Coil assembly

Abstract

The present disclosure provides a coil component, which includes: a winding coil having a winding portion and a lead-out portion, the winding portion including at least one turn, the lead-out portion extending from an end of the winding portion to form a spacing space together with the winding portion, the winding coil being formed by a metal wire, and an insulating coating portion being provided on the surface of the metal wire; a main body, in which the winding coil is embedded and includes magnetic powder particles and an insulating resin; and an insulating layer provided on at least one surface of the winding portion and the lead-out portion that form the spacing space.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2020-0006393 filed on January 17, 2020, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety for all purposes by reference. Technical Field

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

[0003] An example of the coil assembly is a wound coil assembly using a wound coil.

[0004] The winding coil is formed by winding a metal wire having an insulating coating formed on its surface two or more times to form a winding portion (first process). When the first process is completed, both ends of the metal wire extend parallel to each other from both ends of the winding portion. Both ends of the metal wire of the first process are bent in a direction perpendicular to the direction in which it extends (second process, forming process).

[0005] Due to the external force of the above-mentioned forming process, the insulating coating between the outermost turn of the winding part and both ends of the metal wire may be damaged, and the metal wire of the winding part may be exposed to the outside in the corresponding area. Summary of the invention

[0006] An aspect of the present disclosure is to provide a coil component that can reduce leakage current.

[0007] According to one aspect of the present disclosure, a coil component includes: a winding coil having a winding portion and a lead-out portion, the winding portion including at least one turn, the lead-out portion extending from an end of the winding portion to form a spacing space together with the winding portion, the winding coil being formed by a metal wire, and an insulating coating portion being provided on the surface of the metal wire; a main body, in which the winding coil is embedded and including magnetic powder particles and an insulating resin; and an insulating layer provided on at least one surface of the winding portion and the lead-out portion that form the spacing space.

[0008] According to one aspect of the present disclosure, a coil component includes: a winding coil, including a metal wire, an insulating coating portion is provided on the surface of the metal wire, and the winding coil has a winding portion and a lead-out portion, the winding portion has at least one turn, and the lead-out portion extends from an end of the winding portion to provide a spacing space together with the winding portion; a main body, including magnetic metal powder particles and an insulating resin, and the winding coil is embedded therein; and an insulating layer is provided on the exposed surface of the metal wire exposed from the insulating coating portion, and faces the spacing space. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above and other aspects, features and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings.

[0010] Figure 1 is a schematic diagram of a coil component according to a first embodiment of the present disclosure.

[0011] Figure 2 yes Figure 1 Floor plan.

[0012] Figure 3 It is along Figure 2 A cross-sectional view taken along line II' in FIG.

[0013] Figure 4 yes Figure 3 Magnified view of part A.

[0014] Figure 5 A modified example of the insulating layer is shown and Figure 5 The enlarged view of the A' portion corresponds to Figure 4 .

[0015] Figure 6 is a schematic diagram of a coil component according to a second embodiment of the present disclosure and corresponds to Figure 2 .

[0016] Figure 7 yes Figure 6 Magnified view of part B.

[0017] Figure 8 It is along Figure 6 A cross-sectional view taken along line II-II'.

[0018] Fig. 9 yes Figure 8 Magnified view of part D.

[0019] Fig.10 is a schematic diagram of a coil component according to a third embodiment of the present disclosure and corresponds to Figure 2 .

[0020] Fig.11 yes Fig.10 Magnified view of part E.

[0021] Fig.12 It is along Fig.10 A cross-sectional view taken along line III-III'.

[0022] Fig.13 yes Fig.12 Magnified view of part F. DETAILED DESCRIPTION

[0023] The terms used in the description of the present disclosure are used to describe specific embodiments and are not intended to limit the present disclosure. Unless otherwise specified, singular terms include plural forms. The terms "including", "comprising", "constructed to ...", etc. in the description of the present disclosure are used to indicate the existence of features, quantities, steps, operations, elements, parts, or combinations thereof, without excluding the possibility of combining or adding one or more other features, quantities, steps, operations, elements, parts, or combinations thereof. In addition, the terms "disposed on ...", "positioned on ...", etc. may indicate that an element is positioned above or below an object, and do not necessarily mean that an element is positioned above an object relative to the direction of gravity.

[0024] The terms “coupled to,” “combined to,” and the like may not only indicate that elements are in direct and physical contact with each other but also include a configuration in which another element is interposed between elements so that the element also contacts another element.

[0025] The sizes and thicknesses of elements shown in the drawings are shown as examples to facilitate description, and the present disclosure is not limited thereto.

[0026] In the drawings, the L direction is a first direction or a length (longitudinal) direction, the W direction is a second direction or a width direction, and the T direction is a third direction or a thickness direction.

[0027] Hereinafter, a coil component according to an exemplary embodiment of the present disclosure will be described in detail with reference to the accompanying drawings. Referring to the accompanying drawings, the same or corresponding components may be denoted by the same reference numerals, and repeated descriptions will be omitted.

[0028] In electronic devices, various types of electronic components may be used, and various types of coil components may be used between the electronic components to remove noise or for other purposes.

[0029] In other words, in electronic devices, the coil component can be used as a power inductor, a high frequency (HF) inductor, a general magnetic bead, a high frequency (GHz) magnetic bead, a common mode filter, etc.

[0030] First embodiment

[0031] Figure 1 is a schematic diagram of a coil component according to a first embodiment of the present disclosure. Figure 2 yes Figure 1 Floor plan. Figure 3 It is along Figure 2 A cross-sectional view taken along line II' in FIG. Figure 4 yes Figure 3 Magnified view of part A. Figure 5 A modified example of the insulating layer is shown and Figure 5 The enlarged view of the A' portion corresponds to Figure 4 .exist Figure 2 , for the description of the present disclosure, a part of the components is explicitly shown.

[0032] Reference Figures 1 to 5 , a coil component 1000 according to an example embodiment includes a body 100 , a wound coil 200 , an insulating layer 300 , and external electrodes 400 and 500 .

[0033] The body 100 may form the exterior of the coil component 1000 , and may embed the wound coil 200 therein.

[0034] The body 100 may be formed to generally have a hexahedral shape.

[0035] based on Figure 1 , the body 100 has a first surface and a second surface opposite to each other in the length direction L, a third surface and a fourth surface opposite to each other in the width direction W, and a fifth surface and a sixth surface opposite to each other in the thickness direction T. Each of the first to fourth surfaces of the body 100 may correspond to a wall surface of the body 100 connecting the fifth surface and the sixth surface of the body 100. Hereinafter, the two end surfaces of the body 100 may refer to the first surface and the second surface of the body 100, respectively, the two side surfaces of the body 100 may refer to the third surface and the fourth surface of the body 100, respectively, and one surface and the other surface (two main surfaces) of the body 100 may refer to the sixth surface and the fifth surface of the body 100, respectively.

[0036] The body 100 may be formed such that the coil component 1000 (including the external electrodes 400 and 500 to be described later) has a length of 2.0 mm, a width of 1.2 mm, and a thickness of 0.65 mm, but is not limited thereto.

[0037] The body 100 includes magnetic powder particles 10 and an insulating resin R. As an example, the body 100 may be formed by laminating a magnetic composite sheet having a structure in which the magnetic powder particles 10 are disposed in the insulating resin R on a winding coil 200 to be described later. As another example, the body 100 may be formed by placing the winding coil 200 in a mold and filling the mold with a magnetic composite material including the magnetic powder particles 10 and the insulating resin R. In the above example, the core C of the body 100 may be formed by filling an empty space of a winding portion 210 of the winding coil 200 to be described later with a magnetic composite sheet or a magnetic composite material, but the method of forming the core C is not limited thereto.

[0038] The magnetic powder particles 10 may be ferrite powder particles or magnetic metal powder particles.

[0039] Examples of ferrite powder particles may include one or more of the following ferrites: spinel ferrites (such as Mg-Zn-based ferrites, Mn-Zn-based ferrites, Mn-Mg-based ferrites, Cu-Zn-based ferrites, Mg-Mn-Sr-based ferrites, Ni-Zn-based ferrites, etc.), hexagonal ferrites (such as Ba-Zn-based ferrites, Ba-Mg-based ferrites, Ba-Ni-based ferrites, Ba-Co-based ferrites, Ba-Ni-Co-based ferrites, etc.), garnet-type ferrites (such as Y-based ferrites, etc.) and Li-based ferrites.

[0040] The magnetic metal powder particles 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 powder particles may include one or more of the following powders: pure iron powder, Fe-Si-based alloy powder, Fe-Si-Al-based alloy powder, Fe-Ni-based alloy powder, Fe-Ni-Mo-based alloy powder, Fe-Ni-Mo-Cu-based alloy powder, Fe-Co-based alloy powder, Fe-Ni-Co-based alloy powder, Fe-Cr-based alloy powder, Fe-Cr-Si-based alloy powder, Fe-Si-Cu-Nb-based alloy powder, Fe-Ni-Cr-based alloy powder and Fe-Cr-Al-based alloy powder.

[0041] Hereinafter, it will be assumed that the magnetic powder particles 10 are magnetic metal powder particles, but the present disclosure is not limited thereto.

[0042] The magnetic metal powder particles may be amorphous or crystalline. For example, the magnetic metal powder particles may be Fe-Si-B-Cr based amorphous alloy powder, but are not limited thereto.

[0043] Each of the magnetic metal powder particles 10 may have an average diameter of about 0.1 μm to 50 μm, but is not limited thereto.

[0044] The magnetic metal powder particles 10 may include an insulating coating formed on the surface thereof. Since the magnetic metal powder particles 10 themselves may have electrical conductivity, the insulating coating may surround the surface of the magnetic metal powder particles 10 to prevent the magnetic metal powder particles 10 from short-circuiting. The insulating coating may include epoxy resin, polyimide, liquid crystal polymer, etc. in a single form or in a combined form, but is not limited thereto. For example, the material and formation method of the insulating coating may vary as long as the insulating coating can be formed on the surface of the magnetic metal powder particles 10 by an electrically insulating material.

[0045] The body 100 may include two or more types of magnetic metal powder particles 10. In this case, the term "different types of magnetic metal powder particles" means that the magnetic powder particles are distinguished from each other by diameter, composition, crystallinity, and shape. Figure 4 , the body 100 is shown to include three types of magnetic metal powder particles 10 having particle size distributions different from each other (trimodal). However, since this is merely illustrative, the body 100 may include two types of magnetic metal powder particles 10 having particle size distributions different from each other (bimodal). Since the body 100 includes two or more types of magnetic metal powder particles 10 having particle size distributions different from each other, the volume of the magnetic metal powder particles 10 in the body 100 may be increased (the filling rate is increased) based on the body 100 having the same volume.

[0046] The insulating resin R may include epoxy resin, polyimide, liquid crystal polymer, etc. in a single form or in a combined form, but is not limited thereto.

[0047] The winding coil 200 is embedded in the body 100 to exhibit characteristics of the coil component. For example, when the coil component 1000 according to the present embodiment is used as a power inductor, the winding coil 200 can be used to stabilize the power supply of the electronic device by storing the electric field as a magnetic field and maintaining the output voltage.

[0048] The wound coil 200 includes a winding portion 210 (air-core coil) and lead portions 221 and 222 extending from both ends of the winding portion 210 to be exposed to the first and second surfaces of the body 100 , respectively.

[0049] The winding portion 210 may be formed by winding a metal wire MW (such as a copper wire whose surface is covered with an insulating coating portion CI) in a spiral shape. As a result, each turn of the winding portion 210 has a form covered with the insulating coating portion CI. The winding portion 210 may include at least one layer. Each layer of the winding portion 210 is formed to have a planar spiral shape and may have at least one turn.

[0050] The lead-out portions 221 and 222 extend from both ends of the winding portion 210 to be exposed to the first surface and the second surface of the body 100, respectively. The lead-out portions 221 and 222 may be integrated with the winding portion 210. The winding portion 210 and the lead-out portions 221 and 222 may be integrated with each other using a metal wire MW coated with an insulating coating portion CI. The lead-out portions 221 and 222 may be both ends of the metal wire MW coated with the insulating coating portion CI.

[0051] In the case where the winding coil is applied to the winding coil assembly, a metal wire having an insulating coated surface can be wound by a winding machine to form a winding portion having at least one turn (first process). The metal wire processed for the first time may have two ends, which extend from the outermost turns of the winding portion and extend parallel to each other in substantially the same direction. When the winding coil in which the two ends of the metal wire are arranged parallel to each other is embedded in the main body, both the first lead-out portion and the second lead-out portion of the winding coil may be exposed on one surface of the main body. Therefore, a process of increasing the distance between the two ends of the metal wire processed for the first time may be performed to expose the first lead-out portion and the second lead-out portion of the winding coil to two surfaces of the main body opposite to each other (second process, forming process).

[0052] In the second process, since an external force is applied to both ends of the metal wire in directions in which both ends of the metal wire are opposite to each other, a region of the outermost turn of the winding portion and a region of each of the two ends of the metal wire, which are set to be in contact with each other, are separated from each other. However, in this process, an insulating coating portion of a region of the outermost turn of the winding portion and / or a region of each of the two ends of the metal wire may be damaged, thereby exposing the metal wire to an external entity. In the case where the insulating coating portion is damaged, when the body surrounding the winding coil includes conductive magnetic metal powder particles, a leakage current may be generated, thereby deteriorating the component characteristics.

[0053] In the present embodiment, in order to solve the above-mentioned problem, an insulating layer 300 is provided on at least one of the surfaces of the winding portion 210 forming the spacing space S and the surfaces of the lead-out portions 221 and 222. For example, since the metal wire MW may be exposed in the spacing space S, an insulating layer may be provided on at least one of the surfaces of the winding portion 210 forming the spacing space and the surfaces of the lead-out portions 221 and 222 to prevent the metal wire MW from directly contacting the magnetic metal powder particles 10.

[0054] In the present specification, the “interval space S between the winding portion 210 and the first lead-out portion 221” may refer to, for example, a circular sector formed by a tangent line of each of the winding portion 210 and the first lead-out portion at a contact point between the winding portion 210 and the first lead-out portion 221 and a circle centered at the contact point, based on a cross section in the length-width direction (LW), and the radius of the circle corresponds to an average diameter of a magnetic metal powder particle having a maximum diameter among a plurality of magnetic metal powder particles, for example, when the magnetic metal powder particle D having the maximum diameter is 10 50When the radius of the circle is 50 μm, the radius of the circle is 50 μm or less. Optionally, the "interval between the winding portion 210 and the first lead portion 221" may also refer to an area including the entire circular sector-shaped area between the surface of the winding portion 210 and the surface of the first lead portion 221 based on a cross-section in the length-width (LW) direction. Optionally, the "interval between the winding portion 210 and the first lead portion 221" may refer to an area including a portion of the circular sector-shaped area between the surface of the winding portion 210 and the surface of the first lead portion 221 based on a cross-section in the length-width (LW) direction.

[0055] The above meanings can also be applied to the spacing space S between the winding portion 210 and the second lead portion 222. Hereinafter, a description will be given while focusing on the spacing space S between the winding portion 210 and the first lead portion 221, but the description will be equally applied to the spacing space S between the winding portion 210 and the second lead portion 222.

[0056] The insulating layer 300 may include a metal oxide layer disposed on the surface of the metal wire MW exposed to the spacing space S. The metal oxide layer may be formed by forming a metal oxide layer having electrical insulation on at least one of the surface of the winding portion 210 and the surface of the first lead-out portion 221 of the second processed winding coil 200. The type of metal (or metal ion) contained and the method for forming the metal oxide layer are not limited as long as they have electrical insulation and include metal. In one example, the thickness of the insulating layer 300 may be less than the thickness of the insulating coating portion CI, but the thickness relationship is not limited thereto. In one example, the insulating layer 300 and the insulating coating portion CI may be made of different insulating materials, but the materials used to form the insulating layer 300 and the insulating coating portion CI are not limited thereto. As a non-limiting example, when the metal wire MW is a copper wire, the metal oxide layer may be a copper oxide layer, and the copper oxide layer may be formed by oxidizing the exposed surface of the exposed copper wire. In this case, the process may be simplified compared to the case where an additional metal oxide layer is performed, and because the metal wire MW and the metal oxide layer include the same metal, the bonding force between the metal wire MW and the metal oxide layer may be increased. In addition, the metal oxide layer may be selectively formed only on the exposed surface of the metal wire MW. Although not shown in the drawings, when the metal oxide layer is formed by another method other than oxidation treatment of the exposed surface of the metal wire MW, the metal oxide layer 310 may extend not only to the exposed surface of the metal wire MW but also upward to at least a portion of the insulating coating portion CI.

[0057] Reference Figure 5, the insulating layer 300 applied to the modified example may also include a metal oxide layer 310 and a resin insulating layer 320. Cracks may occur in the metal oxide layer 310 to generate leakage current. In this modified example, after the metal oxide layer 310 is formed, a resin insulating layer 320 may be additionally formed on the metal oxide layer 310 to more reliably prevent leakage current. The resin insulating layer 320 may be formed by applying an insulating resin for forming a resin insulating layer or a layer forming an insulating resin on one of the surfaces of the winding portion 210 and the surface of the first lead-out portion 221 of the spacing space S forming the winding coil 200 (on which the process of forming the metal oxide layer 310 is performed). The resin insulating layer 320 may include the same resin as the insulating resin R included in the main body 100, but the scope of the present disclosure is not limited thereto. When the resin insulating layer 320 includes the same resin as the insulating resin R included in the main body 100, the bonding force between the main body 100 and the winding coil 200 may be improved.

[0058] The external electrodes 400 and 500 are disposed on the first and second surfaces of the body 100 to respectively contact and be connected to the lead-out portions 221 and 222. Specifically, the first external electrode 400 is disposed on the first surface of the body 100 to be connected to the first lead-out portion 221, and the second external electrode 500 is disposed on the second surface of the body 100 to be connected to the second lead-out portion 222.

[0059] Each of the external electrodes 400 and 500 may be formed of a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), chromium (Cr), titanium (Ti), or an alloy thereof, but the material thereof is not limited thereto.

[0060] Each of the external electrodes 400 and 500 may be formed to have a single-layer structure or a multi-layer structure. For example, the first external electrode 400 may include a first layer including copper (Cu), a second layer disposed on the first layer and including nickel (Ni), and a third layer disposed on the second layer and including tin (Sn). Each of the first to third layers may be formed by electroplating, but the formation method thereof is not limited thereto. Each of the external electrodes 400 and 500 may include a conductive resin layer and an electroplating layer. The conductive resin layer may be formed by applying and curing a conductive paste containing conductive powder particles including silver (Ag) and / or copper (Cu) and an insulating resin such as an epoxy resin.

[0061] Second embodiment

[0062] Figure 6 is a schematic diagram of a coil component according to a second embodiment of the present disclosure and corresponds to Figure 2 . Figure 7 yes Figure 6Magnified view of part B. Figure 8 It is along Figure 6 A cross-sectional view taken along line II-II'. Fig. 9 yes Figure 8 Magnified view of part D.

[0063] Reference Figures 1 to 5 as well as Figures 6 to 9 , when the coil component 2000 according to the present embodiment is compared with the coil component 1000 according to the first embodiment, the positions of the insulating layer 300 are different from each other. Therefore, in the description of the present embodiment, the description will be given while focusing on the position of the insulating layer 300. The description of the first embodiment will be equivalently or similarly applied to other components of the present embodiment.

[0064] Reference Figures 6 to 9 , the insulating layer 300 is provided to surround the surface of the winding coil 200 including the spacing space S. For example, the insulating layer 300 is inserted between all surfaces of the winding coil 200 and the main body 100. The insulating layer 300 may be formed by dipping the winding coil 200 on which the second process is completed in a liquid insulating resin, but the scope of the present disclosure is not limited thereto. The insulating layer 300 may include the same resin as the insulating resin R of the main body 100, but the scope of the present disclosure is not limited thereto. When the insulating layer 300 and the main body 100 include the same resin, the bonding force between the insulating layer 300 and the main body 100 may be improved.

[0065] In the winding coil 200, during the first process and / or the second process, the metal wire MW may also be exposed to external entities in a region other than the region in which the spacing space S is formed. In the present embodiment, the insulating layer 300 may be formed to surround all surfaces of the winding coil 200 to further improve the leakage current reduction effect. In addition, in the case of the present embodiment, the insulating layer 300 may be formed by a simpler method.

[0066] Third embodiment

[0067] Fig.10 is a schematic diagram of a coil component according to a third embodiment of the present disclosure and corresponds to Figure 2 . Fig.11 yes Fig.10 Magnified view of part E. Fig.12 It is along Fig.10 A cross-sectional view taken along line III-III'. Fig.13 yes Fig.12 Magnified view of part F.

[0068] Reference Figures 1 to 5 as well as Figures 10 to 13, when the coil component 3000 according to the present embodiment is compared with the coil component 1000 according to the first embodiment, the main body 100 is different from each other. Therefore, in the description of the present embodiment, the description will be given while focusing on the main body 100. The description of the first embodiment will be equivalently or similarly applied to other components of the present embodiment.

[0069] Reference Figures 10 to 13 The body 100 has a low-density portion 110 filling the spacing space S and a high-density portion 120 disposed outside the low-density portion 110 and having magnetic powder particles of higher density than the low-density portion 110 .

[0070] The low-density portion 110 and the high-density portion 120 may be formed by, for example, forming a high-density portion forming material on the upper and lower portions of the winding coil after filling the spacing space between the winding portion 210 and the lead-out portions 221 and 222 of the winding coil 200 processed for the second time with the low-density portion forming material. The low-density portion forming material and the high-density portion forming material may include the same curable insulating resin and / or different curable insulating resins, respectively, and may be a first magnetic composite resin and a second magnetic composite resin having different filling rates of magnetic metal powder particles. The filling rate of the magnetic metal powder particles 10 of the first magnetic composite resin (low-density portion forming material) is lower than the filling rate of the magnetic metal powder particles 10 of the second magnetic composite resin (high-density portion forming material). Therefore, the density of the metal magnetic powder particles 10 in the first magnetic composite resin may be lower than the density of the metal magnetic powder particles 10 in the second magnetic composite resin (high-density portion forming material), and the high-density portion forming material may be a magnetic composite sheet including the second magnetic composite resin. In the above example, when the insulating resin included in each of the low-density portion forming material and the high-density portion forming material is the same resin or a curable resin capable of cross-linking with each other, the low-density portion 110 and the high-density portion 120 of the body 100 can be integrated with each other, and thus, the boundary can be formed invisibly.

[0071] As another example, the low-density portion forming material may not include the magnetic metal powder particles 10, and only the high-density portion forming material may include the magnetic metal powder particles 10. In this case, the magnetic metal powder particles 10 included in the high-density portion forming material can be prevented from flowing into the spacing space during the process of laminating and curing the high-density portion forming material on the upper and lower parts of the winding coil 200. When the low-density portion forming material includes an insulating resin, the insulating resin included in the low-density portion forming material may have a melting point lower than the curing temperature of the insulating resin included in the high-density portion forming material. The insulating resin included in the low-density portion forming material may be, for example, wax (the melting point is lower than the curing temperature of the epoxy resin included in the high-density portion forming material), but the scope of the present disclosure is not limited thereto. The insulating resin included in the low-density portion forming material may melt during the curing process of forming the main body 100 to reduce the concentration (density) in the direction from the spacing space S toward the surface of the main body 100.

[0072] In the above example, when the low-density portion forming material is a liquid material, the low-density portion forming material disposed in the spacing space may have an inwardly curved shape in a direction toward the contact point between the winding portion 210 and the first lead-out portion 221 due to the surface tension of the low-density portion forming material (liquid material). Fig.11 As shown in , the low-density portion 110 filling the spacing space S may have a shape that is bent inwardly in a direction toward a contact point between the winding portion 210 and the first lead-out portion 221. Fig.13 As shown in FIG. 1 , the central portion of the low-density portion 110 may also be recessed toward the center of the spacing space S in the thickness direction.

[0073] exist Fig.11 and Fig.13 In the figure, the low density portion 110 is shown as not including the magnetic metal powder particles 10. However, this is merely an example for the convenience of description and understanding of the present disclosure. Therefore, the scope of the present disclosure is not limited to Fig.11 and Fig.13 An example of the low-density portion 110 is shown in FIG.

[0074] In the coil component 3000 according to the present embodiment, the low density portion 110 of the magnetic metal powder particles 10 having relatively low density may fill the interval space between the winding portion 210 and the lead portions 221 and 222 where the possibility of generating leakage current is high to reduce the leakage current.

[0075] As described above, according to example embodiments, leakage current of a coil component may be reduced.

[0076] While example embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations may be made without departing from the scope of the present disclosure as defined by the appended claims.

Claims

1. A coil assembly, comprising: A winding coil including a metal wire provided with an insulating coating portion on an outer peripheral surface, the winding coil having a winding portion and a lead-out portion, the winding portion being formed by winding the metal wire provided with the insulating coating portion to include a plurality of turns, the lead-out portion being an end portion of the metal wire provided with the insulating coating portion and extending from an end of an outermost turn of the winding portion to provide a spacing space together with the outermost turn of the winding portion; a main body in which the wound coil is embedded and includes magnetic powder particles and an insulating resin; and An insulating layer is provided on at least one of the side surfaces of the outermost turn of the winding portion providing the spacing space and the side surfaces of the lead portion facing the spacing space, and the insulating layer is spaced apart from the inner turns of the multiple turns of the winding portion.

2. The coil assembly according to claim 1, wherein: A portion of the metal wire is exposed from the insulating coating portion and faces the spacing space, and The insulating layer is disposed on the exposed surface of the metal line.

3. The coil assembly according to claim 2, wherein: The insulating layer includes a metal oxide layer.

4. The coil assembly according to claim 3, wherein: The metal oxide layer includes the same metal as that included in the metal wire.

5. The coil assembly according to claim 4, wherein: The metal oxide layer is disposed only on the exposed surface of the metal line.

6. The coil assembly according to any one of claims 3 to 5, wherein: The thickness of the metal oxide layer is smaller than the thickness of the insulating coating portion.

7. The coil assembly according to any one of claims 3 to 5, wherein: The insulating layer further includes a resin insulating layer disposed on the metal oxide layer.

8. The coil assembly according to any one of claims 1 to 5, wherein: The insulating layer is disposed only in the spacing space.

9. The coil assembly according to any one of claims 1 to 5, wherein: The body has a low-density portion and a high-density portion, the low-density portion is disposed in the spacing space, the high-density portion is disposed outside the low-density portion, and the density of magnetic powder particles in the high-density portion is higher than that of magnetic powder particles in the low-density portion.

10. The coil assembly according to claim 9, wherein: The low-density portion includes a low-melting-point resin having a melting point lower than a curing temperature of an insulating resin of the body.

11. The coil assembly according to claim 9, wherein: The low-density portion and the high-density portion are integrated with each other.

12. The coil assembly according to any one of claims 1 to 5, wherein: The insulating layer includes the same resin as the insulating resin of the body.

13. The coil assembly according to claim 1, wherein: The magnetic powder particles include conductive magnetic metal powder particles.

14. The coil assembly according to any one of claims 1 to 5, wherein: The thickness of the insulating coating portion is different from the thickness of the insulating layer.

15. The coil assembly according to any one of claims 1 to 5, wherein: The material of the insulating coating portion is different from that of the insulating layer.

16. A coil assembly, comprising: A winding coil, comprising a metal wire having an insulating coating portion provided on an outer peripheral surface thereof, and having a winding portion and a lead-out portion, the winding portion being formed by winding the metal wire having the insulating coating portion to have a plurality of turns, the lead-out portion being an end portion of the metal wire having the insulating coating portion and extending from an end of an outermost turn of the winding portion to provide a spacing space together with the outermost turn of the winding portion; a main body, comprising magnetic metal powder particles and insulating resin, and in which the wound coil is embedded; as well as An insulating layer is provided on an exposed surface of the metal wire exposed from the insulating coating portion, faces the spacing space, and is spaced apart from an inner turn among the plurality of turns of the winding portion.

17. The coil assembly according to claim 16, wherein: The insulating layer includes a metal oxide layer including the same metal as that in the metal line and disposed only on the exposed surface of the metal line.

18. The coil assembly according to claim 16 or 17, wherein: The thickness of the insulating coating portion is different from the thickness of the insulating layer.

19. The coil assembly according to claim 16 or 17, wherein: The material of the insulating coating portion is different from that of the insulating layer.

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