a cross-sectional view of the electronic component taken along line A6-A6inFIG.14.

An electronic component1F according to the sixth embodiment is different from the electronic component1E according to the fifth embodiment in that the electronic component1F includes a coil-shaped inductor9G whose winding axis direction is a direction intersecting the lamination direction.

As illustrated inFIG.14, the electronic component1F includes three surface conductors4, two internal conductors7, and two inductor conductors18A and18B. The three surface conductors4include surface conductors4H to4J. The two internal conductors7include internal conductors7D and7E. Similarly to the electronic component1D according to the fourth embodiment, the internal conductor7D and the grounded internal conductor7E face each other in the lamination direction to constitute a capacitor17D.

Each of the surface conductors4extends in the short-side direction (up-down direction inFIG.14) of the outer shape of the electronic component1F when viewed from the lamination direction. In the present embodiment, the three surface conductors4are arranged in a non-rotationally symmetric manner with respect to the virtual center point of the electronic component1F when viewed from the lamination direction.

As illustrated inFIG.15, the inductor conductor18B is formed in an intermediate layer23G. That is, the inductor conductor18B is formed between the intermediate layer23F and the intermediate layer23H. The thickness of the inductor conductor18B is the same as or substantially the same as the thickness of the intermediate layer23G. Similarly, the inductor conductor18A (not illustrated inFIG.15) is also formed in the intermediate layer23G (that is, a portion between the intermediate layer23F and the intermediate layer23H). The inductor conductors18A and18B are formed, for example, by filling holes formed in portions corresponding to the inductor conductors18A and18B of the insulating layer sheet12(described later) with a conductive paste16(described later) and firing the paste16.

One end portion of the surface conductor4J is connected to the internal conductor7D via ten via conductors3penetrating a first surface layer21and nine intermediate layers23A to23I. The other end portion of the surface conductor4J is connected to one end portion of the inductor conductor18B via seven via conductors3penetrating the first surface layer21and the six intermediate layers23A to23F. As illustrated inFIG.14, the other end portion of the inductor conductor18B is connected to one end portion of an end portion of the surface conductor4I closer to one end portion of the surface conductor4J via the via conductor3. The other end portion of the surface conductor4J is connected to one end portion of the inductor conductor18A via the via conductor3. The other end portion of the inductor conductor18A is connected to one end portion of the end portion of the surface conductor4H closer to one end portion of the surface conductor4I via the via conductor3. The other end portion of the surface conductor4H is connected to the internal conductor7E via the via conductor3.

The surface conductor4, the inductor conductor18A,18B, and the via conductor3connecting the surface conductor4and the inductor conductor18A,18B or each of the internal conductors7D and7E constitute the inductor9G. The inductor9G is a coil whose winding axis direction is a long-side direction of the outer shape of the electronic component1F when viewed from the lamination direction. The via conductor3connected to each surface conductor4is an example of a “connection conductor” in the present disclosure.

As illustrated inFIG.15, each surface conductor4includes a first portion41and a second portion42that is continuous with the first portion41along a surface21aof the first surface layer21and is thinner in the lamination direction than the first portion41. In the example illustrated inFIG.15, a surface conductor4J includes two first portions41and a second portion42arranged between the two first portions41.

The thickness T4of the first portion41is larger than the thickness T2of the intermediate layer23A and larger than the thickness of the internal conductor7. For example, the thickness T4of the first portion41is larger than the thickness of the thickest internal conductor7of the electronic component1F. In the present embodiment, the thickness of the first portion41is larger than twice the thickness T2of the intermediate layer23A and larger than the thickness T3of the intermediate layer23D. In addition, the first portion41may be thicker than twice the thickness T3of the intermediate layer23D. The thickness T4of the first portion41is, for example, 50 μm. The thickness T5of the second portion42is, for example, 25 μm.

A boundary portion43between the first portion41and the second portion42is arranged in a non-rotationally symmetric manner with respect to the virtual center point of the electronic component1F when viewed from the lamination direction. In the boundary portion43, a shadow S1is generated due to a difference in thickness between the first portion41and the second portion42.FIG.14illustrates the shadows S1generated when the electronic component1F is illuminated from slightly above both end portions of the surface conductor4.

According to the electronic component1F according to the sixth embodiment, there is a difference in thickness at the boundary portion43between the first portion41and the second portion42, and the shadow S1is generated at the boundary portion43. The shadow S1can be used as a directional mark indicating the direction of the electronic component1F. This eliminates the need to separately provide a directional mark, so that the manufacturing efficiency of the electronic component1F can be improved. In addition, since the area occupied by the directional mark is unnecessary on the surface21aof the insulating layer2, it is possible to reduce the size of the electronic component1F and to further arrange wiring, components, and the like.

<<Method for Manufacturing Electronic Component>>

Next, an example of a method for manufacturing an electronic component according to the present disclosure will be described with reference toFIGS.16to24.FIGS.16to24are cross-sectional views illustrating an example of a method for manufacturing an electronic component according to the present disclosure. InFIGS.21and24, a boundary line between a forming sheet11and an insulating layer sheet12(both will be described later) and a part of the conductive paste16(described later) are omitted for convenience of description.

As illustrated inFIG.21, the electronic component1is manufactured by dividing a laminated body10into a plurality of laminated pieces101. The laminated body10is formed by integrating the plurality of laminated pieces101in an arranged state. Each laminated piece101corresponds to one electronic component1. InFIGS.16to20, for convenience of description, only a portion corresponding to one laminated piece101of the laminated body10is illustrated.

In the manufacture of the electronic component1, first, as illustrated inFIG.16, the forming sheet11for forming the surface conductor4and the insulating layer sheet12constituting the insulating layer2are formed. By mixing raw materials including a main agent, a plasticizer, a binder, and the like corresponding to each of the sheets11and12, a slurry constituting each of the sheets11and12is prepared.

For the forming sheet11, for example, a resin that burns out during firing (described later), a non-sinterable ceramic powder, or the like is used as a main agent. As a result, the forming sheet11can be burned out during firing or can be removed by cleaning after firing.

For the insulating layer sheet12, for example, a sinterable ceramic powder or the like is used as a main agent. As the plasticizer, for example, phthalic acid ester or di-n-butyl phthalate is used. As the binder, for example, an acrylic resin, polyvinyl butyral, or the like is used.

The slurry constituting each of the sheets11and12is formed into a sheet shape on a carrier film13using, for example, a lip coater, a doctor blade, or the like. As a result, the sheets11and12as illustrated inFIG.16are obtained. As the carrier film13, for example, a polyethylene terephthalate (PET) film or the like is used. The thickness of the forming sheet11is, for example, 1 to 150 μm before firing. In addition, the thickness of the insulating layer sheet12is set to, for example, a thickness such that the thickness after firing is 1 to 150 μm.

In the present manufacturing example, two forming sheets11A and11B (seeFIGS.17and18) for forming the surface conductor4and insulating layer sheets12A to12E (seeFIGS.17to19) for preparing five insulating layers2A to2E (seeFIGS.22and23) are prepared.

Next, as illustrated inFIG.17, a surface conductor hole portion111penetrating the forming sheet11and the carrier film13is formed. In addition, in a case where an electronic component including the via conductors3is manufactured, via conductor hole portions121penetrating the insulating layer sheet12and the carrier film13are formed. For forming each hole portion111,121, for example, a mechanical punch, a UV laser, a CO2laser, or the like is used.

Next, as illustrated inFIG.18, each hole portion111,121is filled with the conductive paste16. The conductive paste16is prepared, for example, by mixing raw materials containing a conductive powder, a plasticizer, and a binder. In addition, for example, a eutectic material such as a ceramic powder mixed in each of the sheets11and12may be added to the conductive paste16in order to adjust the shrinkage rate during firing.

Next, as illustrated inFIG.19, conductors thinner than the surface conductor4such as the land conductor5and the internal conductor7are formed. The conductive paste16is formed on the surface of the insulating layer sheet12by, for example, screen printing, inkjet printing, gravure printing, or the like. The composition of the conductive paste16may be changed according to the applied conductor.

Next, as illustrated inFIG.20, the sheets11and12excluding the carrier film13are laminated and pressure-bonded in a mold. By the steps so far, the laminated body10is obtained.

Next, as illustrated inFIG.21, the laminated body10is cut into laminated pieces101corresponding to one electronic component1. For cutting the laminated body10, for example, a dicing saw, a guillotine cutter, a laser, or the like is used. After the laminated body10is cut, the corners and edges of the laminated piece101may be polished by, for example, barrel processing or the like.

Then, by firing the laminated piece101, the insulating layers2A to2E, the via conductors3, the surface conductor4, the land conductor5, and the internal conductors7are obtained. At this time, in a case where the forming sheet11is configured to burn out, the forming sheet11is removed as illustrated inFIG.22. In addition, in a case where the forming sheet11is configured not to burn out, the forming sheet11is removed by cleaning the laminated piece101after firing.

Then, as illustrated inFIG.23, the surface conductor4is trimmed as necessary. As a result, the electrical characteristics of an element or the like are adjusted. At this time, since the first portion41of the surface conductor4is thicker than the second portion42, only the first portion41can be trimmed by a planar processing method. Examples of the planar processing method include etching and surface grinding.

When trimming is performed by surface grinding, for example, as illustrated inFIG.24, the plurality of laminated pieces101are arranged such that the surface corresponding to the surface22aof the second surface layer22is in contact with an adhesive sheet202arranged on a stage201. At this time, the surface conductors4provided on the laminated pieces101face the opposite side (the upper side inFIG.24) of the stage201. By bringing a grindstone203into contact with the surface conductors4provided on the plurality of laminated pieces101, it is possible to simultaneously perform planar processing on the plurality of laminated pieces101.

By the trimming, the thickness of the surface conductor4is reduced. That is, the conductor cross-sectional area of the surface conductor4decreases. As a result, the electrical characteristics of an element or the like including the surface conductor4can be adjusted. For example, in the second embodiment in which the surface conductor4constitutes a part of the inductor9, when the surface conductor4is trimmed, the inductance value of the inductor9increases. As a result, when the inductor9constitutes a part of the resonator, the resonance frequency of the resonance circuit decreases.

Through the above steps, the electronic component1in which the surface conductor4is exposed is manufactured. Further, when the plating film6, the resin layer8, and the like are formed, the electronic component1A illustrated inFIGS.1to3, the electronic component1B illustrated inFIGS.4to6, and the like are obtained.

Next, an example of a resin layer forming method for the electronic component according to the present disclosure will be described with reference toFIGS.25to27.FIGS.25to27are views illustrating an example of a resin layer forming method for the electronic component according to the present disclosure.

In the present forming method, the electronic component1B illustrated inFIGS.4to6is obtained by further forming the resin layer8on the electronic component1manufactured by the above-described method.

First, as illustrated inFIG.25, the electronic component1manufactured as described above is immersed in a liquid resin31. As a result, the resin31adheres to the outer surface of the electronic component1. As the resin31, a resin that can be cured only in a desired region is selected. Examples of the resin31include a thermosetting resin and an ultraviolet curable resin.

After the immersion, as illustrated inFIG.26, the electronic component1is arranged on an adhesive surface of an adhesive sheet32with the vertical direction aligned.

Next, the resin31attached to the region of the electronic component1where the resin layer8is to be formed is subjected to a curing treatment to form the resin layer8. For example, when a thermosetting resin is used, as illustrated inFIG.26, a hot plate33is pressed against the upper surface of the electronic component1, whereby only the resin31attached to the upper surface can be cured.

When an ultraviolet curable resin is used, the resin31can be cured by irradiating a desired region including at least a part of the surface conductor4with ultraviolet rays. In addition, by applying a mask that does not transmit ultraviolet rays to a region where the resin layer8is not formed, formation of the resin layer8outside a desired region can be prevented.

Next, the uncured resin31is removed from the electronic component1. For example, as illustrated inFIG.27, the uncured resin31is removed by cleaning the electronic component1in a cleaning liquid34. Through the above steps, the electronic component1B including the resin layer8is manufactured.

According to this forming method, the resin layer8can be formed by attaching the resin31to the entire electronic component1and curing the resin31only at a desired portion on the electronic component1. Therefore, unlike the method for forming the resin layer8by applying the resin31only to a desired portion, it is not necessary to align the electronic components1in order to attach the resin31. Therefore, the manufacturing efficiency of the electronic component1B can be improved.

Note that the present disclosure is not limited to the embodiments and the example of the manufacturing method, and can be implemented in various other modes. For example, in the above description, the electronic components1A to1F include the five or eleven insulating layers2, but the present disclosure is not limited thereto. The electronic components1A to1F only need to include at least one insulating layer2, and the number of laminated layers is not limited.

In the above description, the via conductor3is an example of the connection conductor, but the connection conductor is not limited to the via conductor3. For example, the connection conductor may be a wiring pattern (not illustrated) formed on the front surface21aof the first surface layer21, the land conductor5(seeFIG.1), or the like. In addition, the “plurality of connection conductors” in the present disclosure may be one of the via conductors3, the wiring patterns, the land conductors5, and the like, or may be a combination thereof.

In the above description, the first portions41of the surface conductor4A and the surface conductor4B are trimmed in the thickness direction, but the present disclosure is not limited thereto. The surface conductor4may be trimmed not only in the thickness direction but also in the width direction. In the surface conductor4B, only a part of the first portion41of the surface conductor4B may be trimmed. In addition, the second portion42may be trimmed. As the trimming method, not only a planar processing method but also a method using a laser, for example, can be adopted. The trimming step is a step performed as necessary, and is not an essential step in the manufacture of the electronic components1,1A, and1B.

In the above description, the surface conductor4is arranged on the surface21aof the first surface layer21, but may be arranged on another surface. For example, the surface conductor4may be arranged on the surface22aof the second surface layer22, or may be arranged on both the surface21aof the first surface layer21and the surface22aof the second surface layer22.

In the second embodiment, the three surface conductors4are arranged in parallel to each other, but the present disclosure is not limited thereto. The number of surface conductors4may be arbitrary. In addition, even when the surface conductors4constitute a part of the inductor, the surface conductors4are not necessarily arranged in parallel.

In the second embodiment, the “inductor conductor” in the present disclosure is the internal conductor7, but the present disclosure is not limited thereto. The “inductor conductor” in the present disclosure only needs to be electrically connected to the surface conductor4via the via conductor3, and may be, for example, a conductor formed on the insulating layer2, a conductor formed on the surface22aof the second surface layer22, wire bonding, or the like.

In the second embodiment, the winding axis direction of the inductor9is the direction in which the insulating layer2extends and the direction perpendicular to the direction in which the surface conductor4extends, but the present disclosure is not limited thereto. The winding axis direction of the inductor9is not particularly limited, and may be, for example, the lamination direction of the insulating layer2.

In the second embodiment, the surface conductor4is covered with the resin layer8, but may be covered with a glass layer instead of the resin layer8. Even when the surface conductor4is covered with the glass layer, the same effect as the above-described effect by the resin layer8covering the surface conductor4is achieved.

In the second embodiment, the resin layer8is formed on the entire surface21aof the first surface layer21, but the present disclosure is not limited thereto. For example, the resin layer8may be formed such that the thickness from the first surface layer21is thinner than that of the surface conductor4and the resin layer8surrounds the surface conductor4in plan view.

In the above description, the resin layer8is formed by immersing the electronic component1in the liquid resin31, but the method for forming the resin layer8is not limited thereto. For example, the resin layer8may be formed by applying a resin only to a desired region of the electronic component and curing the resin. Examples of the applying method in such a case include screen printing, inkjet printing, and dispensing.

Note that, by appropriately combining any embodiments from the various embodiments described above, the effects of the respective embodiments can be achieved.

Although the present disclosure has been fully described in connection with preferred embodiments with reference to the accompanying drawings, various modifications and corrections will be apparent to those skilled in the art. Such modifications and corrections are to be understood as being included within the scope of the present disclosure as set forth in the appended claims as long as they do not depart therefrom.

Since the electronic component according to the present disclosure has a large trimmable thickness of a conductor and a large adjustment range of electrical characteristics of an element or the like, it is useful for an electronic component or the like that requires trimming of a conductor.1,1A-1F electronic component2,2A-2E insulating layer21first surface layer21asurface22second surface layer22asurface23,23A-231intermediate layer3via conductor4,4A-4J surface conductor41first portion42second portion43boundary portion5,5A,5B land conductor6plating film7,7A-7E internal conductor8resin layer8aouter surface9,9A-9G inductor10laminated body101laminated piece11,11A,11B forming sheet111surface conductor hole portion12,12A-12E insulating layer sheet121via conductor hole portion13carrier film16conductive paste17A-17D capacitor18A,18B inductor conductor31resin32adhesive sheet33hot plate34cleaning liquid201stage202adhesive sheet203grindstone