Coil assembly

Abstract

A coil assembly includes a main body, a coil part disposed inside the main body, first and second outer electrodes disposed apart from each other on one surface of the main body and connected to the coil part, first and second insulating layers connected to the one surface of the main body, respectively, disposed to side surfaces of the main body and extending onto the one surface of the main body, respectively, and second and third insulating layers connected to the one surface of the main body, respectively, disposed to end surfaces of the main body and extending onto the one surface of the main body, respectively. An exposed portion of each of the first and second outer electrodes from the first to fourth insulating layers is spaced apart from each of a plurality of edges of the one surface of the main body.

Description

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2020-0083863, filed on July 8, 2020, with the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] This disclosure relates to a coil assembly. Background Technology

[0003] An inductor (a type of coil assembly) is a typical passive electronic component used in electronic devices along with resistors and capacitors.

[0004] As electronic devices achieve higher performance and become smaller, the number of electronic components used in these devices is increasing while being miniaturized.

[0005] Typically, the external electrodes of a coil assembly are formed by applying conductive paste to two end surfaces opposite each other along the length of the assembly body and then curing the applied conductive paste. In this case, the total thickness of the coil assembly may increase. When the assembly with the aforementioned external electrodes is mounted on a substrate, bonding members such as solder are formed on the mounting surface of the substrate, extending from the assembly in both the width and length directions, thus increasing the effective mounting area. Summary of the Invention

[0006] One aspect of this disclosure is to provide a coil assembly that achieves lightweight and compactness.

[0007] Another aspect of this disclosure is to provide a coil assembly that can reduce the actual installation area.

[0008] According to one aspect of this disclosure, a coil assembly includes: a body; a coil portion disposed inside the body; a first external electrode and a second external electrode, spaced apart from each other on a surface of the body and connected to the coil portion; a first insulating layer and a second insulating layer, respectively connected to the one surface of the body and respectively disposed on two opposing side surfaces of the body extending uniformly to the one surface of the body; and a second insulating layer and a third insulating layer, respectively connected to the one surface of the body and respectively disposed on two opposing end surfaces of the body extending uniformly to the one surface of the body. The exposed portions of each of the first and second external electrodes from the first to the fourth insulating layer are spaced apart from each of a plurality of edges of the one surface of the body.

[0009] According to one aspect of this disclosure, a coil assembly includes: a body; a coil portion disposed inside the body; a first external electrode and a second external electrode disposed spaced apart from each other and connected to the coil portion on a surface of the body; and a plurality of insulating layers covering a plurality of edges of the one surface of the body in such a way that portions of the first external electrode and the second external electrode exposed from the plurality of insulating layers are spaced apart from each of the plurality of edges of the one surface of the body. Among the plurality of insulating layers, two insulating layers disposed on a vertex region of the one surface of the body overlap each other in the vertex region.

[0010] According to one aspect of this disclosure, a coil assembly includes: a body having a first surface and a second surface opposite to each other in the width direction of the body, a third surface and a fourth surface opposite to each other in the length direction of the body, and a fifth surface and a sixth surface opposite to each other in the thickness direction of the body; a coil portion disposed inside the body; a first external electrode and a second external electrode connected to the coil portion and spaced apart from each other on the sixth surface of the body; a first insulating layer disposed on the first surface and extending to a portion of each of the third surface, the fourth surface, the fifth surface, and the sixth surface; a second insulating layer disposed on the second surface and extending to another portion of each of the third surface, the fourth surface, the fifth surface, and the sixth surface; a third insulating layer disposed on the third surface and extending to a portion of each of the first surface, the second surface, the fifth surface, and the sixth surface; and a fourth insulating layer disposed on the fourth surface and extending to another portion of each of the first surface, the second surface, the fifth surface, and the sixth surface. Attached Figure Description

[0011] The above and other aspects, features, and advantages of this disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0012] Figure 1 This is a schematic perspective view of a coil assembly according to an exemplary embodiment of the present disclosure.

[0013] Figure 2 It is when from the bottom (along) Figure 1 A diagram of a coil assembly according to an exemplary embodiment of the present disclosure, when viewed from direction A.

[0014] Figure 3 It is along Figure 1 The cross-sectional view taken from line I-I'.

[0015] Figure 4 It is along Figure 1 The cross-sectional view taken from line II-II'.

[0016] Figures 5 to 9 This is a view illustrating a method of manufacturing a coil assembly according to an exemplary embodiment of the present disclosure. Detailed Implementation

[0017] The terminology used in the description of this disclosure is for describing particular embodiments and is not intended to limit the disclosure. Unless otherwise indicated, singular terms include plural forms. The terms “comprising,” “including,” “constructed as,” etc., in the description of this disclosure are used to indicate the presence of features, quantities, steps, operations, elements, components, or combinations thereof, and do not preclude the possibility of combining or adding one or more additional features, quantities, steps, operations, elements, components, or combinations thereof. Furthermore, the terms “set on,” “located on,” etc., may indicate that an element is located on or below an object, but do not necessarily mean that the element is above the object relative to the direction of gravity.

[0018] The terms “integrated into” and “combined into” can indicate not only that elements are in direct and physical contact with each other, but can also include a configuration in which other elements are interposed between the elements such that the elements are also in contact with the other elements.

[0019] For ease of description, the dimensions and thicknesses of the elements shown in the accompanying drawings are illustrative and this disclosure is not limited thereto.

[0020] In the attached figures, the L direction is the first direction or the length (longitudinal) direction, the W direction is the second direction or the width direction, and the T direction is the third direction or the thickness direction.

[0021] In the following, a coil assembly according to exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Referring to the drawings, identical or corresponding components may be designated by the same reference numerals, and repeated descriptions will be omitted.

[0022] In electronic devices, various types of electronic components can be used, and various types of coil assemblies can be used between electronic components to remove noise or for other purposes.

[0023] In other words, in electronic devices, coil assemblies can be used as power inductors, high-frequency (HF) inductors, ordinary ferrite beads, high-frequency (GHz) ferrite beads, common-mode filters, etc.

[0024] Figure 1 This is a schematic perspective view of a coil assembly according to an exemplary embodiment of the present disclosure. Figure 2 It is when from the bottom (along) Figure 1 A diagram of a coil assembly according to an exemplary embodiment of the present disclosure, when viewed from direction A. Figure 3 It is along Figure 1 The cross-sectional view taken from line I-I'. Figure 4 It is along Figure 1 The cross-sectional view taken from line II-II'. Figures 5 to 9 This is a view illustrating a method of manufacturing a coil assembly according to an exemplary embodiment of the present disclosure.

[0025] Reference Figures 1 to 4 According to an exemplary embodiment, the coil assembly 1000 may include a main body 100, a support substrate 200, a coil portion 300, insulating layers 410, 420, 510, 520, 530, and 540, and external electrodes 600 and 700. Additionally, refer to... Figure 3 and Figure 4 The coil assembly 1000 may also include an insulating film IF.

[0026] The main body 100 can form the appearance of the coil assembly 1000, and the coil portion 300 and the support substrate 200 can be disposed in the main body 100.

[0027] The main body 100 can be generally formed into a hexahedral shape.

[0028] based on Figure 1 , Figure 3 and Figure 4 The body 100 has a first surface 101 and a second surface 102 that are opposite to each other in the width direction W, a third surface 103 and a fourth surface 104 that are opposite to each other in the length direction L, and a fifth surface 105 and a sixth surface 106 that are opposite to each other in the thickness direction T. Each of the first surface 101, the second surface 102, the third surface 103, and the fourth surface 104 of the body 100 may correspond to a wall surface of the body 100 that connects the fifth surface 105 and the sixth surface 106 of the body 100. In the following, the two side surfaces of the body 100 may respectively represent the first surface 101 and the second surface 102, the two end surfaces of the body 100 may respectively represent the third surface 103 and the fourth surface 104 of the body 100, and one surface and another surface of the body 100 may respectively represent the sixth surface 106 and the fifth surface 105 of the body 100.

[0029] As an example, the body 100 may be formed in such a way that the coil assembly 1000, including the outer electrodes 600 and 700 and the insulating layers 410, 420, 510, 520, 530 and 540 (described later), has a length of 2.0 mm, a width of 1.2 mm and a thickness of 0.65 mm, but this disclosure is not limited thereto.

[0030] The term "length of coil assembly 1000" can be defined as: the maximum length of a plurality of line segments connecting two opposing boundary lines in the length (L) direction of the body 100, taken on an optical microscope image of the coil assembly 1000 on the fifth surface 105 of the body 100 and parallel to the length (L) direction. Alternatively, the term "length of coil assembly 1000" can be defined as: the minimum length of a plurality of line segments connecting two opposing boundary lines in the length (L) direction of the body 1000, based on an image, and parallel to the length (L) direction of the body 1000. Alternatively, the term "length of coil assembly 1000" may refer to the arithmetic mean of the lengths of at least three line segments connecting two boundary lines opposite each other in the length (L) direction of the body 100 and parallel to the length (L) direction of the body 100 among the outermost boundary lines of the coil assembly 1000 shown in the image.

[0031] The term "width of coil assembly 1000" can be defined as: the maximum length of a plurality of line segments connecting two opposing boundary lines in the width (W) direction of the body 100, parallel to the width (W) direction, based on an optical microscope image of the coil assembly 1000 taken on the fifth surface 105 of the body 100. Alternatively, the term "width of coil assembly 1000" can be defined as: the minimum length of a plurality of line segments connecting two opposing boundary lines in the width (W) direction of the body 1000, parallel to the width (W) direction of the body 1000, based on the image. Alternatively, the term "width of coil assembly 1000" may refer to the arithmetic mean of the lengths of at least three line segments connecting two boundary lines opposite each other in the width (W) direction of the body 100 and parallel to the width (W) direction of the body 100 among the outermost boundary lines of the coil assembly 1000 shown in the image.

[0032] The term "thickness of coil assembly 1000" can be defined as: the maximum length of a plurality of line segments connecting two opposing boundary lines in the thickness (T) direction of the body 100 and parallel to the thickness (T) direction, based on an optical microscope image of the coil assembly 1000 taken on the first surface 101 of the body 100 and directed toward the first surface 101 of the body 100. Alternatively, the term "thickness of coil assembly 1000" can be defined as: the minimum length of a plurality of line segments connecting two opposing boundary lines in the thickness (T) direction of the body 100 and parallel to the thickness (T) direction of the body 100, based on the image. Alternatively, the term "thickness of coil assembly 1000" may refer to the arithmetic mean of the lengths of at least three line segments connecting two boundary lines opposite each other in the thickness (T) direction of the body 100 among the outermost boundary lines of the coil assembly 1000 shown in the image and parallel to the thickness (T) direction of the body 100.

[0033] Optionally, the length, width, and thickness of the coil assembly 1000 can be measured using a micrometer method. In the micrometer method, measurement is performed by setting a zero point using a micrometer with metrological repeatability and reproducibility (R&R), inserting the coil assembly 1000 between the ends of the micrometer, and rotating the measuring rod of the micrometer. When measuring the length of the coil assembly 1000 using the micrometer method, the length of the coil assembly 1000 can refer to a single measurement or the arithmetic mean of multiple measurements. The same applies to the width and thickness of the coil assembly 1000.

[0034] The body 100 may include a magnetic material 10 and a resin. Specifically, the body 100 may be formed by laminating at least one magnetic composite sheet in which the magnetic material is dispersed in a resin. However, the body 100 may have a structure other than that in which the magnetic material is dispersed in a resin. For example, the body 100 may be formed using a magnetic material such as ferrite.

[0035] Magnetic materials can be ferrites or magnetic metal powder particles.

[0036] Examples of ferrite powder particles may include one or more of spinel-type 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.

[0037] 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, magnetic metal powder particles may be one or more selected from 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.

[0038] Magnetic metal powder particles can be amorphous or crystalline. For example, magnetic metal powder particles can be Fe-Si-B-Cr based amorphous alloy powder particles, but are not limited to this.

[0039] Each of the magnetic metal powder particles may have an average diameter of about 0.1 μm to about 30 μm, but is not limited thereto.

[0040] The body 100 may include two or more types of magnetic metal powder particles dispersed in a resin. The term "different types of magnetic powder particles" means that the magnetic powder particles dispersed in the resin are distinguished from each other by at least one of average diameter, composition, crystallinity, and shape.

[0041] Resins can be in single or combined forms, including but not limited to epoxy resins, polyimides, liquid crystal polymers, etc.

[0042] The main body 100 may include a core 110 extending through the central portion of each of the support substrate 200 and the coil portion 300. The core 110 may be formed by filling the central portion of the coil portion 300 and the support substrate 200 with a magnetic composite sheet, but this disclosure is not limited thereto.

[0043] The support substrate 200 can be embedded in the main body 100. The support substrate 200 can support the coil section 300 (described later).

[0044] The support substrate 200 may include an insulating material, such as a thermosetting insulating resin (e.g., epoxy resin), a thermoplastic insulating resin (e.g., polyimide), or a photosensitive insulating resin, or the support substrate 200 may include an insulating material in which a reinforcing material (e.g., glass fiber or inorganic filler) is impregnated with an insulating resin. For example, the support substrate 200 may include insulating materials such as prepreg, Ajinomoto Build-up Film (ABF), FR-4, bismaleimide triazine (BT) film, photosensitive dielectric (PID) film, etc., but is not limited thereto.

[0045] Inorganic fillers may be selected from one or more of the group consisting of silicon dioxide (SiO2), aluminum oxide (Al2O3), silicon carbide (SiC), barium sulfate (BaSO4), talc, mud, 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).

[0046] When the support substrate 200 is formed using an insulating material including reinforcing material, the support substrate 200 provides better rigidity. When the support substrate 200 is formed using an insulating material that does not include glass fiber, the support substrate 200 can facilitate a thinner coil assembly 1000. Furthermore, based on a body 100 of the same size, the volume occupied by the coil portion 300 and / or magnetic material can be increased to improve assembly characteristics. When the support substrate 200 is formed using an insulating material including a photosensitive insulating resin, the number of processes for forming the coil portion 300 can be reduced. Therefore, this can be advantageous in terms of reducing production costs, and fine vias can be formed.

[0047] The coil section 300 is disposed inside the main body 100 to exhibit the characteristics of the coil assembly 1000. For example, when the coil assembly 1000 is used as a power inductor, the coil section 300 can store the electric field as a magnetic field to maintain the output voltage for stabilizing the power supply of electronic devices.

[0048] The coil portion 300 includes coil patterns 311 and 312 and a via 320. Specifically, based on Figure 3 and Figure 4In the orientation of the first coil pattern 311, the first coil pattern 311 can be disposed on the lower surface of the support substrate 200 opposite to the sixth surface 106 of the main body 100, and the second coil pattern 312 can be disposed on the upper surface of the support substrate 200 opposite to the lower surface of the support substrate 200. A via 320 can be connected through the support substrate 200 to the inner end of each of the first coil pattern 311 and the second coil pattern 312. Therefore, the coil portion 300 can generally be used as a single coil. The outer end of the first coil pattern 311 can be exposed to the third surface 103 of the main body 100, and the outer end of the second coil pattern 312 can be exposed to the fourth surface 104 of the main body 100. The outer ends of the first coil pattern 311 and the second coil pattern 312 exposed to the third surface 103 and the fourth surface 104 of the main body 100 can contact and connect with the first electrode layers 610 and 710 (described later) of the external electrodes 600 and 700, respectively.

[0049] Each of the first coil pattern 311 and the second coil pattern 312 may be in the form of a planar spiral forming at least one turn around the core 110. For example, the first coil pattern 311 may be formed at least one turn around the core 110 on the lower surface of the support substrate 200.

[0050] At least one of the coil patterns 311 and 312 and the via 320 may include at least one conductive layer. For example, when the second coil pattern 312 and the via 320 are formed by performing a plating process on one side of the upper surface of the support substrate 200, each of the second coil pattern 312 and the via 320 may include a seed layer and an electroplated layer. Each of the seed layer and the electroplated layer may have a single-layer structure or a multi-layer structure. An electroplated layer with a multi-layer structure may have a conformal structure in which one electroplated layer covers another electroplated layer, or it may have a form in which another electroplated layer is only stacked on one surface of one electroplated layer. The seed layer of the second coil pattern 312 and the seed layer of the via 320 may be integrated with each other, and therefore, there may be no boundary between them, but this is not a limitation. The electroplated layer of the second coil pattern 312 and the electroplated layer of the via 320 may be integrated with each other, and therefore, there may be no boundary between them, but this is not a limitation.

[0051] As another example, the coil portion 300 can be formed by separately forming a first coil pattern 311 disposed on one side of the lower surface of the support substrate 200 and a second coil pattern 312 disposed on one side of the upper surface of the support substrate 200, and then batch-laminating the first coil pattern 311 and the second coil pattern 312 onto the support substrate 200. In this case, the via 320 may include a high-melting-point metal layer and a low-melting-point metal layer, the melting point of the low-melting-point metal layer being lower than that of the high-melting-point metal layer. The low-melting-point metal layer may be formed using solder comprising lead (Pb) and / or tin (Sn). At least a portion of the low-melting-point metal layer may melt due to the pressure and temperature during batch lamination. For this reason, an intermetallic compound layer (IMC layer) may be formed, for example, on a portion of the boundary between the low-melting-point metal layer and the second coil pattern 312.

[0052] For example, such as Figure 3 and Figure 4 As shown, coil patterns 311 and 312 can be formed to protrude from the lower and upper surfaces of the support substrate 200, respectively. As another example, the first coil pattern 311 can be formed to protrude from the lower surface of the support substrate 200, and the second coil pattern 312 can be embedded in the upper surface of the support substrate 200 to expose the upper surface of the second coil pattern 312 to the upper surface of the support substrate 200. In this case, a recessed portion can be formed on the upper surface of the second coil pattern 312, such that the upper surface of the support substrate 200 and the upper surface of the second coil pattern 312 are not necessarily on the same plane.

[0053] Each of the coil patterns 311 and 312 and the via 320 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), chromium (Cr), or alloys thereof, but is not limited to such conductive materials.

[0054] The first insulating layer 510 and the second insulating layer 520 can both be connected to one surface 106 of the body 100, and can be respectively disposed on two opposing side surfaces 101 and 102 of the body 100 to extend to one surface 106 of the body 100. The third insulating layer 530 and the fourth insulating layer 540 can both be connected to one surface 106 of the body 100, and can be disposed on two opposing end surfaces 103 and 104 of the body 100 to extend to one surface 106 of the body 100.

[0055] Specifically, a first insulating layer 510 may be disposed on a first surface 101 of the body 100 and may extend to a sixth surface 106 of the body 100 to cover the edge 106-1 between the first surface 101 and the sixth surface 106 of the body 100. As a result, the first insulating layer 510 may cover the first vertex region C1 and the fourth vertex region C4 of the sixth surface 106 of the body 100. A second insulating layer 520 may be disposed on a second surface 102 of the body 100 and may extend to the sixth surface 106 of the body 100 to cover the second edge 106-2 between the second surface 102 and the sixth surface 106 of the body 100. As a result, the second insulating layer 520 may cover the second vertex region C2 and the third vertex region C3 of the sixth surface 106 of the body 100. A third insulating layer 530 may be disposed on a third surface 103 of the body 100 and may extend to the sixth surface 106 of the body 100 to cover the third edge 106-3 between the third surface 103 and the sixth surface 106 of the body 100. As a result, the third insulating layer 530 may cover the first vertex region C1 and the second vertex region C2 of the sixth surface 106 of the body 100. A fourth insulating layer 540 may be disposed on the fourth surface 104 of the body 100 and may extend to the sixth surface 106 of the body to cover the fourth edge 106-4 between the fourth surface 104 and the sixth surface 106 of the body 100. As a result, the fourth insulating layer 540 may cover the third vertex region C3 and the fourth vertex region C4 of the sixth surface 106 of the body 100.

[0056] The first insulating layer 510, the second insulating layer 520, the third insulating layer 540, and the fourth insulating layer 540 may form overlapping regions in the vertex regions C1, C2, C3, and C4 of a surface 106 of the body 100. For example, in the first vertex region C1, the third insulating layer 530 may be disposed on the first insulating layer 510 to form overlapping regions. In the second vertex region C2, the third insulating layer 530 may be disposed on the second insulating layer 520 to form overlapping regions. In the third vertex region C3, the fourth insulating layer 540 may be disposed on the second insulating layer 520 to form overlapping regions. In the fourth vertex region C4, the fourth insulating layer 540 may be disposed on the first insulating layer 510 to form overlapping regions. In this specification, the term "edge" may refer to a boundary formed by two connected surfaces of the body 100. Additionally, in this specification, the term "vertex region" may refer to a boundary region formed by three connected surfaces of the body 100 and may not correspond to a vertex in a mathematical sense.

[0057] In this embodiment, since the multiple edges 106-1, 106-2, 106-3, and 106-4 of the sixth surface 106 of the body 100, as well as the multiple vertex regions C1, C2, C3, and C4, are covered by the first insulating layer 510, the second insulating layer 520, the third insulating layer 540, and the fourth insulating layer 540, they are not exposed to the external entity. Typically, the edges and vertex regions (the boundaries between the surfaces of the body) are highly susceptible to cracking and exposure of conductive magnetic metal powder particles. Cracks and exposed magnetic metal powder particles can serve as transmission paths for leakage current and can cause electrical short circuits between the external electrodes of the component, thereby degrading the component's characteristics. In this embodiment, the edges 106-1, 106-2, 106-3, and 106-4 of the sixth surface 106 of the body 100, as well as the vertex regions C1, C2, C3, and C4, can all be covered by the first insulating layer 510, the second insulating layer 520, the third insulating layer 540, and the fourth insulating layer to address the aforementioned problems. In particular, each of the vertex regions C1, C2, C3 and C4 of the sixth surface 106 of the body 100, which have a relatively high probability of the presence of cracks and exposed magnetic metal powder particles, can be double-covered with insulating layers 510, 520, 530 and 540 to improve the aforementioned improvement effect.

[0058] On one surface 106 of the body 100, the length of each of the first insulating layer 510 and the second insulating layer 520 in the second direction W is greatest at both ends of each of the first insulating layer 510 and the second insulating layer 520 in the first direction L. On one surface 106 of the body 100, the length of each of the third insulating layer 103 and the fourth insulating layer 104 in the first direction L is greatest at both ends of each of the third insulating layer 103 and the fourth insulating layer 104 in the second direction W. Specifically, on the sixth surface 106 of the body 100, the length of the first insulating layer 510 in the width direction W is greatest in the first vertex region C1 and the fourth vertex region C4 (the two ends of the first insulating layer 510 in the length direction L). On the sixth surface 106 of the body 100, the length of the second insulating layer 520 in the width direction W is greatest in the second vertex region C2 and the third vertex region C3 (the two ends of the second insulating layer 520 in the length direction L). On the sixth surface 106 of the body 100, the length of the third insulating layer 530 in the longitudinal direction L is greatest in the first vertex region C1 and the second vertex region C2 (the two ends of the third insulating layer 530 in the width direction W). On the sixth surface 106 of the body 100, the length of the fourth insulating layer 540 in the longitudinal direction L is greatest in the third vertex region C3 and the fourth vertex region C4 (the two ends of the fourth insulating layer 510 in the width direction W). Typically, external stress is concentrated in the edge regions of the component, causing cracks to extend relatively long. In this embodiment, each of the first insulating layer 510, the second insulating layer 520, the third insulating layer 540, and the fourth insulating layer 540 may be formed to be longer in the vertex regions C1, C2, C3, and C4 than in other regions to more effectively prevent the properties of the component from deteriorating due to cracks.

[0059] According to the above structure, the first insulating layer 510, the second insulating layer 520, the third insulating layer 540, and the fourth insulating layer 540 are formed to expose a region of the sixth surface 106 of the body 100. The outer electrodes 600 and 700 (described later) can be formed to be spaced apart from each other in the exposed region of the sixth surface 106. For the reasons described above, the outer electrodes 600 and 700 can be spaced apart from each of the first edge 106-1, the second edge 106-2, the third edge 106-3, and the fourth edge 106-4 of the body 100. Furthermore, for the reasons described above, the distances between the outer electrodes 600 and 700 and the first edge 106-1, the second edge 106-2, the third edge 106-3, and the fourth edge 106-4 of the body 100 are greatest in the vertex regions C1, C2, C3, and C4 of the sixth surface 106. The outer electrodes 600 and 700 may be spaced apart from the first edge 106-1, the second edge 106-2, the third edge 106-3, and the fourth edge 106-4 of the sixth surface 106 of the body 100, and the distance between the outer electrodes 600 and 700 and the vertex regions C1, C2, C3, and C4 may be increased to prevent the components from deteriorating.

[0060] External electrodes 600 and 700 may be spaced apart from each other on a surface 106 of the body 100 and may be connected to the coil portion 300. Each of the external electrodes 600 and 700 may include: a connecting portion disposed on two end surfaces 103 and 104 of the body 100 to contact and connect with the two ends of the coil portion 300; and a pad portion extending from the connecting portion to a surface 106 of the body 100. Specifically, the first electrode layer 610 of the first external electrode 600 may be disposed on the third surface 103 of the body 100 to contact and connect with the outermost end of the first coil pattern 311 exposed on the third surface 103 of the body 100, and may extend to the sixth surface 106 of the body 100. In the first electrode layer 610 of the first external electrode 600, the area disposed on the third surface 103 of the body 100 may correspond to the connecting portion of the first external electrode 600. In the first electrode layer 610 of the first external electrode 600, the area disposed on the sixth surface 106 of the body 100 may correspond to the pad portion of the first external electrode 600. The second external electrode 700 may be disposed on the fourth surface 104 of the body 100 to contact and connect with the outermost end of the second coil pattern 312 exposed on the fourth surface 104 of the body 100. In the first electrode layer 710 of the second external electrode 700, the area disposed on the fourth surface 104 of the body 100 may correspond to the connection portion of the second external electrode 700. In the second electrode layer 710 of the second external electrode 700, the area disposed on the sixth surface 106 of the body 100 may correspond to the pad portion of the second external electrode 700. The pad portions of the first external electrode 600 and the second external electrode 700 may be spaced apart from each other on the sixth surface 106 of the body 100 by a lower insulating layer 420 (described later). The second electrode layers 620 and 720 and the third electrode layers 630 and 730 may be further disposed on each region of the first electrode layers 610 and 710 disposed on the sixth surface 106 of the body 100. In this case, the pad portions of the outer electrodes 600 and 700 may include the second electrode layers 620 and 720 and the third electrode layers 630 and 730.

[0061] The regions of the first electrode layers 610 and 710 that serve as the connection portions of the external electrodes 600 and 700 can be covered by the third insulating layer 530 provided on the third surface 103 of the main body 100 and the fourth insulating layer 540 provided on the fourth surface 104 of the main body 100, respectively. (Refer to...) Figures 5 to 7The first electrode layers 610 and 710 may be formed after the upper insulating layer 410 and the lower insulating layer 420 are formed on the fifth surface 105 and the sixth surface 106 of the body 100, respectively, and after the first insulating layer 510 and the second insulating layer 520 are formed on the first surface 101 and the second surface 102 of the body, respectively. In this case, the first insulating layer 510 may be formed not only extending from the first surface 101 of the body 100, but also extending to at least a portion of each of the third surface 103, the fourth surface 104, the fifth surface 105, and the sixth surface 106 connected to the first surface 101. The second insulating layer 520 may be formed not only extending from the second surface 102 of the body 100, but also extending to at least a portion of each of the third surface 103, the fourth surface 104, the fifth surface 105, and the sixth surface 106 connected to the second surface 102. Therefore, the connection portions of the external electrodes 600 and 700 can be formed on each of the third surface 103 and the fourth surface 104 of the body 100, but do not extend to the edges between the third surface 103 and each of the first surface 101 and the second surface 102, or between the fourth surface 104 and each of the first surface 101 and the second surface 102. Since the connection portions of the external electrodes 600 and 700 do not extend to the edges between the third surface 103 and each of the first surface 101 and the second surface 102, or between the fourth surface 104 and each of the first surface 101 and the second surface 102, short circuits caused by leakage current can be prevented, and degradation of the component's characteristics can be prevented.

[0062] The external electrodes 600 and 700 may be formed by vapor deposition (such as sputtering) and / or plating. However, this disclosure is not limited thereto, and the external electrodes 600 and 700 may be formed by coating a conductive resin comprising conductive powder particles such as copper (Cu) onto the surface of the body 100 and curing the coated conductive resin.

[0063] The external electrodes 600 and 700 may be formed using conductive materials such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), molybdenum (Mo), chromium (Cr), or alloys thereof, but this disclosure is not limited thereto. The external electrodes 600 and 700 may be formed having a single-layer structure or a multi-layer structure. As an example, the external electrodes 600 and 700 include a first electrode layer 610 and 710 comprising copper (Cu), a second electrode layer 620 and 720 comprising nickel (Ni), and a third electrode layer 630 and 730 comprising tin (Sn), but this disclosure is not limited thereto.

[0064] The second electrode layers 620 and 720, and the third electrode layers 630 and 730, may be disposed only on the sixth surface 106 of the main body 100. The second electrode layers 620 and 720, and the third electrode layers 630 and 730, may be formed sequentially on the upper insulating layer 410 and lower insulating layer 420, the first insulating layer 510 and the second insulating layer 520, and the first electrode layers 610 and 620, and then on the third surface 103 and the fourth surface 104 of the main body 100, after which the third insulating layer 530 and the fourth insulating layer 540 are formed. When the third insulating layer 530 and the fourth insulating layer 540 are formed on the surface of the main body 100, the surface of the main body 100 may be completely covered by the upper insulating layer 410 and lower insulating layer 420, the first insulating layer 510, the second insulating layer 520, the third insulating layer 540 and the fourth insulating layer 540, and the first electrode layers 610 and 710. Furthermore, the first electrode layers 610 and 710 can be exposed by the upper insulating layer 410 and the lower insulating layer 420, as well as the first insulating layer 510, the second insulating layer 520, the third insulating layer 530, and the fourth insulating layer 540, spaced apart from each other only on the sixth surface 106 of the body 100. Since the second electrode layers 620 and 720 and the third electrode layers 630 and 730 are formed in this manner, they can be disposed only on the sixth surface 106 of the body 100.

[0065] An insulating film IF may be disposed between the coil portion 300 and the body 100, and between the support substrate 200 and the body 100. The insulating film IF may be formed along the surfaces of the support substrate 200 and the coil portion 300, but this disclosure is not limited thereto. The insulating film IF may be configured to insulate the coil portion 300 and the body 100 from each other, and may include known insulating materials such as parylene, but this disclosure is not limited thereto. As another example, in addition to parylene, the insulating film IF may include insulating materials such as epoxy resin. The insulating film IF may be formed by vapor deposition, but this disclosure is not limited thereto. As another example, the insulating film IF may be formed by laminating an insulating film for forming the insulating film IF onto both surfaces of the support substrate 200 on which the coil portion 300 is formed, and then curing the laminated insulating film. Alternatively, the insulating film IF may be formed by applying an insulating paste for forming the insulating film IF to both surfaces of the support substrate 200 on which the coil portion 300 is formed, and then curing the applied insulating paste.

[0066] While exemplary embodiments of the present disclosure have been described based on the support substrate 200 and the coil portion 300 formed on the support substrate 200 by plating, the scope of the present disclosure is not limited thereto. For example, in another exemplary embodiment of the present disclosure, a wound coil formed by winding a metal wire having an insulating coating surface can be used as the coil portion. In this case, the support substrate 200 and the insulating film IF described above can be omitted in the corresponding exemplary embodiment.

[0067] As described above, the size of the coil assembly can be reduced according to an exemplary embodiment.

[0068] According to an exemplary embodiment, the actual mounting area of ​​the coil assembly can be reduced.

[0069] While exemplary 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 invention as defined by the appended claims.

Claims

1. A coil assembly comprising: a main body; a coil portion provided inside the main body; first and second outer electrodes provided to be spaced apart from each other on one surface of the main body and connected to the coil portion; first and second insulating layers respectively provided on side surfaces of the main body and each extending onto the one surface of the main body, the side surfaces of the main body being respectively connected to the one surface of the main body and opposite to each other; and third and fourth insulating layers respectively provided on end surfaces of the main body and each extending onto the one surface of the main body, the end surfaces of the main body being respectively connected to the one surface of the main body and opposite to each other, wherein a portion of each of the first and second outer electrodes exposed from the first, second, third, and fourth insulating layers is spaced apart from each of a plurality of edges of the one surface of the main body on the one surface of the main body, and wherein each of the first and second outer electrodes is spaced apart from an edge between the one surface and the side surfaces of the main body. Distances from each of the plurality of edges of the one surface of the main body to the first and second outer electrodes are greatest in a vertex region of the one surface of the main body.

2. The coil assembly of claim 1, wherein, Two adjacent ones of the first, second, third, and fourth insulating layers overlap each other in the vertex region of the one surface of the main body.

3. The coil assembly of claim 1, wherein, The third or fourth insulating layer is provided on at least a portion of the first or second insulating layer on the vertex region of the one surface of the main body.

4. The coil assembly of claim 3, wherein, The end surfaces of the main body are opposite to each other in a first direction, and the side surfaces of the main body are opposite to each other in a second direction perpendicular to the first direction, and 5. The coil assembly of claim 1, wherein, a length of each of the first and second insulating layers in the second direction is greatest on both end portions of each of the first and second insulating layers in the first direction on the one surface of the main body. The end surfaces of the main body are opposite to each other in a first direction, and the side surfaces of the main body are opposite to each other in a second direction perpendicular to the first direction, and 6. The coil assembly of claim 1, wherein, a length of each of the third and fourth insulating layers in the first direction is greatest on both end portions of each of the third and fourth insulating layers in the second direction on the one surface of the main body. 7.The coil assembly of claim 1, further comprising: a fifth insulating layer provided between the first and second outer electrodes on the one surface of the main body, wherein each of the first and second insulating layers is provided on at least a portion of the fifth insulating layer. end portions of the coil portion are respectively exposed to the end surfaces of the main body, and 8. The coil assembly of claim 1, wherein, ​ Each of the first and second outer electrodes includes a connection portion provided on one of the end surfaces of the main body to contact and connect with one of the end portions of the coil portion, and a pad portion extending from the connection portion to the one surface of the main body.

9. The coil assembly of claim 8, wherein, The third and fourth insulating layers respectively cover the connection portions provided on the end surfaces.

10. The coil assembly of claim 8, wherein, The first and second insulating layers respectively extend to the end surfaces of the main body in such a manner that each of the first and second insulating layers covers a portion of the connection portion spaced apart from an edge between the end surface of the main body and the side surface of the main body.

11. The coil assembly of claim 1, further comprising: a support substrate provided inside the main body, wherein the coil portion includes a first coil pattern provided on one surface of the support substrate, a second coil pattern provided on another surface of the support substrate opposite to the one surface of the support substrate, and a via hole penetrating through the support substrate to connect the first and second coil patterns to each other.

12. The coil assembly of claim 1, wherein, Each of the first and second outer electrodes is spaced apart from a vertex region of the one surface of the main body.

13. The coil assembly of claim 8, wherein, The connection portion of each of the first and second outer electrodes is spaced apart from an edge between the side surface and the end surface of the main body.

14. A coil assembly comprising: a main body; a coil portion provided inside the main body; first and second outer electrodes provided to be spaced apart from each other on one surface of the main body and connected to the coil portion; and a plurality of insulating layers covering a plurality of edges of the one surface of the main body in such a manner that portions of the first and second outer electrodes exposed from the plurality of insulating layers are spaced apart from each of the plurality of edges of the one surface of the main body, wherein, among the plurality of insulating layers, two insulating layers provided on a vertex region of the one surface of the main body overlap with each other in the vertex region. Each of the plurality of insulating layers has a maximum width in the vertex region.

15. The coil assembly of claim 14, wherein, 16. A coil assembly comprising: a main body having a first surface and a second surface opposite to each other in a width direction of the main body, a third surface and a fourth surface opposite to each other in a length direction of the main body, and a fifth surface and a sixth surface opposite to each other in a thickness direction of the main body; a coil portion provided inside the main body; first and second outer electrodes connected to the coil portion and spaced apart from each other on the sixth surface of the main body; a first insulating layer provided on the first surface and extending to a portion of each of the third, fourth, fifth, and sixth surfaces; a second insulating layer provided on the second surface and extending to another portion of each of the third, fourth, fifth, and sixth surfaces; ​ a third insulating layer disposed on the third surface and extending onto a portion of each of the first surface, the second surface, the fifth surface, and the sixth surface; and a fourth insulating layer disposed on the fourth surface and extending onto another portion of each of the first surface, the second surface, the fifth surface, and the sixth surface.

17. The coil assembly of claim 16, wherein, Each of the third insulating layer and the fourth insulating layer overlaps a portion of the first insulating layer on the sixth surface, and each of the third insulating layer and the fourth insulating layer overlaps a portion of the second insulating layer on the sixth surface.

18. The coil assembly of claim 16, wherein, The overlapping portions of the third insulating layer and the first insulating layer, the overlapping portions of the fourth insulating layer and the first insulating layer, the overlapping portions of the third insulating layer and the second insulating layer, and the overlapping portions of the fourth insulating layer and the second insulating layer are respectively disposed on an apex region of the sixth surface.

19. The coil assembly of claim 16, wherein, The first external electrode includes a first connecting portion disposed on the third surface of the main body to be connected to one end portion of the coil portion, and a first land portion extending from the first connecting portion to the sixth surface of the main body, and The second external electrode includes a second connecting portion disposed on the fourth surface of the main body to be connected to the other end portion of the coil portion, and a second land portion extending from the second connecting portion to the sixth surface of the main body.

20. The coil assembly of claim 19, wherein, The first connecting portion is covered by the third insulating layer, The first land portion is exposed from the first insulating layer, the second insulating layer, the third insulating layer, and the fourth insulating layer, The second connecting portion is covered by the fourth insulating layer, and The second land portion is exposed from the first insulating layer, the second insulating layer, the third insulating layer, and the fourth insulating layer.

21. The coil assembly according to claim 19, further comprising a fifth insulating layer disposed on the sixth surface at least between the first land portion and the second land portion.

22. The coil assembly of claim 21, wherein, Each of the first insulating layer and the second insulating layer covers a portion of the fifth insulating layer on the sixth surface.

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