Coil component

Abstract

The invention provides a coil assembly. The coil component includes: a body having a first surface and a second surface opposite to each other in a first direction and a third surface and a fourth surface opposite to each other in a second direction perpendicular to the first direction; a support member provided inside the main body and having one surface and another surface opposite to each other and a side surface connecting the one surface and the another surface to each other; a coil disposed on the support member and including coil portions each having at least one turn and lead-out portions extending from respective outermost turns of the coil portions and bent toward the first surface; and external electrodes disposed on the first surface and connected to the corresponding lead-out portions.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0140075 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] 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 become increasingly high-performance and miniaturized, the number of electronic components used in the electronic devices is increasing, and the electronic components are becoming smaller and smaller.

[0005] In addition, when the outer electrode is only provided on the lower surface of the coil component, the risk of short circuit with adjacent components when mounted on a circuit board is reduced, which is beneficial to integration. Therefore, a coil component is required that can ensure an effective volume while having such a lower electrode structure. Summary of the invention

[0006] An aspect of the present disclosure is to provide a coil component in which an external electrode is disposed only on a lower surface of a body, increasing an effective volume compared with a coil component of the same size, thereby improving inductance characteristics.

[0007] Another aspect of the present disclosure is to improve plating quality and insulation reliability of a lead-out portion by realizing a coil covered with an insulating film and led out from a lower surface of a body and then forming the body.

[0008] 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 and a third surface and a fourth surface opposite to each other in a second direction perpendicular to the first direction; a support member arranged inside the main body and having one surface and another surface opposite to each other and a side surface connecting the one surface and the other surface to each other; a coil arranged on the support member and including a coil portion and a lead-out portion, the coil portion respectively having at least one turn, the lead-out portion extending from the corresponding outermost turn of the coil portion and bending toward the first surface; and an external electrode arranged on the first surface and connected to the corresponding lead-out portion.

[0009] According to another aspect of the present disclosure, a coil component includes: a main body; a support member embedded in the main body; a coil, including a first coil portion arranged on one surface of the support member and a second coil portion arranged on another surface of the support member opposite to the one surface; a first lead-out portion and a second lead-out portion extending from the corresponding outermost turns of the first coil portion and the second coil portion toward the same side surface of the main body; and a first external electrode and a second external electrode arranged on the main body and connected to the first lead-out portion and the second lead-out portion, respectively, wherein the first lead-out portion and the second lead-out portion respectively have a first bend portion and a second bend portion located in the main body, the first lead-out portion is further extended through the first bend portion to be connected to the first external electrode, and the second lead-out portion is further extended through the second bend portion to be connected to the second external electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] 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 1 is a schematic perspective view showing a coil component according to a first exemplary embodiment of the present disclosure; Figure 2 yes Figure 1 Exploded stereogram of Figure 3 is along Figure 1 A cross-sectional view taken along line II'; Figure 4 is along Figure 1 A cross-sectional view taken along line II-II'; Figure 5 is along Figure 1 A cross-sectional view taken along line III-III'; Figure 6 is along Figure 1 A cross-sectional view taken along line IV-IV'; Figure 7 is a schematic perspective view showing a coil component according to a second exemplary embodiment of the present disclosure; Figure 8 is along Figure 7 A cross-sectional view taken along line V-V'; Fig.9A and Fig. 9B is a schematic diagram showing a state of a coil bar before a plurality of coils are individualized; Fig. 10A and Fig. 10B is a schematic diagram showing a process of bending a lead-out portion; Fig.11 is a schematic diagram showing a process of forming a body using a mold; and Fig.12 is a schematic diagram showing a process of forming a body by stacking magnetic sheets. DETAILED DESCRIPTION

[0011] The terms used in this specification are only used to describe specific exemplary embodiments, and do not limit the present disclosure. Unless the context clearly states otherwise, the singular form is intended to include the plural form. 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 located on the upper side based on the direction of gravity, but means that any element is located above or below the target portion.

[0012] Furthermore, the term “coupled” refers not only to a case where two components are physically in direct contact with each other but also to a case where two components are in a contact relationship with another component interposed therebetween.

[0013] 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 (eg, thickness) of various components shown in the drawings.

[0014] In the drawings, a thickness direction T refers to a first direction, a width direction W refers to a second direction, and a length direction L refers to a third direction.

[0015] Hereinafter, a coil component according to an exemplary embodiment of the present disclosure will be described in detail with reference to the accompanying drawings. When 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.

[0016] 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.

[0017] That is, the coil component used in the electronic device may be a power inductor, a high-frequency inductor, a general-purpose magnetic bead, a magnetic bead for high frequency (eg, for GHz band), a common mode filter, or the like.

[0018] First Exemplary Embodiment Figure 1 is a schematic perspective view showing a coil component 1000 according to a first exemplary embodiment in the present disclosure. Figure 2 yes Figure 1 Exploded three-dimensional diagram. Figure 3 is along Figure 1 A cross-sectional view taken along line II'. Figure 4 is along Figure 1 A cross-sectional view taken along line II-II'. Figure 5 is along Figure 1 A cross-sectional view taken along line III-III'. Figure 6 is along Figure 1 A cross-sectional view taken along line IV-IV'.

[0019] exist Figure 1 and Figure 2 , the insulating film IF on the coil 300 and the insulating layer 500 on the body 100 that may be applied to the present exemplary embodiment are omitted to more clearly illustrate the bonding manner between the components.

[0020] Reference Figures 1 to 6 , the coil component 1000 according to the first exemplary embodiment in the present disclosure may include a body 100 , a support member 200 , a coil 300 , and external electrodes 410 and 420 .

[0021] In the coil component 1000 according to the present exemplary embodiment, the coil 300 can be set on the support member 200 by plating. Specifically, the lead-out portions 331 and 332 included in the coil 300 can be bent toward the first surface 101 of the body 100, so that the external electrodes 410 and 420 set on the first surface 101 corresponding to the mounting surface can be connected to the lead-out portions 331 and 332, respectively.

[0022] In this exemplary embodiment, the lower electrode structure can be easily implemented without a separate process (such as forming a via hole in the lower surface of the body 100 or forming a recess for exposing the lead portions 331 and 332), and the effective volume occupied by the magnetic material in the body 100 can be ensured, thereby improving the inductance characteristics.

[0023] In addition, the insulating film IF may also be provided in the region where the lead-out portions 331 and 332 are bent downward, and thus, insulation reliability between the lead-out portions 331 and 332 and the body 100 may be enhanced.

[0024] In addition, the lead-out portions 331 and 332 may extend and then bend downward in a coil bar state in which a plurality of coils 300 are connected in a lattice form. Therefore, compared with a process in which the lead-out portions 331 and 332 are formed by plating after forming a via hole in the lower surface of the body 100, the plating quality of the lead-out portions 331 and 332 may also be improved.

[0025] Hereinafter, main components of the coil component 1000 according to the present exemplary embodiment will be described in detail.

[0026] The body 100 may form an appearance of the coil component 1000 according to the present exemplary embodiment, and the support member 200 and the coil 300 may be embedded in the body 100 .

[0027] The body 100 may generally have a hexahedral shape.

[0028] like Figure 1 As shown in , the body 100 may have a first surface 101 and a second surface 102 opposite to each other in a thickness direction T (first direction), a third surface 103 and a fourth surface 104 opposite to each other in a width direction W (second direction), and a fifth surface 105 and a sixth surface 106 opposite to each other in a length direction L (third direction). Each of the third to sixth surfaces 103 to 106 of the body 100 may correspond to a wall surface of the body 100 connecting the first surface 101 and the second surface 102 to each other.

[0029] As an example, the body 100 can be formed in such a manner that the coil component 1000 including the external electrodes 410 and 420 according to the present exemplary embodiment has a length of 2.5 mm, a width of 2.0 mm, and a thickness of 0.8 mm; a length of 2.0 mm, a width of 1.2 mm, and a thickness of 0.6 mm; a length of 1.6 mm, a width of 0.8 mm, and a thickness of 0.6 mm; a length of 1.6 mm, a width of 0.8 mm, and a thickness of 0.4 mm; a length of 1.4 mm, a width of 1.2 mm, and a thickness of 0.65 mm; a length of 1.0 mm, a width of 0.7 mm, and a thickness of 0.65 mm; a length of 0.8 mm, a width of 0.4 mm, and a thickness of 0.65 mm; a length of 0.8 mm, a width of 0.4 mm, and a thickness of 0.65 mm; or a length of 0.8 mm, a width of 0.4 mm, and a thickness of 0.5 mm, but is not limited thereto.

[0030] In addition, since the above exemplary numerical values ​​of the length, width, and thickness of the coil component 1000 refer to numerical values ​​that do not reflect process errors, it should be considered that numerical values ​​within the allowable range of process errors correspond to the above exemplary numerical values.

[0031] The length of the coil component 1000 may refer to: in an image of a cross section of the central portion of the coil component 1000 in the width direction W (the image is taken by an optical microscope or a scanning electron microscope (SEM), and the cross section is intercepted along the length direction L and the thickness direction T), the maximum value of the sizes of multiple line segments connecting the two outermost boundary lines of the coil component 1000 facing each other in the length direction L and spaced apart from each other in the thickness direction T in a direction parallel to the length direction L. Alternatively, the length of the coil component 1000 may refer to the minimum value of the sizes of the multiple line segments. Alternatively, the length of the coil component 1000 may refer to the arithmetic mean of at least three of the sizes of the multiple line segments. Here, the multiple line segments parallel to the length direction L may be equally spaced apart from each other in the thickness direction T, but the scope of the present disclosure is not limited thereto.

[0032] The thickness of the coil component 1000 may refer to: in an image of a cross section of the central portion of the coil component 1000 in the width direction W (the image is taken by an optical microscope or a scanning electron microscope (SEM), and the cross section is intercepted along the length direction L and the thickness direction T), the maximum value of the sizes of multiple line segments connecting the two outermost boundary lines of the coil component 1000 facing each other in the thickness direction T in a direction parallel to the thickness direction T and spaced apart from each other in the length direction L. Optionally, the thickness of the coil component 1000 may refer to the minimum value of the sizes of the multiple line segments. Optionally, the thickness of the coil component 1000 may refer to the arithmetic mean of at least three of the sizes of the multiple line segments. Here, the multiple line segments parallel to the thickness direction T may be equally spaced apart from each other in the length direction L, but the scope of the present disclosure is not limited thereto.

[0033] The width of the coil component 1000 may refer to: in an image of a cross section of the central portion of the coil component 1000 in the thickness direction T (the image is taken by an optical microscope or a scanning electron microscope (SEM), and the cross section is intercepted along the length direction L and the width direction W), the maximum value of the sizes of multiple line segments that connect the two outermost boundary lines of the coil component 1000 facing each other in the width direction W and are spaced apart from each other in the length direction L in a direction parallel to the width direction W. Alternatively, the width of the coil component 1000 may refer to the minimum value of the sizes of the multiple line segments. Alternatively, the width of the coil component 1000 may refer to the arithmetic mean of at least three of the sizes of the multiple line segments. Here, the multiple line segments parallel to the width direction W may be equally spaced apart from each other in the length direction L, but the scope of the present disclosure is not limited thereto.

[0034] Optionally, each of the length, width and thickness of the coil component 1000 can be measured by a micrometer measurement method. The micrometer measurement method can be performed using a micrometer with metrological repeatability and reproducibility (R&R) in the following manner: setting a zero point, inserting the coil component 1000 according to the present exemplary embodiment between the tips of the micrometer, and rotating the measuring rod of the micrometer. In addition, when the length of the coil component 1000 is measured by the micrometer measurement method, the length of the coil component 1000 may refer to a value obtained by performing a single measurement, or an arithmetic mean of the values ​​obtained by performing multiple measurements. This may also be applied to the width and thickness of the coil component 1000.

[0035] The main body 100 may include a magnetic material and a resin. Specifically, the main body 100 may be formed by stacking one or more magnetic composite sheets in which a magnetic material is dispersed in a resin. However, the main body 100 may also have a structure other than a structure in which a magnetic material is dispersed in a resin. For example, the main body 100 may include a magnetic material such as ferrite or may include a non-magnetic material.

[0036] The magnetic material can be ferrite or magnetic metal powder.

[0037] The ferrite may be, for example, 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 or Ni-Zn-based ferrite), 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), garnet-type ferrite (such as Y-based ferrite) and Li-based ferrite.

[0038] The magnetic metal 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 magnetic metal 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.

[0039] The magnetic metal powder may be amorphous or crystalline. For example, the magnetic metal powder may be Fe-Si-B-Cr based amorphous alloy powder, but is not necessarily limited thereto.

[0040] The ferrite and the magnetic metal powder may each have an average diameter of about 0.1 μm to 30 μm, but is not limited thereto.

[0041] The body 100 may include two or more kinds of magnetic materials dispersed in the resin. Here, different kinds of magnetic materials refer to that the magnetic materials dispersed in the resin are distinguished from each other by any one of average diameter, composition, crystallinity, and shape.

[0042] The resin may include epoxy, polyimide, liquid crystal polymer (LCP), or a mixture thereof, but is not limited thereto.

[0043] The body 100 may include a core 110 passing through the support member 200 and the coil 300. The core 110 may be formed by filling a through hole of the support member 200 with a magnetic composite sheet, but is not limited thereto.

[0044] Reference Figure 3 and Figure 4 , the body 100 may include a core 110 passing through the support member 200 and the coil 300. The core 110 may be disposed in a central region of an innermost turn of the coil 300, that is, in a winding central region of the coil 300.

[0045] Reference Figures 2 to 4 , the core 110 may be formed by filling the through hole H passing through the center of the coil 300 and the center of the support member 200 with a magnetic composite sheet containing a magnetic material, but is not limited thereto. In the case where the body 100 is formed by compression molding or the like, the core 110 may be formed by filling the through hole H passing through the center of the coil 300 and the center of the support member 200 with a magnetic material and a resin.

[0046] The support member 200 may be disposed inside the body 100, and may have one surface and another surface opposite to each other and a side surface connecting the one surface and the other surface to each other. The support member 200 may support the coil 300. In addition, a central portion of the support member 200 may be removed by trimming to form a through hole H, and the core 110 may be disposed in the through hole H. Here, the through hole H formed in the support member 200 may be formed in a shape corresponding to the shape of the innermost turn of the coil 300.

[0047] 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 may be formed using an insulating material obtained by impregnating a reinforcing material such as glass fiber or an inorganic filler in these insulating resins. As an 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) resin, or a photosensitive dielectric (PID), but is not limited thereto.

[0048] 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.

[0049] 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 beneficial to reducing the thickness of the coil component 1000 according to the present exemplary embodiment. In addition, based on the main body 100 having the same size, the volume occupied by the coil 300 and / or the magnetic metal powder can be increased, so that the characteristics of the coil component can be improved. 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 coil 300 can be reduced, which can be beneficial to reducing production costs and can be beneficial to forming fine vias 320.

[0050] For example, the thickness of the support member 200 may be greater than or equal to 10 μm and less than or equal to 50 μm, but is not limited thereto.

[0051] The coil 300 may be disposed inside the body 100 and may implement the characteristics of the coil component 1000. For example, when the coil component 1000 according to the present exemplary embodiment is used as a power inductor, the coil 300 may be used to store an electric field as a magnetic field to maintain an output voltage, thereby stabilizing power of an electronic device.

[0052] The coil component 1000 according to the present exemplary embodiment may include a coil 300 supported by a support member 200 inside a body 100. The coil 300 may have at least one turn around a core 110.

[0053] Reference Figures 1 to 4 The coil 300 of the present exemplary embodiment may include first and second coil portions 311 and 312 and first and second lead portions 331 and 332 , and may further include a via 320 that passes through the support member 200 and connects the first and second coil portions 311 and 312 to each other.

[0054] Specifically, the first coil portion 311 and the first lead-out portion 331 extending from the outermost turn of the first coil portion 311 may be disposed on one surface of the support member 200 facing the first surface 101 of the body 100. In addition, the second coil portion 312 and the second lead-out portion 332 extending from the outermost turn of the second coil portion 312 may be disposed on the other surface of the support member 200 facing the second surface 102 of the body 100.

[0055] Reference Figures 2 to 4 , each of the first coil portion 311 and the second coil portion 312 may have at least one turn around the core 110. Each of the first coil portion 311 and the second coil portion 312 may have a planar spiral shape.

[0056] The first coil part 311 may be disposed on one surface of the support member 200 and have at least one turn around the core 110 as an axis. The second coil part 312 may be disposed on the other surface of the support member 200 and have at least one turn around the core 110 as an axis.

[0057] Reference Figure 4 The coil 300 may include a via 320 that connects a first coil portion 311 disposed on one surface of the support member 200 and a second coil portion 312 disposed on another surface of the support member 200 to each other. The via 320 may electrically connect the first coil portion 311 and the second coil portion 312 on both surfaces of the support member 200.

[0058] The via hole 320 may connect the end of the innermost turn of the first coil part 311 and the end of the innermost turn of the second coil part 312 to each other. In addition, the via hole 320 may pass through the support member 200, but is not limited thereto.

[0059] The diameter of the via hole 320 according to the present exemplary embodiment may be smaller than the line width of each of the coil parts 311 and 312 , and only one via hole 320 may be provided inside the support member 200 , however, the diameter of the via hole 320 and the number of the via holes 320 are not limited thereto.

[0060] Reference Figure 1 , Figure 2 , Figure 5 and Figure 6The coil 300 may include a first lead-out portion 331 and a second lead-out portion 332 extending from outermost turns of the coil parts 311 and 312 , respectively, and bent toward the first surface 101 of the body 100 .

[0061] Specifically, the first lead-out portion 331 and the second lead-out portion 332 may have a first bent portion and a second bent portion, respectively, located in the body 100. The first lead-out portion 331 disposed on one surface of the support member 200 may extend from the end of the outermost turn of the first coil portion 311, further extend through the first bent portion (specifically, bend toward the first surface 101 of the body 100), and be connected to the first external electrode 410. In addition, the second lead-out portion 332 disposed on the other surface of the support member 200 may extend from the end of the outermost turn of the second coil portion 312, further extend through the second bent portion (specifically, bend toward the first surface 101 of the body 100), and be connected to the second external electrode 420. Here, portions of the first lead-out portion 331 and the second lead-out portion 332 extending between the ends of the respective outermost turns of the first coil portion 311 and the second coil portion 312 and the respective bent portions of the first lead-out portion 331 and the second lead-out portion 332 may be substantially parallel to the first surface 101 of the body 100. On the other hand, portions of the first and second lead out portions 331 and 332 extending between respective bent portions thereof and the first and second external electrodes 410 and 420 may be substantially perpendicular to the first surface 101 of the body 100 .

[0062] Those skilled in the art will understand that the expression "substantially parallel" or "substantially perpendicular" may not only mean precise parallelism (0°) or perpendicularity (90°), but may also mean close parallelism or perpendicularity including process errors, positional deviations and / or measurement errors that may occur during the manufacturing process, and the range of process errors, positional deviations and / or measurement errors may be widely accepted in the art. In one or more aspects, the terms "about", "substantially" and "approximately" may provide industry-accepted tolerances for their corresponding terms and / or relativity between items, such as tolerances from one to ten percent less than a specified actual value to one to ten percent greater than a specified actual value and other suitable tolerances.

[0063] Reference Figure 1 and Figure 2 , the first lead-out portion 331 and the second lead-out portion 332 may extend in the same direction.

[0064] Specifically, the first lead-out portion 331 and the second lead-out portion 332 may extend in the second direction W toward the third surface 103 of the body 100 , and bend in the first direction T toward the first surface 101 of the body 100 .

[0065] Here, the third surface 103 may be closer to the position where the first lead-out portion 331 and the second lead-out portion 332 are bent than the fourth surface 104. That is, the first lead-out portion 331 and the second lead-out portion 332 extend toward the third surface 103 of the body 100 and are bent toward the first surface 101 of the body 100, and therefore, the position where the first lead-out portion 331 and the second lead-out portion 332 are bent may be set in a manner offset toward the third surface 103 of the body 100.

[0066] In addition, refer to Figure 6 , at least a portion of the side surface of the support member 200 may be covered by the second lead-out portion 332 .

[0067] That is, the second lead-out portion 332 is continuously disposed along the other surface and the side surface of the support member 200 and is connected to the second external electrode 420, and thus, at least a portion of the second lead-out portion 332 may be disposed on the side surface of the support member 200. In addition, the insulating film IF may be interposed between the side surface of the support member 200 and the second lead-out portion 332.

[0068] With such a structure, the second lead portion 332 on the other surface of the support member 200 can be directly connected to the second external electrode 420 disposed on the first surface 101 of the body 100 without forming a separate via hole in the region of the support member 200 where the second lead portion 332 is disposed.

[0069] Therefore, the coil component 1000 according to the present exemplary embodiment may have an electrode structure implemented through a simpler process.

[0070] Reference Figure 2 For example, when a signal is input to the first external electrode 410 , the input signal may be output to the second external electrode 420 through the first lead portion 331 , the first coil portion 311 , the via 320 , the second coil portion 312 , and the second lead portion 332 in sequence.

[0071] In this manner, the coil 300 may function as a single coil as a whole between the first external electrode 410 and the second external electrode 420 .

[0072] At least one of the first and second coil parts 311 and 312 , the via hole 320 , and the first and second lead-out parts 331 and 332 may include at least one conductive layer.

[0073] For example, when the first coil portion 311, the via 320 and the first lead-out portion 331 are formed by plating on one surface of the support member 200, the first coil portion 311, the via 320 and the first lead-out portion 331 may each include a seed 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 into a conformal film structure in which another electroplating layer is formed along the surface of any one electroplating layer, or may be formed into a shape in which another electroplating layer is stacked only on one surface of any one electroplating layer. The seed layer may be formed by a vapor deposition method such as an electroless plating method or a sputtering method. The seed layers of the first coil portion 311, the via 320 and the first lead-out portion 331 may be formed integrally with each other so that no boundary is formed between them. However, the seed layers of the first coil portion 311, the via 320 and the first lead-out portion 331 are not limited thereto. The plating layers of the first coil part 311, the via hole 320, and the first lead-out part 331 may be formed integrally with each other so that no boundary is formed therebetween. However, the plating layers of the first coil part 311, the via hole 320, and the first lead-out part 331 are not limited thereto.

[0074] Each of the first coil part 311 , the via 320 , and the first lead-out part 331 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), chromium (Cr), or an alloy thereof, but is not limited thereto.

[0075] In the coil component 1000 according to the present exemplary embodiment, the first lead-out portion 331 and the second lead-out portion 332 are formed on the support member 200 by plating in a direction parallel to the second direction W and then bent downward in the first direction T. Therefore, in the bending regions of the first lead-out portion 331 and the second lead-out portion 332 , the metal component may be somewhat stretched to have a round shape, but the scope of the present disclosure is not limited thereto.

[0076] In addition, since the lead portions 331 and 332 are bent after the insulating film IF is provided on the first and second lead portions 331 and 332 , the insulating film IF may also be provided in regions of the first and second lead portions 331 and 332 substantially parallel to the first direction T.

[0077] Reference Figures 3 to 6 The coil component 1000 according to the present embodiment may further include an insulating film IF. The insulating film IF may be a component that may increase insulation reliability of the coil component 1000 by preventing current leakage between the coil 300 and the body 100.

[0078] The insulating film IF may be disposed between the coil 300 and the body 100 and cover the coil 300. Specifically, the insulating film IF may be disposed along surfaces of the first and second coil parts 311 and 312 and the first and second lead-out parts 331 and 332 disposed on the support member 200.

[0079] The insulating film IF can insulate between adjacent turns of the first coil portion 311 , between adjacent turns of the second coil portion 312 , between the outermost turn of the first coil portion 311 and the first lead portion 331 , and between the outermost turn of the second coil portion 312 and the second lead portion 332 .

[0080] Reference Figure 5 and Figure 6 , the insulating film IF may be provided to cover the regions of the first lead portion 331 and the second lead portion 332 that are bent toward the first surface 101 of the body 100. That is, since the first lead portion 331 and the second lead portion 332 are bent toward the first surface 101 of the body 100 after the insulating film IF is provided on the first lead portion 331 and the second lead portion 332, the regions of the first lead portion 331 and the second lead portion 332 that are parallel to the first direction T may also be covered by the insulating film IF.

[0081] With such a structure, in the coil component 1000 according to the present exemplary embodiment, the external electrodes 410 and 420 provided on the lower surface of the body 100 and the coil 300 may be connected to each other inside the body 100, thereby minimizing the loss of the effective volume of the body 100. In addition, the insulating film IF may also be provided on the first lead-out portion 331 and the second lead-out portion 332 as a connection path between the coil 300 and the external electrodes 410 and 420, thereby improving insulation reliability.

[0082] In addition, refer to Figure 6 , the insulating film IF may be disposed after the coil 300 is disposed on the support member 200 and the support member 200 is partially removed, and then the second lead-out portion 332 is bent. In this case, the insulating film IF may be interposed between the side surface of the support member 200 and the bent second lead-out portion 332, but is not limited thereto.

[0083] The insulating film IF according to the present exemplary embodiment may include a known insulating material such as polyparaxylene, but is not limited thereto. As another example, the insulating film IF may include an insulating material such as epoxy resin instead of polyparaxylene. The insulating film IF may be formed by a vapor deposition method, but is not limited thereto. As another example, the insulating film IF may be formed by stacking an insulating film on the support member 200 on which the coil 300 is disposed and then curing the insulating film, or may be formed by applying an insulating paste to both surfaces of the support member 200 on which the coil 300 is disposed and then curing the insulating paste.

[0084] In addition, due to the above reasons, the insulating film IF may be omitted in the present exemplary embodiment. That is, when the body 100 has sufficient resistance at the designed operating current and voltage of the coil component 1000 according to the present exemplary embodiment, the insulating film IF may be omitted in the present exemplary embodiment.

[0085] When the coil component 1000 is mounted on a circuit board, the external electrodes 410 and 420 may be connected to a circuit through a bonding member such as solder.

[0086] Reference Figures 1 to 3 , Figure 5 and Figure 6 , the external electrodes 410 and 420 may be disposed on the first surface 101 of the body 100 and connected to the first lead-out portion 331 and the second lead-out portion 332 , respectively.

[0087] Specifically, the first and second external electrodes 410 and 420 may be disposed to be spaced apart from each other on the first surface 101 of the body 100 , the first external electrode 410 may be connected to the first lead-out portion 331 , and the second external electrode 420 may be connected to the second lead-out portion 332 .

[0088] The first and second external electrodes 410 and 420 according to the present exemplary embodiment may be disposed only on the first surface 101 of the body 100 , and may not be disposed on the remaining surfaces, but is not limited thereto.

[0089] When the first external electrode 410 and the second external electrode 420 are only arranged on the first surface 101 of the main body 100 as in the present exemplary embodiment, a lower electrode structure is realized, so that the possibility of short circuit with adjacent components when the coil component 1000 is mounted on a circuit board can be reduced, which is beneficial to integration and can ensure the effective volume of the main body 100 as much as possible within the limited size of the coil component 1000.

[0090] The first and second external electrodes 410 and 420 may be formed by a vapor deposition method such as sputtering and / or a plating method, but are not limited thereto.

[0091] The first and second external electrodes 410 and 420 may be formed using a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), chromium (Cr), titanium (Ti), or alloys thereof, but are not limited thereto.

[0092] The first external electrode 410 and the second external electrode 420 may be formed in a single-layer structure or a multi-layer structure. As an example, the first external electrode 410 and the second external electrode 420 may each include a first conductive layer including copper (Cu), a second conductive layer disposed on the first conductive layer and including nickel (Ni), and a third conductive layer disposed on the second conductive layer and including tin (Sn). At least one of the second conductive layer and the third conductive layer may be formed to cover the first conductive layer, but the scope of the present disclosure is not limited thereto. The first conductive layer may be a plating layer or a conductive resin layer, the conductive resin layer being formed by coating a conductive resin including a conductive powder and a resin and then curing the conductive resin, the conductive powder including at least one of copper (Cu) and silver (Ag). The second conductive layer and the third conductive layer may be plating layers, but the scope of the present disclosure is not limited thereto.

[0093] Reference Figures 3 to 6 The coil component 1000 according to the present exemplary embodiment may further include an insulating layer 500 covering at least a portion of the first to sixth surfaces 101 to 106 of the body 100 and exposing the external electrodes 410 and 420 .

[0094] The insulating layer 500 may be disposed in regions other than regions where the external electrodes 410 and 420 are disposed among the first to sixth surfaces 101 to 106 of the body 100 .

[0095] At least portions of the insulating layer 500 disposed on the first to sixth surfaces 101 to 106 of the body 100 may be integrally formed with one another in the same process without forming boundaries therebetween, but the scope of the present disclosure is not limited thereto.

[0096] The insulating layer 500 may be formed by a method such as printing, vapor deposition, spraying, or film lamination, but is not limited thereto.

[0097] The insulating layer 500 may include a thermoplastic resin (such as polystyrene, vinyl acetate, polyester, polyethylene, polypropylene, polyamide, rubber or acrylic resin), a thermosetting resin (such as phenol, epoxy resin, polyurethane, melamine or alkyd resin), a photosensitive resin, polyparaxylene, SiO x or SiN x The insulating layer 500 may further include an insulating filler such as an inorganic filler, but is not limited thereto.

[0098] Second Exemplary Embodiment Figure 7 is a schematic perspective view showing a coil component 2000 according to a second exemplary embodiment in the present disclosure. Figure 8 is along Figure 7 A cross-sectional view taken along line V-V'.

[0099] Figure 7 and Figure 8 The coil assembly 2000 shown in FIG. Figure 1 and Figure 3 The coil component 1000 shown in FIG. 1 is different in that the support member 200 further includes protrusions 210 and 220 .

[0100] Therefore, when describing the present exemplary embodiment, only the shapes of the protrusions 210 and 220 of the support member 200 that are different from the support member 200 in the first exemplary embodiment of the present disclosure will be described. The description in the first exemplary embodiment of the present disclosure can be applied to other components of the present exemplary embodiment as it is.

[0101] Reference Figure 7 and Figure 8 , the supporting member 200 according to the present exemplary embodiment may include a protrusion protruding toward at least one of the fifth surface 105 and the sixth surface 106 of the body 100 .

[0102] Specifically, the support member 200 according to the present exemplary embodiment may include a first protrusion 210 protruding toward the fifth surface 105 of the body 100 and a second protrusion 220 protruding toward the sixth surface 106 of the body 100. However, the scope of the present disclosure is not limited thereto, and only one of the first protrusion 210 and the second protrusion 220 may be formed on the support member 200.

[0103] The lead-out portions 331 and 332 may not be disposed on the protrusions 210 and 220 , and the protrusions 210 and 220 may correspond to regions that remain unremoved when trimming is performed to remove a remaining portion after the coil 300 is disposed on the support member 200 .

[0104] Reference Figure 7 and Figure 8 , the protrusions 210 and 220 may extend in the third direction L and be exposed to the fifth surface 105 and the sixth surface 106 of the body 100 .

[0105] Specifically, the first protrusion 210 according to the present exemplary embodiment may extend in the third direction L and may be exposed to the fifth surface 105 of the body 100, and the second protrusion 220 may extend in the third direction L and may be exposed to the sixth surface 106 of the body 100. However, the scope of the present disclosure is not limited thereto, and only one of the first protrusion 210 and the second protrusion 220 of the support member 200 may be exposed to the surface of the body 100.

[0106] Reference Figure 8, the protrusions 210 and 220 exposed to the surface of the body 100 may be covered by the insulating layer 500 disposed on the fifth surface 105 and the sixth surface 106 of the body 100 .

[0107] Specifically, the first protrusion 210 according to the present exemplary embodiment may be at least partially covered by the insulating layer 500 disposed on the fifth surface 105 of the body 100, and the second protrusion 220 may be at least partially covered by the insulating layer 500 disposed on the sixth surface 106 of the body 100. However, the scope of the present disclosure is not limited thereto, and only one of the first protrusion 210 and the second protrusion 220 may be covered by the insulating layer 500.

[0108] Since the coil component 2000 according to this exemplary embodiment includes protrusions 210 and 220, an anchoring effect can be generated between the protrusions 210 and 220 and the main body 100, so that the supporting force of the supporting member 200 supporting the coil 300 can be increased, and the defect of misalignment of the coil 300 during the process of forming the main body 100 can be reduced.

[0109] In addition, in the process of trimming the support member 200 into the shape of the coil 300 in a coil bar state (in the coil bar state, a plurality of coils 300 are connected to each other in a lattice shape on a support member 200 having a substrate shape), the process efficiency can also be improved by partially retaining the portions where the support members 200 are connected to each other as protrusions 210 and 220.

[0110] Coil assembly manufacturing process Fig.9A and Fig. 9B 1 is a schematic diagram showing the state of the coil bar before the plurality of coils 300 are individualized. Fig. 10A and Fig. 10B is a schematic diagram showing a process of bending the lead portion. Fig.11 2 is a schematic diagram showing a process of forming the main body 100 using the mold MF. Fig.12 is a schematic diagram illustrating a process of forming the body 100 by stacking magnetic sheets (MS).

[0111] Fig.9A is a schematic diagram showing a state of a coil bar before a plurality of coils are individualized according to one example.

[0112] Reference Fig.9A , a plurality of coil parts 311 and 312 may be patterned on the support member 200 having the shape of the substrate by using a plating solution supplied from the plating rod PE. At this time, the area connected to the plating rod PE may be cut along the cutting line DL and then bent to serve as the lead-out parts 331 and 332.

[0113] Furthermore, by leaving the portion of the support member 200 between the plurality of coils 300 , the protrusions 210 and 220 having an anchoring effect may be formed on the support member 200 as in the second exemplary embodiment.

[0114] In addition, the structure of the coil component 1000 according to the first exemplary embodiment can be realized when the protrusions 210 and 220 are trimmed into the shape of the coil 300. In this case, the magnetic material of the body 100 can be disposed in the area where the protrusions 210 and 220 are removed, thereby ensuring an effective volume.

[0115] Fig. 10A 3 is a schematic diagram illustrating a process of bending the first lead-out portion 331 and the second lead-out portion 332 .

[0116] Reference Fig. 10A , in such Fig.9A In the case where the first lead-out portion 331 and the second lead-out portion 332 are connected to each other as shown, after the insulating film IF is formed on the coil 300, the portion of the support member 200 located below the first lead-out portion 331 and the second lead-out portion 332 may be partially removed according to the length of the first lead-out portion 331 and the second lead-out portion 332 extending along the second direction. Next, the coil 300 may be cut along the cutting line DL using the trimming member TM, and a predetermined length of the first lead-out portion 331 and the second lead-out portion 332 of the coil 300 is reserved for bending (hereinafter, the reserved lead-out portion having the predetermined length is referred to as a bending region of the lead-out portion).

[0117] For example, when the coil component 1000 has a length of 1.0 mm, a width of 0.7 mm, and a thickness of 0.65 mm, preferably, the length of the bending area of ​​the first lead-out portion 331 is 0.3125 mm, and the length of the bending area of ​​the second lead-out portion 332 is 0.2775 mm, but the length of the bending area is not limited thereto.

[0118] Next, pressure may be applied downward to the cut end of the second lead-out portion 332 by using the bending member BM, and similarly, pressure may be applied upward to the cut end of the first lead-out portion 331 by using the bending member BM.

[0119] As a result, the first lead-out portion 331 may be bent upward, the second lead-out portion 332 may be bent downward, and the second lead-out portion 332 disposed on the upper surface of the support member 200 may be bent downward to cover a portion of the side surface of the support member 200 .

[0120] In addition, according to the arrangement order of the insulating film IF, the insulating film between the second lead-out portion 332 and the side surface of the support member 200 may be formed as one layer or two layers. For example, in the case where the portion of the support member 200 located below the second lead-out portion 332 is removed, the insulating film IF is formed, and then the second lead-out portion 332 is bent downward, the insulating film between the second lead-out portion 332 and the side surface of the support member 200 may be formed as two layers, but is not limited thereto, and the insulating film IF may be integrated in a manner that no boundary is formed between them. In addition, in the case where the insulating film IF is formed on the surface of the second lead-out portion 332, the portion of the support member 200 located below the second lead-out portion 332 is removed, and then the second lead-out portion 332 is bent downward, the insulating film between the second lead-out portion 332 and the side surface of the support member 200 may be formed as one layer.

[0121] However, the method of forming the coil 300 is not limited to the method described above. Fig. 9B and Fig. 10B , a method of forming a coil 300 according to another example is described based on the differences from the method of forming a coil 300 according to one example, and the remaining description of the method of forming a coil 300 according to one example may also be equally applied to the method of forming a coil 300 according to another example.

[0122] Reference Fig. 9B , a plurality of coil parts 312 and 312' may be patterned on the support member 200 having the shape of a substrate by using a plating solution supplied from the plating rod PE. At this time, the area connected to the plating rod PE may be cut along the cutting line DL and then bent to serve as the lead-out parts 332 and 332'.

[0123] Reference Fig. 10B , in such Fig. 9B In the case where the second lead-out portion 332 and the second lead-out portion 332' are connected to each other as shown, after the insulating film IF is formed on the coil 300, the portion of the support member 200 located below the second lead-out portion 332 and the second lead-out portion 332' may be partially removed according to the length of the second lead-out portion 332 and the second lead-out portion 332' extending along the second direction. Next, the coil 300 may be cut along the cutting line DL using the trimming member TM, and the predetermined length of the second lead-out portion 332 and the second lead-out portion 332' of the coil 300 is retained for bending.

[0124] Next, pressure may be applied downward to the cut ends of the second lead-out portion 332 and the second lead-out portion 332 ′ by using the bending member BM.

[0125] As a result, the second lead-out portion 332 and the second lead-out portion 332 ′ may be bent downward, and the second lead-out portion 332 and the second lead-out portion 332 ′ disposed on the upper surface of the support member 200 may be bent downward to cover a portion of the side surface of the support member 200 .

[0126] Fig.11 2 is a schematic diagram showing a process of forming the main body 100 using the mold MF.

[0127] Reference Fig.11 The body 100 may be formed by placing a coil bar into a mold MF, filling the mold MF with a composite material including the magnetic powder 10 and the resin 20, and then pressing the mold MF. The pressing may be performed under high temperature and high pressure conditions, but is not limited thereto.

[0128] Next, the insulating layer 500 may be disposed on the surface of the body 100 formed as a separate component. The insulating layer 500 may be formed by a method such as printing, vapor deposition, spraying, or film lamination, but is not limited thereto.

[0129] Next, the insulating layer 500 may be partially removed using a laser to expose the first and second lead-out portions 331 and 332 in regions on the lower surface of the body 100 where the external electrodes 410 and 420 are to be disposed.

[0130] Next, the external electrodes 410 and 420 may be disposed in the region where the insulating layer 500 has been removed by plating, and the first and second external electrodes 410 and 420 may be formed to have a single-layer structure or a multi-layer structure.

[0131] Fig.12 is shown with Fig.11 Schematic diagram of different processes of forming the body 100 by stacking magnetic sheets MS. The process of forming the support member 200 and the coil 300 is the same as described above.

[0132] Reference Fig.12 First, a required number of magnetic sheets MS may be stacked on the pressing member PM, and the coil 300 disposed on the supporting member 200 may be disposed on the stacked magnetic sheets MS. At this time, preferably, the magnetic sheets MS are arranged in such a manner that the total thickness of the magnetic sheets MS does not exceed 1 / 2 of the thickness of the body 100 to prevent the coil 300 from being deformed during pressing, but is not limited thereto.

[0133] Next, the remaining magnetic sheets MS may be stacked on the upper side of the coil 300 disposed on the support member 200 by using the press member PM.

[0134] Next, the body 100 formed by pressing and curing may be formed into separate components by cutting along the cutting lines DL using a cutting blade or a laser.

[0135] After cutting, the Fig.11 The coil component 1000 is obtained by providing the insulating layer 500 and the external electrodes 410 and 420 as described in FIG.

[0136] As described above, according to exemplary embodiments in the present disclosure, the external electrodes are disposed only on the lower surface of the coil component, thereby increasing the effective volume and improving the inductance characteristics compared with the coil component of the same size.

[0137] According to exemplary embodiments in the present disclosure, plating quality and insulation reliability of a lead-out portion may be improved by implementing a coil covered with an insulating film and led out from a lower surface of a body and then forming the body.

[0138] 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 invention 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 and a third surface and a fourth surface opposite to each other in a second direction perpendicular to the first direction; a supporting member disposed inside the main body and having one surface and another surface opposite to each other and a side surface connecting the one surface and the other surface to each other; a coil disposed on the support member and comprising a coil portion and a lead-out portion, the coil portions each having at least one turn, the lead-out portion extending from a corresponding outermost turn of the coil portion and bending toward the first surface; as well as The external electrodes are disposed on the first surface and connected to the corresponding lead-out portions.

2. The coil assembly according to claim 1, wherein: The coil portion includes a first coil portion provided on the one surface of the support member and a second coil portion provided on the other surface of the support member, The lead-out portion includes a first lead-out portion extending from an outermost turn of the first coil portion and a second lead-out portion extending from an outermost turn of the second coil portion, and The first lead-out portion and the second lead-out portion extend in the same direction.

3. The coil assembly according to claim 2, wherein: The first lead-out portion and the second lead-out portion extend toward the third surface along the second direction, and are bent toward the first surface along the first direction.

4. The coil assembly according to claim 1, wherein: The third surface is closer to a position where the lead-out portion is bent than the fourth surface. 5 . The coil component according to claim 2 , further comprising an insulating film disposed between the coil and the body and covering the coil.

6. The coil assembly according to claim 5, wherein: The insulating film covers a region of the lead portion that is bent toward the first surface.

7. The coil assembly according to claim 5, wherein: At least a portion of the side surface of the support member is covered by the second lead-out portion.

8. The coil assembly according to claim 7, wherein: The insulating film is interposed between the side surface of the support member and the second lead-out portion.

9. The coil assembly according to claim 1, wherein: The body further has a fifth surface and a sixth surface, the fifth surface and the sixth surface are opposite to each other in a third direction perpendicular to the first direction and the second direction, and The support member includes a protrusion protruding toward at least one of the fifth surface and the sixth surface.

10. The coil assembly according to claim 9, wherein: The protrusion extends along the third direction and is exposed to the at least one surface of the fifth surface and the sixth surface. 11 . The coil component according to claim 10 , further comprising an insulating layer covering at least a portion of the first to sixth surfaces and exposing the external electrodes.

12. The coil assembly according to claim 11, wherein: The insulating layer is provided on at least one of the fifth surface and the sixth surface and covers the protrusion.

13. The coil assembly according to claim 2, wherein: The coil further includes a via hole that passes through the support member and connects the first coil part and the second coil part to each other.

14. The coil assembly according to claim 2, wherein: The external electrodes include a first external electrode connected to the first lead-out portion and a second external electrode connected to the second lead-out portion, and The second coil part provided on the other surface of the support member is connected to the second external electrode through the second lead-out part continuously provided on the other surface and the side surface of the support member.

15. The coil assembly according to claim 14, wherein: The first external electrode and the second external electrode are disposed only on the first surface.

16. A coil assembly, comprising: main body; A supporting member embedded in the main body; a coil including a first coil portion provided on one surface of the support member and a second coil portion provided on another surface of the support member opposite to the one surface; a first lead-out portion and a second lead-out portion extending from respective outermost turns of the first coil portion and the second coil portion toward a same side surface of the body; as well as A first external electrode and a second external electrode are disposed on the body and connected to the first lead-out portion and the second lead-out portion, respectively, The first lead portion and the second lead portion respectively have a first bent portion and a second bent portion located in the body, the first lead portion is further extended through the first bent portion to be connected to the first external electrode, and the second lead portion is further extended through the second bent portion to be connected to the second external electrode.

17. The coil assembly according to claim 16, wherein: The first external electrode and the second external electrode are disposed on the first surface of the body and are spaced apart from each other.

18. The coil assembly according to claim 17, wherein: Portions of the first and second lead-out portions extending between ends of the respective outermost turns of the first and second coil portions and respective bent portions of the first and second lead-out portions are substantially parallel to the first surface.

19. The coil assembly according to claim 17, wherein: Portions of the first and second lead portions extending between respective bent portions of the first and second lead portions and the first and second external electrodes are substantially perpendicular to the first surface.

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