Coil component

Abstract

The invention provides a coil assembly. The coil component includes: a main body; a support member disposed within the main body and having one surface and another surface opposite to each other; a first coil disposed on the one surface of the support member and including a first core; a second coil disposed on the other surface of the support member and including a second core; a first lead-out portion disposed on the other surface of the support member and connected to the first coil; and a second lead-out portion disposed on the one surface of the support member and connected to the second coil, in which the first core and the second core partially overlap when viewed in a stacking direction of the first coil and the second coil on the support member, and the length of the second coil in one direction is greater than the length of the first coil in the one direction.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0140358 filed on October 19, 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] According to the miniaturization and thinning of electronic devices such as digital televisions (TVs), mobile phones, and laptop computers, miniaturization and thinning of coil components used in such electronic devices have been required. In order to meet such demands, research and development of various winding type coil components or film type coil components have been actively carried out.

[0004] The main problem of miniaturization and thinning of coil components is to achieve the same characteristics as those of existing coil components despite miniaturization and thinning. In order to meet such a demand, the ratio of the magnetic material in the core filled with the magnetic material should be increased. However, there is a limit in increasing the ratio due to changes in the strength of the inductor body, frequency characteristics depending on insulation properties, etc.

[0005] Meanwhile, there is an increasing demand for array type components having the advantage of reducing the installation area of ​​the coil component. Depending on the coupling coefficient or mutual inductance between the plurality of coil parts, such array type coil electronic components may have an uncoupled inductor form or a coupled inductor form or a hybrid form of the uncoupled inductor form and the coupled inductor form.

[0006] In a coupled inductor, leakage inductance is associated with output current ripple, and mutual inductance is associated with inductor current ripple. In order for the coupled inductor to have the same output current ripple as that of an existing uncoupled inductor, the leakage inductance of the coupled inductor is the same as the mutual inductance of the existing uncoupled inductor. In addition, when the mutual inductance increases, the coupling coefficient (k) increases, so that the inductor current ripple can be reduced.

[0007] Therefore, when a coupled inductor can have a reduced inductor current ripple while having an output current ripple that is the same as that of an existing uncoupled inductor at the same size as that of an existing uncoupled inductor, an improvement in efficiency can be achieved without increasing the mounting area. In order to improve the efficiency of the inductor array while maintaining the size of the inductor array, a coupled inductor whose coupling coefficient is increased by increasing the mutual inductance may be required. On the other hand, depending on the needs of the application, a coupled inductor with a relatively small coupling coefficient may be required, in which case the coupling coefficient between the coil portions needs to be reduced to an appropriate level. Summary of the invention

[0008] An aspect of the present disclosure is to enable effective control of coupled inductance between coil parts in a coil component having a coupled inductor structure.

[0009] Another aspect of the present disclosure is to enable effective control of characteristic deviation between coil parts in a coil component having a coupled inductor structure.

[0010] According to one aspect of the present disclosure, a coil component includes: a main body having a first surface and a second surface opposite to each other in a first direction, a third surface and a fourth surface opposite to each other in a second direction, and a fifth surface and a sixth surface opposite to each other in a third direction; a support member arranged in the main body and having one surface and another surface opposite to each other in the third direction; a first coil arranged on the one surface of the support member and having a first core; a second coil arranged on the other surface of the support member and having a second core; a first lead-out portion arranged on the other surface of the support member and connected to the first coil; and a second lead-out portion arranged on the one surface of the support member and connected to the second coil, wherein, when viewed along the third direction of the main body, the first core partially overlaps with the second core, and a length of the second coil in the first direction is greater than a length of the first coil in the first direction.

[0011] According to another aspect of the present disclosure, a coil component includes: a main body having a first surface and a second surface opposite to each other in a first direction, a third surface and a fourth surface opposite to each other in a second direction, and a fifth surface and a sixth surface opposite to each other in a third direction; a first coil arranged in the main body and including a first core; and a second coil arranged to be spaced apart from the first coil in the main body and including a second core, wherein the first core includes a first common core overlapping with the second core in the third direction and a first non-common core that does not overlap with the second core in the third direction, the second core includes a second common core overlapping with the first core in the third direction and a second non-common core that does not overlap with the first core in the third direction, the first non-common core and the second non-common core are arranged to be closer to the second surface of the main body than the first common core and the second common core, and an area of ​​the second non-common core is larger than an area of ​​the first non-common core. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] 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: Figure 1is a schematic perspective isometric view showing a coil component according to a first exemplary embodiment of the present disclosure; Figure 2 It is shown Figure 1 An exploded perspective view of some components of the coil assembly; Figure 3 is a graph showing the Figure 1 A view of a coil assembly; Figure 4 yes Figure 3 An enlarged view of part A; Figure 5 It is shown Figure 1 A view of a coil of a coil assembly; Figure 6 yes Figure 1 A virtual plane diagram in which the coil and the lead-out portion of the coil assembly overlap each other; Fig. 7A and Figure 7B Along Figure 1 A cross-sectional view taken along lines II-I' and II-II'; Figure 8 is a schematic perspective isometric view showing a coil component according to a second exemplary embodiment in the present disclosure; Fig. 9 is a perspective view showing a coil assembly according to a comparative example in the present disclosure; Fig.10 is a graph showing the Fig. 9 A view of a coil assembly; and Fig.11A and Fig. 11B Along Fig. 9 Cross-sectional views taken along lines III-III' and IV-IV'. DETAILED DESCRIPTION

[0013] The terms used in this specification are used only to describe specific exemplary embodiments, rather than to limit the present disclosure. Unless the context clearly states otherwise, the expression in the singular is intended to include the expression in the plural. It should be understood that the terms "including" or "having" used herein specify the presence of features, quantities, steps, operations, components, parts or combinations thereof mentioned in this specification, but do not exclude the presence or addition of one or more other features, quantities, steps, operations, components, parts or combinations thereof. In addition, throughout the specification, "on ... " does not necessarily mean that any element is positioned on the upper side based on the direction of gravity, but represents that any element is positioned above or below the target portion.

[0014] Furthermore, the term “coupled” refers not only to a case where the corresponding components are in direct physical contact with each other but also to a case where the corresponding component is in contact with another component and the other component is interposed between the corresponding components in a contact relationship with the corresponding component.

[0015] Since the sizes (eg, thickness) of various components shown in the drawings are arbitrarily shown for convenience of explanation, the present disclosure is not necessarily limited to the sizes shown in the drawings.

[0016] In the drawings, the X direction refers to a first direction or a length direction, the Y direction refers to a second direction or a width direction, and the Z direction refers to a third direction or a thickness direction.

[0017] Hereinafter, a coil component according to an exemplary embodiment of the present disclosure will be described in detail with reference to the accompanying drawings. In describing the exemplary embodiments of the present disclosure with reference to the accompanying drawings, components identical or corresponding to each other will be denoted by the same reference numerals, and repeated descriptions thereof will be omitted.

[0018] Various electronic components may be used in electronic devices, and various coil components may be appropriately used between these electronic components according to their purposes in order to remove noise or the like.

[0019] That is, the coil component used in the electronic device may be a power inductor, a high frequency (HF) inductor, a general-purpose magnetic bead, a magnetic bead for high frequency (eg, GHz band), a common mode filter, and the like.

[0020] First Exemplary Embodiment Figure 1 is a schematic perspective view showing a coil component according to a first exemplary embodiment in the present disclosure. Figure 2 It is shown Figure 1 An exploded perspective view of some components of the coil assembly. Figure 3 is a graph showing the Figure 1 A view of the coil assembly. Figure 4 yes Figure 3 Magnified view of part A. Figure 5 It is shown Figure 1 A view of the coil of the coil assembly. Figure 6 yes Figure 1 A virtual plane view in which the coil and lead-out portions of the coil assembly overlap each other. Fig. 7A and Figure 7B Along Figure 1 Cross-sectional views taken along lines II' and II-II'.

[0021] Reference Figures 1 to 7B, a coil component 1000 according to an exemplary embodiment in the present disclosure may include a body 100 , a support member 200 , a first coil 310 , a second coil 320 , a first lead-out portion 410 , a second lead-out portion 420 , and external electrodes 531 , 541 , 532 , and 542 .

[0022] The body 100 may form the overall appearance of the coil component 1000 according to the present exemplary embodiment, and may have the coils 310 and 320 and the lead-out portions 410 and 420 embedded therein.

[0023] The body 100 may generally have a hexahedral shape.

[0024] exist Figure 1 In the embodiment, the main body 100 may have a first surface 101 and a second surface 102 opposite to each other in the X direction (first direction), a third surface 103 and a fourth surface 104 opposite to each other in the Y direction (second direction), and a fifth surface 105 and a sixth surface 106 opposite to each other in the Z direction (third direction). The first surface 101, the second surface 102, the third surface 103, and the fourth surface 104 of the main body 100 may correspond to side surfaces of the main body 100 connecting the fifth surface 105 and the sixth surface 106 to each other. Hereinafter, the upper surface and the lower surface of the main body 100 may refer to the fifth surface 105 and the sixth surface 106 based on the surface of the main body 100. Figure 1 The sixth surface 106 and the fifth surface 105 of the body 100 are determined in the direction of. The fifth surface 105 of the body 100 can be used as a mounting surface when the coil component is mounted. However, the mounting surface is not necessarily limited thereto.

[0025] The body 100 may include a resin and a magnetic material. Specifically, the body 100 may be formed by stacking one or more magnetic composite sheets in which a magnetic material is dispersed in a resin. The magnetic material may be ferrite or a metal magnetic powder. The ferrite may be, for example, a 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 or Ni-Zn-based ferrite), a hexagonal ferrite (such as Ba-Zn-based ferrite, Ba-Mg-based ferrite, Ba-Ni-based ferrite, Ba-Co-based ferrite or Ba-Ni-Co-based ferrite), a garnet ferrite (such as Y-based ferrite) and at least one of Li-based ferrite. The metal 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 metal 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. The metal magnetic powder may be amorphous or crystalline. For example, the metal magnetic powder may be a Fe-Si-B-Cr-based amorphous alloy powder, but is not necessarily limited thereto. The ferrite and the metal magnetic powder may each have an average diameter of about 0.1 μm to 30 μm, but are not limited thereto. The 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 distinguished from each other by any one of average diameter, composition, crystallinity, and shape. The resin may include epoxy, polyimide, liquid crystal polymer (LCP), etc., or a mixture thereof, but is not limited thereto.

[0026] The support member 200 may be disposed inside the body 100. Specifically, the support member 200 may be embedded in the body 100. The support member 200 may be configured to support the coils 310 and 320 and the lead-out portions 410 and 420 described below. However, according to some exemplary embodiments, the support member 200 may not be provided. For example, in the case of using a winding type coil, it may not be necessary to separately provide the support member 200. The coil component 1000 according to the first exemplary embodiment may relate to a thin film type coil in which electroplating is performed on the support member 200.

[0027] The support member 200 may be formed using an insulating material including a thermosetting insulating resin such as an epoxy resin, a thermoplastic insulating resin such as a polyimide resin, or a photosensitive insulating resin, or an insulating material having a reinforcing material such as glass fiber or an inorganic filler impregnated in such an insulating resin. As an example, the support member 200 may be formed using an insulating material such as a prepreg, an Ajinomoto built-up film (ABF), FR-4, a bismaleimide triazine (BT) film, or a photosensitive dielectric (PID) film, but is not limited thereto.

[0028] As the material of the inorganic filler, one or more materials selected from the group consisting of 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) can be used.

[0029] In the case where the support member 200 is formed using an insulating material including a reinforcing material, the support member 200 can provide more excellent rigidity. In the case where the support member 200 is formed using an insulating material that does not include glass fiber, the support member 200 can be conducive to thinning the coil component. In the case where the support member 200 is formed using an insulating material including a photosensitive insulating resin, the number of processes for forming the coils 310 and 320 can be reduced, which can be conducive to reducing production costs and can be conducive to forming fine vias.

[0030] The first coil 310 and the second coil 320 may be disposed to be spaced apart from each other in the body 100 to achieve the characteristics of the coil component 1000 according to the present exemplary embodiment. For example, the coil component 1000 according to the present exemplary embodiment may be a coupled inductor in which the absolute value of the coupling coefficient (k) between the first coil 310 and the second coil 320 exceeds 0 and is less than or equal to 1, but is not limited thereto.

[0031] The first coil 310 may include the first core 110, and the second coil 320 may include the second core 120. Since the first coil 310 forms at least one turn around the first core 110, the first core 110 may be defined as a region inside the turn formed by the first coil 310. Likewise, since the second coil 320 forms at least one turn around the second core 120, the second core 120 may be defined as a region inside the turn formed by the second coil 320. Since the first coil 310 and the second coil 320 are spaced apart from each other in the Z direction (third direction) as described below, the first core 110 and the second core 120 may be spaced apart from each other in the third direction of the body 100.

[0032] The cores 110 and 120 may be formed by filling the through holes of the first coil 310 and the second coil 320 with at least a portion of the magnetic composite sheets when the magnetic composite sheets are stacked and cured, but are not limited thereto.

[0033] The area of ​​the second core 120 may be greater than that of the first core 110. In addition, the first core 110 and the second core 120 may partially overlap each other and include a shared core and a non-shared core, which will be described in detail after the description of the coils 310 and 320.

[0034] In the following, reference will be made to Figures 2 to 6 The coils 310 and 320 and the lead-out parts 410 and 420 of the coil component according to the present exemplary embodiment are described in detail.

[0035] Figure 2 It is shown Figure 1 An exploded perspective view of some components of the coil assembly. Specifically, Figure 2 2 is a view showing the coils 310 and 320 and the lead-out parts 410 and 420 of the coil component 1000 according to the present exemplary embodiment. Figure 3 is a graph showing the Figure 1 For convenience, the Figure 3 The supporting member 200 is omitted.

[0036] Reference Figure 2 and Figure 3 , the first coil 310 may be disposed on one surface of the support member 200 ( Figure 2 and Figure 3 The first coil 310 is disposed on an upper surface of the body 100 and may form at least one turn around the first core 110. One end of the first coil 310 may extend to the third surface 103 of the body 100. The other end of the first coil 310 may be connected to a first lead-out portion 410 described below through a first via hole V1.

[0037] Figure 5 It is shown Figure 1 FIG. 1 is a view of coils 310 and 320 of a coil assembly. Figure 5, the first coil 310 may have a first straight portion L1 and a second straight portion L2, the first straight portion L1 being adjacent to and substantially parallel to the third surface 103 of the body 100, and the second straight portion L2 being adjacent to and substantially parallel to the fourth surface 104 of the body 100. Here, the straight portion may refer to the outermost coil portion having a curvature of substantially 0. That is, since the straight portion is substantially parallel to the third surface 103 and the fourth surface 104 of the body 100, its curvature may be substantially 0. In one or more aspects, the terms "about", "substantially", and "approximately" may provide industry-accepted tolerances (such as tolerances from less than one percent of the stated actual value to ten percent of the stated actual value and other suitable tolerances) for their corresponding terms and / or relativity between items.

[0038] Reference Figure 2 and Figure 3 , the second coil 320 may be disposed on another surface of the support member 200 ( Figure 2 and Figure 3 The second coil 320 may be connected to the lower surface of the body 100 and may form at least one turn around the second core 120. One end of the second coil 320 may extend to the fourth surface 104 of the body 100. The other end of the second coil 320 may be connected to the second lead-out portion 420 described below through the second via hole V2.

[0039] The second coil 320 may be disposed closer to the fifth surface 105 of the body 100 than the first coil 310. The fifth surface 105 of the body 100 may be used as a mounting surface when mounting the coil component.

[0040] Reference Figure 5 , the second coil 320 may have a third straight portion L3 and a fourth straight portion L4, the third straight portion L3 being adjacent to and substantially parallel to the third surface 103 of the body 100, and the fourth straight portion L4 being adjacent to and substantially parallel to the fourth surface 104 of the body 100. Here, the straight portion may refer to an outermost coil portion having a curvature of substantially 0. That is, since the straight portion is substantially parallel to the third surface 103 and the fourth surface 104 of the body 100, its curvature may be substantially 0.

[0041] In one embodiment, the first coil 310 may further include a first curved portion and a second curved portion. The first curved portion may extend between one end of the first straight portion L1 and one end of the second straight portion L2, and the second curved portion may extend between the other end of the first straight portion L1 and the other end of the second straight portion L2. Here, the first curved portion may be closer to the first surface 101 of the body 100 than the second curved portion.

[0042] In one embodiment, the second coil 320 may further include a third curved portion and a fourth curved portion. The third curved portion may extend between one end of the third straight portion L3 and one end of the fourth straight portion L4, and the fourth curved portion may extend between the other end of the third straight portion L3 and the other end of the fourth straight portion L4. Here, the third curved portion may be closer to the first surface 101 of the body 100 than the fourth curved portion.

[0043] In one embodiment, the second curved portion and the fourth curved portion may each have at least two bends so as to form an “S” shape, and the first curved portion and the third curved portion may have a semicircular shape.

[0044] In one embodiment, the first lead portion 410 may be exposed to the third surface 103 of the body 100, connected to the first coil 310, and diagonally extended toward one of the at least two bends of the fourth bend. The second lead portion 420 may be exposed to the fourth surface 104 of the body 100, connected to the second coil 320, and diagonally extended toward one of the at least two bends of the second bend.

[0045] Hereinafter, the shapes and sizes of the coils 310 and 320 , which are characteristic components of the present disclosure, will be described in more detail.

[0046] In a coupled inductor according to the prior art, the first coil and the second coil have the same shape and size. The coil close to the mounting surface of the coil component has a problem in that the magnetic flux and capacity are reduced due to the influence of the pad pattern of the mounting surface or the metal layer of the substrate. As a result, characteristic deviations between the coil parts are generated in the coupled inductor.

[0047] Fig. 9 is a perspective view showing a coil component C according to a comparative example in the present disclosure. Fig.10 is a graph showing the Fig. 9 A view of the coil assembly.

[0048] Reference Fig. 9 and Fig.10 In the coil component C according to the comparative example, the first coil 310' and the second coil 320' have the same shape and size. Therefore, when the coil component is installed, the magnetic flux and capacity of the second coil 320' close to the fifth surface 105' set as the mounting surface may be reduced. The coil component C according to the comparative example may include a body 100', a support member 200', a first coil 310', a second coil 320', a first lead-out portion 410', a second lead-out portion 420', and external electrodes 531', 541', 532' and 542'. Fig. 9In the embodiment, the body 100' may have a first surface 101' and a second surface 102' opposite to each other in the X direction (first direction), a third surface 103' and a fourth surface 104' opposite to each other in the Y direction (second direction), and a fifth surface 105' and a sixth surface 106' opposite to each other in the Z direction (third direction).

[0049] In this regard, the present disclosure proposes a coil component having the following structure to solve the above-mentioned problems.

[0050] Figure 6 yes Figure 1 A virtual plane view of the coil assembly in which the coil and lead-out portions overlap each other.

[0051] The length of the second coil 320 of the coil component according to the exemplary embodiment in the present disclosure in the first direction may be greater than the length of the first coil 310 in the first direction. Here, "the length of each of the coils 310 and 320 in the first direction" may mean a straight line distance from one end to the opposite end of each of the coils 310 and 320 in the first direction.

[0052] The length of the second coil 320 in the first direction may be greater than the length of the first coil 310 in the first direction by d. As an example, the value of d may be 0.015 mm (15 μm). However, the value of d is not necessarily limited thereto and may vary according to the size and characteristics of the coil component.

[0053] As described below, the second core 120 formed by the second coil 320 may be larger than the first core 110 formed by the first coil 310. Specifically, the area (e.g., the plane area in a plan view) of the second non-shared core 122 in the second core 120 may be larger than the area (e.g., the plane area in a plan view) of the first non-shared core 112 in the first core 110. That is, the length of the second coil 320 in the first direction may be designed to be larger than the length of the first coil 310 in the first direction, so that the area of ​​the second core 120 is larger than the area of ​​the first core 110.

[0054] Specifically, spare spaces may be ensured on first and second surfaces 101 and 102 of body 100 instead of third and fourth surfaces 103 and 104 to which the lead-out portion of body 100 extends. Therefore, the length of the coil may be designed to be different by using the spare space of the coil component in the first direction.

[0055] The length of the coils 310 and 320 in the first direction may be measured in the following manner. First, the coil assembly may be polished to reveal cross sections in the first direction and the third direction to prepare a cross-sectional sample in which the first via V1 or the second via V2 is exposed. The prepared cross-sectional sample may be observed using an optical microscope or the like, and the length of each of the coils 310 and 320 in the first direction may be measured. As described above, “the length of each of the coils 310 and 320 in the first direction” may mean a straight-line distance from one end to the opposite end of each of the coils 310 and 320 in the first direction. The measurement may be performed multiple times (e.g., 10 times), and the arithmetic mean of the measured values ​​may be obtained as the length.

[0056] In addition, the length of the second coil 320 in the second direction may be substantially the same as the length of the first coil 310 in the second direction. However, the length of the first coil 310 in the second direction and the length of the second coil 320 in the second direction are not necessarily limited thereto and may be different from each other according to the desired characteristics of the coil component.

[0057] The second coil 320 may be disposed closer to the second surface 102 of the body 100 than the first coil 310. Figure 3 , a distance M1 between the first coil 310 and the second surface 102 is greater than a distance M2 between the second coil 320 and the second surface 102 .

[0058] The length of the fourth straight portion L4 of the second coil 320 may be greater than the length of the first straight portion L1 of the first coil 310. As described above, the length of the second coil 320 in the first direction is greater than the length of the first coil 310 in the first direction, and thus the length of the fourth straight portion L4 of the second coil 320 may be greater than the length of the first straight portion L1 of the first coil 310. The fourth straight portion L4 of the second coil 320 may be disposed closer to the second surface 102 of the body 100 than the first straight portion L1 of the first coil 310.

[0059] The distance between the first coil 310 and the first surface 101 of the body 100 may be substantially the same as the distance between the second coil 320 and the first surface 101 of the body 100. That is, by utilizing the spare space on any one of the first surface 101 and the second surface 102 of the body 100, the lengths of the coils may be designed to be different. Here, substantially the same distance refers to a distance including process errors or positional offsets generated during manufacturing and errors generated during measurement. As an example, when the vias V1 and V2 of the coils overlap each other so as to be as Figure 6 When aligned at the same position on the axis along the first direction as shown, one ends of the coils 310 and 320 may be aligned in the first direction.

[0060] The length L1 of the first straight portion may be greater than the length of the second straight portion L2. The length of the fourth straight portion L4 may be greater than the length of the third straight portion L3.

[0061] That is, the first coil 310 and the second coil 320 may each have two straight portions substantially parallel to the third surface 103 and the fourth surface 104 of the body 100, and the length of one straight portion may be greater than the length of the other straight portion. Therefore, when viewed in the third direction (Z direction), the cores 110 and 120 may have a trapezoidal shape, but the shape of the cores 110 and 120 is not necessarily limited thereto.

[0062] The first straight portion L1 may be disposed closer to the second surface 102 of the body 100 than the second straight portion L2, and the fourth straight portion L4 may be disposed closer to the second surface 102 of the body 100 than the third straight portion L3. Therefore, when viewed in the third direction (Z direction), the cores 110 and 120 may not have a trapezoidal shape. In addition, as described below, the first shared core 111 and the second shared core 121 may be disposed closer to the first surface 101 of the body 100 than the first non-shared core 112 and the second non-shared core 122, and the first non-shared core 112 and the second non-shared core 122 may be disposed closer to the second surface 102 of the body 100 than the first shared core 111 and the second shared core 121.

[0063] The first lead-out portion 410 may be disposed on another surface of the support member 200 and may be connected to the first coil 310 through the first via hole V1. The first lead-out portion 410 may not form a turn around the first core 110. The first lead-out portion 410 may extend to the third surface 103 of the body 100.

[0064] The second lead-out portion 420 may be disposed on one surface of the support member 200 and may be connected to the second coil 320 through the second via hole V2. The second lead-out portion 420 may not form a turn around the second core 120. The second lead-out portion 420 may extend to the fourth surface 104 of the body 100.

[0065] The first coil 310 and the second lead-out portion 420 may be disposed on one surface of the support member 200, and the second coil 320 and the first lead-out portion 410 may be disposed on another surface of the support member 200. That is, the first coil 310 and the second coil 320 are disposed to be staggered on the support member 200.

[0066] In this case, the area of ​​the common cores 111 and 121 of the first core 110 and the second core 120 described below can be maximized, and the magnetic flux density can be uniform throughout the entire coil component. In addition, space utilization can be improved compared to the existing coil component.

[0067] Figure 4yes Figure 3 Magnified view of part A. Figure 4 A, only the insulating film IF (described below) may be provided between the first coil 310 and the second lead-out portion 420. In this case, the area of ​​the second non-shared core 122 may be maximized, which may be more conducive to reducing the characteristic deviation of the coil component. However, the first coil 310 and the second lead-out portion 420 are not necessarily limited thereto, and as Figure 4 As shown in A′, a portion of the body 100 may be disposed between the first coil 310 and the second lead-out portion 420 .

[0068] The first via hole V1 may connect the other end of the first coil 310 and the first lead-out portion 410. A first external electrode 531 and a second external electrode 541 described below are disposed on the third surface 103 of the body 100 and thus may be connected to one end of the first coil 310 and the first lead-out portion 410, respectively. In this manner, the first coil 310 may be used as a single coil extending to the first lead-out portion 410.

[0069] The second via hole V2 may connect the other end of the second coil 320 and the second lead-out portion 420. A third external electrode 532 and a fourth external electrode 542 described below are disposed on the fourth surface 104 of the body 100 and are thus respectively connected to one end of the second coil 320 and the second lead-out portion 420. As a result, the second coil 320 may be used as a single coil extending to the second lead-out portion 420.

[0070] Reference Figure 6 , the first via hole V1 and the second via hole V2 may be disposed together on a line segment l parallel to the second direction of the body 100. That is, the line segment l extending through the first via hole V1 and the second via hole V2 may be parallel to the second direction of the body 100. Specifically, when the coils 310 and 320 overlap each other in a manner that one end of the coils 310 and 320 is aligned in the first direction (such as Figure 6 ), the vias V1 and V2 may be disposed at the same position on the axis along the first direction. That is, the length difference between the coils 310 and 320 may be generated on the right side relative to the vias V1 and V2, and the length difference between the coils 310 and 320 may not be generated on the left side relative to the vias V1 and V2. In this way, since the length difference between the coils is generated on the right side relative to the vias V1 and V2, the area difference between the first non-shared core 112 and the second non-shared core 122 described below may be generated.

[0071] In addition, in an actual coil component, the first via hole V1 and the second via hole V2 may be disposed together on a line segment parallel to the second direction of the body, but the positions of the first via hole V1 and the second via hole V2 are not necessarily limited thereto. As an example, even in the case where the first coil 310 and the second coil 320 are offset from each other in an actual coil component, when the coils are aligned and overlapped with each other (such as Figure 6 ), the vias V1 and V2 may be disposed at the same position on the axis along the first direction.

[0072] The coils 310 and 320 and the lead-out portions 410 and 420 may be a plating pattern formed by a plating method used in the prior art (such as a pattern plating method, an anisotropic plating method, or an isotropic plating method), and may be formed to have a multilayer structure by using a plurality of methods among the above methods. That is, the coil component 1000 according to the first exemplary embodiment may be a thin film type inductor.

[0073] Each of the coils 310 and 320 and the lead-out portions 410 and 420 may include a seed layer in contact with the support member 200 and a plating layer disposed on the seed layer. The seed layer may be formed by a thin film forming method such as sputtering or an electroless plating method. In the case where the seed layer is formed by a thin film forming method such as sputtering, at least a portion of the material of the seed layer may penetrate into the surface of the support member 200. This can be confirmed by the fact that a difference is generated in the concentration of the metal material of the seed layer on the support member 200 in the third direction of the body 100.

[0074] The via may include one or more conductive layers. As an example, in the case where the via is formed by electroplating, the via may include a seed layer formed on the inner wall of the via hole penetrating the support member 200 and a plating layer filling the via hole in which the seed layer is formed. The seed layer of the via may be formed integrally with the seed layer of the coils 310 and 320 in the same process, or may be formed in a process different from the process of forming the seed layer of the coils 310 and 320, so that a boundary between the seed layer of the via and the seed layer of the coils 310 and 320 may be formed. The plating layer of the via may be formed integrally with the plating layer of the coils 310 and 320 in the same process, or may be formed in a process different from the process of forming the plating layer of the coils 310 and 320, so that a boundary between the plating layer of the via and the plating layer of the coils 310 and 320 may be formed.

[0075] The coils 310 and 320 , the lead portions 410 and 420 , and the vias V1 and V2 may be formed using a metal having excellent conductivity such as silver (Ag), palladium (Pd), aluminum (Al), nickel (Ni), titanium (Ti), gold (Au), copper (Cu), platinum (Pt), or alloys thereof.

[0076] In the following, reference will be made to Figure 2 , Figure 3 , Fig. 7A and Figure 7B The cores 110 and 120 of the coil component according to the present exemplary embodiment are described in detail. Fig. 7A and Figure 7B Along Figure 1 Cross-sectional views taken along lines II' and II-II'.

[0077] Reference Figure 2 and Figure 3 , the first core 110 may include a first shared core 111 overlapping with the second core 120 and a first non-shared core 112 not overlapping with the second core 120. Here, "overlapping" may mean that the cores 110 and 120 overlap each other when viewed along the axis direction (third direction) of the cores 110 and 120. Therefore, the first core 110 may include a first shared core 111 overlapping with the second core 120 in the third direction and a first non-shared core 112 not overlapping with the second core 120 in the third direction.

[0078] Similarly, the second core 120 may include a second shared core 121 overlapping the first core 110 and a second non-shared core 122 not overlapping the first core 110. Specifically, the second core 120 may include a second shared core 121 overlapping the first core 110 in the third direction and a second non-shared core 122 not overlapping the first core 110 in the third direction.

[0079] The first and second common cores 111 and 121 may refer to regions where the cores 110 and 120 overlap each other, and their areas may be substantially the same as each other. However, the first and second common cores 111 and 121 may be spaced apart from each other in the third direction.

[0080] In the coil component 1000 according to the exemplary embodiment in the present disclosure, the coils 310 and 320 can be formed adjacent to each other while sharing the cores 110 and 120. Therefore, the coupling coefficient can be adjusted by appropriately increasing or decreasing the relative area ratio of the shared core and the non-shared core. As a result, the leakage inductance and the mutual inductance can be adjusted to the desired value. The closer the value of the coupling coefficient is to 1, the greater the coupling coefficient, and the negative (-) sign indicates negative coupling.

[0081] Hereinafter, the arrangement, shape, and size of the cores 110 and 120 , which are characteristic components of the present disclosure, will be described in more detail.

[0082] In a coupled inductor according to the prior art, the first core and the second core have the same shape and size. The coil close to the mounting surface of the coil component has a problem that the magnetic flux and capacity are reduced due to the influence of the pad pattern of the mounting surface or the metal layer of the substrate. As a result, characteristic deviations between the coil parts are generated in the coupled inductor.

[0083] Fig.11A and Fig. 11B Along Fig. 9 Cross-sectional views taken along lines III-III' and IV-IV'.

[0084] Reference Fig.11A and Fig. 11B In the coil component C according to the comparative example, the first core may include a first common core 111' overlapping with the second core and a first non-common core 112' not overlapping with the second core, the second core may include a second common core 121' overlapping with the first core and a second non-common core 122' not overlapping with the first core, and the first non-common core 112' and the second non-common core 122' have the same area. The insulating film IF' may be configured to insulate the coils 310' and 320' from the body 100', and may include any known insulating material (such as polyparaxylene). The insulating material included in the insulating film IF' is not particularly limited, but may be any insulating material. The insulating film IF' 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 surfaces of the support member 200'.

[0085] Therefore, when the coil assembly is mounted, the magnetic flux and capacity of the second coil 320' close to the fifth surface 105' provided as the mounting surface may be reduced.

[0086] In this regard, the present disclosure proposes a coil component having the following structure to solve the above-mentioned problems.

[0087] In the coil component according to the present exemplary embodiment, the first non-shared core 112 and the second non-shared core 122 may be disposed closer to the second surface 102 of the body 100 than the first and second shared cores 111 and 121. In addition, the area of ​​the second non-shared core 122 may be greater than that of the first non-shared core 112.

[0088] Reference Figure 3 , the first non-shared core 112 and the second non-shared core 122 may be disposed on the same side relative to the first shared core 111 and the second shared core 121 ( Figure 3 ). Therefore, coil misalignment due to process variation during coil formation can be minimized, thereby reducing characteristic deviation of the coil component and improving yield.

[0089] Reference Fig. 7A and Figure 7B , the area of ​​the second non-shared core 122 may be greater than the area of ​​the first non-shared core 112. As described above, in the coil component according to the present exemplary embodiment, the length of the second coil 320 in the first direction may be greater than the length of the first coil 310 in the first direction, and accordingly, the area of ​​the second non-shared core 122 may be greater than the area of ​​the first non-shared core 112. Since the area of ​​the second non-shared core 122 is greater than the area of ​​the first non-shared core 112 as described above, the characteristic deviation between the first coil 310 and the second coil 320 can be reduced.

[0090] Reference Figure 3 , Fig. 7A and Figure 7B , the first shared core 111 and the second shared core 121 may be disposed closer to the first surface 101 of the body 100 than the first non-shared core 112 and the second non-shared core 122 .

[0091] Reference Fig. 7A and Figure 7B , the first non-shared core 112 may be disposed closer to the sixth surface 106 of the body 100 than the second non-shared core 122, and the second non-shared core 122 may be disposed closer to the fifth surface 105 of the body 100 than the first non-shared core 112. Such an arrangement may be caused by the arrangement of the first coil 310 and the second coil 320 forming turns on one surface and the other surface of the support member.

[0092] Reference Figure 3 , the first non-shared core 112 may be disposed closer to the third surface 103 of the body 100 than the second non-shared core 122, and the second non-shared core 122 may be disposed closer to the fourth surface 104 of the body 100 than the first non-shared core 112. The first non-shared core 112 and the second non-shared core 122 may be spaced apart from each other in the second direction and thus may not overlap each other.

[0093] The areas of the first shared core 111 and the second shared core 121 may be larger than the areas of the first non-shared core 112 and the second non-shared core 122. However, the areas of the first shared core 111 and the second shared core 121 are not limited thereto and may be smaller than the areas of the first non-shared core 112 and the second non-shared core 122. As the area of ​​the non-shared core increases, the leakage inductance increases and the coupling coefficient (k) decreases accordingly.

[0094] The area of ​​the second core 120 may be greater than that of the first core 110. As described above, the area of ​​the first shared core 111 and the area of ​​the second shared core 121 are the same as each other. Since the area of ​​the second non-shared core 122 is greater than that of the first non-shared core 112, the area of ​​the second core 120 may be greater than that of the first core 110.

[0095] Table 1 below is a table obtained by measuring the inductance (Ls) and saturation current (Isat) in the coil assembly according to the present disclosure (inventive example) and the coil assembly according to the comparative example. Specifically, the inductance (Ls) and saturation current (Isat) of the first coil (upper coil) and the second coil (lower coil) were measured respectively. The difference between the inventive example and the comparative example is that the length of the second coil 320 in the first direction is increased by 0.015 mm (15 μm), and the rest of the conditions are the same.

[0096] Table 1

[0097] Referring to Table 1, it can be seen that the deviation of the inductance (Ls) and the deviation of the saturation current (Isat) between the coils 310 and 320 in the example of the present invention are reduced compared to the comparative example. This is because, as described above, the length of the second coil 320 as the lower coil in the first direction is increased to increase the area of ​​the second non-shared core 122.

[0098] The insulating film IF may be formed on the support member 200, the coils 310 and 320, and the lead-out portions 410 and 420. Hereinafter, the lead-out portions will also be described as a part of the coils 310 and 320 for convenience.

[0099] The insulating film IF may be provided to insulate the coils 310 and 320 from the main body 100, and may include any known insulating material (such as polyparaxylene). The insulating material included in the insulating film IF is not particularly limited, but may be any insulating material. The insulating film IF 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 surfaces of the support member 200. In the former case, the insulating film IF may be formed in the form of a conformal film along the surfaces of the support member 200 and the coils 310 and 320. In addition, in the present disclosure, the insulating film IF is an optional component. Therefore, when the main body 100 has sufficient insulation resistance under the operating voltage and operating current of the coil component 1000 according to the present exemplary embodiment, the insulating film IF may be omitted.

[0100] The first external electrode 531, the second external electrode 541, the third external electrode 532, and the fourth external electrode 542 may be disposed outside the body 100 and connected to the coils 310 and 320 and the lead-out portions 410 and 420. Specifically, the first external electrode 531 and the second external electrode 541 may be disposed on the third surface 103 of the body 100, and the third external electrode 532 and the fourth external electrode 542 may be disposed on the fourth surface 104 of the body 100.

[0101] As described above, one end of the first coil 310 and the first lead-out portion 410 may extend to the third surface 103 of the body 100 , and one end of the second coil 320 and the second lead-out portion 420 may extend to the fourth surface 104 of the body 100 .

[0102] The first and second external electrodes 531 and 541 may be disposed on the third surface 103 of the body 100 and spaced apart from each other, and may be respectively connected to one end of the first coil 310 and the first lead-out portion 410. The third and fourth external electrodes 532 and 542 may be disposed on the fourth surface 104 of the body 100 and spaced apart from each other, and may be respectively connected to one end of the second coil 320 and the second lead-out portion 420.

[0103] The first to fourth external electrodes 531, 541, 532, and 542 may extend to the fifth surface 105 of the body 100. As described above, the fifth surface 105 of the body 100 may be used as a mounting surface when mounting the coil component.

[0104] The first external electrode 531, the second external electrode 541, the third external electrode 532, and the fourth external electrode 542 may be formed using a paste containing a metal having excellent conductivity, such as a conductive paste containing nickel (Ni), copper (Cu), tin (Sn), or silver (Ag) or an alloy thereof. In addition, a plating layer may be provided to cover each of the first external electrode 531, the second external electrode 541, the third external electrode 532, and the fourth external electrode 542. In this case, the plating layer may include one or more selected from the group consisting of nickel (Ni), copper (Cu), and tin (Sn). For example, a nickel (Ni) layer and a tin (Sn) layer may be sequentially formed in the plating layer.

[0105] Second Exemplary Embodiment Figure 8 is a schematic perspective view showing a coil component according to a second exemplary embodiment in the present disclosure.

[0106] Reference Figure 8 , the coil component 2000 according to the second exemplary embodiment in the present disclosure is different from the first exemplary embodiment in the presence or absence of the support member 200 .

[0107] Specifically, the coil component 2000 according to the second exemplary embodiment in the present disclosure may not include the support member 200 .

[0108] As an example, the coil component 2000 according to the second exemplary embodiment may be a wound type inductor. Specifically, the coil of the coil component 2000 according to the second exemplary embodiment may be a wound coil formed by winding a coil several times.

[0109] As another example, the coil component 2000 according to the second exemplary embodiment may be a multilayer inductor. Specifically, the coil component 2000 according to the second exemplary embodiment may be formed by printing coil patterns on a plurality of magnetic sheets and then stacking the plurality of magnetic sheets having the coil patterns printed thereon.

[0110] However, the coil component 2000 is not necessarily limited thereto, and a coil component not including the support member 200 may correspond to the second exemplary embodiment.

[0111] Descriptions of other components overlap with those of the first exemplary embodiment and thus will be omitted hereinafter.

[0112] As described above, according to exemplary embodiments in the present disclosure, the coil component can achieve fine control of the coupling coefficient by adjusting the area of ​​one non-shared core of two coils disposed inside a body in the coil component having a coupled inductor structure.

[0113] The coil component according to the exemplary embodiment in the present disclosure may enable effective control of characteristic deviation between coil parts in a coil component having a coupled inductor structure.

[0114] While example 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 and a second surface opposite to each other in a first direction, a third surface and a fourth surface opposite to each other in the second direction, and a fifth surface and a sixth surface opposite to each other in a third direction; a supporting member disposed in the main body and having one surface and another surface opposite to each other in the third direction; a first coil disposed on the one surface of the support member and including a first core; a second coil disposed on the other surface of the support member and including a second core; a first lead-out portion provided on the other surface of the support member and connected to the first coil; as well as a second lead-out portion provided on the one surface of the support member and connected to the second coil, wherein, when viewed along the third direction of the body, the first core partially overlaps with the second core, and A length of the second coil in the first direction is greater than a length of the first coil in the first direction.

2. The coil assembly according to claim 1, wherein: The second coil is disposed closer to the second surface of the body than the first coil.

3. The coil assembly according to claim 1, wherein: A distance between the first coil and the first surface of the body is substantially the same as a distance between the second coil and the first surface of the body.

4. The coil assembly according to claim 1, wherein: The outer end of the first coil and the first lead-out portion extend to the third surface of the body, and The outer end of the second coil and the second lead-out portion extend to the fourth surface of the body.

5. The coil assembly according to claim 1, further comprising: a first via hole connecting an inner end of the first coil and the first lead-out portion to each other; as well as The second via hole connects the inner end of the second coil and the second lead-out portion to each other.

6. The coil assembly according to claim 5, wherein: The first via hole and the second via hole are disposed together on a line segment parallel to the second direction of the body.

7. The coil assembly according to claim 1, wherein: the first coil has a first straight portion and a second straight portion, the first straight portion being adjacent to and substantially parallel to the third surface of the body, and the second straight portion being adjacent to and substantially parallel to the fourth surface of the body, The second coil has a third straight portion and a fourth straight portion, the third straight portion being adjacent to and substantially parallel to the third surface of the body, and the fourth straight portion being adjacent to and substantially parallel to the fourth surface of the body, and The length of the fourth straight line portion is greater than the length of the first straight line portion.

8. The coil assembly according to claim 7, wherein: The length of the first straight portion is greater than the length of the second straight portion, and The length of the fourth straight line portion is greater than the length of the third straight line portion.

9. The coil assembly according to claim 7, wherein: The first straight portion is disposed closer to the second surface of the body than the second straight portion, and The fourth straight line portion is disposed closer to the second surface of the body than the third straight line portion.

10. The coil assembly of claim 1, further comprising: A first external electrode and a second external electrode, connected to an outer end of the first coil and the first lead-out portion, respectively; as well as A third external electrode and a fourth external electrode are connected to the outer end of the second coil and the second lead-out portion, respectively. wherein the first external electrode and the second external electrode are disposed on the third surface of the body and are spaced apart from each other, and The third external electrode and the fourth external electrode are disposed on the fourth surface of the body to be spaced apart from each other.

11. The coil assembly according to claim 1, wherein: The second coil is disposed closer to the fifth surface of the body than the first coil.

12. A coil assembly, comprising: a main body having a first surface and a second surface opposite to each other in a first direction, a third surface and a fourth surface opposite to each other in the second direction, and a fifth surface and a sixth surface opposite to each other in a third direction; a first coil disposed within the body and comprising a first core; as well as a second coil disposed in the body and spaced apart from the first coil and including a second core, wherein the first core includes a first shared core overlapping with the second core in the third direction and a first non-shared core not overlapping with the second core in the third direction, The second core includes a second shared core overlapping the first core in the third direction and a second non-shared core not overlapping the first core in the third direction, The first non-shared core and the second non-shared core are disposed closer to the second surface of the body than the first shared core and the second shared core, and An area of ​​the second non-shared core is greater than an area of ​​the first non-shared core.

13. The coil assembly according to claim 12, wherein: The first common core and the second common core are disposed closer to the first surface of the body than the first non-common core and the second non-common core.

14. The coil assembly according to claim 12, wherein: The first non-shared core is disposed closer to the sixth surface of the body than the second non-shared core, and The second non-shared core is disposed closer to the fifth surface of the body than the first non-shared core.

15. The coil assembly according to claim 12, wherein: The first non-shared core is disposed closer to the third surface of the body than the second non-shared core, and The second non-shared core is disposed closer to the fourth surface of the body than the first non-shared core.

16. The coil assembly according to claim 12, wherein: The area of ​​the first shared core is greater than the area of ​​the first non-shared core, and An area of ​​the second shared core is greater than an area of ​​the second non-shared core.

17. The coil assembly according to claim 12, wherein: The first coil has a first straight portion and a second straight portion, the first straight portion being adjacent to and substantially parallel to the third surface of the body, and the second straight portion being adjacent to and substantially parallel to the fourth surface of the body, and The second coil has a third straight portion and a fourth straight portion, the third straight portion is adjacent to and substantially parallel to the third surface of the body, and the fourth straight portion is adjacent to and substantially parallel to the fourth surface of the body.

18. The coil assembly according to claim 17, wherein: The first coil further includes a first curved portion and a second curved portion, the first curved portion extending between one end of the first straight portion and one end of the second straight portion, the second curved portion extending between the other end of the first straight portion and the other end of the second straight portion, the first curved portion being closer to the first surface of the body than the second curved portion, and The second coil also includes a third bent portion and a fourth bent portion, the third bent portion extending between one end of the third straight portion and one end of the fourth straight portion, the fourth bent portion extending between the other end of the third straight portion and the other end of the fourth straight portion, and the third bent portion is closer to the first surface of the body than the fourth bent portion.

19. The coil assembly of claim 18, wherein: The second curved portion and the fourth curved portion each have at least two bends to form an "S" shape, and The first curved portion and the third curved portion have a semicircular shape.

20. The coil assembly of claim 19, further comprising: a first lead-out portion, exposed to the third surface of the body, connected to the first coil, and extending diagonally toward one of the at least two bent portions of the fourth bent portion; as well as A second lead-out portion, exposed to the fourth surface of the body, is connected to the second coil and extends diagonally toward one of the at least two bent portions of the second bent portion.

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