Coil component

Abstract

The invention provides a coil assembly. The coil component includes: a main body having a first surface, a second surface opposite to the first surface in a first direction, and a plurality of side surfaces connecting the first surface and the second surface; a coil embedded in the main body; and a support member embedded in the main body and including a support portion supporting the coil and at least one stopper portion provided at a corner of the main body formed by two or more of the plurality of side surfaces in an outer region of the support portion.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0098076 filed on July 27, 2023 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

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

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

[0004] As electronic devices have been improved to have high performance and efficiency, for chip inductor components, miniaturized (low profile) and highly efficient products are required. Summary of the invention

[0005] An aspect of the present disclosure is to provide a coil component that prevents a coil from being deformed during a process of stacking and pressing a magnetic composite sheet.

[0006] Another aspect of the present disclosure is to provide a coil component that can be thinned (low profile) while reducing a defect rate due to coil deformation.

[0007] According to one aspect of the present disclosure, a coil component includes: a main body having a first surface, a second surface opposite to the first surface in a first direction, and a plurality of side surfaces connecting the first surface and the second surface; a coil embedded in the main body; and a supporting member embedded in the main body and including a supporting portion supporting the coil and at least one stop portion, wherein the at least one stop portion is arranged in an outer area of ​​the supporting portion at a corner of the main body formed by two or more of the plurality of side surfaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above and other aspects, features and advantages of the present disclosure will be more clearly understood through the following detailed description in conjunction with the accompanying drawings, in which:

[0009] Figure 1 is a perspective view schematically showing a coil component according to a first exemplary embodiment of the present disclosure;

[0010] Figure 2 is a plan view schematically showing a coil component according to a first exemplary embodiment of the present disclosure;

[0011] Figure 3 yes Figure 2 an enlarged view of part A;

[0012] Figure 4is a plan view showing a modified example of the coil component according to the first exemplary embodiment of the present disclosure;

[0013] Figure 5 is a plan view showing another modified example of the coil component according to the first exemplary embodiment of the present disclosure;

[0014] Figure 6 is a perspective view schematically showing a coil component according to a second exemplary embodiment of the present disclosure;

[0015] Figure 7 is a plan view schematically showing a coil component according to a second exemplary embodiment of the present disclosure;

[0016] Figure 8 is a plan view showing a modified example of the coil component according to the second exemplary embodiment of the present disclosure;

[0017] Fig. 9 is a plan view showing another modified example of the coil component according to the second exemplary embodiment of the present disclosure;

[0018] Fig.10 is a perspective view showing another modified example of the coil component according to the second exemplary embodiment of the present disclosure; and

[0019] Fig.11 is a diagram showing a related art coil component as a comparative example. DETAILED DESCRIPTION

[0020] The terms used in this specification are only used to describe specific exemplary embodiments and are not intended to limit the present disclosure. Unless there is a significantly different meaning in the context, the expression used in the singular includes the expression of the plural number. In this specification, it should be understood that the terms such as "including" or "having" are intended to indicate that there are features, quantities, steps, operations, elements, parts or combinations thereof disclosed in the specification, and are not intended to exclude the possibility that one or more other features, quantities, steps, operations, elements, parts or combinations thereof may be present or may be added. In addition, throughout the specification, "on ... " means being located above or below the target portion, and does not necessarily mean being located on the upper side relative to the direction of gravity.

[0021] Furthermore, the term “coupled to” encompasses not only the case of direct physical contact between respective components in a contact relationship but also the case where another component is interposed between the respective components such that each component is in contact with the other component.

[0022] Since the size (eg, thickness) of each component shown in the drawings is arbitrarily illustrated for convenience of description, the present disclosure is not necessarily limited to the illustrated size (eg, thickness).

[0023] In the drawings, an X direction may be defined as a first direction or a thickness direction, a Y direction may be defined as a second direction or a length direction, and a Z direction may be defined as a third direction or a width direction.

[0024] Hereinafter, a coil component according to an exemplary embodiment in the present disclosure will be described in detail with reference to the accompanying drawings, and in the description with reference to the accompanying drawings, the same or corresponding components are given the same or corresponding reference numerals and a redundant description thereof will be omitted.

[0025] Various types of electronic components are used in electronic devices, and various types of coil components may be appropriately used in these electronic components for purposes such as removing noise.

[0026] In other words, the coil component in the electronic device can be used as a power inductor, a high-frequency inductor, a common magnetic bead, a high-frequency magnetic bead (for example, a magnetic bead suitable for a GHz frequency band), a common mode filter, etc.

[0027] (First Exemplary Embodiment)

[0028] Figure 1 is a perspective view schematically showing a coil component according to a first exemplary embodiment of the present disclosure. Figure 2 is a plan view schematically showing a coil component according to a first exemplary embodiment of the present disclosure. Figure 3 yes Figure 2 An enlarged view of part A of FIG.

[0029] Reference Figures 1 to 3 The coil component 1000 according to the first exemplary embodiment of the present disclosure includes a body 100 , a support member 200 , a coil 310 , and external electrodes 400 and 500 , and optionally, may further include an insulating film 600 .

[0030] The body 100 forms an appearance of the coil component 1000 according to the present exemplary embodiment, and the support member 200 and the coil 310 are embedded in the body 100 .

[0031] The body 100 may have a hexahedral shape as a whole.

[0032] Reference Figures 1 to 3 The main body 100 includes a first surface 101 and a second surface 102 opposite to each other in a first direction (X direction), a first side surface 103 and a second side surface 104 opposite to each other in a second direction (Y direction), and a third side surface 105 and a fourth side surface 106 opposite to each other in a third direction (Z direction). The first side surface 103, the second side surface 104, the third side surface 105, and the fourth side surface 106 correspond to a plurality of side surfaces connecting the first surface 101 and the second surface 102.

[0033] The body 100 may include a plurality of corners. For example, the body 100 may include four corners at which two adjacent side surfaces of the plurality of side surfaces 103, 104, 105, and 106 contact each other.

[0034] Two adjacent side surfaces among the plurality of side surfaces 103, 104, 105, and 106 of the body 100 intersect with each other to form a corner. Since the plurality of side surfaces intersect perpendicularly, the four corners may form a right angle, but are not limited thereto. For example, based on the number of side surfaces and corners, the corner (the angle formed by two adjacent side surfaces) may not be a right angle, and the corner may be rounded by a polishing process.

[0035] As an example, the body 100 is formed such that the coil component 1000 formed with the external electrodes 400 and 500 to be described below according to the present exemplary embodiment may have a length of 2.0 mm, a width of 1.2 mm, and a thickness of 0.65 mm, but is not limited thereto.

[0036] The main body 100 may include a magnetic material and an insulating resin. Specifically, the main body 100 may be formed by stacking one or more magnetic composite sheets including an insulating resin and a magnetic material dispersed in the insulating resin. However, the main body 100 may have a structure other than a structure in which the magnetic material is dispersed in the insulating resin. For example, the main body 100 may be formed using a magnetic material such as ferrite.

[0037] The magnetic material may be magnetic powder particles, for example, ferrite powder particles or magnetic metal powder particles.

[0038] For example, the ferrite powder particles can be at least one of spinel ferrite (such as Mg-Zn-based ferrite, Mn-Zn-based ferrite, Mn-Mg-based ferrite, Cu-Zn-based ferrite, Mg-Mn-Sr-based ferrite, Ni-Zn-based ferrite), hexagonal ferrite (such as Ba-Zn-based ferrite, Ba-Mg-based ferrite, Ba-Ni-based ferrite, Ba-Co-based ferrite and Ba-Ni-Co-based ferrite), garnet-type ferrite (such as Y-based ferrite) and Li-based ferrite.

[0039] The magnetic metal powder particles may include one or more selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), cobalt (Co), molybdenum (Mo), aluminum (Al), niobium (Nb), copper (Cu), and nickel (Ni). For example, the magnetic metal powder particles may be at least one of pure iron powder particles, Fe-Si-based alloy powder particles, Fe-Si-Al-based alloy powder particles, Fe-Ni-based alloy powder particles, Fe-Ni-Mo-based alloy powder particles, Fe-Ni-Mo-Cu-based alloy powder particles, Fe-Co-based alloy powder particles, Fe-Ni-Co-based alloy powder particles, Fe-Cr-based alloy powder particles, Fe-Cr-Si-based alloy powder particles, Fe-Si-Cu-Nb-based alloy powder particles, Fe-Ni-Cr-based alloy powder particles, and Fe-Cr-Al-based alloy powder particles.

[0040] The magnetic metal powder particles may be amorphous or crystalline. For example, the magnetic metal powder particles may be Fe-Si-B-Cr based amorphous alloy powder particles, but are not limited thereto.

[0041] Each of the ferrite powder particles and the magnetic metal powder particles may have an average diameter of about 0.1 μm to about 30 μm, but is not limited thereto.

[0042] The main body 100 may include two or more types of magnetic powder particles dispersed in an insulating resin. Here, different types of magnetic powder particles mean that the magnetic powder particles dispersed in the insulating resin are distinguished from each other by at least one of diameter, composition, crystallinity, and shape. For example, the main body 100 may include two or more magnetic powder particles having different diameters.

[0043] The insulating resin may include epoxy resin, polyimide, liquid crystal polymer, etc., alone or in combination, but is not limited thereto.

[0044] The body 100 includes a core 110 passing through a coil 310 (to be described below). The core 110 may be formed by filling a through hole of a coil unit with a magnetic composite sheet, but is not limited thereto.

[0045] The support member 200 is embedded in the body 100. The support member 200 supports the coil 310 (to be described below).

[0046] The support member 200 may be formed using an insulating material including a thermosetting insulating resin such as epoxy resin, a thermoplastic insulating resin such as polyimide, or a photosensitive insulating resin, or may be formed using an insulating material prepared by impregnating a reinforcing material such as glass fiber or an inorganic filler in the above insulating resin. For example, the support member 200 may be formed using an insulating material such as a prepreg, an Ajinomoto build-up film (ABF), FR-4, a bismaleimide triazine (BT) film, or a photosensitive dielectric (PID) film, but is not limited thereto.

[0047] As an inorganic filler, at least one selected from the group consisting of silica (SiO2), alumina (Al2O3), silicon carbide (SiC), barium sulfate (BaSO4), talc, clay, mica powder particles, aluminum hydroxide (Al(OH)3), magnesium hydroxide (Mg(OH)2), calcium carbonate (CaCO3), magnesium carbonate (MgCO3), magnesium oxide (MgO), boron nitride (BN), aluminum borate (AlBO3), barium titanate (BaTiO3) and calcium zirconate (CaZrO3) can be used.

[0048] When the support member 200 is formed using an insulating material including a reinforcing material, the support member 200 can provide excellent rigidity. When the support member 200 is formed using an insulating material that does not contain glass fiber, the support member 200 is conducive to reducing the total thickness of the coil 310. When the support member 200 is formed using an insulating material including a photosensitive insulating resin, the number of processes for forming the coil 310 can be reduced, which is conducive to reducing production costs, and fine vias can be formed.

[0049] The support member 200 includes a support portion 210 supporting a coil 310 (to be described below) and at least one stopper 220, which is provided at a corner of the body 100 in an outer region of the support portion 210. The support portion 210 is a member that supports the first coil pattern 311 and the second coil pattern 312 (including an end 311-1 (not shown) of the first coil pattern 311 and an end 312-1 of the second coil pattern 312) of the coil 310, and may be formed in a shape corresponding to the shape of the first coil pattern 311 and the second coil pattern 312 (including an end 311-1 of the first coil pattern 311 and an end 312-1 of the second coil pattern 312). As will be described below, the stopper 220 may prevent deformation of the coil from occurring during a process of stacking the magnetic composite sheets.

[0050] Reference Figure 2 and Figure 3, the stopper 220 is disposed at a corner of the body 100 in an outer region of the support portion 210. Here, the outer region of the support portion 210 may refer to a region between a region where the support portion 210 is formed and a plurality of side surfaces of the body 100. Being disposed at a corner of the body 100 may refer to being disposed adjacent to a region (i.e., a corner) where two adjacent side surfaces among the plurality of side surfaces 103, 104, 105, and 106 contact each other.

[0051] The plurality of stoppers 220 may be formed adjacent to each corner formed by the plurality of side surfaces of the body 100. Specifically, the stoppers 220 may include a first stopper 221 adjacent to a corner formed by the first side surface 103 and the third side surface 105 of the body 100, a second stopper 222 adjacent to a corner formed by the second side surface 104 and the third side surface 105 of the body 100, a third stopper 223 adjacent to a corner formed by the second side surface 104 and the fourth side surface 106 of the body 100, and a fourth stopper 224 adjacent to a corner formed by the first side surface 103 and the fourth side surface 106 of the body 100. In this case, when the plurality of stoppers 220 are arranged adjacent to each corner formed by the plurality of side surfaces of the body 100, when the body 100 is formed, stress applied to the support member 200 and the coil 310 may be uniformly dispersed, thereby minimizing deformation of the coil 310.

[0052] The plurality of stoppers 221, 222, 223, and 224 may be formed to be symmetrical to each other. Here, "symmetry" is a concept including not only plane symmetry but also point symmetry. Figure 2 , the first stopper 221 and the second stopper 222 may have a plane symmetric relationship with respect to a plane parallel to the XZ plane. Similarly, the fourth stopper 224 and the third stopper 223 may also have a plane symmetric relationship with respect to a plane parallel to the XZ plane. The first stopper 221 and the fourth stopper 224 may have a plane symmetric relationship with respect to a plane parallel to the XY plane. Similarly, the second stopper 222 and the third stopper 223 may also have a plane symmetric relationship with respect to a plane parallel to the XY plane. The first stopper 221 and the third stopper 223 may have a point symmetric relationship, and the second stopper 222 and the fourth stopper 224 may have a point symmetric relationship.

[0053] The stopper 220 may generally have an L-shape. Specifically, the stopper 220 may generally have an L-shape, and in the plan view of the coil component 1000, the stopper 220 and the corner of the main body 100 adjacent to the stopper 220 generally form a rectangular shape. That is, the area where the support member 200 is not provided is located between the stopper 220 and the corner of the main body 100 adjacent to the stopper 220, and only the main body 100 may exist in the corresponding area. For example, each stopper 220 may include a first portion extending toward one of the side surfaces of the main body 100, a second portion extending toward the other of the side surfaces of the main body 100, and a connecting portion connecting the first portion and the second portion to each other and disposed closer to the support portion 210 than the first portion and the second portion. By disposing a portion of the main body 100 between the stopper 220 and the corner of the main body 100 adjacent to the stopper 220 in this way, the flow of magnetic flux can be smoothed.

[0054] The stopper 220 may not extend to multiple side surfaces of the main body 100. That is, the stopper 220 may be completely embedded in the main body 100. In this case, as will be described below, the metal layer 320 formed on the stopper 220 during the cutting process of the coil component can be prevented from being pushed away (plating diffusion phenomenon). However, the present disclosure is not limited thereto, and the stopper 220 may extend to multiple side surfaces of the main body 100.

[0055] The stopper 220 of the coil component according to the present exemplary embodiment can be used as an area for indirectly supporting the coil 310. That is, when the magnetic composite sheets are stacked, the stopper 220 is used to assist the support 210 that directly supports the coil. Specifically, as the coil component 1000 becomes thinner, the pressure and temperature applied when forming the body 100 of the coil component 1000 may increase, thereby increasing the possibility of deformation of the coil 310. In the case of the present exemplary embodiment, by forming the stopper 220, the stress applied to the coil 310 and the support 210 when forming the body 100 can be reduced. That is, as an example, a portion of the magnetic composite sheet used to form the body 100 may flow into the gap (space) between the stopper 220 and the corner of the body 100, thereby minimizing the deformation of the support 210. In this way, the area that can support the coil can be increased by introducing the stopper 220, thereby preventing the coil from deforming.

[0056] In addition, when the magnetic composite sheets are stacked, the stopper 220 may connect adjacent coil units to each other, thereby preventing deformation of each coil unit.

[0057] The stopper 220 may have a width greater than or equal to 30 μm and less than or equal to 500 μm. As described above, the stopper 220 generally has an L-shape, and therefore, the width W of the stopper 220 can be obtained by measuring the length in the second direction (Y direction) or the third direction (Z direction). The specific method is as follows. First, the coil assembly is polished to a depth of about 1 / 2 along the first direction (X direction) to prepare a sample having a cross section exposing the stopper 220. Next, when the obtained cross-sectional sample is observed with an optical microscope or the like, the stopper 220 can be observed, and the width of the stopper 220 can be measured by measuring the length in the second direction (Y direction) or the third direction (Z direction). For example, the width W of the stopper 220 can be the size of the first part or the second part in the second direction (Y direction) or the third direction (Z direction).

[0058] The following [Table 1] shows the occurrence of coil deformation defects based on the width of the stopper 220, wherein OK indicates that no coil deformation defects occur. No. 1 is a coil component of the prior art in which the stopper 220 is not formed as a comparative example ( Fig.11 ).

[0059] [Table 1]

[0060] serial number Width(μm) Deformation (exposure) defects 1 0 occur 2 10 occur 3 30 OK 4 100 OK 5 300 OK 6 400 OK 7 500 OK

[0061] Referring to [Table 1], if the stopper 220 (No. 1) is not formed or the width is less than 30 μm (No. 2), a deformation defect of the coil 310 may occur. That is, when the body 100 is formed, the coil 310 may be deformed due to the stress applied to the coil 310 and the support member 200. When the width of the stopper 220 exceeds 500 μm, the size of the coil component may become too large, making it difficult to manufacture a slim / small coil component. Therefore, as a coil component according to the present exemplary embodiment, preferably, the width of the stopper 220 may be greater than or equal to 30 μm and less than or equal to 500 μm.

[0062] Figure 4 and Figure 5 is a plan view showing a modified example of the coil component according to the first exemplary embodiment.

[0063] Reference Figure 4 and Figure 5, the stopper 220 may extend to at least one of the plurality of side surfaces 103, 104, 105, and 106 of the body 100. Specifically, the stopper 220 may extend to any two adjacent side surfaces of the plurality of side surfaces 103, 104, 105, and 106 of the body 100. More specifically, the first stopper 221 may extend to the first side surface 103 and the third side surface 105, the second stopper 222 may extend to the second side surface 104 and the third side surface 105, the third stopper 223 may extend to the second side surface 104 and the fourth side surface 106, and the fourth stopper 224 may extend to the first side surface 103 and the fourth side surface 106.

[0064] This is because when the magnetic composite sheets are stacked, the stopper 220 may be an area that connects the coil units to each other. The stoppers 221, 222, 223, and 224 adjacent to the corners of the main body 100 may be formed as support members that connect the support member 200 to other adjacent coil units, and then may be separated from other adjacent coil units by a process that individualizes the coil units. At this time, the stopper 220 may be exposed to multiple side surfaces of the main body 100 of the coil assembly 1000. However, the present disclosure is not limited thereto, and as described above, the stopper 220 may be completely embedded in the main body 100. That is, the stopper 220 may not extend to multiple side surfaces 103, 104, 105, and 106 of the main body 100.

[0065] Surfaces of the stopper 220 extending to two adjacent side surfaces of the body 100 may be spaced apart from each other. Figure 4 , the first stopper 221 may extend to the first side surface 103 and the third side surface 105 of the body 100, and here, the surfaces of the first stopper 221 extending to the first side surface 103 and the third side surface 105 of the body 100 may be spaced apart from each other. That is, a gap may occur between the first stopper 221 and a corner of the body 100 formed by the first side surface 103 and the third side surface 105. As described above, by disposing a portion of the body 100 in the gap between the stopper 220 and the corner of the body 100, the flow of magnetic flux may be smoothed.

[0066] Reference Figure 5 , the stopper 220 may be connected to the support portion 210. That is, the stopper 220 and the support portion 210 may be integrally formed. When the stopper 220 is integrally formed with the support portion 210, the amount of the support member 200 removed when manufacturing the coil component can be minimized. In addition, since the stopper 220 is connected to the coil 310 through the support portion 210, the stress applied to the coil 310 when forming the body 100 can be more effectively reduced.

[0067] The coil 310 is embedded in the body 100 and exhibits characteristics of a coil component. For example, when the coil component 1000 of the present exemplary embodiment is used as a power inductor, the coil 310 can store an electric field as a magnetic field and maintain an output voltage, thereby stabilizing power of an electronic device.

[0068] The coil 310 includes coil patterns 311 and 312 and vias. Figure 1 The first coil pattern 311 and the end 311-1 (not shown) of the first coil pattern 311 are disposed on one surface (lower surface) of the support portion 210, and the second coil pattern 312 and the end 312-1 of the second coil pattern 312 are disposed on the other surface (upper surface) of the support portion 210. The via hole may pass through the support portion 210 and contact each of the first coil pattern 311 and the second coil pattern 312. Therefore, the coil 310 may be used as a single coil that forms one or more turns around the core 110 as a whole.

[0069] Each of the first coil pattern 311 and the second coil pattern 312 may have a planar spiral shape forming at least one turn around the core 110. For example, the first coil pattern 311 may form at least one turn around the core 110 on the lower surface of the support part 210.

[0070] At least one of the via and the coil patterns 311 and 312 may include one or more conductive layers. For example, when the second coil pattern 312, the end 312-1 of the second coil pattern 312 and the via are formed on the other surface of the support portion 210 by plating, the second coil pattern 312, the end 312-1 of the second coil pattern 312 and the via may each include a seed layer (such as an electroless plating layer) and an electroplating layer. Here, the electroplating layer may have a single-layer structure or a multi-layer structure. The electroplating layer with a multi-layer structure may be formed as a conformal film structure in which one electroplating layer is covered by another electroplating layer, or may be formed so that another electroplating layer is only stacked on one surface of an electroplating layer. The seed layer of the second coil pattern 312, the seed layer of the end 312-1 of the second coil pattern 312 and the seed layer of the via may be formed integrally so that no boundary is formed between them, but the present disclosure is not limited thereto. The plating layer of the second coil pattern 312 , the plating layer of the end portion 312 - 1 of the second coil pattern 312 , and the plating layer of the via hole may be integrally formed such that no boundary may be formed therebetween, but the present disclosure is not limited thereto.

[0071] As another example, when based on Figure 1When the first coil pattern 311 and the end 311-1 of the first coil pattern 311 disposed on the lower surface of the support portion 210 and the second coil pattern 312 and the end 312-1 of the second coil pattern 312 disposed on the upper surface of the support portion 210 are formed separately and stacked together on the support portion 210 to form the coil 310, the via may include a high melting point metal layer and a low melting point metal layer having a melting point lower than that of the high melting point metal layer. Here, the low melting point metal layer may be formed using a solder including lead (Pb) and / or tin (Sn). During the co-stacking, at least a portion of the low melting point metal layer may be melted due to pressure and temperature, so that, for example, an intermetallic compound (IMC) layer may be formed at the boundary between the low melting point metal layer and the second coil pattern 312.

[0072] based on Figure 1 In the direction of the support portion 210, the first coil pattern 311 and the end 311-1 of the first coil pattern 311 may protrude from the lower surface of the support portion 210, and the second coil pattern 312 and the end 312-1 of the second coil pattern 312 may protrude from the upper surface of the support portion 210. As another example, the first coil pattern 311 and the end 311-1 of the first coil pattern 311 may protrude from the lower surface of the support portion 210, and the second coil pattern 312 and the end 312-1 of the second coil pattern 312 may be embedded in the upper surface of the support portion 210, so that the upper surface of each of the second coil pattern 312 and the end 312-1 of the second coil pattern 312 may be exposed to the upper surface of the support portion 210. In this case, a concave portion may be formed on the upper surface of the second coil pattern 312 and / or the end 312-1 of the second coil pattern 312, and thus, the upper surface of the second coil pattern 312 and / or the end 312-1 of the second coil pattern 312 may not be coplanar with the upper surface of the support portion 210. As another example, the second coil pattern 312 and the end 312-1 of the second coil pattern 312 may be formed to protrude from the upper surface of the support portion 210, and the first coil pattern 311 and the end 311-1 of the first coil pattern 311 may be embedded in the lower surface of the support portion 210, so that the lower surface of each of the first coil pattern 311 and the end 311-1 of the first coil pattern 311 may be exposed to the lower surface of the support portion 210. In this case, a concave portion may be formed on the lower surface of the first coil pattern 311 and / or the end 311-1 of the first coil pattern 311, so that the lower surface of the first coil pattern 311 and / or the end 311-1 of the first coil pattern 311 may not be coplanar with the lower surface of the support portion 210.

[0073] The via and the coil patterns 311 and 312 may each be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), and alloys thereof, but are not limited thereto.

[0074] The external electrodes 400 and 500 are disposed on the surface of the body 100 and are respectively connected to the two ends 311-1 and 312-1 of the coil 310. In the present exemplary embodiment, the two ends 311-1 and 312-1 of the coil 310 extend to the first side surface 103 and the second side surface 104 of the body 100, respectively. Therefore, the first external electrode 400 may be disposed on the first side surface 103 and contact the end 311-1 of the first coil pattern 311 extending to the first side surface 103 of the body 100, and the second external electrode 500 may be disposed on the second side surface 104 and contact the end 312-1 of the second coil pattern 312 extending to the second side surface 104 of the body 100.

[0075] The external electrodes 400 and 500 may extend onto the first surface 101 of the body 100. That is, the first external electrode 400 may be disposed on the first side surface 103 and the first surface 101 to form an L shape, and the second external electrode 500 may be disposed on the second side surface 104 and the first surface 101 to form an L shape.

[0076] The external electrodes 400 and 500 may be formed as a single layer structure or a multilayer structure. As an example, the external electrodes 400 and 500 include a first layer including copper, a second layer provided on the first layer and including nickel (Ni), and a third layer provided on the second layer and including tin (Sn). Here, the first to third layers may each be formed by plating, but are not limited thereto. As another example, the external electrodes 400 and 500 may include a resin-based electrode including a conductive powder and a resin and a plating layer formed on the resin-based electrode.

[0077] The external electrodes 400 and 500 may be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), and alloys thereof, but are not limited thereto.

[0078] Reference Figure 3, although not fully shown in the drawings, the insulating film 600 may be formed on the support member 200, the coil 310 and the metal layer 320 (to be described below). The insulating film 600 may be used to insulate the coil 310 and the metal layer 320 from the main body 100, and may include a known insulating material (such as polyparaxylene). The insulating material included in the insulating film 600 may be any insulating material, and there is no particular limitation on it. The insulating film 600 may be formed by a method such as vapor deposition, but is not limited thereto, and may be formed by stacking insulating films on both sides of the support member 200. In the former case, the insulating film 600 may be formed in the form of a conformal film along the surfaces of the support member 200, the coil 310 and the metal layer 320. In addition, in the present disclosure, the insulating film 600 is optional, so if the main body 100 can ensure sufficient insulation resistance under the operating voltage and operating current of the coil component 1000 according to the present exemplary embodiment, the insulating film 600 may be omitted.

[0079] (Second exemplary embodiment)

[0080] Figure 6 is a perspective view schematically showing a coil component according to a second exemplary embodiment of the present disclosure. Figure 7 is a plan view schematically showing a coil component according to a second exemplary embodiment of the present disclosure.

[0081] Reference Figure 6 and Figure 7 The coil component 2000 according to the second exemplary embodiment of the present disclosure may further include a metal layer 320. The metal layer 320 may be disposed on both sides of the stopper 220. That is, relative to Figure 6 , the metal layer 320 may be disposed on both the lower surface and the upper surface of the stopper 220 .

[0082] Reference Figure 7 , the metal layer 320 may be spaced apart from the coil 310. The metal layer 320 may not be physically and / or electrically connected to the coil 310. Unlike the coil 310, the metal layer 320 may be a component that does not directly form an inductor in the coil component.

[0083] By forming the metal layer 320 on the stopper 220, the stress applied to the coil 310 and the support 210 when the magnetic composite sheets are stacked can be further reduced. Specifically, the flow of the magnetic composite sheet used to form the body 100 to the gap (space) between the stopper 220 and the corner of the body 100 can be promoted.

[0084] The metal layer 320 may be formed adjacent to each corner formed by the plurality of side surfaces of the body 100. Specifically, the metal layer 320 may include a first metal layer 321 adjacent to a corner formed by the first side surface 103 and the third side surface 105 of the body 100, a second metal layer 322 adjacent to a corner formed by the second side surface 104 and the third side surface 105 of the body 100, a third metal layer 323 adjacent to a corner formed by the second side surface 104 and the fourth side surface 106 of the body 100, and a fourth metal layer 324 adjacent to a corner formed by the first side surface 103 and the fourth side surface 106 of the body 100.

[0085] The plurality of metal layers 321, 322, 323, and 324 may be formed to be symmetrical to each other. Here, "symmetry" is a concept including not only plane symmetry but also point symmetry. Figure 7 , the first metal layer 321 and the second metal layer 322 may have a plane symmetric relationship based on a plane parallel to the XZ plane. Similarly, the fourth metal layer 324 and the third metal layer 323 may also have a plane symmetric relationship based on a plane parallel to the XZ plane. The first metal layer 321 and the fourth metal layer 324 may have a plane symmetric relationship based on a plane parallel to the XY plane. Similarly, the second metal layer 322 and the third metal layer 323 may also have a plane symmetric relationship based on a plane parallel to the XY plane.

[0086] The metal layer 320 may generally have an L-shape to correspond to the shape of the stopper 220. Specifically, the metal layer 320 may generally have an L-shape to generally form a rectangular shape with a corner of the body 100 adjacent to the metal layer 320.

[0087] The metal layer 320 may not extend to multiple side surfaces of the main body 100. That is, the metal layer 320 may be embedded in the main body 100, similar to the stopper 220 embedded in the main body 100. In this case, it is possible to prevent the metal layer 320 from being pushed away during the cutting process of the coil component (plating diffusion phenomenon). However, the present disclosure is not limited thereto, and the metal layer 320 may extend to multiple side surfaces of the main body 100.

[0088] The metal layer 320 may have a width of 30 μm or more and 500 μm or less. That is, the metal layer may be formed to have a width substantially the same as the width of the above-mentioned stopper 220. For a method of measuring the width of the metal layer 320, reference may be made to the description of measuring the width of the stopper 220 of the first exemplary embodiment.

[0089] The metal layer 320 may be formed on the stopper 220 by the same process as the process for forming the coil 310 described above. Specifically, the metal layer 320 may include one or more conductive layers. When the metal layer 320 is formed on the stopper 220 by plating, the metal layer 320 may include a seed layer (such as an electroless plating layer) and an electroplating layer. Here, the electroplating layer may have a single-layer structure or a multi-layer structure. The electroplating layer having a multi-layer structure may be formed as a conformal film structure in which one electroplating layer is covered by another electroplating layer, or may also be formed so that another electroplating layer is stacked only on one surface of one electroplating layer.

[0090] The thickness of the metal layer 320 may be substantially the same as the thickness of the coil 310. Here, the thickness refers to Figure 6 The length in the first direction (X direction) of the coil 310. As described above, the metal layer 320 may be formed in the same process as the process of forming the coil 310, so the metal layer 320 may have substantially the same thickness as the coil 310. The thickness of the metal layer 320 and the coil 310 may be measured by the following method. First, the coil assembly is polished in the second direction (Y direction) to prepare a cross-sectional sample exposing the metal layer 320 and the coil 310. Next, the obtained cross-sectional sample may be observed using an optical microscope or the like, and the length of the metal layer 320 and the coil 310 in the first direction (X direction) may be measured to obtain the corresponding thickness. The thickness may refer to the arithmetic mean of the values ​​obtained by performing multiple measurements at multiple points in the third direction (Z direction). The case where the thickness is substantially the same may include errors occurring during the manufacturing process, for example, the case where the difference in the thickness of the metal layer 320 and the coil 310 is within an error range of ±10%.

[0091] The metal layer 320 may be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), and alloys thereof, but is not limited thereto.

[0092] The metal layer 320 may not be in direct contact with the external electrodes 400 and 500. As described above, the metal layer 320 may not extend to multiple side surfaces of the body 100, and even if the metal layer 320 extends to multiple side surfaces of the body 100, an insulating layer (not shown) may be provided on the surface to which the metal layer 320 extends so that the metal layer 320 does not directly contact the external electrodes 400 and 500.

[0093] Figure 8 : is a plan view showing a modified example of the coil component according to the second exemplary embodiment of the present disclosure, in which the stopper portion is spaced apart from the support portion. Fig. 9 is a plan view showing another modified example of the coil component according to the second exemplary embodiment of the present disclosure, in which the stopper portion is connected to the support portion.

[0094] Reference Figure 8 and Fig. 9 , the metal layer 320 may extend to the plurality of side surfaces 103, 104, 105, and 106 of the body 100. Specifically, the metal layer 320 may extend to any two adjacent side surfaces among the plurality of side surfaces 103, 104, 105, and 106 of the body 100. More specifically, the first metal layer 321 may extend to the first side surface 103 and the third side surface 105, the second metal layer 322 may extend to the second side surface 104 and the third side surface 105, the third metal layer 323 may extend to the second side surface 104 and the fourth side surface 106, and the fourth metal layer 324 may extend to the first side surface 103 and the fourth side surface 106. That is, the metal layer 320 may also extend to any two adjacent side surfaces among the plurality of side surfaces of the body 100 along the shape of the stopper 220.

[0095] Fig.10 is a perspective view showing another modified example of the coil component according to the second exemplary embodiment of the present disclosure.

[0096] Reference Fig.10 In the coil component 2000' according to the modified example of the second exemplary embodiment of the present disclosure, the metal layer 320 may be provided only on one side of the stopper 220. That is, with respect to Fig.10 , the metal layer 320 may be disposed only on the upper surface of the stopper 220 . However, the present disclosure is not limited thereto, and the metal layer 320 may be disposed only on the lower surface of the stopper 220 .

[0097] For the remaining components of the present exemplary embodiment, the description in the first exemplary embodiment of the present disclosure can be applied as it is, and repeated description will be omitted.

[0098] According to the present disclosure, it is possible to prevent the coil from being deformed during the process of stacking and pressing the magnetic composite sheets.

[0099] In addition, according to the present disclosure, it is possible to reduce a defect rate due to coil deformation while forming a coil component to be thinner (low profile).

[0100] While exemplary embodiments have been shown and described above, it will be readily apparent to those skilled in the art that modifications and variations may be made without departing from the scope of the present disclosure as defined by the appended claims.

Claims

1. A coil assembly, comprising: A main body having a first surface, a second surface opposite to the first surface in a first direction, and a plurality of side surfaces connecting the first surface and the second surface; a coil embedded in the body; as well as A support member is embedded in the body and includes a support portion supporting the coil and at least one stopper provided at a corner of the body formed by two or more of the plurality of side surfaces in an outer region of the support portion.

2. The coil assembly according to claim 1, wherein: The stopper has an L-shape, and in a plan view of the coil component, the stopper and a corner of the body adjacent to the stopper form a rectangular shape.

3. The coil assembly according to claim 1, wherein: A portion of the body is disposed between the stopper and a corner of the body adjacent to the stopper.

4. The coil assembly according to claim 1, wherein: The stopper is formed in plural to be adjacent to each corner of the body formed by the plural side surfaces.

5. The coil assembly according to claim 4, wherein: The plurality of stoppers are symmetrical to each other.

6. The coil assembly according to claim 1, wherein: The stopper extends to the two or more side surfaces among the plurality of side surfaces of the body.

7. The coil assembly according to claim 1, wherein: The stopper portion is connected to the support portion.

8. The coil assembly according to claim 1, wherein: The stopper portion is spaced apart from the support portion.

9. The coil assembly according to any one of claims 1 to 8, wherein: The stopper has a width greater than or equal to 30 μm and less than or equal to 500 μm.

10. The coil assembly according to claim 1, further comprising: a metal layer disposed on at least one surface of the stopper portion, Wherein, the metal layer is spaced apart from the coil.

11. The coil assembly according to claim 10, wherein: The metal layer extends to the two or more side surfaces among the plurality of side surfaces of the body.

12. The coil assembly according to claim 10, wherein: The thickness of the metal layer is substantially the same as the thickness of the coil. 13 . The coil component according to claim 10 , further comprising an insulating film disposed on and covering the metal layer and the coil.

14. The coil assembly according to claim 1, wherein: The coil comprises: a first coil pattern having a planar spiral shape and disposed on one surface of the support portion; a second coil pattern having a planar spiral shape and provided on the other surface of the support member opposite to the one surface; and A via hole passes through the support portion to connect the first coil pattern and the second coil pattern.

15. The coil assembly according to claim 1, wherein: Both ends of the coil extend to two side surfaces of the plurality of side surfaces of the body that are opposite to each other in a second direction that is perpendicular to the first direction, respectively.

16. The coil assembly according to claim 1, further comprising: The first and second external electrodes are respectively disposed on two side surfaces of the body facing each other in a second direction perpendicular to the first direction and are respectively connected to ends of the coil.

17. The coil assembly according to claim 16, wherein: The first external electrode and the second external electrode extend to the first surface of the body.

18. The coil assembly according to claim 1, wherein: The stopper portion includes a first portion extending toward one of the two or more side surfaces among the multiple side surfaces of the main body, a second portion extending toward another of the two or more side surfaces among the multiple side surfaces of the main body, and a connecting portion connecting the first portion and the second portion to each other and disposed closer to the support portion than the first portion and the second portion.

19. The coil assembly according to claim 18, wherein: The first portion contacts the one side surface of the two or more side surfaces of the plurality of side surfaces of the body, and the second portion contacts the other side surface of the two or more side surfaces of the plurality of side surfaces of the body.

20. The coil assembly according to claim 18, wherein The first portion is spaced apart from the one side surface of the two or more side surfaces of the plurality of side surfaces of the body, and the second portion is spaced apart from the other side surface of the two or more side surfaces of the plurality of side surfaces of the body.

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