Coil assembly

Abstract

A coil assembly is provided. The coil assembly includes a main body, a support substrate disposed in the main body, a coil part including a coil pattern, a lead-out pattern, and an extension pattern, and disposed on the support substrate, the lead-out pattern being exposed to an outside of the main body, the extension pattern connecting the coil pattern and the lead-out pattern, and an external electrode disposed on the main body and contacting the lead-out pattern, wherein each of the lead-out patterns has an inner portion adjacent to a corresponding one of the extension patterns, an outer portion adjacent to a corresponding one of the external electrodes, and an intermediate portion disposed between the inner portion and the outer portion, and in at least one of the lead-out patterns, a width of the intermediate portion is greater than a width of the inner portion and less than a width of the outer portion.

Description

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2020-0169343, filed on December 7, 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] With the miniaturization and performance improvement of electronic devices, there is a growing demand for miniaturization and performance improvement of electronic components installed in these devices. Summary of the Invention

[0005] One aspect of this disclosure provides a coil assembly in which a portion of the lead pattern of the coil assembly has a large size to improve inductance (Ls) and current characteristics, and this portion is coupled to an external electrode.

[0006] According to one aspect of this disclosure, a coil assembly may include: a body; a support substrate disposed in the body; a coil portion including a coil pattern, a lead-out pattern, and an extension pattern, wherein the coil portion is disposed on the support substrate, the lead-out pattern is exposed to the outside of the body, and the extension pattern connects the coil pattern and the lead-out pattern; and an external electrode disposed on the body and in contact with the lead-out pattern, wherein each lead-out pattern has an inner portion adjacent to one of the extension patterns, an outer portion adjacent to one of the external electrodes, and an intermediate portion disposed between the inner portion and the outer portion, and in at least one lead-out pattern, the width of the intermediate portion is greater than the width of the inner portion and less than the width of the outer portion.

[0007] According to another aspect of this disclosure, a coil assembly may include: a body; a support substrate disposed in the body; a coil portion having a through-hole passing through a central portion of the coil portion and including a first coil pattern, a first lead-out pattern, and a first extension pattern, the first coil pattern, the first lead-out pattern, and the first extension pattern each being disposed on a first surface of the support substrate, the first coil pattern being wound around the through-hole, the first lead-out pattern being exposed to the outside of the body, and the first extension pattern connecting the first coil pattern to the first lead-out pattern; and a first external electrode disposed on the body and contacting the first lead-out pattern, wherein a first side surface of the first lead-out pattern intersects obliquely with the inner surface of the first external electrode.

[0008] According to another aspect of this disclosure, a coil assembly may include: a body; a support substrate disposed in the body; a coil portion having a through-hole passing through a central portion of the coil portion and including a coil pattern, a lead-out pattern, and an extension pattern, the coil pattern, the lead-out pattern, and the extension pattern each being disposed on the support substrate, the coil pattern being wound around the through-hole, the lead-out pattern being exposed to the outside of the body, and the extension pattern connecting the coil pattern to the lead-out pattern; and an external electrode disposed on the body and contacting the lead-out pattern, wherein the extension pattern extends from one end of the coil pattern along an inclined direction relative to the outer surface of the body on which the external electrode is disposed, and the extension pattern includes a generally straight portion. Attached Figure Description

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

[0010] Figure 1 This is a perspective view schematically illustrating a coil assembly according to an exemplary embodiment of the present disclosure;

[0011] Figure 2 This is a plan view showing a coil assembly according to an exemplary embodiment of the present disclosure;

[0012] Figure 3 yes Figure 2 A magnified view of region A. Figure 3 The width of each of the extended and lead-out patterns is shown;

[0013] Figure 4 yes Figure 2 A magnified view of region A. Figure 4 The angle formed by the center line of the extended pattern and the center line of the leading pattern is shown;

[0014] Figure 5This is a plan view illustrating a coil assembly according to another exemplary embodiment of the present disclosure;

[0015] Figure 6 yes Figure 5 A magnified view of region B. Figure 6 The width of each of the extended and lead-out patterns is shown;

[0016] Figure 7 yes Figure 5 A magnified view of region B. Figure 7 The angle formed by the center line of the extended pattern and the center line of the leading pattern is shown;

[0017] Figure 8 It is along Figure 1 A cross-sectional view taken from line I-I';

[0018] Figure 9 It is along Figure 1 A cross-sectional view taken from line II-II';

[0019] Figure 10 This is a diagram illustrating a coil bar for manufacturing a coil assembly according to an exemplary embodiment of the present disclosure; and

[0020] Figure 11 This is a diagram illustrating a coil bar for manufacturing a coil assembly according to another exemplary embodiment of the present disclosure. Detailed Implementation

[0021] In the attached figures, the L direction refers to the first direction or length direction, the W direction refers to the second direction or width direction, and the T direction refers to the third direction or thickness direction.

[0022] In the following, exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings.

[0023] Various electronic components can be used in electronic devices, and various coil components can be appropriately used among these electronic components according to their purpose to remove noise, etc.

[0024] In other words, the coil components used in electronic devices can be power inductors, high-frequency inductors, ordinary ferrite beads, ferrite beads for high frequencies (e.g., suitable for the GHz band), common-mode filters, etc.

[0025] Figure 1 This is a perspective view schematically illustrating a coil assembly according to an exemplary embodiment of the present disclosure.

[0026] Figure 2 This is a plan view illustrating a coil assembly according to an exemplary embodiment of the present disclosure. Figure 3 yes Figure 2 A magnified view of region A. Figure 3 The width of each of the extended and lead-out patterns is shown. Figure 4 yes Figure 2 A magnified view of region A. Figure 4 The angle formed by the center line of the extended pattern and the center line of the leading pattern is shown.

[0027] Figure 5 This is a plan view illustrating a coil assembly according to another exemplary embodiment of this disclosure. Figure 6 yes Figure 5 A magnified view of region B. Figure 6 The width of each of the extended and lead-out patterns is shown. Figure 7 yes Figure 5 A magnified view of region B. Figure 7 The angle formed by the center line of the extended pattern and the center line of the leading pattern is shown.

[0028] Figure 8 It is along Figure 1 The cross-sectional view taken from line I-I'. Figure 9 It is along Figure 1 The cross-sectional view taken from line II-II'.

[0029] Reference Figures 1 to 9 The coil assembly 1000 according to the exemplary embodiments of the present disclosure may include a body 100, a support substrate 200, a coil portion 300, and external electrodes 410 and 420, and may also include an insulating film IF and / or a surface insulating layer 700.

[0030] The main body 100 may form the appearance of the coil assembly 1000 according to this exemplary embodiment, and the coil portion 300 and the support substrate 200 are disposed in the main body 100.

[0031] The main body 100 can typically have a hexahedral shape.

[0032] The main body 100 may have a first surface 101 and a second surface 102 that are opposite each other in the length direction L, a third surface 103 and a fourth surface 104 that are opposite each other in the width direction W, and a fifth surface 105 and a sixth surface 106 that are opposite each other in the thickness direction T. The first surface 101 to the fourth surface 104 of the main body 100 may correspond to the wall surface of the main body 100 that connects the fifth surface 105 and the sixth surface 106 to each other. In the following, the opposite end surfaces (one end surface and the other end surface) of the main body 100 may refer to the first surface 101 and the second surface 102 of the main body 100, respectively; the opposite side surfaces (one side surface and the other side surface) of the main body 100 may refer to the third surface 103 and the fourth surface 104 of the main body 100, respectively; and one surface and the other surface of the main body 100 may refer to the fifth surface 105 and the sixth surface 106 of the main body 100, respectively.

[0033] The main body 100 may be configured such that the coil assembly 1000 according to this exemplary embodiment (in which the external electrodes 410 and 420, described below, and the surface insulating layer 700 are formed) may have, for example, a length of 2.0 mm, a width of 1.2 mm, and a thickness of 0.65 mm, but is not limited thereto. Furthermore, the above values ​​are merely assumed values ​​in the design and do not reflect manufacturing errors, etc. Therefore, it should be understood that the permissible range of manufacturing errors also falls within the scope of this disclosure.

[0034] The length of the coil assembly 1000 can refer to the maximum length of a plurality of line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the length direction L in an image (taken by an optical microscope or scanning electron microscope (SEM)) of a cross-section (a cross-section taken along the length direction L-thickness direction T) of the central portion of the coil assembly 1000 in the width direction W. Alternatively, the length of the coil assembly 1000 can refer to the arithmetic mean of the lengths of at least two line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the length direction L in the cross-sectional image.

[0035] The thickness of the coil assembly 1000 can refer to the maximum length of a plurality of line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the thickness direction T in an image (taken by an optical microscope or SEM) of a cross-section (a cross-section taken along the length direction L-thickness direction T) of the central portion of the coil assembly 1000 in the width direction W. Alternatively, the thickness of the coil assembly 1000 can refer to the arithmetic mean of the lengths of at least two line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the thickness direction T in the cross-sectional image.

[0036] The width of the coil assembly 1000 can refer to the maximum length of a plurality of line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the width direction W in an image (taken by an optical microscope or SEM) of a cross-section (a cross-section taken along the length direction L-width direction W) of the central portion of the coil assembly 1000 in the thickness direction T. Alternatively, the width of the coil assembly 1000 can refer to the arithmetic mean of the lengths of at least two line segments connecting the outermost boundary line of the coil assembly 1000 and parallel to the width direction W in the cross-sectional image.

[0037] Optionally, the length, width, and thickness of the coil assembly 1000 can be measured using a micrometer measurement method. According to the micrometer measurement method, the measurement can be performed by zeroing a micrometer with metrological repeatability and reproducibility (R&R), inserting the coil assembly 1000 according to this exemplary embodiment between the tips of the micrometer, and rotating the measuring rod of the micrometer. Furthermore, when measuring the length of the coil assembly 1000 using the micrometer measurement method, the length of the coil assembly 1000 can refer to a value obtained by performing a single measurement or the arithmetic mean of values ​​obtained by performing multiple measurements. This can also be applied to the width and thickness of the coil assembly 1000.

[0038] The body 100 may comprise an insulating resin 10 and a magnetic material 20. Specifically, the body 100 may be formed by stacking one or more magnetic composite sheets in which the magnetic material 20 is dispersed in the insulating resin 10. The magnetic material 20 may be magnetic powder particles. As an example, the magnetic material 20 may be ferrite or metallic magnetic powder particles.

[0039] Ferrites can be at least one of the following: 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, or Ni-Zn-based ferrites), hexagonal ferrites (such as Ba-Zn-based ferrites, Ba-Mg-based ferrites, Ba-Ni-based ferrites, Ba-Co-based ferrites, or Ba-Ni-Co-based ferrites), garnet-type ferrites (such as Y-based ferrites), and Li-based ferrites.

[0040] The metallic magnetic 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 metallic magnetic powder particles may be at least one of the following: pure iron powder particles, Fe-Si based alloy powder particles, Fe-Si-Al based alloy powder particles, Fe-Ni based alloy powder particles, Fe-Ni-Mo based alloy powder particles, Fe-Ni-Mo-Cu based alloy powder particles, Fe-Co based alloy powder particles, Fe-Ni-Co based alloy powder particles, Fe-Cr based alloy powder particles, Fe-Cr-Si based alloy powder particles, Fe-Si-Cu-Nb based alloy powder particles, Fe-Ni-Cr based alloy powder particles, and Fe-Cr-Al based alloy powder particles.

[0041] The metallic magnetic powder particles can be amorphous or crystalline. For example, the metallic magnetic powder particles can be Fe-Si-B-Cr based amorphous alloy powder particles, but are not limited to this.

[0042] Ferrite and metallic magnetic powder particles may have an average diameter of about 0.1 μm to 30 μm, but are not limited thereto.

[0043] The main body 100 may include two or more magnetic materials dispersed in the resin. Here, different kinds of magnetic materials refer to magnetic materials dispersed in the resin that can be distinguished from each other by any one of average diameter, composition, crystallinity, and shape.

[0044] In the following text, it is assumed that the magnetic material is metallic magnetic powder particles 20. However, the scope of this disclosure is not limited to the body 100 having a structure in which metallic magnetic powder particles 20 are dispersed in insulating resin 10.

[0045] The insulating resin 10 may include, but is not limited to, epoxy resin, polyimide, liquid crystal polymer (LCP), or mixtures thereof.

[0046] The main body 100 includes a core 110 passing through a support substrate 200 and a coil portion 300, which will be described below. The core 110 can be formed by filling through holes in the central portions of the coil portion 300 and the support substrate 200 with a magnetic composite sheet, but is not limited thereto.

[0047] The support substrate 200 is embedded in the main body 100. The support substrate 200 is an assembly that supports the coil section 300, which will be described below.

[0048] The support substrate 200 can be formed using an insulating material, including thermosetting resins such as epoxy resins, thermoplastic resins such as polyimide resins, or photosensitive insulating resins. Alternatively, the support substrate 200 can be formed using an insulating material formed by impregnating a reinforcing material such as glass fiber or inorganic filler in such an insulating resin. As examples, the support substrate 200 can be formed using insulating materials such as prepregs, Ajinomoto build-up film (ABF), FR-4, bismaleimide triazine (BT) resin, photosensitive dielectric (PID), etc., but is not limited to these.

[0049] At least one of the following can be used as an inorganic filler: silicon dioxide (SiO2), aluminum oxide (Al2O3), silicon carbide (SiC), barium sulfate (BaSO4), talc, mud, mica powder particles, 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).

[0050] When the support substrate 200 is formed using an insulating material including reinforcing material, the support substrate 200 can provide superior rigidity. When the support substrate 200 is formed using an insulating material that does not include glass fiber, the support substrate 200 can help reduce the thickness of the coil assembly 1000 according to this exemplary embodiment. Furthermore, the volume occupied by the coil portion 300 and / or the metallic magnetic powder particles 20 relative to the body 100 having the same size can be increased, thereby improving assembly characteristics. When the support substrate 200 is formed using an insulating material including a photosensitive insulating resin, the number of processes used to form the coil portion 300 can be reduced, which helps reduce production costs and allows for the formation of fine vias.

[0051] The coil portion 300 can be disposed in the main body 100 and can realize the characteristics of the coil assembly. For example, when the coil assembly 1000 according to this exemplary embodiment is used as a power inductor, the coil portion 300 can be used to store the electric field as a magnetic field to maintain the output voltage, thereby stabilizing the power of the electronic device.

[0052] The coil section 300 includes coil patterns 311 and 312, via 320, lead-out patterns 331 and 332, and extension patterns 341 and 342.

[0053] Specifically, based on Figures 1 to 9 In the direction of the first coil pattern 311, the first lead-out pattern 331 and the first extension pattern 341 are disposed on the lower surface of the support substrate 200 (the lower surface opposite to the sixth surface 106 of the main body 100), and the second coil pattern 312, the second lead-out pattern 332 and the second extension pattern 342 are disposed on the upper surface of the support substrate 200 (the upper surface opposite to the lower surface of the support substrate 200).

[0054] The via 320 passes through the support substrate 200 and contacts the inner end of each of the first coil pattern 311 and the second coil pattern 312.

[0055] A first extension pattern 341 is disposed between the first coil pattern 311 and the first lead-out pattern 331, connecting the first coil pattern 311 and the first lead-out pattern 331 to each other. A second extension pattern 342 is disposed between the second coil pattern 312 and the second lead-out pattern 332, connecting the second coil pattern 312 and the second lead-out pattern 332 to each other. The first extension pattern 341 and the second extension pattern 342 may each have a width W. E Generally uniform, substantially straight shape. Those skilled in the art will understand that the expression "generally uniform" means uniform or identical by allowing for process errors, positional deviations, and / or measurement errors that may occur during the manufacturing process.

[0056] The first lead-out pattern 331 and the second lead-out pattern 332 are respectively connected to the first extension pattern 341 and the second extension pattern 342, respectively exposed at the first surface 101 and the second surface 102 of the body 100, and respectively connected to the first external electrode 410 and the second external electrode 420, which will be described below. Therefore, the coil portion 300 can be used as a single coil as a whole between the first external electrode 410 and the second external electrode 420.

[0057] Each of the first coil pattern 311 and the second coil pattern 312 may have a planar spiral shape forming at least one turn around the core 110. As an example, the first coil pattern 311 may form at least one turn around the core 110 on the lower surface of the support substrate 200.

[0058] Patterns 331 and 332 are exposed on the first surface 101 and the second surface 102 of the main body 100, respectively.

[0059] Specifically, the first lead-out pattern 331 is exposed on the first surface 101 of the body 100, and the second lead-out pattern 332 is exposed on the second surface 102 of the body 100.

[0060] The lead-out patterns 331 and 332 may have an inner portion adjacent to the extended pattern, an outer portion adjacent to the outer electrode, and an intermediate portion disposed between the inner portion and the outer portion.

[0061] Specifically, the first lead-out pattern 331 may have a first inner portion (not shown) adjacent to the first extended pattern 341, a first outer portion (not shown) adjacent to the first outer electrode 410, and a first intermediate portion (not shown) disposed between the first inner portion (not shown) and the first outer portion (not shown). Furthermore, referring to… Figures 2 to 7 The second lead-out pattern 332 may have a second inner portion 332A adjacent to the second extended pattern 342, a second outer portion 332C adjacent to the second outer electrode 420, and a second intermediate portion 332B disposed between the second inner portion 332A and the second outer portion 332C.

[0062] Here, in at least one of the lead-out patterns 331 and 332, the width of the lead-out pattern may increase from the inner portion toward the outer portion. Specifically, in lead-out pattern 332, the width W of the middle portion 332B... B It can be larger than the width W of the internal part 332A. A And smaller than the width W of the outer part 332C. C .

[0063] According to exemplary embodiments in this disclosure, refer to Figures 2 to 4 The extended pattern 342 has a generally uniform width WE The lead-out pattern 332 can have different widths (W) depending on its position. A W B and W C Furthermore, the width of the lead-out pattern 332 can continuously increase from the inner portion 332A toward the outer portion 332C. In other words, the lead-out pattern 332 can have a radial structure in its overall shape.

[0064] Reference Figure 4 The extension pattern 342 and the lead-out pattern 332 can be divided based on the virtual boundary line BL. In the lead-out pattern 332, the region adjacent to the virtual boundary line BL can be the inner portion 332A, the region adjacent to the outer electrode 420 can be the outer portion 332C, and the region between the inner portion 332A and the outer portion 332C can be the middle portion 332B.

[0065] The extended pattern 342 can be formed such that the connection width W E Virtual centerline C of the center point E With connection width W A W B and W C Virtual centerline C of the center point L They intersect at an angle. In other words, the two center lines C E and C L They can intersect in an inclined direction while maintaining a specific angle (θ), rather than being parallel or perpendicular to each other.

[0066] Furthermore, the width W of the extended pattern 342 is limited. E Of the opposite side surfaces, the side surface adjacent to the coil pattern 312 (i.e., one side surface) can define the width W of the lead-out pattern 332. A W B and W C The side surfaces of the lead-out pattern 332 adjacent to the coil pattern 312 in the opposite side surfaces are substantially coplanar. Those skilled in the art will understand that the expression "substantially coplanar" means that they are located on the same plane by allowing for process errors, positional deviations and / or measurement errors that may occur during the manufacturing process.

[0067] In other words, in this case, the side surfaces of the extension pattern 342 and the lead-out pattern 332 adjacent to the coil pattern 312 can be as follows: Figures 2 to 4 The plan view shown is arranged in a generally straight line shape.

[0068] On the other hand, the width W of the lead-out pattern 332 is limited. A W B and W COn the opposite side surface, the other side surface of the pattern 332 adjacent to the outer electrode 420 may intersect the inner surface of the outer electrode 420 at an angle.

[0069] Reference Figure 3 The other side surface of the lead-out pattern 332 may intersect the inner surface of the outer electrode 420 at an angle, and the other side surface of the lead-out pattern 332 is opposite to but not parallel to one of the side surfaces of the lead-out pattern 332 and the coil pattern 312.

[0070] In this embodiment, the acute angle between one side surface of the lead-out pattern 332 and the inner surface of the outer electrode 420 may be different from (for example, smaller than) the acute angle between the other side surface of the lead-out pattern 332 and the inner surface of the outer electrode 420. One side surface of the lead-out pattern 332 may also intersect the inner surface of the outer electrode 420 at an angle.

[0071] According to another exemplary embodiment of this disclosure, referring to Figures 5 to 7 The lead-out pattern 332 can have different widths (W) depending on its position. A W B and W C Furthermore, the width of pattern 332 can gradually increase from the inner portion 332A toward the middle portion 332B and the outer portion 332C.

[0072] However, unlike the radial structure in the above exemplary embodiment, in this exemplary embodiment, the width W of the internal portion 332A is... A The width W of the middle part 332B B The width W of the outer part 332C C Each of them is generally uniform. That is to say, the lead-out pattern 332 can have a structure with an overall stepped shape.

[0073] Reference Figure 7 The extension pattern 342 and the lead-out pattern 332 can be divided based on the virtual boundary line BL. In the lead-out pattern 332, the region adjacent to the virtual boundary line BL can be the inner portion 332A, the region adjacent to the outer electrode 420 can be the outer portion 332C, and the region between the inner portion 332A and the outer portion 332C can be the middle portion 332B.

[0074] The extended pattern 342 can be formed such that the connection width W E Virtual centerline C of the center point E With connection width W A W B and W C Virtual centerline C of the center point L They intersect at an angle. In other words, the two center lines C E and CL They can intersect in an inclined direction while maintaining a specific angle (θ), rather than being parallel or perpendicular to each other.

[0075] Reference Figures 1 to 7 The extended pattern 342 can extend from one end of the coil pattern 312 along an inclined direction relative to the outer surface of the body on which the outer electrode 420 is disposed (e.g., parallel to the direction of the coil pattern 312). Figure 4 and Figure 7 The virtual center line C in E Extension. In one example, the extended pattern 342 may include generally straight portions. Those skilled in the art will understand that the expression "generally straight" means straight by allowing for process errors, positional deviations, and / or measurement errors that may occur during the manufacturing process.

[0076] At least one of the coil patterns 311 and 312, via 320, lead-out patterns 331 and 332, and extension patterns 341 and 342 may include at least one conductive layer.

[0077] As an example, when the second coil pattern 312, via 320, second lead-out pattern 332, and second extension pattern 342 are formed on the upper surface of the support substrate 200 by plating, each of the second coil pattern 312, via 320, second lead-out pattern 332, and second extension pattern 342 may include a seed layer and an electroplated layer. Here, the electroplated layer may have a single-layer structure or a multi-layer structure. The multi-layer electroplated layer may be formed in a conformal film structure in which one electroplated layer is formed along the surface of another electroplated layer, or it may be formed in a shape in which one electroplated layer is stacked only on one surface of another electroplated layer. The seed layer may be formed by an electroless plating method or a vapor deposition method such as sputtering. The seed layers of the second coil pattern 312, the via 320, the second lead-out pattern 332, and the second extension pattern 342 may be integrally formed with each other such that no boundary is formed between them. However, the seed layer is not limited to this. The electroplated layers of the second coil pattern 312, the via 320, the second lead-out pattern 332, and the second extension pattern 342 can be integrally formed with each other, such that no boundary is formed between them. However, the electroplated layers are not limited to this.

[0078] As another example, in the case where the first coil pattern 311, the first lead-out pattern 331, and the first extension pattern 341 disposed on the lower surface of the support substrate 200, and the second coil pattern 312, the second lead-out pattern 332, and the second extension pattern 342 disposed on the upper surface of the support substrate 200 are formed separately and stacked together on the support substrate 200 to form the coil portion 300, the via 320 may include a high-melting-point metal layer and a low-melting-point metal layer with a melting point lower than that of the high-melting-point metal layer. Here, the low-melting-point metal layer may be formed using solder comprising lead (Pb) and / or tin (Sn). As an example, at least a portion of the low-melting-point metal layer may melt due to the pressure and temperature during co-stacking, such that an intermetallic compound (IMC) layer may be formed at the boundary between the low-melting-point metal layer and the second coil pattern 312.

[0079] As an example, such as Figure 8 and Figure 9 As shown, coil pattern 311, lead-out pattern 331, and extension pattern 341 can protrude from the lower surface of the support substrate 200, and coil pattern 312, lead-out pattern 332, and extension pattern 342 can protrude from the upper surface of the support substrate 200. As another example, the first coil pattern 311, the first lead-out pattern 331, and the first extension pattern 341 can protrude from the lower surface of the support substrate 200, and the second coil pattern 312, the second lead-out pattern 332, and the second extension pattern 342 can be embedded in the upper surface of the support substrate 200, and the upper surfaces of the second coil pattern 312, the second lead-out pattern 332, and the second extension pattern 342 can be exposed on the upper surface of the support substrate 200. In this case, a recess is formed on each of the upper surfaces of the second coil pattern 312, the second lead-out pattern 332, and / or the second extension pattern 342, such that the upper surface of the support substrate 200 does not necessarily have to be substantially coplanar with the upper surfaces of the second coil pattern 312, the second lead-out pattern 332, and / or the second extension pattern 342.

[0080] Each of the coil patterns 311 and 312, via 320, lead-out patterns 331 and 332, and extension patterns 341 and 342 may be formed using, but is not limited to, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), chromium (Cr), or alloys thereof.

[0081] External electrodes 410 and 420 are spaced apart from each other on the main body 100 and connected to the coil portion 300. Specifically, the first external electrode 410 may be disposed on the first surface 101 of the main body 100 and contact the first lead-out pattern 331 exposed on the first surface 101 of the main body 100. Furthermore, the second external electrode 420 may be disposed on the second surface 102 of the main body 100 and contact the second lead-out pattern 332 exposed on the second surface 102 of the main body 100.

[0082] The external electrodes 410 and 420 may be formed by vapor deposition methods such as sputtering and / or plating methods, but are not limited thereto.

[0083] The external electrodes 410 and 420 may be formed using conductive materials such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), chromium (Cr), titanium (Ti), or alloys thereof, but are not limited thereto. The external electrodes 410 and 420 may each have a single-layer structure or a multi-layer structure. As an example, the first external electrode 410 may include a first conductive layer, a second conductive layer, and a third conductive layer. The first conductive layer contains at least one of silver (Ag) and copper (Cu), the second conductive layer is disposed on the first conductive layer and contains nickel (Ni), and the third conductive layer is disposed on the second conductive layer and contains tin (Sn). At least one of the second and third conductive layers may be formed to cover the first conductive layer, but the scope of this disclosure is not limited thereto. At least one of the second and third conductive layers may be disposed only on the sixth surface 106 of the body 100, but the scope of this disclosure is not limited thereto. The first conductive layer may be a plating layer or a conductive resin layer formed by coating and curing a conductive resin comprising conductive powder particles (including at least one of copper (Cu) and silver (Ag)) and a resin. The second and third conductive layers may be plating layers, but the scope of this disclosure is not limited thereto.

[0084] An insulating film IF is disposed between the coil portion 300 and the main body 100, and also between the support substrate 200 and the main body 100. The insulating film IF may be formed along the surface of the support substrate 200 on which coil patterns 311 and 312, lead-out patterns 331 and 332, and extension patterns 341 and 342 are formed, but is not limited thereto.

[0085] An insulating film IF may be provided to insulate the coil portion 300 from the body 100, and the insulating film IF may contain any known insulating material, such as, but not limited to, parylene. As another example, the insulating film IF may contain insulating materials other than parylene, such as epoxy resin.

[0086] The insulating film IF can be formed by vapor deposition, but is not limited thereto. As another example, the insulating film IF can be formed by stacking an insulating film for forming the insulating film IF on the opposing surface of the support substrate 200 on which the coil portion 300 is formed, and then curing the insulating film. Alternatively, the insulating film IF can be formed by coating an insulating paste for forming the insulating film IF onto the opposing surface of the support substrate 200 on which the coil portion 300 is formed, and then curing the insulating paste.

[0087] Furthermore, the insulating film IF is a component that can be omitted in this exemplary embodiment. That is, if the body 100 has sufficient resistance at the design operating current and voltage of the coil assembly 1000 according to this exemplary embodiment, the insulating film IF can be omitted in this exemplary embodiment.

[0088] The coil assembly 1000 according to this exemplary embodiment may further include a surface insulation layer 700 disposed on the fifth surface 105 of the body 100 and covering the body 100 to protect the body 100 from external influences.

[0089] The surface insulating layer 700 may extend from the fifth surface 105 of the body 100 to at least a portion of the first surface 101 to the fourth surface 104 and the sixth surface 106. In this exemplary embodiment, the surface insulating layer 700 may be disposed on each of the third surface 103 to the sixth surface 106 of the body 100.

[0090] At least portions of the surface insulating layers 700 disposed on the third to sixth surfaces 106 of the body 100 may be formed using the same process and may be integrally formed with each other such that no boundary is formed between them. However, the scope of this disclosure is not limited thereto.

[0091] The surface insulating layer 700 may comprise thermoplastic resins (such as polystyrene, vinyl acetate, polyester, polyethylene, polypropylene, polyamide, rubber, or acrylic), thermosetting resins (such as phenol, epoxy resin, urethane, melamine, or alkyd resin), photosensitive resins, parylene, SiO2, etc. x or SiN x The surface insulation layer 700 may also contain insulating fillers such as inorganic fillers, but is not limited thereto.

[0092] Figure 10 This is a diagram illustrating a coil bar 2000 for manufacturing a coil assembly 1000 according to an exemplary embodiment of the present disclosure.

[0093] Reference Figure 10 The coil assembly 1000 can be manufactured by using a coil strip 2000 on a support substrate 200 to form a plurality of coil portions 300 and by stacking magnetic composite sheets and performing cutting.

[0094] In this exemplary embodiment, the left coil portion 301 and the right coil portion 302 are mirror-symmetrical to each other with respect to the rod to which the plurality of coil portions 300 are connected. That is, in a plane where the x-axis is the length direction (L direction) and the y-axis is the width direction (W direction), the left coil portion 301 and the right coil portion 302 are symmetrical to each other with respect to the y-axis.

[0095] In this configuration, the left coil portion 301 can form a turn counterclockwise from the outside of the coil portion 300 toward the center, and the right coil portion 302 can form a turn clockwise. That is, the left coil portion 301 and the right coil portion 302 can form turns in opposite directions.

[0096] Figure 11 This is a diagram illustrating a coil bar 2000' for manufacturing a coil assembly 1000 according to another exemplary embodiment of the present disclosure.

[0097] Reference Figure 11 The coil assembly 1000 can be manufactured by using coil strips 2000' with multiple coil portions 300 formed on a support substrate 200 and by stacking magnetic composite sheets and performing cutting.

[0098] In this exemplary embodiment, the left coil portion 301 and the right coil portion 302 are symmetrical about their origins with respect to the rod to which the plurality of coil portions 300 are connected. That is, in a plane where the x-axis is the length direction (L direction) and the y-axis is the width direction (W direction), the left coil portion 301 and the right coil portion 302 are symmetrical about their origins with respect to the center point p where the lead-out patterns of the left coil portion 301 and the right coil portion 302 intersect each other.

[0099] In this case, the left coil portion 301 can form a turn from the outside of the coil portion 300 toward the center in a counterclockwise direction, and the right coil portion 302 can similarly form a turn in a counterclockwise direction. That is, the left coil portion 301 and the right coil portion 302 can each form a turn in the same direction.

[0100] According to this disclosure, the lead-out pattern can have a radial structure or a stepped structure as described above. As a result, compared with the conventional horizontal structure according to the prior art, the portion of the lead-out pattern in contact with the external electrode has a larger size, thus maintaining good DC resistance (Rdc) and current characteristics. Furthermore, due to the smaller volume of the lead-out pattern, a larger space for the magnetic powder particles 20 can be ensured in the body, thus improving the inductance (Ls) characteristics.

[0101] In addition, it can reduce electrode wear that may occur when cutting is performed during the use of coil strip 2000 in the manufacturing of coil assembly 1000.

[0102] As described above, according to exemplary embodiments of the present disclosure, a coil assembly may be provided in which a portion of the lead pattern of the coil assembly has a large size to improve inductance (Ls) and current characteristics, and this portion is coupled to an external electrode.

[0103] Although exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and changes may be made without departing from the scope of this disclosure as defined by the appended claims.

Claims

1. A coil assembly, comprising: main body; A support substrate is disposed in the main body; The coil portion includes a coil pattern, a lead-out pattern, and an extension pattern, and the coil portion is disposed on the support substrate. The lead-out pattern is exposed to the outside of the body, and the extension pattern connects the coil pattern to the lead-out pattern. as well as An external electrode is disposed on the main body and contacts the lead-out pattern. Each of the lead-out patterns has an inner portion adjacent to one of the extended patterns, an outer portion adjacent to one of the outer electrodes, and an intermediate portion disposed between the inner portion and the outer portion. In at least one of the lead-out patterns, the width of the middle portion is greater than the width of the inner portion and less than the width of the outer portion, and the surface of the at least one lead-out pattern that contacts the outer electrode surface has a first interior angle with one side surface of the at least one lead-out pattern, and the surface of the at least one lead-out pattern that contacts the outer electrode surface has a second interior angle with the other side surface of the at least one lead-out pattern, both the first and second interior angles being acute angles and being opposite to each other in the width direction of the at least one lead-out pattern.

2. The coil assembly according to claim 1, wherein, The width of each lead-out pattern increases continuously from the surface in contact with one of the extended patterns toward the surface in contact with one of the external electrodes.

3. The coil assembly according to claim 1, wherein, The virtual center line connecting the center point of the width of one of the extended patterns intersects obliquely with the virtual center line connecting the center point of the width of one of the lead-out patterns.

4. The coil assembly according to claim 1, further comprising an insulating film disposed between the coil portion and the body and between the support substrate and the body.

5. The coil assembly according to claim 1, wherein, In the side surface of one of the extended patterns, the side surface adjacent to one of the coil patterns is substantially coplanar with the side surface of one of the lead-out patterns adjacent to the coil pattern in the coil pattern.

6. The coil assembly according to claim 1, wherein, The coil pattern includes a first coil pattern and a second coil pattern. The first coil pattern is disposed on a first surface of the supporting substrate, and the second coil pattern is disposed on a second surface of the supporting substrate opposite to the first surface of the supporting substrate. The lead-out pattern includes a first lead-out pattern and a second lead-out pattern. The first lead-out pattern is disposed on the first surface of the support substrate, and the second lead-out pattern is disposed on the second surface of the support substrate. The extended pattern includes a first extended pattern and a second extended pattern. The first extended pattern is disposed on the first surface of the support substrate and connects the first coil pattern and the first lead-out pattern to each other. The second extended pattern is disposed on the second surface of the support substrate and connects the second coil pattern and the second lead-out pattern to each other. The external electrode includes a first external electrode and a second external electrode. The first external electrode is disposed on the first end surface of the main body and contacts the first lead-out pattern, and the second external electrode is disposed on the second end surface of the main body and contacts the second lead-out pattern.

7. The coil assembly according to claim 6, wherein, The first lead-out pattern has a first inner portion adjacent to the first extended pattern, a first outer portion adjacent to the first outer electrode, and a first intermediate portion disposed between the first inner portion and the first outer portion. The second lead-out pattern has a second inner portion adjacent to the second extended pattern, a second outer portion adjacent to the second outer electrode, and a second intermediate portion disposed between the second inner portion and the second outer portion. The width of the first middle portion is greater than the width of the first inner portion and less than the width of the first outer portion, and The width of the second middle portion is greater than the width of the second inner portion and less than the width of the second outer portion.

8. The coil assembly according to claim 6 or 7, wherein, The coil section also includes a via that passes through the support substrate and connects the first coil pattern and the second coil pattern to each other.

9. The coil assembly according to any one of claims 1-7, wherein, The main body comprises insulating resin and magnetic material.

10. A coil assembly, comprising: main body; A support substrate is disposed in the main body; The coil portion has a through hole passing through the central portion of the coil portion and includes a first coil pattern, a first lead-out pattern and a first extension pattern. The first coil pattern, the first lead-out pattern and the first extension pattern are each disposed on a first surface of the support substrate. The first coil pattern is wound around the through hole. The first lead-out pattern is exposed to the outside of the body. The first extension pattern connects the first coil pattern to the first lead-out pattern. as well as The first external electrode is disposed on the main body and contacts the first lead-out pattern. Wherein, the first side surface of the first lead-out pattern intersects the inner surface of the first outer electrode at an angle, the second side surface of the first lead-out pattern is opposite to the first side surface but not parallel to each other, and the first side surface and the second side surface of the first lead-out pattern intersect the inner surface of the first outer electrode at an angle. The first lead-out pattern has a first interior angle between the surface in contact with the first outer electrode surface and the first side surface, and the first lead-out pattern has a second interior angle between the surface in contact with the first outer electrode surface and the second side surface. Both the first interior angle and the second interior angle are acute angles and are opposite to each other.

11. The coil assembly of claim 10, wherein, The side surfaces of the first extended pattern and the first lead-out pattern adjacent to the first coil pattern are arranged in a generally straight line shape.

12. The coil assembly of claim 10, wherein, The acute angle between the first side surface of the first lead-out pattern and the inner surface of the first outer electrode is different from the acute angle between the second side surface of the first lead-out pattern and the inner surface of the first outer electrode.

13. The coil assembly of claim 10, wherein, The first extended pattern has a first side surface and a second side surface that are opposite to each other, and The first side surface of the first extended pattern is at an angle to the first side surface of the first lead-out pattern, and the second side surface of the first extended pattern is substantially coplanar with the second side surface of the first lead-out pattern.

14. The coil assembly of claim 13, wherein, The acute angle between the first side surface of the first lead-out pattern and the inner surface of the first outer electrode is greater than the acute angle between the second side surface of the first lead-out pattern and the inner surface of the first outer electrode.

15. The coil assembly of claim 10, wherein, The first lead-out pattern has a first inner portion that contacts the first extended pattern, a first outer portion that contacts the first outer electrode, and a first intermediate portion disposed between the first inner portion and the first outer portion. The width of the first middle portion is greater than the width of the first inner portion and less than the width of the first outer portion.

16. The coil assembly according to any one of claims 10-15, further comprising a second external electrode disposed on the body opposite to the first external electrode. in, The coil portion further includes a second coil pattern, a second extension pattern, and a second lead-out pattern, each of which is disposed on a second surface of the support substrate opposite to the first surface of the support substrate. The second lead pattern is connected to the second external electrode.

17. A coil assembly, comprising: main body; A support substrate is disposed in the main body; The coil portion has a through hole passing through the central portion of the coil portion and includes a coil pattern, a lead-out pattern and an extension pattern, the coil pattern, the lead-out pattern and the extension pattern are each disposed on the support substrate, the coil pattern is wound around the through hole, the lead-out pattern is exposed to the outside of the body, and the extension pattern connects the coil pattern to the lead-out pattern. as well as An external electrode is disposed on the main body and contacts the lead-out pattern. The extended pattern extends from one end of the coil pattern along an inclined direction relative to the outer surface of the main body on which the outer electrode is disposed. The extended pattern includes generally straight portions, and The lead-out pattern has an inner portion adjacent to the extended pattern, an outer portion adjacent to the outer electrode, and an intermediate portion disposed between the inner portion and the outer portion. The lead-out pattern is constructed in a stepped shape, and the width of the middle portion is greater than the width of the inner portion and less than the width of the outer portion.

18. The coil assembly of claim 17, wherein the width of each of the inner portion, the intermediate portion, and the outer portion is substantially uniform.

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