Coil component

Abstract

The present disclosure provides a coil component comprising: a body having a first surface, a second surface opposite to the first surface in a first direction, and one or more side surfaces connecting the first surface and the second surface to each other; a first support member and a second support member disposed to be spaced apart from each other in the first direction within the body; and a coil part, comprising a first coil and a third coil disposed on two surfaces of the first support member facing each other in the first direction, a first via hole connecting the first coil and the third coil to each other, and a second via hole connecting the second coil and the third coil to each other, a second coil and a fourth coil disposed on two surfaces of the second support member opposite to each other in the first direction, and a second via connecting the second coil and the fourth coil to each other, in which the third coil and the fourth coil are coupled to each other within the main body.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0141652 filed on October 23, 2023 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. Technical Field

[0002] The present disclosure relates to a coil assembly. Background Art

[0003] An inductor (coil component) is a representative passive electronic component used in electronic devices together with a resistor and a capacitor.

[0004] Currently, the demand for inductors in electric vehicles and cloud servers is increasing rapidly around the world. In such applications, the size restrictions are small, so large-sized power inductors are used. Since such power inductors require particularly low current characteristics, a structure with a large thickness and width of the inductor conductor is usually required. Therefore, the most common type of power inductor at present is the wire-wound type.

[0005] However, even in the case of a large inductor size, a thin-film type power inductor using a plating method may not be able to fully utilize the internal space due to limitations in plating thickness, and therefore may be considered inferior to a wire-wound type inductor in achieving high capacitance. Summary of the invention

[0006] One aspect of the present disclosure may be to improve the characteristics of a coil assembly through the methods and structures proposed herein.

[0007] According to one aspect of the present disclosure, a coil component includes: a main body having a first surface, a second surface opposite to the first surface in a first direction, and one or more side surfaces connecting the first surface and the second surface to each other; a first support member and a second support member, which are arranged to be spaced apart from each other in the first direction within the main body; and a coil portion, including a first coil and a third coil arranged on two surfaces of the first support member opposite to each other in the first direction, a first via connecting the first coil and the third coil to each other, a second coil and a fourth coil arranged on two surfaces of the second support member opposite to each other in the first direction, and a second via connecting the second coil and the fourth coil to each other, wherein the third coil and the fourth coil are combined with each other within the main body. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above and other aspects, features and advantages of the present disclosure will be more clearly understood through the following detailed description in conjunction with the accompanying drawings, in which: Figure 1is a schematic diagram showing a coil component according to a first exemplary embodiment of the present disclosure; Figure 2 It is shown Figure 1 A schematic exploded perspective view of the first support member, the second support member and the coil portion; Figure 3 is along Figure 1 A cross-sectional view taken along line I-I'; Figure 4 is along Figure 1 A cross-sectional view taken along line II-II'; Figure 5 yes Figure 4 An enlarged view of part A; Figure 6 is a coil component showing a modified example of the first exemplary embodiment in the present disclosure and corresponds to Figure 4 ; Figure 7 is a coil component showing a second exemplary embodiment according to the present disclosure and corresponding to Figure 4 sectional view of; Figure 8 yes Figure 7 an enlarged view of part B of ; and Fig. 9 is a coil component showing a modified example of the second exemplary embodiment in the present disclosure and corresponds to Figure 4 . DETAILED DESCRIPTION

[0009] The terms used in this specification are only used to describe specific exemplary embodiments, rather than to limit the present disclosure. Unless the context clearly states otherwise, the singular form is intended to include the plural form. It should be understood that the terms "including" or "having" used herein specify the presence of the features, quantities, steps, operations, components, parts or their combinations mentioned in this specification, but do not exclude the presence or addition of one or more other features, quantities, steps, operations, components, parts or their combinations. In addition, throughout the specification, "on ... " does not necessarily mean that any element is positioned on the upper side based on the direction of gravity, but means that any element is positioned above or below the target portion.

[0010] In addition, the term “coupled” refers not only to the case where respective components are in direct physical contact with each other but also to the case where respective components are in indirect contact with each other, which means that another component is interposed between and in contact with each component.

[0011] Since the sizes (eg, thickness) of various components shown in the drawings are arbitrarily shown for convenience of explanation, the present disclosure is not necessarily limited to the sizes (eg, thickness) shown in the drawings.

[0012] In the drawings, the X direction refers to a first direction or a thickness direction, the Y direction refers to a second direction or a length direction, and the Z direction refers to a third direction or a width direction.

[0013] Hereinafter, a coil component according to an exemplary embodiment of the present disclosure will be described in detail with reference to the accompanying drawings. When describing the exemplary embodiments of the present disclosure with reference to the accompanying drawings, components identical to or corresponding to each other will be denoted by the same reference numerals, and repeated descriptions thereof will be omitted.

[0014] Various types of electronic components may be used in electronic devices, and among these electronic components, various types of coil components may be appropriately used according to their uses to remove noise and the like.

[0015] In other words, the coil components used in electronic devices can be power inductors, high-frequency inductors, ordinary magnetic beads, high-frequency magnetic beads (for example, magnetic beads suitable for GHz frequency bands), common mode filters, etc.

[0016] First Exemplary Embodiment Figure 1 is a schematic diagram showing a coil component according to a first exemplary embodiment in the present disclosure. Figure 2 It is shown Figure 1 Schematic exploded perspective view of the first and second supporting members and the coil portion in FIG. Figure 3 is along Figure 1 A cross-sectional view taken along line I-I'. Figure 4 is along Figure 1 A cross-sectional view taken along line II-II'. Figure 5 yes Figure 4 Magnified view of part A.

[0017] Reference Figures 1 to 5 , the coil component 1000 according to the first exemplary embodiment in the present disclosure may include a body 100 , support members 210 and 220 , and a coil part 300 , and may further include external electrodes 410 and 420 , an insulating layer 600 , and an insulating film IF.

[0018] The body 100 may form an appearance of the coil component 1000 according to the present exemplary embodiment, and the support members 210 and 220 and the coil part 300 may be embedded in the body 100 .

[0019] The body 100 may generally have a hexahedral shape.

[0020] The first exemplary embodiment in the present disclosure will be described hereinafter assuming that the body 100 has a hexahedral shape. However, such description does not exclude a coil component including a body having a shape other than a hexahedral shape from the scope of the present exemplary embodiment.

[0021] Reference Figure 1 , the body 100 may have a first surface 101 and a second surface 102 opposite to each other in a first direction (X direction), a first side surface 103 and a second side surface 104 opposite to each other in a second direction (Y direction), and a third side surface 105 and a fourth side surface 106 opposite to each other in a third direction (Z direction). The first side surface 103, the second side surface 104, the third side surface 105, and the fourth side surface 106 of the body 100 may correspond to a plurality of side surfaces of the body 100 connecting the first surface 101 and the second surface 102 of the body 100 to each other.

[0022] As an example, the body 100 may be formed such that the coil component 1000 according to the present exemplary embodiment in which the outer electrodes 410 and 420 described below are formed may have a length of 4.1 mm, a width of 4.1 mm, and a thickness of 1.45 mm, but is not limited thereto. In addition, the above dimensions are merely design dimensions that do not reflect process errors, etc., and therefore, the dimensions within the range identified as process errors should be considered to fall within the scope of the present disclosure.

[0023] The main body 100 may include a magnetic material and a resin. Specifically, the main body 100 may be formed by stacking one or more magnetic composite sheets in which a magnetic material is dispersed in a resin. However, the main body 100 may also have a structure other than a structure in which a magnetic material is dispersed in a resin. For example, the main body 100 may be formed using a magnetic material such as ferrite or may be formed using a non-magnetic material.

[0024] The magnetic material may be ferrite or a magnetic metal material.

[0025] The ferrite may be, for example, at least one of spinel ferrite (such as Mg-Zn-based ferrite, Mn-Zn-based ferrite, Mn-Mg-based ferrite, Cu-Zn-based ferrite, Mg-Mn-Sr-based ferrite or Ni-Zn-based ferrite), hexagonal ferrite (such as Ba-Zn-based ferrite, Ba-Mg-based ferrite, Ba-Ni-based ferrite, Ba-Co-based ferrite or Ba-Ni-Co-based ferrite), garnet-type ferrite (such as Y-based ferrite) and Li-based ferrite.

[0026] The magnetic metal material may include one or more selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), cobalt (Co), molybdenum (Mo), aluminum (Al), niobium (Nb), copper (Cu) and nickel (Ni). For example, the magnetic metal material may be at least one of pure iron, Fe-Si based alloy, Fe-Si-Al based alloy, Fe-Ni based alloy, Fe-Ni-Mo based alloy, Fe-Ni-Mo-Cu based alloy, Fe-Co based alloy, Fe-Ni-Co based alloy, Fe-Cr based alloy, Fe-Cr-Si based alloy, Fe-Si-Cu-Nb based alloy, Fe-Ni-Cr based alloy and Fe-Cr-Al based alloy.

[0027] The magnetic metal material may be amorphous or crystalline. For example, the magnetic metal material may be a Fe-Si-B-Cr based amorphous alloy, but is not necessarily limited thereto.

[0028] The magnetic metal material may have an average diameter of about 0.1 μm to 30 μm, but is not limited thereto.

[0029] The body 100 may include two or more kinds of magnetic materials dispersed in the resin. Here, different kinds of magnetic materials refer to that the magnetic materials dispersed in the resin are distinguished from each other by any one of average diameter, composition, crystallinity, and shape.

[0030] The resin may include epoxy resin, polyimide, liquid crystal polymer (LCP), etc., or a mixture thereof, but is not limited thereto.

[0031] The body 100 may include a core 110 passing through a central portion of each of the support members 210 and 220 and the coil part 300 described below. The core 110 may be formed by filling a through hole in a central portion of each of the support members 210 and 220 and the coil part 300 with a magnetic composite sheet, but is not limited thereto.

[0032] The support members 210 and 220 may be disposed inside the body 100 and support the coil part 300 described below. The support members 210 and 220 may be spaced apart from each other inside the body 100. Specifically, referring to Figure 1 and Figure 2, the first support member 210 and the second support member 220 may be arranged in parallel to the first surface 101 of the body 100, and may be arranged to be spaced apart from each other in the first direction (Z direction) inside the body 100. The first support member 210 may be arranged closer to the first surface 101 of the body 100 than the second support member 220. The first coil 311 and the third coil 313 of the coil part 300 described below are arranged on the first support member 210, and the second coil 312 and the fourth coil 314 of the coil part 300 described below may be arranged on the second support member 220. The thickness of each of the support members 210 and 220 may be greater than or equal to 20 μm and less than or equal to 70 μm, but is not necessarily limited thereto. As described below, after forming the coils 311 and 313 on the first support member 210 and forming the coils 312 and 314 on the second support member 220, the first support member 210 on which the coils 311 and 313 are formed and the second support member 220 on which the coils 312 and 314 are formed may be combined to form one coil component 1000. In some embodiments, the first support member 210 and the second support member 220 may have substantially the same thickness.

[0033] The support members 210 and 220 may be formed using an insulating material including at least one of a thermosetting insulating resin such as an epoxy resin, a thermoplastic insulating resin such as a polyimide resin, and a photosensitive insulating resin, or may be formed using an insulating material formed by impregnating a reinforcing material such as glass fiber or an inorganic filler into the above-mentioned thermosetting insulating resin, thermoplastic insulating resin, or photosensitive insulating resin. As an example, the support members 210 and 220 may be formed using an insulating material such as a copper clad laminate (CCL), a prepreg (PPG), an Ajinomoto Build-up Film (ABF), FR-4, a bismaleimide triazine (BT) resin, or a photosensitive dielectric (PID), but are not limited thereto.

[0034] As the material of the inorganic filler, one or more materials selected from the group consisting of silica (SiO2), alumina (Al2O3), silicon carbide (SiC), barium sulfate (BaSO4), talc, clay, mica powder, aluminum hydroxide (Al(OH)3), magnesium hydroxide (Mg(OH)2), calcium carbonate (CaCO3), magnesium carbonate (MgCO3), magnesium oxide (MgO), boron nitride (BN), aluminum borate (AlBO3), barium titanate (BaTiO3) and calcium zirconate (CaZrO3) can be used.

[0035] In the case where the support members 210 and 220 are formed using an insulating material including a reinforcing material, the support members 210 and 220 may provide more excellent rigidity. In the case where the support members 210 and 220 are formed using an insulating material that does not include glass fiber, the support members 210 and 220 may be advantageous in reducing the overall thickness of the coil part 300. In the case where the support members 210 and 220 are formed using an insulating material including a photosensitive insulating resin, the number of processes may be reduced, which may be advantageous in reducing production costs and forming fine vias.

[0036] The coil part 300 may be embedded in the body 100 and may realize the characteristics of the coil component. For example, when the coil component 1000 according to the present exemplary embodiment is used as a power inductor, the coil part 300 may be used to store an electric field as a magnetic field to maintain an output voltage, thereby stabilizing the power of the electronic device.

[0037] Will refer to Figures 2 to 4 The structure of the coil portion 300 is described.

[0038] The coil portion 300 may include a plurality of coils 311, 312, 313, and 314 spaced apart from each other and a first via hole 321 and a second via hole 322. Specifically, the coil portion 300 may include a first coil 311 and a third coil 313 disposed on both surfaces of a first support member 210 close to a first surface 101 of the body 100, a first via hole 321 connecting the first coil 311 and the third coil 313 to each other, a second coil 312 and a fourth coil 314 disposed on both surfaces of a second support member 220 close to a second surface 102 of the body 100, and a second via hole 322 connecting the second coil 312 and the fourth coil 314 to each other.

[0039] Each of the plurality of coils 311, 312, 313, and 314 may have a thickness of 175 μm or more. The total thickness of the first to fourth coils may be 700 μm or more, and the first to fourth coils form a single coil. Therefore, the limitation of the plating thickness in the coil assembly according to the prior art can be overcome. However, the thickness of the plurality of coils is not necessarily limited thereto.

[0040] The first coil 311 and the third coil 313 may be respectively disposed on two surfaces of the first support member 210. Specifically, the first coil 311 may be disposed on one surface ( Figure 1 and Figure 2 ), and the third coil 313 may be disposed on another surface ( Figure 1 and Figure 2The inner end of each of the first coil 311 and the third coil 313 may contact and be connected to the first via hole 321. The outer end of the first coil 311 may extend to the first side surface 103 of the body 100 and be connected to the first external electrode 410 described below.

[0041] The second coil 312 and the fourth coil 314 may be respectively disposed on two surfaces of the second support member 220. Specifically, the second coil 312 may be disposed on one surface ( Figure 1 and Figure 2 ), and the fourth coil 314 may be disposed on another surface ( Figure 1 and Figure 2 The inner end of each of the second coil 312 and the fourth coil 314 may contact and be connected to the second via hole 322. The outer end of the second coil 312 may extend to the second side surface 104 of the body 100 and be connected to the second external electrode 420 described below.

[0042] In addition, the outer end of the third coil 313 and the outer end of the fourth coil 314 are combined with each other inside the body 100. As a result, the first coil 311 to the fourth coil 314 can be connected in series between the first external electrode 410 and the second external electrode 420, so that the coil part 300 can be used as a single coil. Here, the expression "inside the body" does not exclude the case where the coil is combined on the surface of the body. As an example, the coil may be combined inside the body, and the combined surface may extend (exposed) to the surface of the body.

[0043] The outer end portions of the third coil 313 and the fourth coil 314 may have shapes different from those of the inner end portions of the third coil 313 and the fourth coil 314. Specifically, the outer end portions of the third coil 313 and the fourth coil 314 may each have a straight line shape protruding toward the third side surface 105 of the body 100. In the case where the outer end portions of the third coil 313 and the fourth coil 314 each have such a straight line shape, direct contact between the third coil 313 and the fourth coil 314 described below may become easy.

[0044] In contrast, the inner end portion of the third coil 313 and the inner end portion of the fourth coil 314 may each have a circular shape, which may be similar to a via pad for connection to the vias 321 and 322 .

[0045] Will refer to Figure 5The combined structure is described in detail. At least a portion of the outer end of the third coil 313 may be connected to at least a portion of the outer end of the fourth coil 314 inside the body 100. The third coil 313 and the fourth coil 314 may be directly in contact with each other by resistance welding, laser welding, copper-copper direct bonding, etc. In the above method, the third coil 313 and the fourth coil 314 may be partially melted and then solidified, so that the third coil 313 and the fourth coil 134 may be directly connected to each other. However, the connection between the third coil 313 and the fourth coil 314 is not necessarily limited to this. According to the second exemplary embodiment described below, the third coil 313 and the fourth coil 314 may be connected by a connecting portion 500.

[0046] Here, the outer end of the coil may refer to an area including the tip of the coil. Therefore, direct connection of the "outer end" may not necessarily mean connection of only the tip of the coil. As an example, the connection of the coil may be performed not only at the tip but also at least a portion of the area corresponding to the outer end.

[0047] That is, the coil component according to this exemplary embodiment can be designed in such a way that the third coil 313 and the fourth coil 314 formed on different supporting members are in direct contact with each other without using a complex via structure according to the prior art, so that a defect-free multi-layer coil structure can be achieved with a simple process.

[0048] In a coil structure including a multilayer coil pattern according to the prior art, at least two coil patterns and at least one insulating layer are alternately formed on one surface of a single support member. In this case, it is difficult to achieve a stable plating height, and therefore, there is a limitation in increasing the thickness of the coil pattern. In addition, it has been difficult to achieve alignment between a coil pattern formed relatively closer to one surface of the support member and a coil pattern formed relatively farther from one surface of the support member.

[0049] In the present exemplary embodiment, after forming the first and third coils on the first support member 210 and forming the second and fourth coils on the second support member 220, the third and fourth coils are combined by welding, etc. A coil component having a large coil thickness can be manufactured by the method described herein.

[0050] In the present exemplary embodiment, the process of forming at least one insulating layer on one surface of the support member and the process of forming the coil pattern on the insulating layer, which are necessary in the multilayer coil structure according to the prior art, can be omitted. Therefore, defects caused by misalignment between the coil patterns can be reduced.

[0051] In addition, in the present exemplary embodiment, the via pad and the via structure according to the related art are not used to connect the third coil 313 and the fourth coil 314 located in the middle adjacent to each other. Instead, the outer end of the third coil 313 and the outer end of the fourth coil 314 can be combined with each other inside the body 100, thereby realizing a multi-layer coil structure through a simpler process.

[0052] The outer end portions of the third coil 313 and the fourth coil 314 may extend to only one of the third side surface 105 and the fourth side surface 106 of the body 100 that are opposite to each other in the third direction. Figure 1 , the outer ends of the third coil 313 and the fourth coil 314 may extend to the third side surface 105. However, the extension of the outer ends of the third coil 313 and the fourth coil 314 is not necessarily limited thereto, and the outer ends of the third coil 313 and the fourth coil 314 may not extend to the third side surface 105 and the fourth side surface 106, as in a modified example described below.

[0053] The main body 100 may not be disposed between the third coil 313 and the fourth coil 314. The magnetic metal material and the resin may not be disposed in the region where the third coil 313 and the fourth coil 314 overlap each other between the third coil 313 and the fourth coil 314. As described below, in some embodiments, only the insulating film IF may be disposed in the region where the third coil 313 and the fourth coil 314 overlap each other, and the main body 100 may not be disposed in the region. Here, "overlap" may refer to overlapping in the first direction (X direction) when viewed from the first direction.

[0054] However, the body 100 may be disposed in a region where the third coil 313 and the fourth coil 314 do not overlap each other. For example, a portion of the body 100 may be disposed between adjacent turns of the third coil 313 and between adjacent turns of the fourth coil 314.

[0055] The first via hole 321 may penetrate the first support member 210 and connect the inner ends of the first coil 311 and the third coil 313. Similarly, the second via hole 322 may penetrate the second support member 220 and connect the inner ends of the second coil 312 and the fourth coil 314.

[0056] Each of the first to fourth coils 311 to 314 may have a planar spiral shape forming at least one turn around the core 110 of the body 100 .

[0057] At least one of the first to fourth coils 311 to 314 and the first and second vias 321 and 322 may be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), molybdenum (Mo), or alloys thereof, but is not limited thereto.

[0058] At least one of the first to fourth coils 311 to 314 and the first and second vias 321 and 322 may include at least one conductive layer. As an example, in the case where the third coil 313 and the first via 321 are formed by plating, each of the third coil 313 and the first via 321 may include a seed layer formed by electroless plating or vapor deposition such as sputtering and an electroplating layer. Here, the electroplating layer may have a single-layer structure or a multi-layer structure. The electroplating layer having a multi-layer structure may be formed into a conformal film structure in which another electroplating layer covers any one of the electroplating layers, or may be formed into a shape in which another electroplating layer is stacked only on one surface of any one of the electroplating layers.

[0059] The seed layer of the third coil 313 and the seed layer of the first via 321 may be formed integrally with each other so that no boundary is formed between them. However, the seed layer of the third coil 313 and the seed layer of the first via 321 are not limited thereto. The electroplating layer of the third coil 313 and the electroplating layer of the first via 321 may be formed integrally with each other so that no boundary is formed between them. However, the electroplating layer of the third coil 313 and the electroplating layer of the first via 321 are not limited thereto.

[0060] The first external electrode 410 and the second external electrode 420 may be disposed to be spaced apart from each other on the body 100, and may be connected to the coil part 300. Specifically, the first external electrode 410 may be disposed on the first side surface 103 of the body 100, and contact and connect with the outer end of the first coil 311 exposed to the first side surface 103 of the body 100. Specifically, the second external electrode 420 may be disposed on the second side surface 104 of the body 100, and contact and connect with the outer end of the second coil 312 exposed to the second side surface 104 of the body 100. The second external electrode 420 may be spaced apart from the first external electrode 410.

[0061] The first external electrode 410 and the second external electrode 420 may extend onto the first surface 101 of the body 100. That is, the first external electrode 410 and the second external electrode 420 may each have an "L" shape.

[0062] The external electrodes 410 and 420 may include a plurality of layers. The plurality of layers may be formed by coating and curing a conductive resin containing a conductive material, or may be formed by a vapor deposition method such as sputtering, an electroless plating method, or an electroplating method. As an example, the first external electrode 410 may include a first conductive layer containing copper (Cu) and a second conductive layer disposed on the first conductive layer. The first conductive layer may be formed by applying an insulating layer 600 (described later) to an area on the surface of the body 100 other than an area where the external electrodes 410 and 420 are to be formed, and then performing plating using the insulating layer 600 as a plating resist. Alternatively, the first conductive layer may be formed by coating and then curing a curable conductive paste, the curable conductive paste including a conductive material of at least one of copper (Cu) and silver (Ag) and an insulating resin. The second conductive layer may have a double-layer structure of a metal layer containing nickel and a metal layer containing tin.

[0063] The external electrodes 410 and 420 may be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), or an alloy thereof, but are not limited thereto.

[0064] The coil component 1000 according to the first exemplary embodiment in the present disclosure may further include an insulating layer 600 disposed on the outer surface of the body 100. The insulating layer 600 may be formed on the first surface 101, the second surface 102, and a plurality of side surfaces of the body 100. The insulating layer 600 may be disposed on a surface of the body 100 on which the external electrodes 410 and 420 are not formed, and may be used to electrically protect the coil component, reduce leakage current, and prevent plating diffusion when the external electrodes are formed.

[0065] The insulating layer 600 may include a thermoplastic resin (such as polystyrene, vinyl acetate, polyester, polyethylene, polypropylene, polyamide, rubber, or acrylic resin), a thermosetting resin (such as phenol, epoxy resin, polyurethane, melamine, or alkyd resin), a photosensitive resin, polyparaxylene, SiO x or SiN x .

[0066] The insulating layer 600 may contact the outer end of the third coil 313 and the outer end of the fourth coil 314. As described above, the outer end of the third coil 313 and the outer end of the fourth coil 314 may extend to the third side surface 105 of the body 100 and thus may contact the insulating layer 600 disposed on the third side surface 105.

[0067] The coil component 1000 according to the first exemplary embodiment in the present disclosure may also include an insulating film IF. The insulating film IF may be formed on the support members 210 and 220 and the coil portion 300. Specifically, the insulating film IF may be provided on each of the first coil 311 to the fourth coil 314. The insulating film IF may be provided to insulate the coil portion 300 from the body 100, and may include any known insulating material such as polyparaxylene. The insulating material included in the insulating film IF is not particularly limited, but may be any insulating material. The insulating film IF may be formed by a method such as vapor deposition, but is not limited thereto, and may be formed by stacking insulating films on both surfaces of the support members 210 and 220. In the former case, the insulating film IF may be formed in the form of a conformal film along the surfaces of the support members 210 and 220 and the coil portion 300.

[0068] The insulating films IF provided on the third coil 313 and the fourth coil 314 may be in direct contact with each other. The main body 100 may not be provided between the insulating films of the third coil 313 and the fourth coil 314 that are in contact with each other. That is, as described above, the third coil 313 and the fourth coil 314 may be combined with each other inside the main body 100. Therefore, only the insulating film IF may be provided between the third coil 313 and the fourth coil 314 that overlap in the first direction (X direction).

[0069] Reference Figure 5 , the insulating film IF may be in the form of a conformal film along the surface of the coil. That is, the insulating film IF may cover the upper surface and the side surface of the coil. In addition, a portion of the main body 100 may be filled between adjacent turns of the coil. However, the insulating film IF is not limited thereto. The insulating film IF may be in the form of a partition wall filled between the coils, and the main body 100 may not be filled between adjacent turns of the coil.

[0070] The insulating film IF may not be provided in the region where the third coil 313 and the fourth coil 314 are coupled to each other inside the body 100. That is, the third coil 313 and the fourth coil 314 may be coupled to each other through the above process after the insulating film IF is partially removed from the region to be coupled to the third coil 313 and the fourth coil 314.

[0071] The thickness of the insulating film IF may be less than 15 μm, but is not necessarily limited thereto. The insulating film IF may have a thickness smaller than that of the above-described supporting members 210 and 220 .

[0072] As described above, the thickness of the support members 210 and 220 may be greater than or equal to 20 μm and less than or equal to 70 μm, and T1>2T2, where the thickness of the first support member 210 is T1 and the thickness of the insulating film IF is T2. In the case where the thickness of the insulating film IF exceeds 10 μm, the thickness of the support members 210 and 220 may also be appropriately adjusted to satisfy the above relationship.

[0073] The thickness of the insulating film IF and the supporting members 210 and 220 can be measured by the following method. First, the coil component can be polished to a depth of about 1 / 2 in the second direction (Y direction) to prepare a cross-sectional sample. Next, when the collected cross-sectional sample is observed with an optical microscope or the like, the insulating film IF and the supporting members 210 and 220 can be observed, and the thickness of the insulating film IF and the supporting members 210 and 220 can be obtained by measuring the length of the insulating film IF and the supporting members 210 and 220 in the first direction (X direction).

[0074] Since the insulating film IF has a relatively smaller thickness than that of the support members 210 and 220 , a distance between the first coil 311 and the third coil 313 may be greater than a distance between the third coil 313 and the fourth coil 314 .

[0075] Will refer to Figure 6 A coil component 1000 ′ according to a modified example of the first exemplary embodiment in the present disclosure is described.

[0076] Figure 6 is a coil component showing a modified example of the first exemplary embodiment in the present disclosure and corresponds to Figure 4 .

[0077] The modified example is different from the above-described first exemplary embodiment in that the third coil 313 and the fourth coil 314 may not extend to the third side surface 105 and the fourth side surface 106 of the body 100. That is, the outer end of the third coil 313 and the outer end of the fourth coil 314 may face only one of the third side surface 105 and the fourth side surface 106 of the body that are opposite to each other in the third direction, and may not extend to the third side surface 105 and the fourth side surface 106. The outer end of the third coil 313 and the outer end of the fourth coil 314 may be spaced apart from the third side surface 105 and the fourth side surface 106. Therefore, a space may be formed between the outer end of the third coil 313 and the outer end of the fourth coil 314 and the insulating layer 600, and a portion of the body 100 may be disposed in the space.

[0078] Reference Figure 6, the outer ends of the third coil 313 and the fourth coil 314 may not extend to the third side surface 105 of the body 100. A portion of the body 100 may be disposed between the outer ends of the third coil 313 and the fourth coil 314 and the insulating layer 600.

[0079] Second Exemplary Embodiment Figure 7 is a coil component showing a second exemplary embodiment according to the present disclosure and corresponding to Figure 4 Cross-sectional view of . Figure 8 yes Figure 7 Magnified view of part B.

[0080] The difference between the coil component 2000 of the second exemplary embodiment in the present disclosure and the coil component of the first exemplary embodiment may be that the coil component 2000 may also include a connecting portion 500. Specifically, the connecting portion 500 may be arranged between the third coil 313 and the fourth coil 314, and connects at least a portion of the outer end of the third coil 313 and at least a portion of the outer end of the fourth coil 314 to each other. The connecting portion 500 may be arranged in the body 100. As described above in the first exemplary embodiment, the outer end of the coil may refer to the area including the tip of the coil. Therefore, the direct connection of the "outer end" may not necessarily mean only the connection of the tip of the coil. As an example, the connection of the coil can be performed not only at the tip, but also at at least a portion of the area corresponding to the outer end.

[0081] The connection part 500 may be implemented by solder, and may include one or more selected from the group consisting of tin (Sn), lead (Pb), copper (Cu), and silver (Ag). That is, the third coil 313 and the fourth coil 314 may be connected to each other by solder.

[0082] That is, in the coil component according to the second exemplary embodiment, the third coil 313 and the fourth coil 314 are bonded to each other by solder, and thus a material different from the third coil 313 and the fourth coil 314 may be interposed therebetween.

[0083] The connection part 500 may not extend to the third side surface 105 of the body 100 .

[0084] As for the remaining configuration of the second exemplary embodiment, the description in the above-mentioned first exemplary embodiment can be applied as it is, and the detailed description is redundant and will be omitted.

[0085] Fig. 9 is a coil component 2000′ showing a modified example of the second exemplary embodiment in the present disclosure and corresponding to Figure 4. In a modified example of the second exemplary embodiment, similar to the coil component 1000' according to the modified example of the first exemplary embodiment described above, the third coil 313 and the fourth coil 314 may not extend to the third side surface 105 and the fourth side surface 106 of the main body 100. That is, the outer end of the third coil 313 and the outer end of the fourth coil 314 may be directed only toward one of the third side surface 105 and the fourth side surface 106 of the main body that are opposite to each other in the third direction, and may not extend to the third side surface 105 and the fourth side surface 106. Therefore, a space may be formed between the outer end of the third coil 313 and the outer end of the fourth coil 314 and the insulating layer 600, and a portion of the main body 100 may be disposed in the space.

[0086] Reference Fig. 9 , the outer ends of the third coil 313 and the fourth coil 314 may not extend to the third side surface 105 of the body 100. A portion of the body 100 may be disposed between the outer ends of the third coil 313 and the fourth coil 314 and the insulating layer 600.

[0087] As described above, according to exemplary embodiments in the present disclosure, the characteristics of a coil component may be improved by using a relatively simple method.

[0088] While example embodiments have been shown and described above, it will be readily apparent to those skilled in the art that modifications and variations may be made without departing from the scope of the present invention as defined by the appended claims.

Claims

1. A coil assembly, comprising: a body having a first surface, a second surface opposite to the first surface in a first direction, and a first side surface, a second side surface, a third side surface, and a fourth side surface connecting the first surface and the second surface to each other; a first support member and a second support member spaced apart from each other in the first direction within the body; as well as a coil portion, comprising a first coil and a third coil disposed on a lower surface and an upper surface of the first supporting member opposite to each other in the first direction, a first via hole connecting the first coil and the third coil to each other, a second coil and a fourth coil disposed on an upper surface and a lower surface of the second supporting member opposite to each other in the first direction, and a second via hole connecting the second coil and the fourth coil to each other, Wherein, the third coil and the fourth coil are combined with each other in the main body.

2. The coil assembly according to claim 1, wherein: The outer end portion of the first coil and the outer end portion of the second coil extend to the first side surface and the second side surface of the body, respectively, which are opposite to each other in the second direction.

3. The coil assembly according to claim 1, wherein: The outer end portion of the third coil and the outer end portion of the fourth coil extend to only one of the third side surface and the fourth side surface of the body which are opposite to each other in the third direction.

4. The coil assembly according to claim 1, wherein: The outer end portion of the third coil and the outer end portion of the fourth coil face only one of the third side surface and the fourth side surface of the body that are opposite to each other in the third direction, and The outer end portion of the third coil and the outer end portion of the fourth coil are spaced apart from the third side surface and the fourth side surface.

5. The coil assembly according to claim 1, wherein: At least a portion of an outer end portion of the third coil is connected to at least a portion of an outer end portion of the fourth coil within the body.

6. The coil component according to claim 1, further comprising a connecting portion, the connecting portion being disposed between the third coil and the fourth coil and connecting at least a portion of an outer end portion of the third coil and at least a portion of an outer end portion of the fourth coil, in, The connecting portion is arranged in the main body.

7. The coil assembly according to claim 6, wherein: The connection portion includes one or more metals selected from the group consisting of tin, lead, copper, and silver.

8. The coil assembly according to claim 1, wherein: The main body includes a magnetic metal material and a resin, and Here, the magnetic metal material and the resin are not provided in a region between the third coil and the fourth coil where the third coil and the fourth coil overlap each other.

9. The coil component according to claim 1, further comprising an insulating film provided on each of the first coil, the second coil, the third coil, and the fourth coil, in, The insulating film provided on the third coil and the insulating film provided on the fourth coil are in direct contact with each other.

10. The coil assembly according to claim 9, wherein: The insulating film is provided along a surface of the first coil, a surface of the second coil, a surface of the third coil, and a surface of the fourth coil.

11. The coil assembly according to claim 9, wherein: The insulating film is not provided in a region inside the body where the third coil and the fourth coil are coupled to each other.

12. The coil component according to claim 3, further comprising an insulating layer provided on at least one of the first surface, the second surface, the third side surface, and the fourth side surface of the body, in, The insulating layer is in contact with the third coil and the fourth coil.

13. The coil assembly according to claim 1, wherein: A distance between the first coil and the third coil is greater than a distance between the third coil and the fourth coil.

14. The coil assembly according to claim 9, wherein: T1>2T2, wherein the thickness of the first support member is T1, and the thickness of the insulating film is T2.

15. The coil assembly according to claim 1, wherein: The first via hole passes through the first supporting member and is connected to an inner end portion of each of the first coil and the third coil, and The second via hole passes through the second supporting member and is connected to an inner end portion of each of the second coil and the fourth coil.

16. The coil assembly according to claim 1, further comprising: a first outer electrode connected to an outer end of the first coil; as well as a second outer electrode connected to an outer end of the second coil, The first external electrode and the second external electrode are respectively disposed on the first side surface and the second side surface of the body which are opposite to each other in the second direction.

Images