Coil assembly

Abstract

A coil assembly is provided. The coil assembly includes a main body having one surface and another surface opposite to each other and a plurality of walls connecting the one surface and the other surface to each other, a coil part disposed within the main body, a first outer electrode and a second outer electrode disposed on the one surface of the main body while being spaced apart from each other and connected to the coil part, a first insulating layer disposed on the other surface of the main body and extending to at least a portion of each of the plurality of walls of the main body, and a second insulating layer disposed on the one surface of the main body.

Description

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2021-0050039, filed on April 16, 2021, 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 become more powerful and smaller, the number of electronic components used in these devices increases, and the size of these components decreases.

[0005] Recently, with the development of technologies such as smartphones, wearable devices, and autonomous vehicles, the use of passive components has increased rapidly. In particular, the demand for power inductors, ranging from large to small wafers, has increased rapidly, as power inductors are used as key components in various filters and power-related integrated circuits (ICs) such as power management integrated circuits (PMICs). Furthermore, in addition to existing standard-sized wafers, the demand for square wafers is also increasing.

[0006] Another important technological trend is circuit integration, and in the case of passive components, there is a need to develop lower surface electrode implementation technologies that enable circuit integration. In the case of square wafers, productivity decreases and costs increase due to the need for vision sorting equipment for wafer arrangement. Therefore, there is a need for technologies to implement L-shaped electrodes and lower surface electrode structures in wafers with square structures. Summary of the Invention

[0007] One aspect of this disclosure is to provide a coil assembly that is lightweight, thin, and compact.

[0008] Another aspect of this disclosure provides a coil assembly that can improve productivity and significantly reduce man-hours by simplifying the manufacturing process.

[0009] Another aspect of this disclosure may provide a coil assembly in which the volume of a magnetic body is increased to increase its inductance.

[0010] Another aspect of this disclosure provides a coil assembly capable of reducing the effective mounting area.

[0011] According to one aspect of this disclosure, a coil assembly may include: a body having one surface and another surface opposite to each other and a plurality of walls connecting the one surface and the other surface to each other; a coil portion disposed within the body; a first external electrode and a second external electrode disposed on the one surface of the body while being spaced apart from each other and connected to the coil portion; a first insulating layer disposed on the other surface of the body and extending to at least a portion of each of the plurality of walls of the body; and a second insulating layer disposed on the one surface of the body.

[0012] According to another aspect of this disclosure, a coil assembly may include: a body having one surface and another surface opposite to each other and a plurality of walls connecting the one surface and the other surface to each other; a coil portion disposed within the body; a first external electrode and a second external electrode disposed spaced apart from each other on the one surface of the body and connected to the coil portion; a first insulating layer and a second insulating layer disposed respectively on the other surface of the body and the one surface of the body; and a third insulating layer and a fourth insulating layer respectively connected to the one surface of the body, disposed respectively on opposite end surfaces of the body in a first direction, and each extending to the one surface of the body, wherein the second insulating layer is spaced apart from each of the plurality of edges of the one surface of the body, and the length of each of the third insulating layer and the fourth insulating layer on the first surface of the body in the second direction is longest at the opposite ends of each of the third insulating layer and the fourth insulating layer in the first direction. Attached Figure Description

[0013] 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:

[0014] Figure 1 This is a schematic perspective view of a coil assembly according to an exemplary embodiment;

[0015] Figure 2 It shows from below ( Figure 1 A) A bottom view of the coil assembly according to an exemplary embodiment, viewed from direction A.

[0016] Figure 3 It is along Figure 1 A cross-sectional view taken from line I-I';

[0017] Figure 4 It is along Figure 1 A cross-sectional view taken from line II-II';

[0018] Figure 5It shows from above ( Figure 1 (B) Observation according to the exemplary embodiment Figure 1 A perspective view of the coil assembly;

[0019] Figure 6 This is a schematic perspective view of a coil assembly according to another exemplary embodiment;

[0020] Figure 7 It shows from below ( Figure 6 Direction A) of observation according to another exemplary embodiment Figure 6 A bottom view of the coil assembly;

[0021] Figure 8 It is along Figure 6 A cross-sectional view taken from line I-I';

[0022] Figure 9 It is along Figure 6 A cross-sectional view taken from line II-II';

[0023] Figure 10 This is a schematic perspective view of a coil assembly according to another exemplary embodiment;

[0024] Figure 11 It shows from below ( Figure 10 Direction A) of observation according to another exemplary embodiment Figure 10 A bottom view of the coil assembly;

[0025] Figure 12 It is along Figure 10 A cross-sectional view taken from line I-I';

[0026] Figure 13 It is along Figure 10 A cross-sectional view taken from line II-II';

[0027] Figure 14 This is a schematic perspective view of a coil assembly according to another exemplary embodiment;

[0028] Figure 15 It shows from below ( Figure 14 Direction A) of observation according to another exemplary embodiment Figure 14 A bottom view of the coil assembly;

[0029] Figure 16 It is along Figure 14 A cross-sectional view taken from line I-I';

[0030] Figure 17 It is along Figure 14 The cross-sectional view taken from line II-II'; and

[0031] Figures 18 to 20 This is a process diagram showing, in sequence, a method for manufacturing a coil assembly according to exemplary embodiments of the present disclosure. Detailed Implementation

[0032] In the following, exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings.

[0033] 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.

[0034] Various electronic components can be used in electronic devices, and various coil assemblies can be appropriately used among these electronic components for purposes such as noise reduction.

[0035] In other words, the coil components used in electronic devices can be power inductors, high-frequency (HF) inductors, ordinary ferrite beads, high-frequency ferrite beads (e.g., ferrite beads suitable for the GHz band), common-mode filters, etc.

[0036] Figure 1 This is a schematic perspective view of a coil assembly according to an exemplary embodiment.

[0037] Figure 2 It shows from below ( Figure 1 A) A bottom view of the coil assembly according to an exemplary embodiment, viewed from the direction of A.

[0038] Figure 3 It is along Figure 1 The cross-sectional view taken from line I-I'.

[0039] Figure 4 It is along Figure 1 The cross-sectional view taken from line II-II'.

[0040] Figure 5 From above ( Figure 1 (B) Observation according to the exemplary embodiment Figure 1 A perspective view of the coil assembly.

[0041] Reference Figures 1 to 4 The coil assembly 1000 according to the first exemplary embodiment of the present disclosure may include a body 100, a substrate 200, a coil portion 300, insulating layers 410, 420, 430 and 440, and a first external electrode 500 and a second external electrode 600, wherein the coil portion 300 includes a first coil pattern 310 and a second coil pattern 320, and the coil assembly 1000 according to the first exemplary embodiment of the present disclosure may also include an insulating film IF.

[0042] The main body 100 may form the appearance of the coil assembly 1000 according to the first exemplary embodiment, and the coil portion 300 and the substrate 200 are disposed within the main body 100.

[0043] The main body 100 can typically have a hexahedral shape.

[0044] like Figure 1 , Figure 3 and Figure 4 As shown, the body 100 may have a first surface 101 and a second surface 102 opposite to each other in the thickness direction T, a third surface 103 and a fourth surface 104 opposite to each other in the width direction W, and a fifth surface 105 and a sixth surface 106 opposite to each other in the length direction L. The third surface 103 to the sixth surface 106 of the body 100 may correspond to a plurality of walls of the body 100 that connect the first surface 101 and the second surface 102 to each other. In the following, the opposite end surfaces of the body 100 may refer to the third surface 103 and the fourth surface 104 of the body 100, respectively; the opposite side surfaces of the body 100 may refer to the fifth surface 105 and the sixth surface 106 of the body 100, respectively; and one surface and another surface of the body 100 may refer to the second surface 102 and the first surface 101 of the body 100, respectively.

[0045] As an example, the body 100 may be configured such that the coil assembly 1000 according to the first exemplary embodiment (in which the external electrodes 500 and 600, which will be described later, and the insulating layers 410, 420, 430 and 440 are formed) may have a length of 4.0 mm and a width of 4.0 mm, but the size of the coil assembly 1000 is not limited thereto.

[0046] Here, the length of the coil assembly 1000 according to the first exemplary embodiment can refer to: the maximum value among the lengths of a plurality of line segments connecting two boundary lines facing each other in the length direction L of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the optical micrograph being obtained by imaging the first surface 101 of the body 100 of the coil assembly 100 from above the first surface 101 of the body 100, the plurality of line segments being parallel to the length direction L. Optionally, the length of the coil assembly 1000 can refer to: the minimum value among the lengths of a plurality of line segments connecting two boundary lines facing each other in the length direction L of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the length direction L. Optionally, the length of the coil assembly 1000 can refer to: the arithmetic mean of the lengths of three or more line segments connecting two boundary lines facing each other in the length direction L of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the length direction L.

[0047] Here, the width of the coil assembly 1000 can refer to the maximum value among the lengths of a plurality of line segments connecting two adjacent boundary lines in the width direction W of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the optical micrograph being obtained by imaging the first surface 101 of the body 100 of the coil assembly 100 from above the first surface 101 of the body 100, the plurality of line segments being parallel to the width direction W. Alternatively, the width of the coil assembly 1000 can refer to the minimum value among the lengths of a plurality of line segments connecting two adjacent boundary lines in the width direction W of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the width direction W. Alternatively, the width of the coil assembly 1000 can refer to the arithmetic mean of the lengths of three or more line segments connecting two adjacent boundary lines in the width direction W of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the width direction W.

[0048] Here, the thickness of the coil assembly 1000 can refer to the maximum value among the lengths of a plurality of line segments connecting two boundary lines facing each other in the thickness direction T of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the optical micrograph being obtained by imaging the third surface 103 of the body 100 of the coil assembly 100 from above the third surface 103 of the body 100, the plurality of line segments being parallel to the thickness direction T. Alternatively, the thickness of the coil assembly 1000 can refer to the minimum value among the lengths of a plurality of line segments connecting two boundary lines facing each other in the thickness direction T of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the thickness direction T. Alternatively, the thickness of the coil assembly 1000 can refer to the arithmetic mean of the lengths of three or more line segments connecting two boundary lines facing each other in the thickness direction T of the outermost boundary line of the coil assembly 1000 shown in an optical micrograph, the plurality of line segments being parallel to the thickness direction T.

[0049] 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 subjected to metrological repeatability and reproducibility (R&R), inserting the coil assembly 1000 according to the first 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 the value obtained by performing a single measurement, or the arithmetic mean of the values ​​obtained by performing multiple measurements. The same applies to the width and thickness of the coil assembly 1000.

[0050] The body 100 may comprise a magnetic material and a resin. Specifically, the body 100 may be formed by stacking one or more magnetic composite sheets in which the magnetic material is dispersed in a resin. However, the body 100 may have a structure other than one 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.

[0051] When viewed in the thickness direction T, the cross-section of the body 100 according to this disclosure may have a square shape. That is, each of the first surface 101 and the second surface 102 of the body 100 may have a square shape, and the width W and the length L of the body 100 may have similar values. Therefore, it may be difficult to specify the length and width directions of the body 100 based solely on its appearance.

[0052] For example, the main body 100 may have a length of 4.0 mm, a width of 4.0 ± 0.2 mm, and a thickness of 1.0 mm. That is, referring to... Figure 2 and Figure 5 The distance between the fifth surface 105 and the sixth surface 106 of the main body 100 can be 4.0 mm, and the distance between the third surface 103 and the fourth surface 104 of the main body 100 can be 4.0 ± 0.2 mm. Therefore, the absolute value of the difference between the length (A) and width (B) of the main body 100 can be 0.2 mm or less. However, the scope of this disclosure is not limited to the above-described dimensions of the main body 100. That is, the scope of this disclosure can include situations where, even if the dimensions of the main body 100 are different from the above-described dimensions, it is difficult to specify the length and width directions of the main body 100 solely based on its appearance because the length and width of the main body 100 have nearly the same value. Furthermore, since the above-described dimensions of the main body 100 are numerical values ​​that do not reflect manufacturing errors, the actual dimensions of the main body 100 may have values ​​different from the above-described values ​​due to manufacturing errors, etc.

[0053] Therefore, when the cross-section of the main body in the thickness direction T has a square shape or a shape similar to a square shape, and it is therefore difficult to distinguish the length direction and the width direction of the main body 100, together with the lead-out structure of the coil portion 300 which will be described later, it is not necessary to distinguish the width direction and the length direction of the main body 100 from each other during the manufacturing process.

[0054] Magnetic materials may include ferrites or metallic magnetic powders.

[0055] 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.

[0056] The metallic magnetic powder 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 may be at least one of 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.

[0057] Metallic magnetic powders can be amorphous or crystalline. For example, metallic magnetic powders can be Fe-Si-B-Cr based amorphous alloy powders, but are not limited to this.

[0058] Metallic magnetic powders can have an average diameter of about 0.1 μm to about 30 μm, but are not limited thereto.

[0059] The main body 100 may include two or more magnetic materials dispersed in a resin. Here, different kinds of magnetic materials refer to magnetic materials dispersed in a resin that are different from each other according to any one of the following: average diameter, composition, crystallinity, and shape of the magnetic materials.

[0060] The resin may include, but is not limited to, epoxy resins, polyimides, liquid crystal polymers (LCPs), or mixtures thereof.

[0061] The body 100 may include a core 110 that passes through the central portion of each of the substrate 200 and the coil portion 300, which will be described later. The core 110 may be formed by filling the central portion of each of the coil portion 300 and the substrate 200 with a magnetic composite sheet, but is not limited thereto.

[0062] The substrate 200 may be embedded in the body 100. The substrate 200 may be an assembly that supports the coil portion 300, which will be described later. The substrate 200 may support the first coil pattern 310 and the second coil pattern 320, which will be described later, and may have a plurality of end portions, which may be exposed on the outer surface of the body 100.

[0063] As an example, the substrate 200 may include a plurality of end portions, including a first main end portion 211 and a second main end portion 221, and a first auxiliary end portion 212 and a second auxiliary end portion 222. The first main end portion 211 and the second main end portion 221 may respectively support the first main lead portion 311 and the second main lead portion 321, which will be described later. The first auxiliary end portion 212 and the second auxiliary end portion 222 may respectively support the first auxiliary lead portion 312 and the second auxiliary lead portion 322, which will be described later. Furthermore, the first main end portion 211 may be exposed together with the first main lead portion 311 on the fifth surface 105 of the body 100, the second main end portion 221 may be exposed together with the second main lead portion 321 on the sixth surface 106 of the body 100, the first auxiliary end portion 212 may be exposed together with the first auxiliary lead portion 312 on the third surface 103 of the body 100, and the second auxiliary end portion 222 may be exposed together with the second auxiliary lead portion 322 on the fourth surface 104 of the body 100.

[0064] The 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 substrate 200 can be formed using an insulating material prepared by impregnating a reinforcing material (such as glass fiber or inorganic filler) in an insulating resin. For example, the substrate 200 can be formed using insulating materials such as prepregs, Ajinomoto build-up films (ABF), FR-4, bismaleimide triazine (BT) resin, photosensitive dielectrics (PID), etc., but is not limited thereto.

[0065] 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, clay, mica powder, aluminum hydroxide (Al(OH)3), magnesium hydroxide (Mg(OH)2), calcium carbonate (CaCO3), magnesium carbonate (MgCO3), magnesium oxide (MgO), boron nitride (BN), aluminum borate (AlBO3), barium titanate (BaTiO3), and calcium zirconate (CaZrO3).

[0066] When the substrate 200 is formed using an insulating material including reinforcing material, the substrate 200 can provide superior rigidity. When the substrate 200 is formed using an insulating material that does not include glass fibers, the substrate 200 can help reduce the thickness of the coil assembly 1000 according to the first exemplary embodiment. In addition, the volume occupied by the coil portion 300 and / or magnetic material relative to the body 100 having the same size can be increased, thus improving the characteristics of the assembly. When the 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 to reduce production costs and allows for the formation of fine vias.

[0067] The coil portion 300 can be disposed within the main body 100 and can realize the characteristics of a 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 an electric field as a magnetic field to maintain the output voltage, thereby stabilizing the power of the electronic device.

[0068] The coil portion 300 may include a first coil pattern 310, a second coil pattern 320, and a through hole 330. Specifically, in Figure 3 and Figure 4 In the direction of the coil, a first coil pattern 310 may be disposed on the lower surface of the substrate 200 facing the second surface 102 of the body 100, and a second coil pattern 320 may be disposed on the upper surface of the substrate 200 opposite to the lower surface of the substrate 200. A via 330 may penetrate the substrate 200 and connect to the inner end of each of the first coil pattern 310 and the second coil pattern 320. In doing so, the coil portion 300 can be used as a single coil as a whole. Each of the first coil pattern 310 and the second coil pattern 320 may have an outer end exposed to the outer surface of the body 100. The outer end of the first coil pattern 310 may include a first main lead 311 exposed to the fifth surface 105 of the body, and a first auxiliary lead 312 exposed to the third surface 103 of the body. The outer end of the second coil pattern 320 may include a second main lead 321 and a second auxiliary lead 322, with the second main lead 321 exposed on the sixth surface 106 of the body and the second auxiliary lead 322 exposed on the fourth surface 104 of the body.

[0069] As a result, in the coil assembly 1000 according to the first exemplary embodiment, even without identifying and specifying the surfaces on which the first external electrode 500 and the second external electrode 600, as described later, will be formed, the first external electrode 500 and the second external electrode 600 can be more easily connected to the coil portion 300. That is, even when it is difficult to specify the width direction and length direction because the width and length of the body 100 are similar to each other, the first external electrode 500 and the second external electrode 600 can be connected to the coil portion 300 as long as the first external electrode 500 and the second external electrode 600 are formed on two opposing surfaces among the third surface 103, the fourth surface 104, the fifth surface 105, and the sixth surface 106 of the body 100. Specifically, as Figure 5 As shown, the first external electrode 500 and the second external electrode 600 can be formed on the fifth surface 105 and the sixth surface 106 of the body 100, which are opposite to each other in the length direction L, respectively. However, the surfaces on which the first external electrode 500 and the second external electrode 600 are formed are not limited to this, and the first external electrode 500 and the second external electrode 600 can be formed on the third surface 103 and the fourth surface 104 of the body 100, which are opposite to each other in the width direction W, respectively, so as to easily connect the first external electrode 500 and the second external electrode 600 to the coil portion 300. Therefore, the coil assembly 1000 according to the first exemplary embodiment does not require the use of separate identification marks when forming the first external electrode 500 and the second external electrode 600.

[0070] The first main lead 311 and the first auxiliary lead 312 can be formed together with the first coil pattern 310 in the same process, so no boundary is formed between them. That is, the first main lead 311, the first auxiliary lead 312, and the first coil pattern 310 can be formed integrally. The second main lead 321 and the second auxiliary lead 322 can be formed together with the second coil pattern 320 in the same process, so no boundary is formed between them. That is, the second main lead 321, the second auxiliary lead 322, and the second coil pattern 320 can be formed integrally.

[0071] The areas of the first main lead 311 exposed on the fifth surface 105 of the main body 100, the areas of the first auxiliary lead 312 exposed on the third surface 103 of the main body 100, the areas of the second main lead 321 exposed on the sixth surface 106 of the main body 100, and the areas of the second auxiliary lead 322 exposed on the fourth surface 104 of the main body 100 can be substantially the same. In this case, regardless of which surface of the main body 100 the first external electrode 500 and the second external electrode 600 are formed on, the reliability of the connection between the coil portion 300 and the first external electrode 500 and the second external electrode 600 can be maintained consistently.

[0072] The outer ends of the first coil pattern 310 and the second coil pattern 320 exposed on the fifth surface 105 and the sixth surface 106 of the body 100 can contact the first electrode layers 510 and 610 of the external electrodes 500 and 600, which will be described later, respectively. Specifically, the first main lead 311 exposed on the fifth surface 105 of the body 100 can contact the first external electrode 500, which will be described later, and the second main lead 321 exposed on the sixth surface 106 of the body 100 can contact the second external electrode 600.

[0073] On the other hand, the first auxiliary lead-out portion 312 exposed on the third surface 103 of the body 100 can contact the third insulating layer 430, which will be described later, and the second auxiliary lead-out portion 322 exposed on the fourth surface 104 of the body 100 can contact the fourth insulating layer 440, which will be described later.

[0074] Each of the first coil pattern 310 and the second coil pattern 320 may have a planar spiral shape forming at least one turn around the core 110. As an example, the first coil pattern 310 may form at least one turn around the core 110 on the lower surface of the substrate 200.

[0075] At least one of coil pattern 310, coil pattern 320, and via 330 may include at least one conductive layer. As an example, in the case where the second coil pattern 320 and via 330 are formed by plating onto the upper surface of substrate 200, each of the second coil pattern 320 and via 330 may include a seed layer and an electroplated layer. Here, the electroplated layer may have a single-layer structure or a multi-layer structure. An electroplated layer with a multi-layer structure may be formed in a conformal film structure where one electroplated layer is formed along the surface of another electroplated layer, or it may be formed in a shape where 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 layer of the second coil pattern 320 and the seed layer of the via 330 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 layer of the second coil pattern 320 and the electroplated layer of the via 330 may be integrally formed with each other such that no boundary is formed between them. However, the electroplated layer is not limited to this.

[0076] As another example, if a first coil pattern 310 disposed on the lower surface of the substrate 200 and a second coil pattern 320 disposed on the upper surface of the substrate 200 are formed separately and then stacked together on the substrate 200 to form a coil portion 300, the via 330 may include a high-melting-point metal layer and a low-melting-point metal layer, wherein the melting point of the low-melting-point metal layer is 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). In some embodiments, at least a portion of the low-melting-point metal layer may melt due to 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 320.

[0077] In some embodiments, such as Figure 3 and Figure 4 As shown, coil patterns 310 and 320 may protrude from the lower and upper surfaces of the substrate 200, respectively. As another example, the first coil pattern 310 may protrude from the lower surface of the substrate 200, and the second coil pattern 320 may be embedded in the upper surface of the substrate 200 such that the upper surface of the second coil pattern 320 is exposed to the upper surface of the substrate 200. In this case, a recess may be formed in the upper surface of the second coil pattern 320, such that the upper surface of the substrate 200 and the upper surface of the second coil pattern 320 are not on the same plane.

[0078] The coil patterns 310 and 320 and the via 330 may each be formed using conductive materials such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), chromium (Cr) or alloys thereof, but are not limited thereto.

[0079] The first insulating layer 410 and the second insulating layer 420 may be respectively disposed on the first surface 101 and the second surface 102 of the main body 100.

[0080] According to this exemplary embodiment, a first insulating layer 410 may be disposed on a first surface 101 of the body 100 corresponding to another surface, and extend to at least a portion of the plurality of surfaces (also referred to as walls) 103, 104, 105, and 106 of the body 100 that respectively connect the first surface 101 and the second surface 102. This is because the first insulating layer 410 is formed by a pad printing method, which will be described later. Therefore, when the first insulating layer 410 extends to at least a portion of the plurality of walls 103, 104, 105, and 106 of the body 100 (e.g. Figure 1 , Figure 3 and Figure 4 As shown, the first insulating layer 410 can cover the upper vertex regions U1, U2, U3, and U4, which are the corresponding vertex regions of the first surface 101. Here, the upper vertex regions U1, U2, U3, and U4 formed between the first surface 101 and the third surface 103, fourth surface 104, fifth surface 105, and sixth surface 106 can refer to the four vertex regions located on the edge of the first surface 101 among the eight vertex regions of the body 100 having a hexahedral shape. When the first insulating layer 410 covers all the upper vertex regions U1, U2, U3, and U4, more reliable insulation properties can be maintained. Furthermore, in this specification, a vertex region can refer to the boundary region formed by the three connecting surfaces of the body 100, and may not be consistent with a vertex in a mathematical sense.

[0081] In addition, such as Figure 1 As shown, the first insulating layer 410 can cover the edge between the first surface 101 of the body and the third surface 103, fourth surface 104, fifth surface 105 and sixth surface 106 of the body.

[0082] Figure 2 When observing the second surface 102 of the coil assembly 1000 from the outside (i.e., from...) Figure 1 The view of the coil assembly 1000 (when viewed from direction A). A second insulating layer 420 may be disposed on a second surface 102, which corresponds to a surface of the body 100 opposite to another surface, and the second insulating layer 420 may be spaced apart from each edge of the second surface 102 by a predetermined distance. (See reference...) Figure 2For example, the distance between the second insulating layer 420 and each of the plurality of edges of the second surface 102 may correspond to 1 / 8 of the width or length of the second insulating layer 420. That is, the width and length of the second insulating layer 420 may correspond to 0.8 times the width and length of the second surface 102 of the body 100, respectively, but this is only an example, and the width and length of the second insulating layer 420 are not limited thereto. In some cases, the width and length of the second insulating layer 420 may correspond to 0.8 times or more the width and length of the second surface 102 of the body 100, respectively. In addition, the second insulating layer 420 may have a square shape on the second surface 102 of the body 100. Therefore, the length of each of the plurality of edges of the second insulating layer 420 may correspond to 0.8 times the length of each of the plurality of edges of the second surface 102 of the body 100. However, the scope of this disclosure is not limited to the above-described shape of the second insulating layer 420. In other words, the scope of this disclosure may include the following situations: even when the shape of the second insulating layer 420 is different from the shape described above, it is difficult to specify the length direction and width direction of the second insulating layer 420 solely by means of its appearance, since the length and width of the second insulating layer 420 have almost the same value.

[0083] In the area of ​​the second surface 102 of the main body 100, excluding the area covered by the second insulating layer 420, the third insulating layer 430 and the fourth insulating layer 440, a first external electrode 500 and a second external electrode 600, which will be described later, may be provided.

[0084] The third insulating layer 430 and the fourth insulating layer 440 may each be connected to a second surface 102 of the body 100 corresponding to one of its surfaces, and may be respectively disposed on opposing end surfaces 103 and 104 of the body 100, and may each extend to at least a portion of each of the first surface 101, second surface 102, fifth surface 105, and sixth surface 106 of the body 100 connected to the opposing end surfaces 103 and 104. Here, the third insulating layer 430 and the fourth insulating layer 440 extending to the first surface 101 of the body 100 may cover at least a portion of the first insulating layer 410 to form an overlapping area. Furthermore, the third insulating layer 430 and the fourth insulating layer 440 extending to the second surface 102 of the body 100 may cover at least a portion of the second insulating layer 420 to form an overlapping area.

[0085] When the third insulating layer 430 and the fourth insulating layer 440 are provided, each of the upper vertex regions U1, U2, U3, and U4, which are already covered by the first insulating layer 410, can be doubly covered by either the third insulating layer 430 or the fourth insulating layer 440. As a result, more reliable insulation properties can be ensured. Furthermore, when the third insulating layer 430 and the fourth insulating layer 440 extend to the second surface 102 of the body 100, each of the lower vertex regions D1, D2, D3, and D4 of the second surface 102 can be covered by either the third insulating layer 430 or the fourth insulating layer 440. In particular, when the external electrodes 500 and 600, which will be described later, are disposed on the second surface 102 of the body 100, each of the lower vertex regions D1, D2, D3 and D4 of the second surface 102 may be covered by the third insulating layer 430 or the fourth insulating layer 440, so as to prevent plating failure of the external electrodes 500 and 600, and at the same time prevent short circuits with other external electrodes near the lower vertex regions D1, D2, D3 and D4.

[0086] Typically, cracks are highly likely to exist at edges and vertices (boundaries between surfaces of the body), and there is a high probability of exposed conductive metallic magnetic powder. Cracks and exposed metallic magnetic powder can become pathways for leakage current and may cause electrical short circuits between components and external electrodes, thereby degrading the characteristics of the assembly. According to this exemplary embodiment, all of the plurality of edges of the first surface 101 of the body 100, as well as the upper vertex regions U1, U2, U3, and U4, can be covered by a first insulating layer 410, a third insulating layer 430, and a fourth insulating layer 440, thereby solving the above-mentioned problems. In particular, each of the upper vertex regions U1, U2, U3, and U4 of the first surface 101 of the body 100 (locations where cracks and exposed metallic magnetic powder are more likely to exist) can be doubly covered by the first insulating layer 410 and the third insulating layer 430 or the fourth insulating layer 440, thereby improving the above-mentioned effects.

[0087] The length of each of the third insulating layer 430 and the fourth insulating layer 440 on the second surface 102 (as a surface) of the body 100 is longest in the second direction W at the opposite ends of each of the third insulating layer 430 and the fourth insulating layer 440 in the first direction L. Specifically, the length of the third insulating layer 430 on the second surface 102 of the body 100 in the width direction W is longest at the second lower vertex region D2 and the third lower vertex region D3 (opposite ends of the third insulating layer 430 in the length direction L). The length of the fourth insulating layer 440 on the second surface 102 of the body 100 in the width direction W is longest at the first lower vertex region D1 and the fourth lower vertex region D4 (opposite ends of the fourth insulating layer 440 in the length direction L). Typically, external stress is concentrated in the edge regions of the assembly. Therefore, cracks may extend relatively long. By forming the third insulating layer 430 to be longer in the vertex regions D2 and D3 than in other regions, and forming the fourth insulating layer 440 to be longer in the vertex regions D1 and D4 than in other regions, the degradation of component characteristics due to cracks can be prevented more effectively.

[0088] like Figure 4 As shown, when the third insulating layer 430 and the fourth insulating layer 440 are respectively disposed on the third surface 103 and the fourth surface 104 of the main body 100, the first auxiliary lead-out portion 312 and the second auxiliary lead-out portion 322 exposed on the third surface 103 and the fourth surface 104 of the main body 100 can respectively contact the third insulating layer 430 and the fourth insulating layer 440. That is, the first auxiliary lead-out portion 312 and the second auxiliary lead-out portion 322 exposed on the third surface 103 and the fourth surface 104 of the main body 100 can respectively be covered by the third insulating layer 430 and the fourth insulating layer 440.

[0089] According to the above structure, the second insulating layer 420, the third insulating layer 430, and the fourth insulating layer 440 can expose a region of the second surface 102 of the body 100. The external electrodes 500 and 600, which will be described later, are disposed in the exposed region of the second surface 102, while being spaced apart from each other. For the reasons described above, the external electrodes 500 and 600 can be spaced apart from the edges of the second surface 102 of the body 100 that are fully covered by the third insulating layer 430 and the fourth insulating layer 440. Furthermore, for the reasons described above, the distance between each of the external electrodes 500 and 600 and the edges of the second surface 102 of the body 100 that are fully covered by each of the third insulating layer 430 and the fourth insulating layer 440 can be the longest among the lower vertex regions D1, D2, D3, and D4 of the second surface 102 of the body 100. In other words, as... Figure 2As shown, the outer electrodes 500 and 600 each have a region in which the width of the outer electrodes 500 and 600 decreases in the width direction W as the distance from the center of the second surface 102 of the body 100 in the longitudinal direction L increases. The outer electrodes 500 and 600 may be spaced apart from multiple edges of the second surface 102 of the body 100, and the distance between each of the outer electrodes 500 and 600 and each of the lower vertex regions D1, D2, D3 and D4 may be increased, thereby effectively preventing the degradation of component characteristics.

[0090] In addition, refer to Figure 2 In the multiple edges of the second surface 102 of the main body 100, the first external electrode 500 and the second external electrode 600 may be disposed at edges opposite to each other along the first direction L, and the third insulating layer 430 and the fourth insulating layer 440 may be disposed at edges opposite to each other along the second direction W. Therefore, instead of multiple insulating layers at the edges of the second surface 102, only one of the third insulating layer 430 and the fourth insulating layer 440 is disposed at the edge of the second surface 102. This allows the volume of the insulating layers on the second surface 102 to be relatively reduced to ensure the volume of the main body 100, thereby increasing the volume of the magnetic material to improve inductance.

[0091] The first insulating layer 410, the second insulating layer 420, the third insulating layer 430, and the fourth insulating layer 440 may each be formed using an insulating material including a thermosetting resin such as epoxy resin, a thermoplastic resin such as polyimide resin, or a photosensitive insulating resin. Alternatively, the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, and the fourth insulating layer 440 may each be formed using an insulating material prepared by impregnating a reinforcing material (such as glass fiber or inorganic filler) in an insulating resin. For example, the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, and the fourth insulating layer 440 may be formed using insulating materials such as prepreg, Ajinomoto Build-up Film (ABF), FR-4, bismaleimide triazine (BT) resin, photosensitive dielectric (PID), etc., but are not limited thereto. The materials used for the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, and the fourth insulating layer 440 may be the same as or different from each other.

[0092] Reference Figure 3External electrodes 500 and 600 may be spaced apart from each other and disposed on the second surface 102 of the main body 100, and may be connected to the coil portion 300. External electrodes 500 and 600 may include: a connecting portion disposed on opposing side surfaces 105 and 106 of the main body 100 in the first direction L and in contact with opposing ends of the coil portion 300; and a pad portion extending from the connecting portion to the second surface 102 of the main body 100. Furthermore, the arrangement of external electrodes 500 and 600 is not limited thereto, and external electrodes 500 and 600 may be disposed on opposing end surfaces 103 and 104 of the main body 100 in the second direction W, respectively. In this case, a third insulating layer 430 and a fourth insulating layer 440 may be disposed on opposing side surfaces 105 and 106 of the main body 100 in the first direction L.

[0093] Specifically, the first electrode layer 510 of the first external electrode 500 may be disposed on the fifth surface 105 of the main body 100, contacting the outermost end of the first coil pattern 310 exposed on the fifth surface 105 of the main body 100, and extending to the second surface 102 of the main body 100. Specifically, the first electrode layer 510 of the first external electrode 500 may contact the first main lead 311 exposed on the fifth surface 105 of the main body 100. The area of ​​the first electrode layer 510 of the first external electrode 500 disposed on the fifth surface 105 of the main body 100 may correspond to the connection portion of the first external electrode 500, and the area of ​​the first electrode layer 510 of the first external electrode 500 disposed on the second surface 102 of the main body 100 may correspond to the pad portion of the first external electrode 500.

[0094] The first electrode layer 610 of the second external electrode 600 may be disposed on the sixth surface 106 of the main body 100, contacting the outermost end of the second coil pattern 320 exposed on the sixth surface 106 of the main body 100, and extending to the second surface 102 of the main body 100. Specifically, the first electrode layer 610 of the second external electrode 600 may contact the second main lead 321 exposed on the sixth surface 106 of the main body 100. The area of ​​the first electrode layer 610 of the second external electrode 600 disposed on the sixth surface 106 of the main body 100 may correspond to the connection portion of the second external electrode 600, and the area of ​​the first electrode layer 610 of the second external electrode 600 disposed on the second surface 102 of the main body 100 may correspond to the pad portion of the second external electrode 600.

[0095] The first external electrode 500 and the second external electrode 600 can be spaced apart from each other on the second surface 102 of the main body 100 through the aforementioned second insulating layer 420. Furthermore, the second electrode layers 520 and 620 can be further disposed on the first electrode layers 510 and 610, respectively.

[0096] Reference Figure 1The first external electrode 500 and the second external electrode 600 can be disposed in the regions of the fifth surface 105 and the sixth surface 106 of the body 100, excluding the areas to which the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440 extend. That is, when the first external electrode 500 and the second external electrode 600 are formed by plating, the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440 extending to the fifth surface 105 and the sixth surface 106 can be used as plating stop regions. Therefore, the first external electrode 500 and the second external electrode 600 on the fifth surface 105 and the sixth surface 106 can be spaced apart from the edges of each of the fifth surface 105 and the sixth surface 106 by a predetermined distance from each of the first surface 101, the third surface 103, and the fourth surface 104. Specifically, the first external electrode 500 can be formed by plating in the region of the fifth surface 105 that is spaced apart from the edges of each of the fifth surface 105 and the first surface 101, the third surface 103, and the fourth surface 104 by a predetermined distance. The second external electrode 600 can be formed by plating in a region of the sixth surface 106 that is spaced at a predetermined distance from the edges of each of the sixth surface 106 and the first surface 101, the third surface 103 and the fourth surface 104.

[0097] In addition, refer to Figures 1 to 3After forming a first insulating layer 410 and a second insulating layer 420 on the first surface 101 and the second surface 102 of the body 100, respectively, and forming a third insulating layer 430 and a fourth insulating layer 440 on the third surface 103 and the fourth surface 104 of the body 100, respectively, the first electrode layers 510 and 610 can be formed. Here, the third insulating layer 430 can not only be formed on the third surface 103 of the body 100, but can also extend to at least a portion of each of the first surface 101, the second surface 102, the fifth surface 105, and the sixth surface 106 connected to the third surface 103. The fourth insulating layer 440 can not only be formed on the fourth surface 104 of the body 100, but can also extend to at least a portion of each of the first surface 101, the second surface 102, the fifth surface 105, and the sixth surface 106 connected to the fourth surface 104. Therefore, the connection portions of the external electrodes 500 and 600 can be formed on the fifth surface 105 and the sixth surface 106 of the main body 100, respectively, but do not need to extend to the edges between the fifth surface 105 and each of the first surface 101, the third surface 103, and the fourth surface 104, or the edges between the sixth surface 106 and each of the first surface 101, the third surface 103, and the fourth surface 104, respectively. Since the connection portions of the external electrodes 500 and 600 do not extend to the edges between the fifth surface 105 and each of the first surface 101, the third surface 103, and the fourth surface 104, or the edges between the sixth surface 106 and each of the first surface 101, the third surface 103, and the fourth surface 104, respectively, electrical short circuits caused by leakage current can be prevented, and degradation of component characteristics can be prevented.

[0098] The external electrodes 500 and 600 can be formed by vapor deposition methods such as sputtering and / or plating methods, but the methods for forming the external electrodes 500 and 600 are not limited thereto. The external electrodes 500 and 600 can also be formed by coating the surface of the body 100 with a conductive resin containing a conductive powder such as copper (Cu) and curing the conductive resin.

[0099] The external electrodes 500 and 600 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 500 and 600 may each have a single-layer structure or may each have a multi-layer structure. For example, the external electrodes 500 or 600 may include a first electrode layer 510 or 610 comprising copper (Cu) and a second electrode layer 520 or 620 comprising at least one of nickel (Ni) and tin (Sn), but the external electrodes 500 and 600 are not limited thereto.

[0100] An insulating film IF may be disposed between the coil portion 300 and the body 100, and between the substrate 200 and the body 100. The insulating film IF may be formed along the surfaces of the substrate 200 and the coil portion 300, but is not limited thereto. The insulating film IF may be disposed to insulate the coil portion 300 and the body 100 from each other, and the insulating film IF may contain any known insulating material, such as parylene, but is not limited thereto. As another example, the insulating film IF may contain an insulating material other than parylene, such as epoxy resin. The insulating film IF may be formed by a vapor deposition method, but is not limited thereto. As another example, the insulating film IF may be formed by stacking an insulating film for forming the insulating film IF on the opposing surface of the substrate 200 on which the coil portion 300 is formed, and then curing the insulating film. Alternatively, the insulating film IF may be formed by coating an insulating paste for forming the insulating film IF onto the opposing surface of the substrate 200 on which the coil portion 300 is formed, and then curing the insulating paste.

[0101] Furthermore, in the above description, exemplary embodiments of the present disclosure have been described using a substrate 200 and a coil portion 300 formed on the substrate 200 by plating. However, the scope of the present disclosure is not limited thereto. That is, in another exemplary embodiment of the present disclosure, a winding coil formed by winding a metal wire having a surface subjected to an insulating coating can be used as the coil portion. In this case, the substrate 200 and the insulating film IF described above can be omitted in the exemplary embodiment.

[0102] Figure 6 This is a perspective view schematically illustrating a coil assembly according to another exemplary embodiment.

[0103] Figure 7 It shows from below ( Figure 6 Direction A) of observation according to another exemplary embodiment Figure 6 A bottom view of the coil assembly.

[0104] Figure 8 It is along Figure 6 The cross-sectional view taken from line I-I'.

[0105] Figure 9 It is along Figure 6 The cross-sectional view taken from line II-II'.

[0106] Reference Figures 6 to 9Unlike the coil assembly 1000 according to the first exemplary embodiment of this disclosure, the coil assembly 2000 according to this exemplary embodiment may further include a fifth insulating layer 450 and a sixth insulating layer 460. Therefore, in describing this exemplary embodiment, only the arrangement structure of the fifth insulating layer 450, the sixth insulating layer 460, and the external electrodes 500 and 600 will be described. For the remaining configurations of this exemplary embodiment, the description in the first exemplary embodiment of this disclosure can be applied as is.

[0107] Reference Figure 6 The fifth insulating layer 450 and the sixth insulating layer 460 can be respectively disposed on the fifth surface 105 and the sixth surface 106 of the main body 100.

[0108] Specifically, the fifth insulating layer 450 and the sixth insulating layer 460 may each be connected to the second surface 102 of the body 100 (corresponding to one surface), and may be respectively disposed on opposing side surfaces 105 and 106 of the body 100 that are opposite to each other in the first direction L, and may each extend to at least a portion of each of the first surface 101, second surface 102, third surface 103, and fourth surface 104 of the body 100 that connect the opposing side surfaces 105 and 106. Here, the fifth insulating layer 450 and the sixth insulating layer 460 extending to the first surface 101 of the body 100 may each cover at least a portion of the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440 to form an overlapping area. Furthermore, the fifth insulating layer 450 and the sixth insulating layer 460 extending to the second surface 102 of the body 100 may cover at least a portion of each of the third insulating layer 430 and the fourth insulating layer 440 disposed on the second surface 102 to form an overlapping area.

[0109] Figure 7 It shows from below ( Figure 6 Direction A) of observation according to the second exemplary embodiment Figure 6 Bottom view of the coil assembly 2000.

[0110] Reference Figure 7 and Figure 8First, a second insulating layer 420 may be disposed on the second surface 102 of the main body 100. A third insulating layer 430 and a fourth insulating layer 440 may extend to the second surface 102. Then, the first electrode layers 510 and 610 of the first external electrode 500 and the second external electrode 600 may be disposed on the fifth surface 105 and the sixth surface 106, respectively, and the first electrode layers 510 and 610 of the first external electrode 500 and the second external electrode 600 may be disposed on the second surface 102. That is, the pad portions of the first electrode layers 510 and 610 may be disposed on the second surface 102 of the main body 100. Subsequently, a fifth insulating layer 450 and a sixth insulating layer 460 may extend from the fifth surface 105 and the sixth surface 106 to the second surface 102, respectively, exposing at least a portion of the first electrode layers 510 and 610 on the second surface 102. Subsequently, second electrode layers 520 and 620 may be disposed on the exposed first electrode layers 510 and 610, respectively.

[0111] According to the second exemplary embodiment, the second electrode layers 520 and 620 may be disposed only on the second surface 102 of the body 100. When the fifth insulating layer 450 and the sixth insulating layer 460 are formed on the surface of the body 100, all surfaces of the body 100 may be covered by the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, the sixth insulating layer 460, and the first electrode layers 510 and 610. Furthermore, the first electrode layers 510 and 610 may be exposed only on the second surface 102 of the body 100 while being spaced apart from each other by the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, and the sixth insulating layer 460. Because the second electrode layers 520 and 620 are formed in this manner, they may be disposed only on the second surface 102 of the body 100. In other words, the first external electrode 500 and the second external electrode 600 exposed on the second surface 102 of the body 100 can be spaced apart from each of the plurality of edges of the second surface 102 of the body 100 by a predetermined distance. When the first external electrode 500 and the second external electrode 600 are spaced apart from the edges of the body 100, short circuits between the components and adjacent external components can be prevented.

[0112] In this way, the fifth insulating layer 450 and the sixth insulating layer 460 can, while covering the connection portions of the first external electrode 500 and the second external electrode 600 on the fifth surface 105 and the sixth surface 106 of the body 100, expose at least a portion of the pad portions of the first external electrode 500 and the second external electrode 600 on the second surface 102 of the body 100. Therefore, the first external electrode 500 and the second external electrode 600 can be exposed on the second surface 102 of the body 100 to function as external electrodes.

[0113] In the coil assembly 2000 according to the second exemplary embodiment, the fifth insulating layer 450 and the sixth insulating layer 460 may respectively cover the connection portions of the first external electrode 500 and the second external electrode 600 on the fifth surface 105 and the sixth surface 106, thereby protecting the first external electrode 500 and the second external electrode 600 on the fifth surface 105 and the sixth surface 106 and preventing short circuits between adjacent components or conductors and the first external electrode 500 and the second external electrode 600.

[0114] The materials of the fifth insulating layer 450 and the sixth insulating layer 460 may include at least one of the insulating materials used in the first insulating layer 410, the second insulating layer 420, the third insulating layer 430 and the fourth insulating layer 440, but the materials of the fifth insulating layer 450 and the sixth insulating layer 460 need not be the same as the materials of the first insulating layer 410, the second insulating layer 420, the third insulating layer 430 and the fourth insulating layer 440.

[0115] In the coil assembly 2000 according to the second exemplary embodiment, similar to the third insulating layer 430 and the fourth insulating layer 440, the fifth insulating layer 450 and the sixth insulating layer 460 may cover the upper vertex regions U1, U2, U3 and U4 and the lower vertex regions D1, D2, D3 and D4.

[0116] Specifically, each of the upper vertex regions U1, U2, U3 and U4 may be provided with a triple insulating layer through the first insulating layer 410 and the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450 and the sixth insulating layer 460, so as to ensure more reliable insulation characteristics.

[0117] Furthermore, unlike the first exemplary embodiment where only one insulating layer is provided in the lower vertex regions D1, D2, D3, and D4 via the third insulating layer 430 and the fourth insulating layer 440, the lower vertex regions D1, D2, D3, and D4 can have double insulating layers via the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, and the sixth insulating layer 460, thereby ensuring more reliable insulation characteristics. In particular, the double insulation structure of the lower vertex regions D1, D2, D3, and D4 can prevent accidental short circuits between adjacent components or conductors and the first external electrode 500 and the second external electrode 600.

[0118] As described above, there is a high probability of cracks existing at the edges and vertices (boundaries between the surfaces of the main body), and a high probability of exposed conductive metallic magnetic powder. Cracks and exposed metallic magnetic powder can become transmission paths for leakage current and may cause electrical short circuits between the component and the external electrode, thereby degrading the characteristics of the component. However, in the coil assembly 2000 according to the second exemplary embodiment, the fifth insulating layer 450 and the sixth insulating layer 460 can cover the edges between the surfaces of the main body that are not covered by the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440, and can also cover the vertex regions of the main body that are covered by the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440, thereby solving the above-mentioned problems.

[0119] Since the rest of the content is basically the same as the above, repeated descriptions will be omitted.

[0120] Figure 10 This is a perspective view schematically illustrating a coil assembly according to another exemplary embodiment.

[0121] Figure 11 It shows from below ( Figure 10 Direction A) of observation according to another exemplary embodiment Figure 10 A bottom view of the coil assembly.

[0122] Figure 12 It is along Figure 10 The cross-sectional view taken from line I-I'.

[0123] Figure 13 It is along Figure 10 The cross-sectional view taken from line II-II'.

[0124] Reference Figures 1 to 10 Regarding the shape of the second insulating layer 420, the coil assembly 3000 according to this exemplary embodiment differs from the coil assembly 1000 according to the first exemplary embodiment of this disclosure. Therefore, in describing this exemplary embodiment, only the shape of the second insulating layer 420 and the arrangement structure of the external electrodes 500 and 600 will be described. For the remaining construction of this exemplary embodiment, the description in the first exemplary embodiment of this disclosure can be applied as is.

[0125] In the coil assembly 3000 according to the third exemplary embodiment, reference is made to... Figure 10 and Figure 11The second insulating layer 420 disposed on the second surface 102 of the body 100 may have a cross-shaped form and extend from the central portion of the second surface 102 to each of the plurality of edges of the second surface 102. The second insulating layer 420 disposed on the second surface 102 may not extend to the plurality of other walls. The second surface 102 of the body 100 may be divided into four regions by the second insulating layer 420, and the first external electrode 500 and the second external electrode 600 may be disposed in the four separate regions by subsequent plating.

[0126] In the coil assembly 3000 according to the third exemplary embodiment, similarly, firstly, a second insulating layer 420 may be disposed on the second surface 102 of the body 100, a third insulating layer 430 and a fourth insulating layer 440 may extend to the second surface 102, then a first external electrode 500 and a second external electrode 600 may be disposed on a fifth surface 105 and a sixth surface 106 respectively, and the first external electrode 500 and the second external electrode 600 may be disposed on the second surface 102.

[0127] The first external electrode 500 and the second external electrode 600 disposed on the second surface 102 can be disposed in areas of the second surface 102 other than the area where the second insulating layer 420 is disposed. Because the second insulating layer 420 has the above-described and... Figure 11 As shown in the shape, the first external electrode 500 and the second external electrode 600 can be spaced apart from each other. In addition, the first external electrode 500 can be separated by the second insulating layer 420, and the second external electrode 600 can also be separated by the second insulating layer 420.

[0128] However, each of the first external electrode 500 and the second external electrode 600 may be separated only on the second surface 102 by the second insulating layer 420, and not separated on the fifth surface 105 and the sixth surface 106 of the body 100. Specifically, the pad portion of the first external electrode 500 disposed on the second surface 102 of the body 100 may be divided into two regions by the second insulating layer 420, but these two regions may be connected by the connecting portion of the first external electrode 500 disposed on the fifth surface 105 of the body 100. Similarly, the pad portion of the second external electrode 600 disposed on the second surface 102 of the body 100 may be divided into two regions by the second insulating layer 420, but these two regions may be connected by the connecting portion of the second external electrode 600 disposed on the sixth surface 106.

[0129] Furthermore, as described above, since the second insulating layer 420 may also be disposed on at least a portion of each of the plurality of edges of the second surface 102 of the body 100, the regions of the third insulating layer 430 and the fourth insulating layer 440 covering the edges of the second surface 102 of the body 100 may additionally cover the second insulating layer 420. Therefore, each of the third insulating layer 430 and the fourth insulating layer 440 may be formed to overlap with the second insulating layer 420, and each of the third insulating layer 430 and the fourth insulating layer 440 may each have a bend in each of the regions of the third insulating layer 430 and the fourth insulating layer 440 that overlap with the second insulating layer 420. For example, as... Figure 10 As shown, the bend caused by the second insulating layer 420 can be formed in the region at the edge between the second surface 102 and the third surface 103 of the body 100 covered by the third insulating layer 430.

[0130] Therefore, at least a portion of each of the multiple edges of the second surface 102 of the body 100 that are opposite to each other in the second direction W may be covered by the second insulating layer 420 and the third insulating layer 430 or the fourth insulating layer 440.

[0131] Even in the structure of the coil assembly 3000 according to the third exemplary embodiment, the second insulating layer 420 may have a symmetrical structure, and specifically, when viewed along a third direction T on the second surface 102 of the body 100, the second insulating layer 420 may have a point-symmetric shape. However, the scope of this disclosure is not limited to the above-described shape of the second insulating layer 420. That is, the scope of this disclosure may include situations where, even if the shape of the second insulating layer 420 differs from the above-described shape, it is difficult to specify the length and width directions of the second insulating layer 420 solely by its appearance because the length and width of the second insulating layer 420 have nearly identical values.

[0132] Therefore, in the coil assembly 3000 according to the third exemplary embodiment, each of the second electrode layer 520 of the first external electrode 500 and the second electrode layer 620 of the second external electrode 600 can be divided into two regions, and a structure is disclosed in which the lower surface electrode is exposed in a total of four regions. Therefore, the volume of the first external electrode 500 and the second external electrode 600 on the second surface 102 of the body 100 can be reduced, and a relatively thin second insulating layer 420 can be formed by inkjet printing or screen printing. Therefore, the volume of the body 100 and the volume of the magnetic material can be increased. Therefore, the inductance and magnetic flux of the assembly can be improved.

[0133] Since the rest of the content is basically the same as the above, repeated descriptions will be omitted.

[0134] Figure 14This is a perspective view schematically illustrating a coil assembly according to another exemplary embodiment.

[0135] Figure 15 It shows from below ( Figure 14 Direction A) of observation according to another exemplary embodiment Figure 14 A bottom view of the coil assembly.

[0136] Figure 16 It is along Figure 14 The cross-sectional view taken from line I-I'.

[0137] Figure 17 It is along Figure 14 The cross-sectional view taken from line II-II'.

[0138] Reference Figures 1 to 14 Unlike the coil assembly 3000 according to the third exemplary embodiment of this disclosure, the coil assembly 4000 according to this exemplary embodiment may further include a fifth insulating layer 450 and a sixth insulating layer 460. Therefore, in describing this exemplary embodiment, only the arrangement structure of the fifth insulating layer 450, the sixth insulating layer 460, and the external electrodes 500 and 600 will be described. For the remaining configurations of this exemplary embodiment, the description in the third exemplary embodiment of this disclosure can be applied as is.

[0139] Reference Figure 14 In the coil assembly 4000 according to the fourth exemplary embodiment, the fifth insulating layer 450 and the sixth insulating layer 460 may be disposed on the fifth surface 105 and the sixth surface 106 of the body 100, respectively.

[0140] Specifically, the fifth insulating layer 450 and the sixth insulating layer 460 may each be connected to a second surface 102 of the body 100 corresponding to one of its surfaces, and may be respectively disposed on opposing side surfaces 105 and 106 of the body 100 in the first direction L, and may each extend to at least a portion of each of the first surface 101, second surface 102, third surface 103, and fourth surface 104 of the body 100 that is connected to the opposing side surfaces 105 and 106. Here, the fifth insulating layer 450 and the sixth insulating layer 460 extending to the first surface 101 of the body 100 may each cover at least a portion of the first insulating layer 410, the third insulating layer 430, and the fourth insulating layer 440 to form an overlapping area. Furthermore, the fifth insulating layer 450 and the sixth insulating layer 460 extending to the second surface 102 of the body 100 may cover at least a portion of each of the third insulating layer 430 and the fourth insulating layer 440 disposed on the second surface 102 to form an overlapping area.

[0141] Additionally, the fifth insulating layer 450 and the sixth insulating layer 460 extending to the second surface 102 of the body 100 may cover at least a portion of the second insulating layer 420 adjacent to the edges of the second surface 102 of the body 100 that are opposite to each other in the first direction L. Therefore, among the plurality of edges of the second surface 102 of the body 100, at least a portion of each of the edges that are opposite to each other in the second direction W may be covered by the second insulating layer 420 and the third insulating layer 430 or the fourth insulating layer 440, and at least a portion of each of the edges that are opposite to each other in the first direction L may be covered by the second insulating layer 420 and the fifth insulating layer 450 or the sixth insulating layer 460.

[0142] The fifth insulating layer 450 and the sixth insulating layer 460 may each have a bend in each region of the fifth insulating layer 450 and the sixth insulating layer 460 that overlaps with the second insulating layer 420. For example, as Figure 14 As shown, the bend caused by the second insulating layer 420 can be formed in the region of the edge between the second surface 102 and the fifth surface 105 of the body 100 covered by the fifth insulating layer 450.

[0143] Reference Figure 15 and Figure 16 First, a second insulating layer 420 may be disposed on the second surface 102 of the main body 100. A third insulating layer 430 and a fourth insulating layer 440 may extend to the second surface 102. Then, the first electrode layers 510 and 610 of the first external electrode 500 and the second external electrode 600 may be disposed on the fifth surface 105 and the sixth surface 106, respectively, and the first electrode layers 510 and 610 of the first external electrode 500 and the second external electrode 600 may be disposed on the second surface 102. That is, the pad portions of the first electrode layers 510 and 610 may be disposed on the second surface 102 of the main body 100. Subsequently, a fifth insulating layer 450 and a sixth insulating layer 460 may extend from the fifth surface 105 and the sixth surface 106 to the second surface 102, respectively, and at least a portion of the first electrode layers 510 and 610 may be exposed on the second surface 102. Subsequently, second electrode layers 520 and 620 may be disposed on the exposed first electrode layers 510 and 610, respectively.

[0144] According to the fourth exemplary embodiment, the second electrode layers 520 and 620 may be disposed only on the second surface 102 of the body 100. When the fifth insulating layer 450 and the sixth insulating layer 460 are formed on the surface of the body 100, all surfaces of the body 100 may be covered by the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, the sixth insulating layer 460, and the first electrode layers 510 and 610. Furthermore, the first electrode layers 510 and 610 may be exposed only on the second surface 102 of the body 100 while being spaced apart from each other by the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, and the sixth insulating layer 460. Because the second electrode layers 520 and 620 are formed in this manner, they may be disposed only on the second surface 102 of the body 100. In other words, the first external electrode 500 and the second external electrode 600 exposed on the second surface 102 of the body 100 can be spaced apart from each of the plurality of edges of the second surface 102 of the body 100 by a predetermined distance. When the first external electrode 500 and the second external electrode 600 are spaced apart from the edges of the body 100, short circuits between the components and adjacent external components can be prevented.

[0145] In this way, the fifth insulating layer 450 and the sixth insulating layer 460 can, while covering the connection portions of the first external electrode 500 and the second external electrode 600 on the fifth surface 105 and the sixth surface 106 of the body 100, expose at least a portion of the pad portions of the first external electrode 500 and the second external electrode 600 on the second surface 102 of the body 100. Therefore, the first external electrode 500 and the second external electrode 600 can be exposed on the second surface 102 of the body 100 to function as external electrodes.

[0146] Therefore, in the coil assembly 4000 according to the fourth exemplary embodiment, each of the second electrode layers 520 and 620 of the first external electrode 500 and the second external electrode 600 can be divided into two regions, and a structure in which the lower surface electrode is exposed in a total of four regions is disclosed. Therefore, the volume of the first external electrode 500 and the second external electrode 600 on the second surface 102 of the body 100 can be reduced, and a relatively thin second insulating layer 420 can be formed by inkjet printing or screen printing. Therefore, the volume of the body 100 and the volume of the magnetic material can be increased. Therefore, the inductance and magnetic flux of the assembly can be improved.

[0147] Furthermore, the description of the fifth insulating layer 450 and the sixth insulating layer 460 in the coil assembly 2000 according to the second exemplary embodiment and its effects can be equivalently applied to the covering structure and multiple insulating structure for the vertex region in the coil assembly 4000 according to the fourth exemplary embodiment.

[0148] Figures 18 to 20 This is a process diagram showing sequentially a method for manufacturing a coil assembly according to exemplary embodiments of the present disclosure.

[0149] Reference Figures 18 to 20 After forming a first insulating layer 410 and a second insulating layer 420 on the first surface 101 and the second surface 102 of the body 100, respectively, and forming a third insulating layer 430 and a fourth insulating layer 440 on the third surface 103 and the fourth surface 104 of the body 100, respectively, the first electrode layers 510 and 610 can be formed. Figure 18 As shown, the first insulating layer 410 disposed on each of the third surface 103 and the fourth surface 104 of the body 100 has a region in which the width of the first insulating layer 410 in the thickness direction T increases with the increase of the distance from the center of each of the third surface 103 and the fourth surface 104 of the body 100 in the length direction L; and the first insulating layer 410 disposed on each of the fifth surface 105 and the sixth surface 106 of the body 100 has a region in which the width of the first insulating layer 410 in the thickness direction T increases with the increase of the distance from the center of each of the fifth surface 105 and the sixth surface 106 of the body 100 in the width direction W. Here, the third insulating layer 430 can not only be formed on the third surface 103 of the body 100, but can also extend to at least a portion of each of the first surface 101, the second surface 102, the fifth surface 105 and the sixth surface 106 connected to the third surface 103. The fourth insulating layer 440 can be formed not only on the fourth surface 104 of the body 100, but also extends to at least a portion of each of the first surface 101, the second surface 102, the fifth surface 105, and the sixth surface 106 connected to the fourth surface 104. Therefore, the connection portions of the external electrodes 500 and 600 can be formed on the fifth surface 105 and the sixth surface 106 of the body 100, respectively, but do not necessarily extend to the edges between the fifth surface 105 and each of the first surface 101, the third surface 103, and the fourth surface 104, or the edges between the sixth surface 106 and each of the first surface 101, the third surface 103, and the fourth surface 104, respectively. Since the connection portions of the external electrodes 500 and 600 do not extend to the edges between the fifth surface 105 and each of the first surface 101, the third surface 103 and the fourth surface 104, and the sixth surface 106 and each of the first surface 101, the third surface 103 and the fourth surface 104, respectively, electrical short circuits due to leakage current can be prevented, and component performance degradation can be prevented.

[0150] Furthermore, according to this disclosure, the first insulating layer 410, the second insulating layer 420, the third insulating layer 430, the fourth insulating layer 440, the fifth insulating layer 450, and the sixth insulating layer 460 can be formed by a pad printing method or a screen printing method. Therefore, compared to forming the insulating layers using other methods such as impregnation, the insulating layers can be formed thinner, and the volume of the magnetic material inside the body 100 can be correspondingly increased, which can help improve magnetic flux and inductance.

[0151] In addition, the opposite side surfaces and opposite end surfaces of the main body can have a square shape or a shape similar to a square shape, and the coil portion 300 can be exposed on all the opposite side surfaces and opposite end surfaces of the main body, so that the process of identifying the opposite side surfaces and opposite end surfaces by using a machine can be omitted during the manufacturing process, thus achieving process simplification and cost reduction.

[0152] As described above, according to exemplary embodiments in this disclosure, coil assemblies that are lightweight, thin, and compact can be provided.

[0153] Coil assemblies can be provided that can improve productivity and significantly reduce man-hours by simplifying the manufacturing process.

[0154] Coil assemblies in which the volume of the magnetic body is increased to increase inductance can be provided.

[0155] Coil assemblies that can reduce the effective installation area are available.

[0156] While exemplary embodiments have been shown and described above, it will be readily understood by those skilled in the art that modifications and variations may be made without departing from the scope of this disclosure as defined by the appended claims.

Claims

1. A coil assembly, comprising: The body has a first surface and a second surface that are opposite to each other in a first direction, and a third surface, a fourth surface, a fifth surface and a sixth surface that connect the first surface and the second surface to each other, wherein the third surface and the fourth surface are opposite to each other in a second direction perpendicular to the first direction; The coil portion is disposed within the main body; The first external electrode and the second external electrode are disposed on the first surface of the main body while being spaced apart from each other, and are connected to the coil portion; A first insulating layer is disposed on the second surface of the body and extends to at least a portion of each of the third, fourth, fifth and sixth surfaces of the body; as well as A second insulating layer is disposed on the first surface of the main body. The first insulating layer and the second insulating layer are spaced apart from each other. The coil assembly further includes a third insulating layer and a fourth insulating layer, the third insulating layer and the fourth insulating layer being respectively disposed on the third surface and the fourth surface of the body, and each extending to and contacting the first surface of the body. Each of the third and fourth insulating layers covers at least a portion of the second insulating layer on the first surface of the body, and Each of the third and fourth insulating layers extends to the second surface of the body and covers at least a portion of the first insulating layer.

2. The coil assembly according to claim 1, wherein, The second insulating layer extends on the first surface of the body to at least a portion of each of the plurality of edges of the first surface of the body.

3. The coil assembly according to claim 1, wherein, The first external electrode and the second external electrode are separated from each other by the second insulating layer on the first surface of the body.

4. The coil assembly according to claim 3, wherein, The first external electrode and the second external electrode each have a region in which the width of the first external electrode and the second external electrode in the second direction decreases as the distance from the center of the first surface of the body in the first direction increases.

5. The coil assembly according to claim 3, wherein, The length of each of the third and fourth insulating layers on the first surface of the body in the second direction is longest at the opposite ends of each of the third and fourth insulating layers in the first direction.

6. The coil assembly according to claim 5, wherein, The fifth surface and the sixth surface are respectively connected to the first surface of the body and are opposite to each other in the first direction. The coil assembly further includes a fifth insulating layer and a sixth insulating layer, the fifth insulating layer and the sixth insulating layer being respectively disposed on the fifth surface and the sixth surface of the body, and each extending to the first surface of the body. The fifth insulating layer and the sixth insulating layer respectively cover at least a portion of the first external electrode and the second external electrode on the first surface of the body.

7. The coil assembly according to claim 6, wherein, Each of the fifth and sixth insulating layers extends to the second surface of the body and covers at least a portion of each of the first, third, and fourth insulating layers on the second surface of the body.

8. The coil assembly according to claim 7, wherein, On the first surface of the body, the regions of the fifth and sixth insulating layers that expose the first and second external electrodes, respectively, are spaced apart from each of the plurality of edges of the first surface of the body.

9. The coil assembly according to claim 8, wherein, The first insulating layer disposed on each of the third and fourth surfaces of the body has a region in which the width of the first insulating layer increases in a third direction as the distance from the center of each of the third and fourth surfaces of the body increases in the first direction, the third direction being perpendicular to the first and second directions. The first insulating layer disposed on each of the fifth and sixth surfaces of the body has a region in which the width of the first insulating layer in the third direction increases with the increase of the distance from the center of each of the fifth and sixth surfaces of the body in the second direction.

10. The coil assembly according to claim 9, wherein, The first external electrode and the second external electrode are disposed on the fifth and sixth surfaces of the main body and are in contact with the opposite ends of the coil portion. The third insulating layer and the fourth insulating layer extend to the fifth surface and the sixth surface of the body, respectively, such that the first external electrode and the second external electrode are spaced apart from the edges between the third surface and the fourth surface of the body and the fifth surface and the sixth surface of the body.

11. The coil assembly according to claim 1, further comprising a substrate disposed within the main body. in, The coil portion includes: a first coil pattern disposed on a first surface of the substrate; a second coil pattern disposed on a second surface of the substrate opposite to the first surface of the substrate; and a through hole penetrating the substrate and connecting the first coil pattern and the second coil pattern to each other.

12. The coil assembly according to claim 11, wherein, The first coil pattern has a first main lead exposed on the fifth surface and a first auxiliary lead exposed on the third surface, and The second coil pattern has a second main lead exposed on the sixth surface and a second auxiliary lead exposed on the fourth surface.

13. A coil assembly, comprising: The main body has a first surface and a second surface that are opposite to each other, and a third surface, a fourth surface, a fifth surface and a sixth surface that connect the first surface and the second surface to each other; The coil portion is disposed within the main body; The first external electrode and the second external electrode are disposed on the first surface of the main body while being spaced apart from each other, and are connected to the coil portion; A first insulating layer and a second insulating layer are respectively disposed on the second surface of the body and the first surface of the body; as well as A third insulating layer and a fourth insulating layer are respectively disposed on the third surface and the fourth surface of the body, which are opposite to each other in a second direction, and each extends to and contacts the first surface of the body. Wherein, the second insulating layer is spaced apart from each of the plurality of edges of the first surface of the body, and The length of each of the third and fourth insulating layers on the first surface of the body in the second direction is the longest at the opposite ends of each of the third and fourth insulating layers in the first direction perpendicular to the second direction.

14. The coil assembly of claim 13, further comprising a fifth insulating layer and a sixth insulating layer, the fifth insulating layer and the sixth insulating layer being respectively connected to the first surface of the body, respectively disposed on the fifth surface and the sixth surface of the body opposite to each other in the first direction, each extending to the first surface of the body, and respectively covering at least a portion of the first external electrode and at least a portion of the second external electrode.

15. The coil assembly of claim 14, wherein, Each of the first external electrode and the second external electrode includes a first electrode layer and a second electrode layer.

16. The coil assembly of claim 15, wherein, The first electrode layer comprises copper, and the second electrode layer comprises at least one of nickel and tin.

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