JP4095075B2 - Substrate base material and coil part manufacturing method - Google Patents

Description

The present invention relates to a substrate base material used for manufacturing a coil component and a method for manufacturing the coil component.

A coil component formed by sandwiching a planar coil with a core is known (for example, see Patent Document 1 below). In a coil component described in Patent Document 1 below, a magnetic part integrated with a core is disposed on an axial center part and an outer peripheral part of a planar coil (see FIG. 26 of Patent Document below).
JP 2002-203732 A

  In the coil component described in Patent Document 1, the cores sandwiching the coil are substantially in close contact with each other. When the cores are bonded and fixed, it is assumed that a minute gap is formed by the adhesive entering between the cores, but it does not function as a gap that affects the characteristics of the coil components. It was.

  By the way, a gap may be provided in the middle of the magnetic path from the viewpoint of direct current superimposition characteristics of the coil component. When forming this gap, for example, the height of the magnetic part that is a part of the core that protrudes in the vicinity of the axial center of the coil and the height of the magnetic part that is a part of the core formed in the peripheral part of the coil. A method is used for differentiating these.

  However, in this method, the magnetic part with the higher height is in contact with the counterpart core, and a gap is formed between the magnetic part with the lower height and the counterpart core. The degree of freedom of the position and number of forming was limited.

Accordingly, the present invention aims to provide a method of manufacturing a coil component with a higher degree of freedom in forming a gap in a magnetic path, and also to provide a substrate base material used in the manufacture thereof. And aim.

  In order to achieve the above object, the present inventors have studied various modes for forming a gap in a coil component. In the course of the study, it has been found that when a plurality of gaps are formed in the magnetic path of the coil component, it is extremely difficult to make the lengths of the gaps along the magnetic path substantially the same. For example, when forming a coil component by sandwiching a coil between a pair of cores, the distance between the cores, that is, the length of the gap can be made the same by adjusting the pressing force when bonding the pair of cores together. Conceivable. However, with this method, it is extremely difficult to control the pressing force. In another example, a member such as a PET sheet may be sandwiched between a pair of cores. However, with this method, it is extremely difficult to form a uniform gap due to variations in the thickness of the PET sheet. In particular, when the gap length was as small as 20 μm, it was impossible to form a substantially uniform and accurate gap. Therefore, the present inventors have accomplished the present invention in order to solve this new problem.

  The substrate base material of the present invention is a substrate base material for manufacturing a coil component including a coil formed along one plane and a first magnetic substrate and a second magnetic substrate disposed so as to sandwich the coil from both sides. A first magnetic substrate base material including a first magnetic substrate base material including a substrate forming region serving as a first magnetic substrate; and a second magnetic substrate base material including a substrate forming region serving as a second magnetic substrate. And the second magnetic substrate base material are disposed so as to face each other, and protrude from at least one of the mutually facing inner surfaces of the first magnetic substrate base material and the second magnetic substrate base material and abut against the other Is formed.

  According to the present invention, the protrusion formed by extending from the inner surface of at least one of the first magnetic substrate base material and the second magnetic substrate base material is in contact with the other inner surface. The magnetic substrate base material and the second magnetic substrate base material can be accurately arranged at a distance corresponding to the height of the protrusion. Accordingly, since the first magnetic substrate and the second magnetic substrate of the coil component manufactured from the substrate base material can be accurately arranged at a predetermined distance, it is uniform between the first magnetic substrate and the second magnetic substrate. A gap can be formed.

  In the substrate base material of the present invention, it is also preferable that the protrusions are formed at positions along the outer edges of the first magnetic substrate base material and the second magnetic substrate base material. Since the projection is formed at a position along the outer edge, for example, the substrate formation region can be arranged more efficiently by forming it at a position where the projection is not formed in the substrate formation region.

  In the substrate base material of the present invention, the substrate forming region of the first magnetic substrate base material is formed with a portion serving as an inner leg portion extending to a region around the axial center of the coil, and the second magnetic substrate base material In the substrate formation region, a portion that becomes an outer leg portion that extends to an outer region of the coil is formed, and the distance between the first magnetic substrate base material and the portion that becomes the outer leg portion, and the second magnetic It is also preferable that the distance between the substrate base material and the portion serving as the inner leg is substantially the same. The distance between the portion serving as the inner leg portion extending from the inner surface of the first magnetic substrate base material and the second magnetic substrate base material, the portion serving as the outer leg portion extending from the inner surface of the second magnetic substrate base material, and the first Since the distance between the magnetic substrate base material and the magnetic substrate base material is substantially the same, when a coil component is used, a plurality of gaps having substantially the same length along the closed magnetic path are provided. Can be formed.

  In the substrate base material of the present invention, the length from the inner surface of the first magnetic substrate base material to the tip of the portion serving as the inner leg portion, and the length from the inner surface of the second magnetic substrate base material to the tip of the portion serving as the outer leg portion. It is also preferable that the length is substantially the same. The length from the inner surface of the first magnetic substrate base material to the tip of the portion serving as the inner leg is substantially the same as the length from the inner surface of the second magnetic substrate base material to the tip of the portion serving as the outer leg portion. Therefore, by maintaining the first magnetic substrate base material and the second magnetic substrate base material at a predetermined interval, the gap in the inner leg portion and the gap in the outer leg portion can be formed uniformly.

  The method for manufacturing a coil component according to the present invention is a method for manufacturing a coil component including a coil formed along one plane, and a first magnetic substrate and a second magnetic substrate arranged so as to sandwich the coil from both sides. A first magnetic substrate base material including a substrate formation region serving as a first magnetic substrate, a second magnetic substrate base material including a substrate formation region serving as a second magnetic substrate, and a coil assembly in which a plurality of coils are formed; A preparatory step for preparing a protrusion, a protrusion forming step for forming a protrusion on at least one main surface of the first magnetic substrate base material and the second magnetic substrate base material, and a main surface on which the protrusion is formed. The coil assembly is sandwiched between the first magnetic substrate base material and the second magnetic substrate base material from both sides of the coil assembly, and bonded so that the protrusions are in contact with the other main surface to produce a coil assembly assembly. Process and the coil assembly produced And a cutting step of the coil component detach aggregate.

  According to the present invention, a coil component is manufactured in which the distance between the inner surface of the first magnetic substrate and the outer leg portion is substantially the same as the distance between the inner surface of the second magnetic substrate and the inner leg portion. can do. In particular, since the protrusion is formed on at least one main surface of the first magnetic substrate base material and the second magnetic substrate base material, the distance between the first magnetic substrate base material and the second magnetic substrate base material is accurately determined. Can hold. Therefore, for example, even when the distance between the first magnetic substrate base material and the second magnetic substrate base material is extremely short, the distance can be accurately maintained.

  In the present invention, it is also preferable that the protrusion is formed in a region other than the substrate formation region in the protrusion formation step. Since the protrusion is formed outside the substrate formation region, the coil component can be manufactured using all of the first magnetic substrate and the second magnetic substrate included in the substrate formation region.

  In the present invention, it is also preferable that the protrusion is formed in the substrate formation region in the protrusion formation step. Since the protrusion is formed in the substrate formation region, the substrate formation region can be formed up to the outer edges of the first magnetic substrate base material and the second magnetic substrate base material.

  According to the present invention, it is possible to provide a coil component having a plurality of gaps whose lengths along the closed magnetic path are substantially the same. Therefore, for example, a plurality of minute gaps having a gap length of 20 μm, which has been impossible in the past, can be formed along the magnetic path, and the degree of freedom for forming the gap in the magnetic path can be further increased.

  The knowledge of the present invention can be easily understood by considering the following detailed description with reference to the accompanying drawings shown for illustration only. Subsequently, embodiments of the present invention will be described with reference to the accompanying drawings. Where possible, the same parts are denoted by the same reference numerals, and redundant description is omitted.

  A coil component according to an embodiment of the present invention will be described with reference to FIG. FIG. 1 is a perspective view of a coil component 1 in the present embodiment. The coil component 1 is a surface mount type coil component. The coil component 1 includes a flat core structure 10 and external terminals 20 that are electrically connected to other substrates. The core structure 10 is mainly composed of a flat upper ferrite core 11 (second magnetic substrate) and a mainly flat lower ferrite core 12 (first magnetic substrate). The core 12 is combined to form a flat plate shape as a whole.

  An exploded perspective view of the coil structure 10 is shown in FIG. The upper ferrite core 11 has a rectangular flat plate portion 111 and an outer leg portion 112 extending perpendicularly to the flat plate portion 111. A pair of outer leg portions 112 are provided, and one outer leg portion 112 extends in the same direction from one side of the flat plate portion 111 and the other outer leg portion 112 extends from a side parallel to the one side. Therefore, when the upper ferrite core 11 is disposed so that the outer leg portion 112 stands on the lower ferrite core 12, a gap is formed between the flat plate portion 111 of the upper ferrite core 11 and the lower ferrite core 12.

  The lower ferrite core 12 includes a rectangular flat plate portion 121 and an inner leg portion 122 that protrudes from the central portion of the flat plate portion 121. The inner leg portion 122 is a convex portion having a prism shape. When the core structure 10 is configured by abutting the tip surface of the leg portion 112 of the upper ferrite core 11 against the flat plate portion 121 of the lower ferrite core 12, an outer shell portion that is substantially a closed magnetic path is formed, and the outer shell is formed. The inner leg part 122 is arranged inside the part. The detailed structure of the upper ferrite core 11 and the lower ferrite core 12 will be described later as appropriate.

  FIG. 3 shows a perspective view of the state where the external terminal 20 is removed from the state of FIG. As shown in FIG. 3, the coil substrate 30 is housed in a gap portion between the upper ferrite core 11 and the lower ferrite core 12 constituting the core structure 10. The coil substrate 30 is covered with a protective resin layer 33. An adhesive resin layer 40 is provided around the protective resin layer 33. Therefore, the protective resin layer 33 and the adhesive resin layer 40 are interposed between the coil substrate 30 and the core structure 10. The protective resin layer 33 is a resin layer provided to protect the coil substrate 30. The adhesive resin layer 40 is a resin layer for fixing the coil substrate 30 covered with the protective resin layer 33 to the core structure 10.

  One end face of the coil substrate 30 is exposed from the end face where the gap of the core structure 10 faces. At this one end face, the insulating plate 31, the lead-out end electrode 32, and the protective resin layer 33 are exposed. The insulating plate 31 is a substrate that becomes a core portion constituting the coil substrate 30. The lead-out end electrode 32 is electrically connected to a coil, which will be described later, and is a portion that is also electrically connected to the external terminal 20 shown in FIG.

  The coil substrate 30 will be described with reference to FIG. FIG. 4 is a plan view of the coil substrate 30. A hole 35 is formed in the central portion of the coil substrate 30. A coil 34 made of a conductive material is disposed so as to surround the hole 35. The coil 34 is formed in a spiral shape so as to surround the hole 35 outward from a portion desired for the hole 35. The coils 34 are formed on both surfaces of the coil substrate 30 and are electrically connected to the lead-out end electrodes 32, respectively.

  The lead-out end electrode 32 to which the coil 34 formed on one surface of the coil substrate 30 is connected and the lead-out end electrode 32 to which the coil 34 formed on the other surface is connected are respectively a coil substrate. It is provided on 30 opposite sides. In addition, the coils 34 provided on both surfaces of the coil substrate 30 are electrically connected to each other by front and back contact portions 36 formed on the peripheral edge of the hole 35. Therefore, when a voltage is applied between the lead-out end electrode 32 provided on one side of the coil substrate 30 and the lead-out end electrode 32 provided on the other side, it is formed on one surface of the coil substrate 30. A current flows from the coil 34 that is formed to the coil 34 that is formed on the other surface.

  The inner leg portion 122 of the lower ferrite core 12 is inserted into the hole 35 of the coil substrate 30. In order to explain this situation, FIG. 5 shows a cross-sectional view in the vicinity of the inner leg 122 of the lower ferrite core 12 in FIG. As shown in FIG. 5, the inner leg portion 122 of the lower ferrite core 12 is inserted into the hole 35 of the coil substrate 30. The outer leg portion 112 of the upper ferrite core 11 and the inner leg portion 122 of the lower ferrite core 12 are formed to have the same length. Therefore, when the upper ferrite core 11 and the lower ferrite core 12 are arranged at a predetermined interval, a gap is generated between the tip of the inner leg portion 122 and the upper ferrite core 11, and the minute gap 41 can be formed. Similarly, a gap is generated between the tip of the outer leg portion 112 and the lower ferrite core 12, and the minute gap 42 can be formed.

  In the present embodiment, the length from the inner surface of the flat plate portion 121 of the lower ferrite core 12 (the surface facing the upper ferrite core 11) to the tip of the inner leg portion 122, and the inner surface (lower portion of the flat plate portion 111 of the upper ferrite core 11). The length from the surface facing the ferrite core 12) to the tip of the outer leg 112 is substantially the same. Further, the upper ferrite core 11 and the lower ferrite core 12 are arranged at a predetermined interval. Therefore, the distance d1 between the tip of the inner leg 122 and the flat plate portion 111 in the minute gap 41 and the distance d2 between the tip of the outer leg 112 and the flat plate portion 121 in the minute gap 42 are substantially the same. In the present embodiment, d1 and d2 are formed to be 20 μm, and the error is within 10%.

  In the case of this embodiment, the adhesive resin layer 40 is formed along each of the surface on which the inner leg portion 122 of the lower ferrite core 12 is formed and the surface on which the outer leg portion 112 of the upper ferrite core 11 is formed. The coil substrate 30 is fixed so as to be sandwiched. Therefore, the adhesive resin layer 40 is filled in the minute gaps 41 and 42, respectively. The minute gaps 41 and 42 are provided to alleviate the magnetic saturation of the upper ferrite core 11 and the lower ferrite core 12 due to the current flowing through the coil 34 of the coil substrate 30.

  An oxide film 34 a is formed on the surfaces of the coil 34 and the front and back contact portions 36. The oxide film 34 a is uniformly formed on the surfaces of the coil 34 and the front and back contact portions 36. Therefore, the protective resin layer 33 disposed around the coil substrate 30 uniformly enters between the windings of the coil 34. As a result, it is difficult to form a minute cavity between the coil 34 and the protective resin layer 33, and the adhesion between the coil 34 and the protective resin layer 33 is further improved.

  Subsequently, a method for manufacturing the coil component 1 will be described together with a substrate base material used for manufacturing the coil component 1. FIG. 6 is a diagram showing the procedure of the method for manufacturing the coil component 1. The manufacturing method of the coil component 1 according to the present embodiment includes steps of a preparation step S01, a protrusion formation step S02, an assembly step S03, a cutting step S04, and an external electrode formation step S05.

  First, in the preparation step S01, a substrate base material 7 shown in FIG. 7 is prepared. The substrate base material 7 includes a coil assembly 72 in which a plurality of coils 34 (see FIG. 4) are formed, and a pair of lower magnetic substrate base materials 71 (first magnetic substrate) formed in an area corresponding to the coil assembly 72. Base material) and upper magnetic substrate base material 73 (second magnetic substrate base material).

  The coil assembly 72 includes a rectangular flat plate-like insulating plate 721 and a plurality of coils 34 formed on the insulating plate 721 in a plurality of rows. In this embodiment, four coils 34 are arranged in four rows in one row, and a total of 16 coils 34 are formed. In the vicinity of the axial center of each coil 34, a circular hole 35 penetrating the insulating plate 721 is formed. Corresponding to each coil 34, a lead-out electrode 32 is formed around the coil 34. Between each row of the coils 34, three rectangular grooves 722 along the row of the coils 34 are formed at equal intervals. The three grooves 722 are formed in parallel with the sides of the insulating plate 721, respectively. The three grooves 722 are formed so that an outer leg assembly 732 described later can be inserted therethrough.

  Here, a method for manufacturing the coil assembly 92 will be described. First, the insulating plate 721 is prepared. The insulating plate 721 has a plate thickness of 60 μm, a glass cloth is impregnated with BT resin, and the holes 35 and the grooves 722 are already formed.

  Underlayers are simultaneously formed on the front and back surfaces of the insulating plate 721 by electroless plating. A photoresist layer is simultaneously electrodeposited on each of the underlying layers formed simultaneously on the front and back surfaces of the insulating plate 721. In this photoresist layer formed on the front and back surfaces, exposure is performed on each side of the front and back surfaces by photolithography along the pattern to form the coil 34, and then development is performed simultaneously on the front and back surfaces to form removal portions. To do.

  Using the photoresist layer thus patterned as a plating mask, a coil plating layer is formed on both the front and back surfaces simultaneously by selective electroplating in a portion corresponding to the removed portion. After this coil conductor plating layer is formed, the photoresist layer as a plating mask is peeled and removed simultaneously on both the front and back surfaces.

  From this state, the underlying layer other than the portion where the coil plating layer is formed is removed by etching, leaving the underlying portion between the coil plating layer and the insulating plate 721.

  Thereafter, a coil plating layer is further grown and formed by electrodeposition by an electrolytic plating method without a selective plating mask. Thereby, a sufficiently thick conductor as the coil 34 is obtained. The coils 34 can be grown and formed at a high density until the distance between adjacent coils is 15 μm or less.

  After completing the formation of the coil plating layer, the coil 34 is formed on both surfaces of the insulating plate 31, and then an oxide film is formed on the surface of the coil 34. Thereafter, the protective resin layer is printed on both surfaces of the insulating plate 721, and the coil assembly 72 is completed by covering and protecting the coil 34 with the protective resin layer.

  The upper magnetic substrate base material 73 includes a rectangular flat plate portion 731, outer leg aggregates 732 and 733, and a resin stopper 734. The flat plate portion 731 is formed to be larger than the coil assembly 72 by the outer leg assembly 733 and the resin stopper 734. The resin stopper 734 is provided on each of two opposite sides of the flat plate portion 731. The outer leg aggregates 732 and 733 are provided so as to extend in parallel with each other in the same direction from the inner surface 731 b of the flat plate portion 731. The outer leg assembly 733 is provided along the side of the flat plate portion 731 where the resin stopper 734 is not provided. The outer leg portions 732 are arranged at equal intervals between the pair of outer leg portion assemblies 733. The length of the outer leg assembly 732 is about four times the length of the outer leg 123 included in the coil component 1. The width of the outer leg assembly 732 is about twice the width of the outer leg 123.

  The outer leg assembly 732 is provided at a position corresponding to the groove 722 of the coil assembly 72. The interval between the outer leg assembly 732 is set so that the portion of the coil assembly 72 where the coil substrate 30 is formed is accommodated. A resin reservoir 731a is provided between the end of the outer leg assembly 732 and the resin stopper 734 so that a portion connecting the portions of the coil assembly 72 where the coil substrate 30 is formed is accommodated. Yes. Therefore, the coil assembly 72 can be accommodated in the recess between the outer leg assembly 732 and 733 and the resin stopper 734 provided in the upper magnetic substrate base material 73. A region where the outer leg aggregates 732 and 733 are formed is a substrate formation region that becomes the upper ferrite core 11.

  The lower magnetic substrate base material 71 has a rectangular flat plate portion 711 and an inner leg portion 122. The inner leg portion 122 is provided so as to extend from the inner surface 711 a of the flat plate portion 711. The inner legs 122 are formed in four rows of four each so as to correspond to the holes 35 formed in the coil assembly 72. The above-described upper magnetic substrate base material 73 and lower magnetic substrate base material 71 are assembled so that the inner surface 731b and the inner surface 711a face each other. In FIG. 7, the inner surface 711 a is shown in view of the visibility of the drawing, but in the assembly step S <b> 03 described later, the lower magnetic substrate base material 71 is inverted from the state of FIG. 7 and assembled.

  Subsequently, a protrusion forming step S02 is performed. In the protrusion forming step S02, protrusions are formed on the lower magnetic substrate base material 71. FIG. 8 shows the lower magnetic substrate base material 71 on which the protrusions 712 are formed. As shown in FIG. 8, the protruding portion 712 is formed on the inner surface 711 a of the flat plate portion 711. Each of the protrusions 712 has a rectangular parallelepiped shape, and four protrusions 712 are provided along a pair of opposite sides of the flat plate portion 711. The side of the flat plate portion 711 on which the protruding portion 712 is formed is a side corresponding to the side on which the outer leg assembly 733 of the upper magnetic substrate base material 73 is provided.

  In the case of this embodiment, the length from the inner surface 711a of the flat plate portion 711 to the tip of the protruding portion 712 is 20 μm. In the present embodiment, the protrusion 712 is formed after preparing the flat plate portion 711 of the lower magnetic substrate base material 71 with the inner leg portion 122 formed. However, the inner leg portion 122 and the protrusion are formed using a ferrite substrate material. The portion 712 may be formed by cutting at the same time. Further, in the present embodiment, the protrusion 712 is formed outside the region where the inner leg portion 122 that is the substrate forming region of the lower magnetic substrate base material 71 is formed, but the inner leg portion 122 is formed. You may form in a board | substrate formation area. In that case, a region where the inner leg portion 122 is formed can be enlarged. In the present embodiment, the protrusions 712 are formed on the lower magnetic substrate base material 71, but may be formed on the upper magnetic substrate base material 73. Further, protrusions may be formed on both the lower magnetic substrate base material 71 and the upper magnetic substrate base material 73.

  Subsequently, an assembly process S03 is performed. In the assembly step S03, the coil assembly 72 is sandwiched and bonded between the lower magnetic substrate base material 71 and the upper magnetic substrate base material 73. When sandwiching the coil assembly 72, the inner surface 711a of the lower magnetic substrate base material 71 and the upper magnetic substrate base material 731b face each other. FIG. 9 shows a cross-sectional view of the substrate base material 7 after bonding. The cross-sectional view shown in FIG. 9 is a cross-sectional view of a portion where the protrusion 712 of the substrate base material 7 and each coil substrate 30 are formed.

  As shown in FIG. 9, the coil substrate 30 of the coil assembly 72 is disposed between the lower magnetic substrate base material 71 and the upper magnetic substrate base material 73 via the adhesive resin layer 40. The height of the inner leg portion 122 formed on the lower magnetic substrate base material 71 and the height of the outer leg aggregates 732 and 733 formed on the upper magnetic substrate base material 73 are set to the same dimension. The height d3 of the protrusion 712 formed on the lower magnetic substrate base material 71 is 20 μm. Therefore, the distance d1 between the tip of the inner leg portion 122 and the upper magnetic substrate base material 73 is also 20 μm. Similarly, the distance d2 between the tips of the outer leg assemblies 732 and 733 and the lower magnetic substrate base material 71 is also 20 μm.

  Subsequently, a cutting step S04 is performed. In the cutting step S04, the assembled substrate base material 7 is cut and divided into elements corresponding to the 16 coil components 1.

  Subsequently, an external electrode forming step S05 is performed. In the external electrode forming step S05, the external electrode 20 is formed on each of the divided elements to complete the coil component 1 shown in FIG.

  According to the present embodiment, the protrusions 712 formed to extend from the inner surface 711 a of the lower magnetic substrate base material 71 are outer leg assembly 733 formed on the inner surface 731 a of the upper magnetic substrate base material 73. Therefore, the lower magnetic substrate base material 71 and the upper magnetic substrate base material 73 can be accurately arranged at a distance corresponding to the height of the protrusion 712. Therefore, the upper ferrite core 11 and the lower ferrite core 12 of the coil component 1 manufactured from the substrate base material 7 including the lower magnetic substrate base material 71 and the upper magnetic substrate base material 73 can be accurately arranged at a predetermined distance. A uniform gap can be formed between the upper ferrite core 11 and the lower ferrite core 12.

  Therefore, in the coil component 1, the distance d1 between the inner leg portion 122 extending from the inner surface of the lower ferrite core 12 and the upper ferrite core 11, and the outer leg portion 112 extending from the inner surface of the upper ferrite core 11 and the lower ferrite Since the distance d2 to the core 12 can be formed to be substantially the same, a plurality of gaps having substantially the same length along the closed magnetic path can be formed.

It is a figure which shows the external appearance of the coil component which is embodiment of this invention. It is a figure which shows the core structure of FIG. It is a figure which shows a mode that the external terminal was taken from the coil components of FIG. It is a top view of the coil board | substrate of FIG. It is sectional drawing in the center vicinity of the coil components of FIG. It is a figure for demonstrating the manufacturing method of the coil components of this embodiment. It is a figure which shows the board | substrate base material used for the manufacturing method demonstrated in FIG. It is a figure which shows the state which formed the projection part in the lower magnetic substrate base material shown in FIG. It is a figure which shows the cross section of the board | substrate base material used for the manufacturing method demonstrated in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Coil component, 10 ... Core structure, 11 ... Upper ferrite core, 12 ... Lower ferrite core, 20 ... External terminal, 30 ... Coil board | substrate, 31 ... Insulating plate, 32 ... Derived end electrode, 33 ... Protective resin layer, 34 ... Coil, 36 ... Front and back contact portions, 40 ... Adhesive resin layer, 71 ... Lower magnetic substrate base material, 72 ... Coil assembly, 73 ... Upper magnetic substrate base material, 122 ... Inner leg portion, 123 ... Outer leg portion.

Claims (7)

A substrate base material for manufacturing a coil component comprising a coil formed along one plane and a first magnetic substrate and a second magnetic substrate disposed so as to sandwich the coil from both sides,
A first magnetic substrate base material including a substrate formation region serving as the first magnetic substrate; and a second magnetic substrate base material including a substrate formation region serving as the second magnetic substrate;
The first magnetic substrate base material and the second magnetic substrate base material are arranged to face each other,
A substrate base material, wherein a protrusion that extends from at least one of the mutually facing inner surfaces of the first magnetic substrate base material and the second magnetic substrate base material and contacts the other is formed.   2. The substrate base material according to claim 1, wherein the protrusion is formed at a position along an outer edge of the first magnetic substrate base material and the second magnetic substrate base material. In the substrate forming region of the first magnetic substrate base material, a portion to be an inner leg portion extending to a region around the axial center of the coil is formed,
In the substrate forming region of the second magnetic substrate base material, a portion to be an outer leg portion extending to an outer region of the coil is formed,
The distance between the first magnetic substrate base material and the outer leg portion and the distance between the second magnetic substrate base material and the inner leg portion are substantially the same. The substrate base material according to claim 1, wherein the substrate base material is arranged as described above.   The length from the inner surface of the first magnetic substrate base material to the tip of the portion serving as the inner leg portion and the length from the inner surface of the second magnetic substrate base material to the tip of the portion serving as the outer leg portion are substantially The substrate base material according to claim 1, wherein the substrate base material is formed so as to be identical to each other. A coil component manufacturing method comprising: a coil formed along one plane; and a first magnetic substrate and a second magnetic substrate disposed so as to sandwich the coil from both sides,
A coil assembly in which a first magnetic substrate base material including a substrate forming region to be the first magnetic substrate, a second magnetic substrate base material including a substrate forming region to be the second magnetic substrate, and a plurality of the coils are formed. And a preparation process to prepare,
A protrusion forming step of forming a protrusion on at least one main surface of the first magnetic substrate base material and the second magnetic substrate base material;
The coil assembly is sandwiched between the first magnetic substrate base material and the second magnetic substrate base material from both sides with the main surface on which the protrusion is formed facing inside, and the protrusion contacts the other main surface. An assembling process for producing a coil assembly assembly by adhering in contact with each other;
A cutting step of separating the produced coil assembly assembly into the coil component;
A method for manufacturing a coil component comprising:   6. The method of manufacturing a coil component according to claim 5, wherein, in the protrusion forming step, the protrusion is formed in a region other than the substrate forming region. 6. The method of manufacturing a coil component according to claim 5, wherein, in the protrusion forming step, the protrusion is formed in the substrate forming region.

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