The inductor includes a coil including a winding portion formed by winding a conductor wire having an insulating coating and lead-out portions extended from the winding portion, and a body made of a magnetic portion including magnetic powder and resin, and containing the coil, and outer electrodes on a body surface. The body includes a mounting surface, an upper surface opposite the mounting surface, a pair of opposing end surfaces adjacent to the mounting and upper surfaces, and a pair of opposing side surfaces adjacent to the mounting surface, the upper surface, and the end surfaces. End portions of the lead-out portions respectively have a flat portion exposed from the body surface, a covered portion adjacent to the flat portion at at least one of the end portions covered with the magnetic portion, and the flat portion is electrically connected to the outer electrode.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit of priority to Japanese Patent Application No. 2019-028494, filed Feb. 20, 2019, the entire content of which is incorporated herein by reference.

BACKGROUND

Technical Field

The present disclosure relates to an inductor.

Background Art

Japanese Unexamined Patent Application Publication No. 2017-201718 describes a surface mount inductor including a coil formed by winding a conductor wire, and a molded body in which the coil is sealed with a sealing material containing a metal magnetic substance powder and a resin. On a surface of the molded body, an end portion of a lead-out portion of the coil is exposed, and a plated layer made of a conductive material constituting an outer electrode is formed at and around the end portion of the lead-out portion. The plated layer forms the outer electrode connected to the end portion of the lead-out portion of the coil.

Generally, an insulating coating is provided on a conductor wire forming a coil. Thus, in order to connect the outer electrode and the end portion of the lead-out portion of the coil, it is necessary to form the outer electrode to be connected to the end portion of the lead-out portion of the coil, after removing the insulating coating. However, when the insulating coating is removed by a laser or the like, a residue of the insulating coating may be generated, or the insulating coating may be removed more than necessary and a groove may be formed. In such case, an electrically discontinuous portion is large between the end portion of the lead-out portion and the metal magnetic substance powder on the surface of the molded body. The plated layer may need to be thicker than necessary in order to form the outer electrode that connects, even when such discontinuous portion exists, the end portion of the lead-out portion to the metal magnetic substance powder on the surface of the molded body.

SUMMARY

Accordingly, the present disclosure provides an inductor in which occurrence of connection failure between a coil and an outer electrode is suppressed even when a plated layer is thin.

An inductor includes a coil including a winding portion formed by winding a conductor wire having an insulating coating and lead-out portions extended from the winding portion, a body made of a magnetic portion including a magnetic powder and a resin, and containing the coil, and outer electrodes disposed on a surface of the body. The body includes a mounting surface, an upper surface opposite the mounting surface, a pair of end surfaces disposed adjacent to the mounting surface and the upper surface and opposite to each other, and a pair of side surfaces disposed adjacent to the mounting surface, the upper surface, and the end surfaces and opposite to each other. End portions of the lead-out portions respectively have a flat portion exposed from the surface of the body, a covered portion adjacent to the flat portion at at least one of the end portions covered with the magnetic portion, and the flat portion is electrically connected to the outer electrode.

DETAILED DESCRIPTION

An inductor includes a coil including a winding portion formed by winding a conductor wire having an insulating coating and lead-out portions extended from the winding portion, and a body made of a magnetic portion including a magnetic powder and a resin, and containing the coil, and externals terminal disposed on a surface of the body. The body includes a mounting surface, an upper surface opposite the mounting surface, a pair of end surfaces disposed adjacent to the mounting surface and the upper surface, and opposite to each other, and a pair of side surfaces disposed adjacent to the mounting surface, the upper surface, and the end surfaces, and opposite to each other. End portions of the lead-out portions respectively have a flat portion exposed from the surface of the body, a covered portion adjacent to the flat portion at at least one of the end portions covered with the magnetic portion. The flat portion of the end portions of the lead-out portions is electrically connected to the outer electrode.

The end portions of the lead-out portion of the coil have the flat portion exposed from the surface of the body, the covered portion adjacent to the flat portion at at least one of the end portions covered with the magnetic portion. Accordingly, it is possible to suppress a residue being generated when the insulating coating of the conductor wire is removed, and to suppress a groove being generated due to excessive removal of the insulating coating. As a result, for example, when the outer electrode is formed by a plating process, occurrence of connection failure between the coil and the outer electrode is suppressed even when a plated layer is thin. In addition, when the plating process is performed by barrel plating, it is possible to reduce a plating time, and it is possible to reduce influence on an external resin film provided on the body. Further, an allowable range of conditions for removing the insulating coating of the conductor wire can be wider, and further productivity can be improved.

At least part of the covered portion may be disposed further inside the body than the flat portion. At the end portions of the lead-out portions, at least one edge portion of the covered portion in a width direction of the conductor wire is disposed further inside the body than the flat portion. This makes it possible to form the covered portion more easily. Further, the allowable range of the conditions can be wider for removing the insulating coating of the conductor wire, and the productivity can be improved further.

The magnetic powder includes metal magnetic substances, and at least some of the metal magnetic substances on the surface of the body where a plated layer is formed may be melted and fused to each other. When the insulating coating of the conductor wire is removed by, for example, laser irradiation, at least some of the metal magnetic substances disposed on the surface of the body are melted and fused to each other. Thereby, adhesion of the plated layer to the surface of the body is improved. Further, a growth rate of the plated layer is improved.

A winding axis of the winding portion may be disposed so as to intersect the mounting surface, and flat portions at the end portion of the lead-out portion may be exposed from the end surfaces, of the body, opposite to each other. Since the coil is disposed so that the end portions of the lead-out portions is exposed from the end surface of the body, the lead-out portions can be easily exposed from the body, and further, the productivity is improved.

A winding axis of the winding portion may be disposed substantially parallel to the mounting surface, and flat portions at the end portion of the lead-out portion may be exposed from the mounting surface. Accordingly, the lead-out portions can be directly exposed from the mounting surface, so that the inductor can be made to have small DC resistance and can support a large current.

The winding portion may be disposed so that a winding axis intersects the mounting surface, and flat portions at the end portion of the lead-out portion may be exposed from the mounting surface. Accordingly, the outer electrode can be formed only on the mounting surface, so that the inductor can be made to have small DC resistance and can support high-density implementation.

A term “step” as used herein includes, not only an independent step, but also a step that cannot be clearly distinguished from other steps, as long as a desired purpose of the step is achieved. Hereinafter, embodiments of the present disclosure are described based on the accompanying drawings. However, the embodiments described below illustrate an inductor for embodying a technical idea of the present disclosure, and the present disclosure is not limited to inductors described below. Note that, members described in the claims are not limited to members of the embodiments. In particular, dimensions, materials, shapes, relative arrangements, and the like of constituent elements described in the embodiments are not intended to limit the scope of the present disclosure, and are merely illustrative, unless otherwise specified. Note that, in the drawings, the same reference numerals are given to the same parts. While the embodiments are illustrated individually for convenience in view of ease of explanation or understanding of the gist, partial substitutions or combinations of structures described in the different embodiments are possible. In Example 2 and subsequent Examples, description of common matters to those in Example 1 is omitted, and only different points are described. In particular, similar effects with a similar configuration are not described for each embodiment.

EXAMPLES

An inductor100according to Example 1 is described with reference toFIG.1toFIG.3.FIG.1illustrates a schematic perspective view of the inductor100as viewed from a side of a mounting surface.FIG.2is a schematic partial see-through plan view of the inductor100as viewed from an upper surface side opposite the mounting surface.

As illustrated inFIG.1andFIG.2, the inductor100includes a coil30, a body10made of a magnetic portion12containing a magnetic powder and a resin, and containing the coil30, and a pair of outer electrodes20disposed on a surface of the body10and electrically connected to the coil30. The body10includes a mounting surface15, an upper surface16opposite the mounting surface15, a pair of end surfaces17disposed adjacent to the mounting surface15and the upper surface16, and opposite to each other, and a pair of side surfaces18disposed adjacent to the mounting surface15, the upper surface16, and the end surfaces17, and opposite to each other.

As the magnetic powder constituting the magnetic portion12, an iron-based metal magnetic powder, such as Fe, Fe—Si—Cr, Fe—Ni—Al, Fe—Cr—Al, Fe—Si, Fe—Si—Al, Fe—Ni, or Fe—Ni—Mo, a metal magnetic powder having other compositions, a metal magnetic powder such as amorphous, a metal magnetic powder in which a surface is covered with an insulator such as glass, a metal magnetic powder having a modified surface, and a nano-level fine metal magnetic powder are used. Further, as the resin, a thermosetting resin, such as an epoxy resin, a polyimide resin, or a phenol resin, and a thermoplastic resin, such as a polyethylene resin or a polyamide resin are used.

The outer electrode20has an L-shaped section and is disposed across the mounting surface15and the end surface17. As illustrated inFIG.2, the coil30includes a winding portion32and a pair of lead-out portions34, each of the lead-out portions34being extended from an outermost periphery of the winding portion32. An end portion of the lead-out portion34is electrically connected to the outer electrode20. Although not illustrated, the surface of the body10except for a portion where the outer electrode20is provided is covered with an external resin film.

The winding portion32of the coil30has an insulating coating, and for example, is formed by winding a conductor wire having a substantially rectangular section (rectangular wire) such that both ends thereof are located at the outermost periphery, to form two tiers, that is, upper and lower tiers, in a state of being connected to each other at an innermost periphery (alpha winding). The winding portion32is disposed so that a winding axis thereof intersects the mounting surface15at a substantially right angle, and is contained in the body10. The lead-out portion34is extended from an outermost periphery of each tier of the winding portion32toward the end surface17of the body10, and the end portion of the lead-out portion34is disposed along the end surface17. A flat portion34ais provided on a conductor wire portion on a side of the end surface17of the end portion of the lead-out portion34, and at least part of the flat portion34ais exposed from the end surface17, and is electrically connected to the outer electrode20. A cross-section orthogonal to a length direction of the conductor wire is, for example, substantially rectangular, and is defined by a width corresponding to a long side of a substantially rectangular shape and a thickness corresponding to a short side of the substantially rectangular shape.

The conductor wire has a width of, for example, about 120 μm or more and about 350 μm or less (i.e., from about 120 μm to about 350 μm), and a thickness of, for example, about 10 μm or more and about 150 μm or less (i.e., from about 10 μm to about 150 μm). In addition, an insulating coating of the conductor wire is formed of an insulating resin such as polyamide imide having a thickness of, for example, about 2 μm or more and about 10 μm or less (i.e., from about 2 μm to about 10 μm), and preferably about 6 μm. A self-fusion layer containing a self-fusing component such as a thermoplastic resin or a thermosetting resin may be further provided on a surface of the insulating coating, and may be formed to have a thickness of about 1 μm or more and about 3 μm or less (i.e., from about 1 μm to about 3 μm).

FIG.3is a partial enlarged view of a vicinity of the outer electrode in a schematic section along line A-A inFIG.2. As illustrated inFIG.3, the end portion of the lead-out portion34is embedded in the magnetic portion12along the end surface17of the body10. The side of the end surface17of the end portion of the lead-out portion34has the flat portion34afrom which the insulating coating is peeled off and a conductor wire40is exposed, and a covered portion34bon which the insulating coating is covered with the magnetic portion12. The covered portions34bare provided on both edge portions of the flat portion34ain a width direction of the conductor wire respectively, so as to be continuous with the flat portion34a. The outer electrode20is formed by plating across the flat portion34aand a surface14of the body10around the flat portion34a, and the surface of the body10except for a portion where the outer electrode is provided is covered with an external resin film50. A ratio of a length of the flat portion34ato the width of the conductor wire is, for example, about 0.5 or more and about 0.9 or less (i.e., from about 0.5 to about 0.9), and a ratio of sum of respective lengths of the covered portions34bto the width of the conductor wire is about 0.1 or more and about 0.5 or less (i.e., from about 0.1 to about 0.5), for example. Note that, the flat portion34ais embedded further inside the body10than the end surface17, and the covered portion34bis covered with the magnetic portion12when the inductor is viewed from a direction orthogonal to the end surface17.

Next, an example of a method for manufacturing the inductor100is described with reference toFIG.4AtoFIG.4D. The method for manufacturing the inductor includes, for example, a coil preparing step, a body molding step, an external resin film forming step, a peeling step, and an outer electrode forming step.FIG.4AtoFIG.4Dare partial enlarged views of the vicinity of the outer electrode of the schematic section along line A-A inFIG.2, and are diagrams for explaining the respective steps.

Coil Preparing Step

In the coil preparing step, a coil is prepared that is formed by winding a conductor wire having an insulating coating on a surface thereof, and having a substantially rectangular-shaped cross-section orthogonal to a length direction, such that an lead-out portion is extended from an outermost periphery of a winding portion, to form two tiers so as to be connected to each other at an innermost periphery. A flat portion is provided on an end portion of the lead-out portion on a surface continuous with an outermost peripheral surface of the winding portion.

Body Molding Step

In the body molding step, the prepared coil is embedded in a magnetic portion material obtained by kneading a magnetic powder and a thermosetting resin, and pressing and heating are performed to form a substantially rectangular parallelepiped shape. Thus, a body is obtained in which a winding axis of the winding portion is disposed in the magnetic portion12so as to intersect substantially perpendicularly to a mounting surface of the body, and an end portion of the lead-out portion is disposed along an end surface adjacent to the mounting surface. At this time, as illustrated inFIG.4A, on the end surface17, an insulating coating42on the flat portion34aprovided at a center portion in a line-width direction of the conductor wire40is exposed from the end surface17, and the covered portions34bprovided at both end portions respectively in the line-width direction are embedded in the body so as to be covered with the magnetic portion12constituting the end surface17.

External Resin Film Forming Step

As illustrated inFIG.4B, the external resin film50having insulation properties is formed in another region of a surface of the molded body from which the insulating coating42is not exposed. The external resin film50is formed, for example, by adding a thermosetting resin such as an epoxy resin, a polyimide resin, or a phenol resin, or a thermoplastic resin such as a polyethylene resin or a polyamide resin to a surface by a measure such as application or dipping, and by curing the added resin as necessary.

Peeling Step

In the peeling step, as illustrated inFIG.4C, the external resin film50and the insulating coating42of the conductor wire are removed to expose the flat portion34aof the conductor wire40to the end surface17of the body. A range from which an external resin is peeled off is a range having an L-shaped section extending across the mounting surface15and the end surface17, and corresponding to the outer electrode20inFIG.1. For removing the external resin film50and the insulating coating42of the conductor wire, for example, laser irradiation is applied. By the laser irradiation, a portion of the insulating coating42on the flat portion34aof the conductor wire40and the adjacent external resin film50are removed, and the flat portion34aof the conductor wire40is exposed from the end surface17. The insulating coating42on the covered portion34bof the conductor wire is covered with the magnetic portion12and thus is not removed and remains.

With the removal of the external resin film50covering the body, a resin component in the magnetic portion12is removed to form a magnetic portion exposed portion12ain which the magnetic powder in the magnetic portion12is exposed to the surface of the body. Further, on a surface of the magnetic portion exposed portion12a, the magnetic powders are melted and fused to each other to form network structure in which the magnetic powders are connected to each other in a network. By forming the magnetic portion exposed portion12ahaving the relatively wide network structure on the surface of the body having the L-shaped section extending across the mounting surface15and the end surface17, for example, contact opportunities between a plated layer and a medium increase during barrel plating, and a growth rate of the plated layer is improved. Further, since both the edge portions of the conductor wire in the width direction are covered with the magnetic portion, generation of a residue of the insulating coating accompanying the removal of the insulating coating of the conductor wire, and generation of a groove portion due to excessive removal of the insulating coating are suppressed.

Outer Electrode Forming Step

In the outer electrode forming step, as illustrated inFIG.4D, a plated layer is formed on each of the magnetic portion exposed portion12aand the flat portion34aof the conductor wire40, for example, by a plating process. The respective plated layers, due to growing of plating, are integrated and electrically connected to each other to form the outer electrode20. The plating process may include, for example, a step of plating a surface of the body10by copper plating, a subsequent nickel plating step, a tin plating step, and the like.

In the outer electrode forming step, the generation of the residue of the insulating coating and the generation of the groove portion are suppressed between the flat portion of the conductor wire and the magnetic portion exposed portion on the surface of the body. Thus, discontinuity of the flat portion and the plated layer formed on the magnetic portion exposed portion is minimized or reduced, and occurrence of connection failure between the coil and the outer electrode is suppressed even when the plated layer is thin. Further, since it is not necessary to make a plating thickness larger than necessary for connecting the end portion of the lead-out portion of the coil to the outer electrode, productivity is improved. Further, when the plating process is performed by barrel plating, a time required for the plating process is reduced, so that damage to the external resin film can be reduced. Further, the generation of the residue and the groove can be suppressed to make an allowable range of a laser irradiation condition wider for removing the insulating coating of the conductor wire, and further, the productivity can be improved.

Comparative Example 1

An inductor according to Comparative example 1 is described with reference toFIG.5AtoFIG.5CandFIG.6AtoFIG.6C.FIG.5AtoFIG.5CandFIG.6AtoFIG.6Care partial enlarged views of the vicinity of the outer electrode in a schematic sectional view taken along line A-A inFIG.2that illustrate a method for forming the outer electrode as enlarged views. The inductor according to Comparative example 1 is configured in the same manner as the inductor according to Example 1 except that a covered portion is not provided at both end portions in a line-width direction of an lead-out portion.

FIG.5AandFIG.6Aillustrate a state after an external resin film forming step. As illustrated inFIG.5AandFIG.6A, in the lead-out portion34, the insulating coating42on a wide surface40aof the conductor wire40is exposed from an end surface of a body10, and another area on a surface of the body10from which the insulating coating is not exposed is covered with the external resin film50.

FIG.5BandFIG.6Billustrate a state after a peeling step. As illustrated inFIG.5B, the insulating coating42disposed on the wide surface40aof the conductor wire40is removed by laser irradiation, so that the wide surface40aof the conductor wire40is exposed from the end surface17. On the other hand, as for the insulating coating42covering a side surface of the conductor wire40, the conductor wire40is not present under the insulating coating42, removal efficiency for the insulating coating42by the laser irradiation is lowered, so that a residue44of the insulating coating42is generated. Further, at least a portion of the external resin film50is removed to form the magnetic portion exposed portion12aon the surface of the body10. The residue44exists between the wide surface40aand the magnetic portion exposed portion12a.

FIG.5Cillustrates a state during an outer electrode forming step. As illustrated inFIG.5C, a plated layer22ais formed on the wide surface40aof the conductor wire by the plating process, and a plated layer22bis formed on the magnetic portion exposed portion12aon the surface of the body10. Since each plated layer grows also in a lateral direction, the wide surface40aand the magnetic portion exposed portion12aare to be integrated with each other with a certain degree of plating thickness. Here, since the plated layer22aon the wide surface40aand the plated layer22bon the magnetic portion exposed portion12aare separated by the residue44, when a thickness of the plated layer22ais not large, connection failure occurs between a coil and the outer electrode.

Further, as illustrated inFIG.6B, the insulating coating42on the wide surface40aof the lead-out portion is removed by the laser irradiation, so that the wide surface40aof the conductor wire40is exposed from the end surface17. Depending on a laser irradiation condition, the insulating coating42on the side surface of the conductor wire40is removed excessively, and a groove46is generated. Further, at least a portion of the external resin film50is removed to form the magnetic portion exposed portion12aon the surface of the body10. The groove46exists between the wide surface40aand the magnetic portion exposed portion12a.

FIG.6Cillustrates a state during the outer electrode forming step. As illustrated inFIG.6C, the plated layer22ais formed on the wide surface40aand the side surface of the conductor wire by the plating process, and the plated layer22bis formed on the magnetic portion exposed portion12aon the surface of the body10. Since each plated layer grows not only in a thickness direction but also in the lateral direction, the plated layer22aformed on the wide surface40aand the plated layer22bformed on the magnetic portion exposed portion12aare to be integrated with each other with a certain degree of plating thickness. Here, since plating is difficult to grow in the groove46between the plated layer22aon the wide surface40aand the plated layer22bon the magnetic portion exposed portion12a, connection failure occurs between the coil and the outer electrode unless the thickness of the plated layer is increased.

An inductor according to Example 2 is described with reference toFIG.7AtoFIG.7C.FIG.7AtoFIG.7Care partial enlarged views of the vicinity of the outer electrode in the schematic sectional view taken along line A-A inFIG.2,FIG.7Aillustrates a state after an external resin film forming step,FIG.7Billustrates a state after a peeling step, andFIG.7Cillustrates a state after an outer electrode forming step. The inductor according to Example 2 is configured in the same manner as the inductor according to Example 1 except that at least a portion of a covered portion at an end portion of an lead-out portion is disposed further inside a body than a flat portion.

As illustrated inFIG.7A, a covered portion34cis formed at both edge portions of the flat portion34ain a width direction of the conductor wire40, and the edge portions of the conductor wire40in the width direction are bent toward an inner direction of the body10to be embedded in the magnetic portion12. That is, the covered portion34cis disposed further inside the body10than the flat portion34a, that is, at a position where a distance from the end surface17is larger than that from the flat portion34a.

As illustrated inFIG.7B, the insulating coating42on the flat portion34aof the conductor wire40is removed by the laser irradiation, so that the flat portion34aof the conductor wire40is exposed from the end surface. Also, a portion of the external resin film50adjacent to the flat portion34ais removed as well. In addition, a resin component in a magnetic portion on the magnetic portion12is removed to form the magnetic portion exposed portion12ain which a magnetic powder in the magnetic portion is exposed to a surface of the body10. The magnetic portion exposed portion12aand the covered portion34care adjacent to each other at different levels with the insulating coating42interposed therebetween.

As illustrated inFIG.7C, a plated layer is formed across the magnetic portion exposed portion12aon the surface of the body10and the covered portion34cand the flat portion34aof the conductor wire40by a plating process, thereby electrically connecting a coil and the outer electrode20.

In the inductor according to Example 2, for example, the coil having a shape in which both edge portions of the flat portion34aare bent in an inner direction of the body10is embedded in the magnetic portion12, at the end portion of the lead-out portion. Thus, structure can easily be realized in which the flat portion34ais exposed from the end surface of the body10, and the covered portion34cis covered with the magnetic portion12. Further, although the covered portion34chas a curved surface, the covered portion34cmay have a flat surface portion at least in a portion thereof.

A modification of the inductor according to Example 2 is described with reference toFIG.8AtoFIG.8C.FIG.8AtoFIG.8Care partial enlarged views of the vicinity of the outer electrode in the schematic sectional view taken along line A-A inFIG.2,FIG.8Aillustrates a state after an external resin film forming step,FIG.8Billustrates a state after a peeling step, andFIG.8Cillustrates a state after an outer electrode forming step. The modification of the inductor according to Example 2 is configured in the same manner as the inductor according to Example 2 except that a covered portion is formed only at one edge portion in a width direction of a conductor wire.

As illustrated inFIG.8A, the covered portion34cis formed on the one edge portion of the flat portion34ain the width direction of the conductor wire40, and is disposed further inside a body10than the flat portion34a. In addition, another edge portion is not formed with a covered portion.

As illustrated inFIG.8B, the insulating coating42on the flat portion34aof the conductor wire40is removed by laser irradiation, so that the flat portion34aof the conductor wire40is exposed from an end surface. Also, a portion of the external resin film50adjacent to the flat portion34ais removed as well. At this time, at the other edge portion of the flat portion34ain the width direction of the conductor wire40, the residue44is generated depending on a laser irradiation condition. Further, at the end surface17of the body10, at least a portion of the external resin film50is removed to form the magnetic portion exposed portion12aon a surface of the body10. AlthoughFIG.8Billustrates a case in which the residue44is generated, a groove portion may be formed by the laser irradiation.

As illustrated inFIG.8C, by a plating process, a plated layer is formed across the magnetic portion exposed portion12aon the surface of the body10and the covered portion34cand the flat portion34aof the conductor wire40, at the one edge portion of the flat portion34a. Further, on the other edge portion of the flat portion34a, the plated layer22on the magnetic portion exposed portion12aand a plated layer24formed on the flat portion34aare separated by the residue44. As described above, when only one side of both the edge portions of the flat portion is bent to form the covered portion, there is a possibility that a residue is generated on one edge portion or a possibility that a groove is generated, but there is no possibility that a residue or a groove is generated on another edge portion, so that a coil and the outer electrode20are reliably connected to each other by the plating process.

An inductor according to Example 3 is described with reference toFIG.9AtoFIG.9C.FIG.9AtoFIG.9Care schematic sectional views taken along line A-A inFIG.2,FIG.9Aillustrates a state after an external resin film forming step,FIG.9Billustrates a state after a peeling step, andFIG.9Cillustrates a state after an outer electrode forming step. The inductor according to Example 3 is configured in the same manner as the inductor according to Example 1 except that a cross-section orthogonal to a length direction of the conductor wire40has a substantially elliptical shape.

As illustrated inFIG.9A, a covered portion34dis formed in a substantially circular arc shape continuous with both edge portions of the flat portion34a, and is covered with the magnetic portion12. An end portion of an lead-out portion having a substantially oval section can be formed by forming a winding portion of a coil by using, for example, a conductor wire having a substantially circular section, and crushing the conductor wire at the end portion of the lead-out portion. Further, inFIG.9A, the respective flat portions34aare formed on both sides, that is, a side from which the end portion of the lead-out portion is exposed and a side opposed thereto, but the flat portion34amay be formed only on the side from which the end portion of the lead-out portion is exposed.

As illustrated inFIG.9B, the insulating coating42on the flat portion34aof the conductor wire40is removed by laser irradiation, so that the flat portion34aof the conductor wire40is exposed from an end surface. Also, a portion of the external resin film50on the covered portion34dadjacent to the flat portion34a, the magnetic portion12, and the insulating coating42is removed, and a portion of the covered portion34dis exposed from the end surface. At least a portion of the external resin film50on the magnetic portion is removed, the magnetic portion exposed portion12ais formed on a surface of a body10, and the magnetic portion exposed portion12aand the covered portion34care adjacent to each other with the insulating coating42interposed therebetween.

As illustrated inFIG.9C, a plated layer is formed across the magnetic portion exposed portion12aon the surface of the body10, the insulating coating42of the covered portion34dand the flat portion34aof the conductor wire40by a plating process, thereby electrically connecting the coil and the outer electrode20.

In the inductor according to Example 3, for example, a substantially circular line having a substantially circular section is crushed at the end portion of the lead-out portion to form the flat portion34a, whereby the covered portion34dhaving a substantially circular arc section is formed, so that structure can be easily formed in which the flat portion34ais exposed from an end surface of the body10, and the covered portion34cis covered with the magnetic portion12.

An inductor110according to Example 4 is described with reference toFIG.10.FIG.10is a schematic partial see-through perspective view of the inductor110as viewed from a side of a mounting surface. The inductor110is configured in the same manner as the inductor according to Example 1 except that the winding portion32of a coil is contained in a body10such that a winding axis N does not intersect the mounting surface15and is substantially parallel to the mounting surface15, and that an end portion of the lead-out portion34of the coil is exposed from the mounting surface15.

In the inductor110, each of the lead-out portions34is extended from an outermost periphery of the winding portion32in a direction of the mounting surface15, and the end portions of the respective lead-out portions34are bent so as to be substantially parallel to the mounting surface15and opposite to each other, and are exposed from the mounting surface15. The end portion of the lead-out portion34in a section (section B-B) along line B-B inFIG.10and parallel to the end surface17, as illustrated in Examples 1 to 3, is provided with the flat portion34aand a covered portion. The outer electrode20is disposed across the mounting surface15and the end surface17of the body10. In the inductor110, since the flat portion34aof the lead-out portion is directly exposed from the mounting surface, DC resistance is reduced.

An inductor120according to Example 5 is described with reference toFIG.11.FIG.11is a schematic partial see-through perspective view of the inductor120as viewed from a side of a mounting surface. The inductor120is configured in the same manner as the inductor according to Example 4 except that the lead-out portions34of a coil are extended in a direction of the mounting surface15so as to intersect each other, when viewed from a direction of the winding axis N.

An end portion of the lead-out portion in a section along line C-C inFIG.11, as illustrated in Examples 1 to 3, is provided with the flat portion34aand a covered portion. Since an angle at which a leading end of the lead-out portion is bent need not be large in the inductor120, deformation of the lead-out portion can be reduced, thereby improving reliability of the lead-out portion.

An inductor130according to Example 6 is described with reference toFIG.12.FIG.12is a schematic partial see-through perspective view of the inductor130as viewed from a side of a mounting surface. The inductor130is configured in the same manner as the inductor according to Example 1 except that a winding portion of a coil is formed by winding a conductor wire having a substantially circular section, the lead-out portion34of the coil is extended in a direction of one end surface of a body10, and is bent so that the flat portion34aat an end portion of the lead-out portion is exposed from the mounting surface, and an outer electrode is disposed only on the mounting surface.

In the inductor130, the coil30is formed by winding the conductor wire having the substantially circular section, and the flat portion34ais formed by crushing, for example, the conductor wire at the end portion of the lead-out portion. Accordingly, as illustrated in Example 3, the flat portion and a covered portion can be formed more easily, at the end portion of the lead-out portion in a section D-D inFIG.12. Further, since the flat portion34aof the lead-out portion34is directly exposed from the mounting surface, it is possible to provide an inductor that has small DC resistance and can support high density implementation.

An inductor140according to Example 7 is described with reference toFIG.13.FIG.13is a schematic partial see-through plan view of the inductor140as viewed from an upper surface side opposite a mounting surface. The inductor140is configured in the same manner as the inductor according to Example 1 except that the lead-out portion34of a coil is extended in a direction of one side surface of a body10, and is bent so that a flat portion of an end portion of the lead-out portion is exposed from the mounting surface.

In the inductor140, the lead-out portion34of the coil is extended while being twisted in the direction of the one side surface of the body10so that a wide surface is parallel to the mounting surface, and is bent approximately 180°, so that the flat portion is exposed from the mounting surface. Also, the outer electrodes20extend over the mounting surface as shown, for example, inFIG.1. Then, as illustrated in Examples 1 to 3, the flat portion and a covered portion are provided at the end portion of the lead-out portion in a section E-E inFIG.13. In the inductor140, since the end portion of the lead-out portion is directly exposed from the mounting surface, DC resistance is reduced.

In the above Examples, the body has a substantially rectangular parallelepiped shape, but sides forming the substantially rectangular parallelepiped shape may be chamfered.

Further, the winding direction of the winding portion of the coil may be wound counterclockwise when viewed from the upper surface side. The winding portion of the coil may have a substantially circular shape, a substantially oval shape, a substantially elliptical shape, a substantially polygonal shape, or the like as viewed from the winding axis direction. The covered portion adjacent to the flat portion may be provided with at least one of the end portions.