Coil component

Abstract

The present disclosure provides a coil component including: a main body including an intermediate layer and having a first surface and a second surface opposite to each other and a plurality of side surfaces connecting the first surface to the second surface; a first coil disposed in the body and including a first coil pattern having at least one turn; a second coil disposed in the body and spaced apart from the first coil, and including a second coil pattern having at least one turn; first and second external electrodes disposed on the main body and connected to the first coil; and third and fourth external electrodes disposed on the main body and connected to the second coil, in which the intermediate layer has a magnetic permeability lower than a magnetic permeability of other regions of the main body except the intermediate layer, the intermediate layer is disposed between the first coil and the second coil, and the intermediate layer has a magnetic permeability lower than a magnetic permeability of other regions of the main body except the intermediate layer. And the intermediate layer is spaced apart from each of the first coil and the second coil.

Description

[0001] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0159119 filed in the Korean Intellectual Property Office on November 16, 2023, 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, may be a representative passive electronic component used in electronic devices along with a resistor and a capacitor.

[0004] As electronic devices have been designed to have high performance and reduced size, the number of electronic components used in the electronic devices has increased and the sizes thereof have decreased.

[0005] In the case of a coupled inductor in which two or more magnetically coupled coils are provided in a coil assembly, it may be necessary to control the distance between the two coils to adjust the coupling coefficient k.

[0006] However, in the case of a coupled inductor in which two coils are arranged in a vertical direction, a magnetic path passing between the two coils may be short, so that a leakage path of magnetic flux may be generated between the two coils, which may reduce the coupling coefficient k.

[0007] In this case, when the distance between the two coils is reduced to increase the coupling coefficient k, the saturation current I sat The characteristics may be degraded, and the achieved coupling coefficient k may also have a problem of increased fluctuation due to process errors. Summary of the invention

[0008] An aspect of the present disclosure is to achieve a desired coupling coefficient k by disposing an intermediate layer having low magnetic permeability between two coils of a coupled inductor and adjusting the thickness and position of the intermediate layer.

[0009] Another aspect of the present disclosure is to mitigate the saturation current I that occurs when the two coils are close to each other by properly maintaining the separation distance between the two coils in the coupled inductor. sat The degradation of characteristics or the increase in the fluctuation of the coupling coefficient k caused by process errors.

[0010] According to one aspect of the present disclosure, a coil component includes: a main body including an intermediate layer, the main body having a first surface and a second surface opposite to each other in a first direction and a plurality of side surfaces connecting the first surface to the second surface; a first coil, arranged in the main body, and the first coil includes a first coil pattern having at least one turn; a second coil, arranged in the main body and spaced apart from the first coil, and the second coil includes a second coil pattern having at least one turn; a first external electrode and a second external electrode, arranged on the main body and connected to the first coil; and a third external electrode and a fourth external electrode, arranged on the main body and connected to the second coil, wherein the intermediate layer has a lower magnetic permeability than other regions of the main body except the intermediate layer, the intermediate layer is arranged between the first coil and the second coil, and the intermediate layer is spaced apart from each of the first coil and the second coil.

[0011] According to another aspect of the present disclosure, a coil component includes: a main body including an intermediate layer, the main body having a first surface and a second surface opposite to each other in a first direction and a plurality of side surfaces connecting the first surface to the second surface; a first coil, arranged in the main body, and the first coil includes a first coil pattern, the first coil pattern has at least one turn and is formed as a single layer; a second coil, arranged in the main body and spaced apart from the first coil, and the second coil includes a second coil pattern, the second coil pattern has at least one turn and is formed as a single layer; a first external electrode and a second external electrode, arranged on the main body and connected to the first coil; and a third external electrode and a fourth external electrode, arranged on the main body and connected to the second coil, wherein the main body includes an Fe-based alloy, and the Fe-based alloy included in the intermediate layer in the main body and the Fe-based alloy included in other regions of the main body except the intermediate layer have different compositions, and wherein the intermediate layer is arranged between the first coil and the second coil, and the intermediate layer is spaced apart from each of the first coil and the second coil. 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 taken in conjunction with the accompanying drawings, in which:

[0013] Figure 1 is a perspective view showing a coil component according to a first embodiment of the present disclosure;

[0014] Figure 2 It is shown Figure 1 An exploded perspective view of the connection relationship between the partial components of the coil assembly shown in FIG.

[0015] Figure 3 is along Figure 1 A cross-sectional view taken along line II' in FIG.

[0016] Figure 4 It is shown Figure 3 An enlarged view of area A shown in;

[0017] Figure 5 It is shown Figure 3 An enlarged view of region B shown in;

[0018] Figure 6 It is shown Figure 3 An enlarged view of a first modified example of the region A shown in FIG.

[0019] Figure 7 It is shown Figure 3 An enlarged view of a second variation example of the region A shown in FIG.

[0020] Figure 8 is a graph of a coupling coefficient k depending on the relative magnetic permeability and thickness of the intermediate layer in the first embodiment of the present disclosure;

[0021] Fig. 9 is a perspective view showing a coil component according to a second embodiment of the present disclosure;

[0022] Fig.10 is along Fig. 9 A cross-sectional view taken along line II-II';

[0023] Fig.11 is a graph of a coupling coefficient k depending on the relative magnetic permeability and thickness of the intermediate layer in the second embodiment of the present disclosure;

[0024] Fig.12 is a perspective view showing a coil component according to a third embodiment of the present disclosure;

[0025] Fig.13 is along Fig.12 A cross-sectional view taken along line III-III';

[0026] Fig.14 is a perspective view showing a coil component according to a fourth embodiment of the present disclosure;

[0027] Fig.15 is along Fig.14 A cross-sectional view taken along line IV-IV';

[0028] Fig.16 is a perspective view showing a coil component according to a fifth embodiment of the present disclosure;

[0029] Fig.17 yes Fig.16 An exploded perspective view of some components of the coil assembly shown in ;

[0030] Fig.18 is along Fig.16 A cross-sectional view taken along line V-V';

[0031] Fig.19 It is shown Fig.18 ; and

[0032] Fig. 20 It is shown Fig.18 is a diagram of another modified example of . DETAILED DESCRIPTION

[0033] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings.

[0034] However, the present disclosure can be illustrated in many different forms and should not be construed as being limited to the specific embodiments set forth herein. Unless the context has a significantly different meaning, expressions used in the singular encompass plural expressions. The terms "comprises," "comprising," "configured to," etc., described herein, are used to indicate the presence of features, quantities, steps, operations, elements, parts, or combinations thereof, and do not exclude the possibility of combining or adding one or more features, quantities, steps, operations, elements, parts, or combinations thereof. In addition, the expression that an element is disposed "on..." may indicate that the element may be disposed above or below the target portion, and does not necessarily indicate that the element is disposed above the target portion in the direction of gravity.

[0035] It will be understood that when an element is described as being “coupled to,” “coupled to,” or “connected to” another element, the element may be directly coupled to, directly coupled to, and there may be intervening elements between the element and the other element. In contrast, it will be understood that when an element is described as being “directly coupled to,” “directly coupled to,” or “directly connected to” another element, there are no intervening elements between the element and the other element.

[0036] The structures, shapes, and sizes described as examples in one exemplary embodiment of the present disclosure may be implemented in another exemplary embodiment without departing from the spirit and scope of the present disclosure.

[0037] In the accompanying drawings, the T direction may be defined as a first direction or a thickness direction (may also be referred to as the "first direction T" or the "thickness direction T" later), the W direction may be defined as a second direction or a width direction (may also be referred to as the "second direction W" or the "width direction W" later), and the L direction may be defined as a third direction or a length direction (may also be referred to as the "third direction L" or the "length direction L" later).

[0038] In the accompanying drawings, the same elements will be indicated by the same reference numerals. In addition, redundant descriptions and detailed descriptions of known functions and elements that may unnecessarily obscure the gist of the present disclosure will not be provided.

[0039] Various types of electronic components are used in electronic devices, and various types of coil components may be appropriately used between these electronic components for the purpose of removing noise.

[0040] That is, in electronic devices, the coil assembly can be used as a power inductor, a high frequency (HF) inductor, a general magnetic bead, a high frequency magnetic bead (for example, a magnetic bead suitable for a GHz band), a common mode filter, etc.

[0041] First embodiment

[0042] Figure 1 is a perspective view showing a coil component 1000 according to the first embodiment. Figure 2 It is shown Figure 1 An exploded perspective view of the connection relationship between some components of the coil assembly 1000 shown in FIG. Figure 3 is along Figure 1 A cross-sectional view taken along line II' in FIG. Figure 4 It is shown Figure 3 An enlarged view of area A is shown in FIG. Figure 5 It is shown Figure 3 An enlarged view of region B is shown in FIG. Figure 6 It is shown Figure 3 An enlarged view of a first modified example of the area A shown in FIG. Figure 7 It is shown Figure 3 An enlarged view of a second variation example of the area A shown in FIG. Figure 8 is a graph of the coupling coefficient k depending on the relative magnetic permeability and thickness of the intermediate layer in the first embodiment of the present disclosure.

[0043] exist Figure 1 In the embodiment, the insulating layer 500 applied on the body 100 is not shown to clearly show the bonding relationship between the components.

[0044] Reference Figures 1 to 8 According to the first embodiment, the coil component 1000 may include a body 100, a first coil 200, a second coil 300, and a first external electrode 410, a second external electrode 420, a third external electrode 430 and a fourth external electrode 440, and the coil component 1000 may also include an insulating layer 500 covering the body 100.

[0045] The first coil 200 and the second coil 300 of the embodiment may be spaced apart from each other in the first direction T in the body 100, so that the first coil 200 and the second coil 300 may be magnetically coupled to each other when powered on, and may have a coupling coefficient k. In addition, the first coil 200 may include a first coil pattern 210 having at least one turn, and the second coil 300 may include a second coil pattern 310 having at least one turn. Here, at least one of the first coil pattern 210 and the second coil pattern 310 may be formed as a single layer.

[0046] In addition, the body 100 in the embodiment may include an intermediate layer 150, which is disposed between the first coil 200 and the second coil 300 and is spaced apart from each of the first coil 200 and the second coil 300 by a predetermined distance G. The intermediate layer 150 may have a lower magnetic permeability than other regions of the body 100. In the present disclosure, the expression of "other regions of the body 100" may mean "other regions of the body 100 except the intermediate layer 150", which will not be repeated below.

[0047] The coil component 1000 may achieve a coupling coefficient k within a desired range without excessively reducing a distance between the first coil 200 and the second coil 300 by disposing the intermediate layer 150 having low magnetic permeability between the first coil 200 and the second coil 300 that are magnetically coupled to each other.

[0048] In addition, the coil component 1000 according to the embodiment can be miniaturized by implementing each of the coil patterns 210 and 310 of the first coil 200 and the second coil 300 that are magnetically coupled to each other as a single layer, and the intermediate layer 150 and the coil patterns 210 and 310 can be spaced apart from each other by a predetermined distance G, so that the coupling coefficient k can be finely adjusted. That is, by adjusting the magnetic permeability μ, the thickness T1 of the intermediate layer 150, and the distance between the intermediate layer 150 and the coil patterns 210 and 310, the leakage magnetic flux flowing between the first coil pattern 210 and the second coil pattern 310 can be adjusted, so that the desired coupling coefficient k can be accurately achieved.

[0049] In the following description, main components included in the coil component 1000 according to the embodiment will be described in more detail.

[0050] The body 100 may form an exterior appearance of the coil component 1000 in the embodiment, and may include an intermediate layer 150 , and the first coil 200 and the second coil 300 may be embedded in the body 100 .

[0051] The body 100 may have a hexahedral shape.

[0052] The body 100 may include a first surface 101 and a second surface 102 opposite to each other in a thickness direction T, a third surface 103 and a fourth surface 104 opposite to each other in a width direction W, and a fifth surface 105 and a sixth surface 106 opposite to each other in a length direction L. Each of the third surface 103, the fourth surface 104, the fifth surface 105, and the sixth surface 106 of the body 100 may be a side surface connecting the first surface 101 to the second surface 102 of the body 100.

[0053] The body 100 may be formed so that the coil component in which the external electrodes 410, 420, 430 and 440 are formed may have 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, or a length of 0.8 mm, a width of 0.4 mm and a thickness of 0.5 mm, but embodiments thereof are not limited thereto. Since the above-described exemplary dimensions of the length, width, and thickness of the coil component 1000 may refer to dimensions that do not reflect process errors, dimensions within the range identified as process errors may correspond to the above-described exemplary dimensions.

[0054] The length of the coil component 1000 may be: in an optical microscope image or a scanning electron microscope (SEM) image obtained from a cross section of the length direction L-thickness direction T taken from the central part of the coil component 1000 in 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 that are opposite to each other in the length direction L in a direction parallel to the length direction L and are spaced apart from each other in the thickness direction T. 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 or more of the sizes of the multiple line segments. Here, the multiple line segments parallel to the length direction L may be spaced apart from each other at equal distances in the thickness direction T, but embodiments thereof are not limited thereto.

[0055] The thickness of the coil component 1000 may be: in an optical microscope image or a scanning electron microscope (SEM) image obtained from a cross section of the length direction L-thickness direction T taken from the central part of the coil component 1000 in 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 that are opposite to each other in the thickness direction T in a direction parallel to the thickness direction T and are spaced apart from each other in the length direction L. Alternatively, the thickness of the coil component 1000 may refer to the minimum value of the sizes of the multiple line segments. Alternatively, the thickness of the coil component 1000 may refer to the arithmetic mean of at least three or more of the sizes of the multiple line segments. Here, the multiple line segments parallel to the thickness direction T may be spaced apart from each other at equal distances in the length direction L, but embodiments thereof are not limited thereto.

[0056] The width of the coil component 1000 may be: in an optical microscope image or a scanning electron microscope (SEM) image obtained from a cross section in the length direction L-width direction W taken from the central part of the coil component 1000 in the thickness direction T, the maximum value of the sizes of multiple line segments that connect the two outermost boundary lines of the coil component 1000 that are opposite to each other in the width direction W in a direction parallel to the width direction W and are spaced apart from each other in the length direction L. Optionally, the width of the coil component 1000 may refer to the minimum value of the sizes of the multiple line segments. Optionally, the width of the coil component 1000 may refer to the arithmetic mean of at least three or more of the sizes of the multiple line segments. Here, the multiple line segments parallel to the width direction W may be spaced apart from each other at equal distances in the length direction L, but embodiments thereof are not limited thereto.

[0057] Optionally, each of the length, width and thickness of the coil assembly 1000 can be measured by a micrometer measurement method. The micrometer measurement method can be a method as follows: determine the zero point with a gage repeatability (gage repeatability) and reproducibility (R&R) micrometer, insert the coil assembly 1000 in the embodiment between the tips of the micrometer, and measure by rotating the measuring rod of the micrometer. When measuring the length of the coil assembly 1000 by the micrometer measurement method, the length of the coil assembly 1000 may refer to a value measured once, or may refer to the arithmetic mean of the values ​​measured multiple times, and the method may be equally applicable to measuring the width and thickness of the coil assembly 1000.

[0058] The body 100 may include a magnetic material and a resin. Specifically, the body 100 may be formed by laminating one or more magnetic composite sheets made by dispersing a magnetic material in an insulating resin.

[0059] The magnetic material can be ferrite or magnetic metal particles.

[0060] 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, Ni-Zn-based ferrite), hexagonal ferrite (such as Ba-Zn-based ferrite, Ba-Mg-based ferrite, Ba-Ni-based ferrite, Ba-Co-based ferrite, Ba-Ni-Co-based ferrite), garnet-type ferrite (such as Y-based ferrite) and Li-based ferrite.

[0061] The magnetic metal particles may include one or more selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), cobalt (Co), molybdenum (Mo), aluminum (Al), niobium (Nb), copper (Cu), and nickel (Ni). For example, the magnetic metal particles may be at least one of pure iron particles, Fe-Si-based alloy particles, Fe-Si-Al-based alloy particles, Fe-Ni-based alloy particles, Fe-Ni-Mo-based alloy particles, Fe-Ni-Mo-Cu-based alloy particles, Fe-Co-based alloy particles, Fe-Ni-Co-based alloy particles, Fe-Cr-based alloy particles, Fe-Cr-Si-based alloy particles, Fe-Si-Cu-Nb-based alloy particles, Fe-Ni-Cr-based alloy particles, and Fe-Cr-Al-based alloy particles.

[0062] The magnetic metal particles may be amorphous or crystalline. For example, the magnetic metal particles may be Fe-Si-B-Cr based amorphous alloy particles, but the embodiment is not limited thereto.

[0063] Each of the ferrite particles and the magnetic metal particles may have an average diameter of about 0.1 μm to about 30 μm, but the embodiment is not limited thereto.

[0064] The body 100 may include two or more types of magnetic materials dispersed in the resin. Here, different types of magnetic materials may refer to magnetic materials dispersed in the resin that can be distinguished from each other by at least one of average diameter, composition, crystallinity, and shape.

[0065] The resin may include epoxy resin, polyimide, liquid crystal polymer, etc. alone or may include a combination thereof, but the embodiment is not limited thereto.

[0066] Reference Figure 3 , the body 100 may include a first core 110 filling a central area of ​​the first coil pattern 210 and a second core 120 filling a central area of ​​the second coil pattern 310 .

[0067] The first core 110 and the second core 120 may be formed by filling a central region of each of the first coil pattern 210 and the second coil pattern 310 with a magnetic composite sheet, but the embodiment is not limited thereto.

[0068] The first core 110 and the second core 120 in the embodiment may include a region where the first core 110 and the second core 120 overlap each other in the first direction T and a region where the first core 110 and the second core 120 do not overlap each other in the first direction T.

[0069] The region where the first core 110 and the second core 120 overlap each other in the first direction T may be a region corresponding to an intersection where a region surrounded by the first coil pattern 210 and a region surrounded by the second coil pattern 310 overlap each other in the first direction T.

[0070] Furthermore, a region in which the first core 110 and the second core 120 do not overlap each other in the first direction T may be a region corresponding to a difference surrounded by only one of the first coil pattern 210 and the second coil pattern 310 .

[0071] In other words, the coil component 1000 in the embodiment may include a common core region where the first core 110 and the second core 120 overlap each other in the first direction T, and a non-overlapping core region where the first core 110 and the second core 120 do not overlap each other in the first direction T.

[0072] Reference Figure 1 and Figure 3 , the body 100 in the embodiment may include a middle layer 150 disposed between the first coil pattern 210 and the second coil pattern 310 and spaced apart from each of the first coil pattern 210 and the second coil pattern 310 .

[0073] The intermediate layer 150 may play a role in adjusting a coupling coefficient k between the first coil 200 and the second coil 300 which are magnetically coupled to each other.

[0074] Reference Figure 3 When the coil component 1000 according to the embodiment is powered on, a flow of magnetic flux may occur around the coil patterns 210 and 310. The magnetic flux generated from the first coil pattern 210 may flow into a leakage magnetic flux path LF1 around the first coil pattern 210 and a coupling magnetic flux path CF1 (hereinafter may also be simply referred to as “coupling path CF1”) around both the first coil pattern 210 and the second coil pattern 310.

[0075] Furthermore, the magnetic flux generated in the second coil pattern 310 may flow into a leakage magnetic flux path LF2 around the second coil pattern 310 and a coupling magnetic flux path CF2 (hereinafter also referred to as “coupling path CF2 ”) around both the first coil pattern 210 and the second coil pattern 310 .

[0076] In a coupled inductor where the first coil pattern 210 and the second coil pattern 310 are spaced apart from each other in the vertical direction, a leakage flux path may be shorter than that in a coupled inductor sharing turns, so that the leakage flux may increase and thus the coupling coefficient k may decrease.

[0077] When the distance between the first coil pattern 210 and the second coil pattern 310 is reduced in order to solve the above problem, a saturation current I sat The side effect is that the characteristics are degraded or the fluctuation of the coupling coefficient k increases due to process errors.

[0078] According to the coil component 1000 of the embodiment, by disposing the intermediate layer 150 between the first coil pattern 210 and the second coil pattern 310, and forming a spacing distance G between the intermediate layer 150 and the coil patterns 210 and 310, the desired coupling coefficient k can be finely adjusted without excessively reducing the distance between the first coil pattern 210 and the second coil pattern 310.

[0079] Reference Figure 1 and Figure 3 , at least a portion of the intermediate layer 150 in the embodiment may extend to at least one of the side surfaces of the body 100 (ie, the third surface 103 , the fourth surface 104 , the fifth surface 105 , and the sixth surface 106 ).

[0080] In this case, the body 100 can be divided into an area between one surface of the intermediate layer 150 (the upper surface in the drawing) and the first surface 101 of the body 100 and an area between another surface of the intermediate layer 150 (the lower surface in the drawing) and the second surface 102 of the body 100.

[0081] The intermediate layer 150 in the embodiment may have a lower magnetic permeability than other regions of the body 100. As an example, although not limited thereto, the relative magnetic permeability of the intermediate layer 150 may have a value less than 36.

[0082] Figure 8 : is a graph of the coupling coefficient k depending on the relative magnetic permeability μ and the thickness T1 of the intermediate layer 150 in the first embodiment.

[0083] The desired coupling coefficient k in the coil component 1000 according to the embodiment may be 0.55±10%, and may be, for example, in the range of 0.495 to 0.605. Based on the coupling coefficient k, the thickness T1 of the intermediate layer 150 is simulated under the condition of changing the relative magnetic permeability μ (it is possible to achieve a coupling coefficient k in the range of 0.495 to 0.605), and the following Table 1 lists the simulation data.

[0084] When the achieved coupling coefficient k satisfies the range of 0.495 to 0.605, “OK” is noted for the sample in the judgment column, and when it exceeds the above reference range, “NG” is noted for the sample in the judgment column.

[0085] [Table 1]

[0086]

[0087]

[0088] Refer to Table 1 and Figure 8 , indicating that when the relative magnetic permeability of the intermediate layer 150 is 36 and the thickness T1 of the intermediate layer 150 is 4 μm or less, the coupling coefficient k within the desired range is achieved. Therefore, the relative magnetic permeability of the intermediate layer 150 in the embodiment may be 36, and the thickness T1 of the intermediate layer 150 in the first direction T may be 4 μm or less.

[0089] In addition, it is also shown that when the relative magnetic permeability of the intermediate layer 150 is 18 and the thickness T1 of the intermediate layer 150 is 10 μm or less, the coupling coefficient k within the desired range is achieved. Therefore, the relative magnetic permeability of the intermediate layer 150 in the embodiment may be 18, and the thickness T1 of the intermediate layer 150 in the first direction T may be 10 μm or less.

[0090] In addition, it is also shown that when the relative magnetic permeability of the intermediate layer 150 is 9 and the thickness T1 of the intermediate layer 150 is 26 μm or less, the coupling coefficient k within the desired range is achieved. Therefore, the relative magnetic permeability of the intermediate layer 150 in the embodiment may be 9, and the thickness T1 of the intermediate layer 150 in the first direction T may be 26 μm or less.

[0091] When the relative magnetic permeability of the intermediate layer 150 is 3, the coupling coefficient k is realized within a desired range of 0.495 to 0.605 regardless of the thickness T1 of the intermediate layer 150 .

[0092] Considering the tendency of the coupling coefficient k according to the change in the relative magnetic permeability of the intermediate layer 150 , when the relative magnetic permeability of the intermediate layer 150 is 3 or less, the coupling coefficient k within a desired range may be achieved regardless of the thickness T1 .

[0093] Here, the thickness T1 of the intermediate layer may be an arithmetic mean of at least three values ​​of the size of a plurality of line segments that connect two outermost boundary lines of the intermediate layer 150 that are opposite to each other in the thickness direction T in a direction parallel to the thickness direction T and are spaced apart from each other in the length direction L, in an optical microscope image or a scanning electron microscope (SEM) image obtained from a cross section of the length direction L-thickness direction T taken from a central portion of the coil component 1000 in the width direction W. Here, the plurality of line segments parallel to the thickness direction T may be spaced apart from each other at equal distances in the length direction L, but embodiments thereof are not limited thereto.

[0094] When it is difficult to measure the magnetic permeability of the intermediate layer 150 in the state of the coil component 1000, the magnetic permeability may be compared by analyzing the type of magnetic material included in the intermediate layer 150 and the area of ​​the body 100 other than the intermediate layer 150, the size of the particles, the filling rate of the particles, etc.

[0095] In the following, please refer to Figures 4 to 7 An example in which the magnetic permeability of the intermediate layer 150 is lower than that of other regions of the body 100 is described in terms of the filling rate of magnetic particles.

[0096] Figure 4 It is shown Figure 3 , which is an enlarged view of region A in FIG. 1 , shows an example in which other regions of the body 100 are filled with magnetic particles. Figure 5 It is shown Figure 3 1 is an enlarged view of a region B in FIG. 1 , illustrating an example in which the intermediate layer 150 included in the body 100 is filled with magnetic particles.

[0097] Reference Figure 4 , the region A (a region belonging to the body 100 excluding the intermediate layer 150 ) may include the magnetic particles P11 , and the insulating material R1 such as resin may be interposed between the magnetic particles P11 .

[0098] Reference Figure 5 , the region B (a region belonging to the intermediate layer 150 ) may include magnetic particles P21 , wherein an insulating material R2 such as a resin may be interposed between the magnetic particles P21 .

[0099] like Figure 4 and Figure 5As shown, the filling rate of the magnetic particles P11 in region A may be higher than the filling rate of the magnetic particles P21 in region B. As an example of a method of obtaining the filling rate, SEM images of region A and region B may be obtained, the ratio of the area occupied by the magnetic particles P11 and P21 in the respective corresponding entire regions may be calculated, and in this case, in order to obtain a more accurate value, the value of the filling rate may be obtained from a plurality of cross sections. Even if not described in the present disclosure, other methods and / or tools understood by those of ordinary skill in the art may be used.

[0100] When there is no significant difference in the size of the magnetic particles P11 in region A and the magnetic particles P21 in region B (for example, the difference between the D50 of the magnetic particles P11 in region A and the D50 of the magnetic particles P21 in region B is 10% or less), the filling rate of the magnetic particles P11 and P21 may affect the magnetic permeability of the corresponding region. Here, the difference in D50 of 10% or less may indicate that the ratio of the difference between the larger value and the smaller value of D50 of the magnetic particles in region A and region B to the larger value of D50 may be 10% or less. As an example, the magnetic particles P11 included in region A may have a diameter ranging from 5μm to 61μm, and similarly, the magnetic particles P21 included in region B may have a diameter ranging from 5μm to 61μm.

[0101] In order to improve the filling rate of the magnetic particles, magnetic particles having different particle size distributions may be used. That is, region A may include two or more types of magnetic particles having different sizes of D50. Figure 6 A variant example A' using two particles P11 and P12 is shown, and Figure 7 A modified example A using three kinds of particles P11, P12 and P13 is shown. By using a variety of magnetic particles having different D50 sizes as described above, the filling rate of the magnetic particles can be improved, and thus the magnetic permeability of the corresponding area in the body 100 can be increased. D50 can be measured from a scanning electron microscope (SEM) image. Even if not described in the present disclosure, other methods and / or tools understood by a person of ordinary skill in the art may be used.

[0102] exist Figure 6 and Figure 7 In the modified examples A' and A" shown in FIG. 5 , the diameter of the first magnetic particle P11 may range from 5 μm to 61 μm, the diameter of the second magnetic particle P12 may range from 0.9 μm to 4.5 μm, and the diameter of the third magnetic particle P13 may range from 10 nm to 800 nm.

[0103] The diameters of the magnetic particles P11, P12, P13, and P21 present in the body 100 can be measured in a cross-sectional image of the body 100. Specifically, a scanning electron microscope can be used to image a plurality of regions (e.g., 5 regions or 10 regions) at equal distances in the second direction W in a length direction L-thickness direction T cross section passing through the center of the body 100, and the diameters of the magnetic particles P11, P12, P13, and P21 can be obtained using an image analysis program. In this case, as a specific example, the image pixel size in the SEM image can be fixed to 10 nm×10 nm, and the working distance can be fixed to 8 mm. Thereafter, an image analysis program (e.g., ORS deep learning tool) can be used to calculate the average value of the diameter.

[0104] The magnetic particles P11, P12, P13, and P21 may have a spherical shape or a substantially spherical shape, but embodiments thereof are not limited thereto. That is, the magnetic particles P11, P12, P13, and P21 may have a non-spherical shape. This shape may be obtained as the sphericity of the magnetic particles P11, P12, P13, and P21 decreases during the oxidation process. When the magnetic particles P11, P12, P13, and P21 are any shape that does not maintain a spherical shape, the above diameters may be explained by replacing them with Feret's diameters, and the average value of the above diameters may also be explained by replacing them with the average value of Feret's diameters. As a method of calculating the diameter average value, a tool in image processing software may be used, and the particle size distribution may be obtained by particle size analysis for each region.

[0105] In the above description, the diameters of the magnetic particles P11, P12, P13 and P21 can be measured based on multiple sections from the coil assembly 1000, but when it is difficult to cut multiple sections, the diameter can be measured at one section (for example, a length direction L-thickness direction T section or a width direction W-thickness direction T section passing through the center of the body 100).

[0106] In the above-mentioned embodiment, the magnetic permeability of the intermediate layer 150 can be adjusted by adjusting the filling rate of the magnetic particles in the main body 100, but differently, the intermediate layer 150 region (including region B) of the main body 100 and other regions of the main body 100 (including region A) may have different materials included in the magnetic particles, thereby adjusting the magnetic permeability.

[0107] Specifically, the body 100 may include an Fe-based alloy, and in the body 100, the Fe-based alloy included in the intermediate layer 150 region (including region B) and the Fe-based alloy included in other regions (including region A) other than the intermediate layer 150 may have different compositions. In this case, the Fe-based alloy included in the intermediate layer 150 region (including region B) may have a Fe content less than that of the Fe-based alloy included in other regions (including region A) of the body 100, wherein the unit of the Fe content may be wt%.

[0108] Furthermore, considering that Si may also affect the magnetic permeability in addition to Fe, the Si content may also be adjusted together with Fe or independently of Fe. For example, the Fe-based alloy included in the body 100 may be a Fe-Si-based alloy, and the Fe-Si-based alloy included in the intermediate layer 150 region (including region B) in the body 100 may have a lower Si content than the Fe-Si-based alloy included in other regions (including region A) of the body 100.

[0109] Specifically, the Si content in the Fe-Si-based alloy in the intermediate layer 150 region (including region B) included in the body 100 may be less than 6.5wt% based on the total weight of the Fe-Si-based alloy, for example, and the Si content in the Fe-Si-based alloy in the other regions (including region A) of the body 100 may be 6.5wt% or more based on the total weight of the Fe-Si-based alloy, for example. More specifically, the Si content in the Fe-Si-based alloy included in the intermediate layer 150 may be greater than or equal to 1wt% and less than or equal to 5wt%. In addition, when the Fe-based alloy in the intermediate layer 150 region (including region B) included in the body 100 and the Fe-based alloy in the other regions (including region A) of the body 100 have different compositions, the types of elements included therein may be different. For example, an element in the Fe-based alloy in the intermediate layer 150 region (including region B) included in the body 100 may not be included in the Fe-based alloy in the other regions (including region A) of the body 100, and vice versa.

[0110] The content of the elements in the alloy disclosed herein can be measured by a scanning electron microscope combined with an energy dispersive X-ray spectrometer (SEM-EDX) or an inductively coupled plasma mass spectrometer (ICP-MS). Even if not described in the present disclosure, other methods and / or tools understood by those of ordinary skill in the art can also be used.

[0111] Unlike the previous embodiment, the intermediate layer 150 may be implemented in the form of a sheet instead of magnetic particles. That is, the intermediate layer 150 may include a magnetic sheet, wherein the magnetic sheet may include ferrite. In this case, the region A may include magnetic particles formed using an Fe-based alloy having a relatively higher magnetic permeability than that of ferrite.

[0112] In some embodiments, the relative magnetic permeability of the intermediate layer 150 can be measured by methods and / or tools understood by those of ordinary skill in the art. In some embodiments, the relative magnetic permeability of the intermediate layer 150 can be related to the relative magnetic permeability of the powder from which the intermediate layer 150 is prepared. The relative magnetic permeability of the powder can be measured by forming a toroidal core sample using the powder, winding a wire around the sample, and measuring the inductance. Even if not described in the present disclosure, other methods and / or tools understood by those of ordinary skill in the art can also be used.

[0113] Reference Figures 1 to 3 , the coil component 1000 according to the embodiment may include a first coil 200 and a second coil 300 magnetically coupled to each other.

[0114] The first coil 200 and the second coil 300 may be embedded in the body 100 and may exhibit the characteristics of the coil component 1000. For example, when the coil component 1000 according to the embodiment is used as a power inductor, the first coil 200 and the second coil 300 may be used to stabilize the power of the electronic device by storing the electric field as a magnetic field and maintaining the output voltage. In addition, the total inductance capacity may be adjusted by adjusting the coupling coefficient k between the first coil 200 and the second coil 300.

[0115] Reference Figures 1 to 3 , the first coil 200 and the second coil 300 may be spaced apart from each other in the first direction T.

[0116] The first coil 200 may include a first coil pattern 210 having at least one turn relative to the first core 110, a first lead-out portion 230 extending from the first coil pattern 210 and connected to the first external electrode 410, a first connection pattern 240 spaced apart from the first coil pattern 210 and connected to the second external electrode 420, and a first via 220 connecting an inner end of the first coil pattern 210 to the first connection pattern 240.

[0117] In addition, the second coil 300 may include a second coil pattern 310 having at least one turn relative to the second core 120, a second lead-out portion 330 extending from the second coil pattern 310 and connected to the third external electrode 430, a second connection pattern 340 spaced apart from the second coil pattern 310 and connected to the fourth external electrode 440, and a second via 320 connecting the inner end of the second coil pattern 310 to the second connection pattern 340.

[0118] Reference Figures 1 to 3 , each of the first coil pattern 210 and the second coil pattern 310 in the embodiment may have a single-layer structure.

[0119] Specifically, the first lead-out portion 230 of the first coil 200 may be disposed at the same level as the first coil pattern 210, and the first connection pattern 240 may be disposed at the same level as the second coil pattern 310. That is, the first coil pattern 210, the first lead-out portion 230, and the second connection pattern 340 may be disposed in a region between the intermediate layer 150 and the first surface 101 of the body 100.

[0120] In addition, the inner end of the first coil pattern 210 and the first connection pattern 240 may be connected to each other through the first via hole 220 , and the first via hole 220 may penetrate the intermediate layer 150 .

[0121] Similarly, the second lead-out portion 330 of the second coil 300 may be disposed at the same level as the second coil pattern 310, and the second connection pattern 340 may be disposed at the same level as the first coil pattern 210. That is, the second coil pattern 310, the second lead-out portion 330, and the first connection pattern 240 may be disposed in a region between the intermediate layer 150 and the second surface 102 of the body 100.

[0122] In addition, the inner end of the second coil pattern 310 and the second connection pattern 340 may be connected to each other through the second via hole 320 , and the second via hole 320 may penetrate the intermediate layer 150 .

[0123] Through this structure, when the coil component 1000 according to the embodiment is mounted on a circuit board, a signal input to the first external electrode 410 can pass through the first lead-out portion 230 , the first coil pattern 210 , the first via 220 , and the first connection pattern 240 , and can be output to the second external electrode 420 .

[0124] In addition, a signal input to the third external electrode 430 may pass through the second lead-out portion 330 , the second coil pattern 310 , the second via hole 320 , and the second connection pattern 340 , and may be output to the fourth external electrode 440 .

[0125] Therefore, the first coil 200 may be used as a coil between the first external electrode 410 and the second external electrode 420 , and the second coil 300 may be used as a coil between the third external electrode 430 and the fourth external electrode 440 .

[0126] In addition, the first coil 200 and the second coil 300 may be magnetically coupled to each other, and may implement positive coupling or negative coupling according to an input direction and an output direction connected to the external electrodes 410 , 420 , 430 , and 440 .

[0127] The first coil 200 and the second coil 300 may be a plating pattern formed using a commonly used plating process (e.g., a method such as pattern plating, anisotropic plating, and isotropic plating), and may be formed into a multilayer structure using a plurality of plating processes among the above plating processes. Examples of materials of the first coil 200 and the second coil 300 may include a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), chromium (Cr), molybdenum (Mo), or alloys thereof, but embodiments thereof are not limited thereto.

[0128] Reference Figure 3 , the coil component 1000 according to the embodiment may include an insulating film IF covering the coils 200 and 300 .

[0129] The insulating film IF may be formed along surfaces of the first and second coils 200 and 300 , and may be disposed between the first and second coils 200 and 300 and the body 100 .

[0130] The insulating film IF may be configured to insulate the first coil 200 and the second coil 300 from the body 100, and may include a commonly used insulating material such as polyparaxylene, but embodiments thereof are not limited thereto. The insulating film IF may be formed by a method such as vapor deposition, but embodiments thereof are not limited thereto, and the insulating film IF may be formed by stacking insulating films.

[0131] When the components of the body 100 have sufficient insulation performance, the insulation film in the embodiment may not be provided.

[0132] Reference Figure 1 and Figure 2 , the coil component 1000 according to the embodiment may include external electrodes 410 and 420 disposed on the body 100 and connected to the first coil 200 , and external electrodes 430 and 440 connected to the second coil 300 .

[0133] The external electrodes 410, 420, 430, and 440 may be configured to electrically connect the coil component 1000 to the circuit board when the coil component 1000 according to the embodiment is mounted on the circuit board. For example, the first external electrode 410, the second external electrode 420, the third external electrode 430, and the fourth external electrode 440 spaced apart from each other on the second surface 102 of the body 100 and the connection portions of the circuit board may be electrically connected to each other.

[0134] The first and second external electrodes 410 and 420 may be spaced apart from each other on the third surface 103 of the body 100 , the first external electrode 410 may be connected to the first lead-out portion 230 , and the second external electrode 420 may be connected to the first connection pattern 240 .

[0135] In addition, the third and fourth external electrodes 430 and 440 may be spaced apart from each other on the fourth surface 104 of the body 100 , the third external electrode 430 may be connected to the second lead-out portion 330 , and the fourth external electrode 440 may be connected to the second connection pattern 340 .

[0136] At least a portion of each of the first external electrode 410 , the second external electrode 420 , the third external electrode 430 , and the fourth external electrode 440 may extend to the second surface 102 (ie, the mounting surface).

[0137] The external electrodes 410, 420, 430 and 440 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 embodiments thereof are not limited thereto.

[0138] The external electrodes 410, 420, 430, and 440 may be formed as a multilayer. For example, the external electrodes 410, 420, 430, and 440 may include a first layer in contact with the lead-out portions 230 and 330 or the connection patterns 240 and 340 and a second layer disposed on the first layer. Specifically, the first external electrode 410 and the second external electrode 420 may include a first layer in contact with the first lead-out portion 230 and the second lead-out portion 330, respectively, and the third external electrode 430 and the fourth external electrode 440 may include a first layer in contact with the first connection pattern 240 and the second connection pattern 340, respectively. Here, the first layer may be a conductive resin layer including conductive particles containing at least one of copper (Cu) and silver (Ag) and an insulating resin, or may be a copper (Cu) plating layer. The second layer may have a double-layer structure, such as a nickel (Ni) plating layer and a tin (Sn) plating layer.

[0139] Reference Figure 3 According to the embodiment, the coil component 1000 may further include an insulating layer 500, which covers the outer surface of the body 100, is arranged in an area on the outer surface of the body 100 except for the area in which the external electrodes 410, 420, 430 and 440 are arranged, and exposes the external electrodes 410, 420, 430 and 440.

[0140] For example, the insulating layer 500 may be formed by applying an insulating material including an insulating resin to the surface of the body 100 and curing it. In this case, the insulating layer may include at least one of a thermoplastic resin (such as a polystyrene-based resin, a vinyl acetate-based resin, a polyester-based resin, a polyethylene-based resin, a polypropylene-based resin, a polyamide-based resin, a rubber-based resin, and an acrylic resin), a thermosetting resin (such as a phenol-based resin, an epoxy-based resin, a urethane-based resin, a melamine-based resin, and an alkyd-based resin), and a photosensitive insulating resin.

[0141] Second embodiment

[0142] Fig. 9 is a perspective view showing a coil component according to a second embodiment. Fig.10 is along Fig. 9 A cross-sectional view taken along line II-II'. Fig.11 is a graph of the coupling coefficient k depending on the relative magnetic permeability and thickness of the intermediate layer in the second embodiment.

[0143] Will Fig. 9 and Figure 1 To compare and Fig.10 and Figure 3 In comparison, the intermediate layer 150 in the embodiment is different in that a through hole H may be formed in a central region of the intermediate layer 150 to physically connect the first core 110 to the second core 120 .

[0144] Therefore, when describing the embodiment, only the form of the intermediate layer 150 and the connection between the first core 110 and the second core 120 that are different from the first embodiment will be described. The description of the first embodiment can be applied to other components in this embodiment.

[0145] Reference Fig. 9 and Fig.10 , the intermediate layer 150 in the embodiment may include a through hole H formed along a region where the first core 110 and the second core 120 overlap each other in the first direction T.

[0146] The region of the intermediate layer 150 in which the through hole H is formed may be filled with the same component as that in other regions of the body 100 , so that the region may have a higher magnetic permeability than that of the intermediate layer 150 .

[0147] Therefore, the first core 110 and the second core 120 can be physically connected to each other in a portion of the region through the through hole H, so that the flow of magnetic flux in the region between the first core 110 and the second core 120 in the coupling paths CF1 and CF2 flowing around both the first coil 200 and the second coil 300 can be smoothed, and thus, the saturation current I of the coil component 2000 can be improved. sat characteristic.

[0148] The intermediate layer 150 in the embodiment may have a lower magnetic permeability than other regions of the body 100. As an example, although not limited thereto, the value of the relative magnetic permeability of the intermediate layer 150 may be less than 18.

[0149] In the coil component 2000 according to the embodiment, the desired coupling coefficient k may be 0.55±10%, and may be in the range of 0.495 to 0.605. Based on the coupling coefficient k, the thickness T2 of the intermediate layer 150 is simulated while varying the relative permeability μ (a coupling coefficient k in the range of 0.495 to 0.605 may be achieved), and Fig.11 is a graph indicating the simulation results.

[0150] Reference Fig.11 , indicating that when the relative magnetic permeability of the intermediate layer 150 is 36, no matter how the thickness T2 of the intermediate layer 150 is, the coupling coefficient k within the desired range is not achieved.

[0151] When the relative permeability of the intermediate layer 150 is 18 and the thickness T2 of the intermediate layer 150 is 5 μm or less, the coupling coefficient k in the desired range is achieved. Therefore, the relative permeability of the intermediate layer 150 in the embodiment is 18 and the thickness T2 of the intermediate layer 150 in the first direction T is 5 μm or less.

[0152] In addition, when the relative permeability of the intermediate layer 150 is 9 and the thickness T2 of the intermediate layer 150 is 13 μm or less, the coupling coefficient k within the desired range is achieved. Therefore, the intermediate layer 150 in the embodiment has a relative permeability of 9 and a thickness T2 in the first direction T of 13 μm or less.

[0153] When the relative magnetic permeability of the intermediate layer 150 is 3, the coupling coefficient k is implemented within a desired range of 0.495 to 0.605 regardless of the thickness T2 of the intermediate layer 150 .

[0154] Considering the graph of the coupling coefficient k depending on the change in the relative magnetic permeability of the intermediate layer 150 , when the relative magnetic permeability of the intermediate layer 150 is 3 or less, the coupling coefficient k within a desired range can be achieved regardless of the thickness T2 .

[0155] Third embodiment

[0156] Fig.12 is a perspective view showing a coil component according to a third embodiment. Fig.13 is along Fig.12 A cross-sectional view taken along line III-III'.

[0157] When the general Fig.12 and Figure 1 To compare and Fig.13 and Figure 3 When comparing, the differences are: Fig.12 and Fig.13 An outer region of the intermediate layer 150 may be partially removed and may be spaced apart from the side surface of the body 100 .

[0158] Therefore, when describing the embodiment, only the outer region of the intermediate layer 150 that is different from the first embodiment will be described. The description of the first embodiment can be applied to other components in this embodiment.

[0159] Reference Fig.12 and Fig.13 , at least a portion of the intermediate layer 150 in the embodiment may be spaced apart by a predetermined distance D from at least one of the side surfaces of the body 100 (ie, the third surface 103 , the fourth surface 104 , the fifth surface 105 , and the sixth surface 106 ).

[0160] A region in which the intermediate layer 150 is spaced apart from the side surface of the body 100 may be filled with the same component as that in other regions of the body 100 , so that the region may have higher magnetic permeability than that of the intermediate layer 150 .

[0161] Therefore, in the coupling paths CF1 and CF2 where the magnetic flux density is relatively high and flows around both the first coil 200 and the second coil 300, the flow of the magnetic flux in the outer region can be smoothed, and thus the saturation current I of the coil component 3000 can be improved. sat characteristic.

[0162] Fourth embodiment

[0163] Fig.14 is a perspective view showing a coil component according to a fourth embodiment. Fig.15 is along Fig.14 A cross-sectional view taken along line IV-IV'.

[0164] Will Fig.14 and Figure 1 To compare and Fig.15 and Figure 3 For comparison, the difference is: Fig.14 and Fig.15 A through hole H is formed in the center of the intermediate layer 150 and an outer region of the intermediate layer 150 may be partially removed and may be spaced apart from the side surface of the body 100 .

[0165] Therefore, when describing the embodiment, only the through hole H and the outer region of the intermediate layer 150 that are different from the first embodiment will be described. The description of the first embodiment can be applied to other components in this embodiment.

[0166] Reference Fig.14 and Fig.15The intermediate layer 150 in the embodiment may include a through hole H formed along an area where the first core 110 and the second core 120 overlap each other in the first direction T, and at least a portion of the intermediate layer 150 may be spaced apart from at least one of the side surfaces of the body 100 (i.e., the third surface 103, the fourth surface 104, the fifth surface 105, and the sixth surface 106) by a predetermined distance D.

[0167] Regions of the intermediate layer 150 in which the through holes H are formed and regions spaced apart from the side surface of the body 100 may be filled with the same components as those in other regions of the body 100 so that these regions may have higher permeability than that of the intermediate layer 150 .

[0168] Therefore, the first core 110 and the second core 120 can be physically connected to each other in a part of the region through the through hole H, so that in the coupling paths CF1 and CF2 around the first coil 200 and the second coil 300, the flow of magnetic flux in the region between the first core 110 and the second core 120 can be smoothed, and the flow of magnetic flux can be smoothed in the outer region where the magnetic flux density is relatively high, so that the saturation current I of the coil component 4000 can be improved. sat characteristic.

[0169] Fifth embodiment and its modified examples

[0170] Fig.16 is a perspective view showing a coil component according to a fifth embodiment. Fig.17 yes Fig.16 An exploded perspective view of some components of the coil assembly shown in FIG. Fig.18 is along Fig.16 A cross-sectional view taken along line V-V'.

[0171] Will Figures 16 to 18 Respectively Figures 1 to 3 In comparison, in the coil component 5000 according to the embodiment, the shapes of the coils 200 and 300 provided in the body 100 may be different.

[0172] Therefore, when describing the embodiment, only the coils 200 and 300 that are different from the first embodiment will be described. The description of the first embodiment can be applied to other components in this embodiment.

[0173] Reference Figures 16 to 18 In the embodiment, the coils 200 and 300 forming turns may be formed as a plurality of layers in a length direction L-thickness direction T cross section.

[0174] The first coil 200 may include a first coil pattern 210 forming at least one turn and lead-out portions 230 and 230' at both ends of the first coil pattern 210. The first coil pattern 210 and the lead-out portions 230 and 230' may be integrated with each other, and thus, unlike the first to fourth embodiments, the first via 220 and the first connection pattern 240 may not be included.

[0175] In addition, the second coil 300 may include a second coil pattern 310 forming at least one turn and lead-out portions 330 and 330' at both ends of the second coil pattern 310. The second coil pattern 310 and the lead-out portions 330 and 330' may be integrated with each other, and thus, unlike the first to fourth embodiments, the second via 320 and the second connection pattern 340 may not be included.

[0176] The first coil 200 and the second coil 300 may have an aspect ratio less than 1, the aspect ratio indicating a ratio of line width to thickness on a section parallel to the first direction T (eg, length direction L-thickness direction T section), but embodiments are not limited thereto.

[0177] Fig.19 It is shown Fig.18 Schematic diagram of a modified example 5000'.

[0178] Reference Fig.19 In the coil component 5000' according to the modified example, the cross-section of the coil patterns 210 and 310 (e.g., the length direction L-thickness direction T cross-section) may have a rectangular shape, and the aspect ratio representing the ratio of the line width to the thickness on the cross-section parallel to the first direction T (e.g., the length direction L-thickness direction T cross-section) may be greater than 1, but the embodiments are not limited thereto.

[0179] Specifically, in the first coil pattern 210 and the second coil pattern 310 in the modified example, the pattern having a rectangular shape with a cross-sectional aspect ratio of 1 or more may form at least one turn around a winding axis parallel to the first direction T. As an example, the first coil pattern 210 and the second coil pattern 310 may include a first layer wound three turns from the outside to the inside and a second layer extending from the first layer and wound three turns from the inside to the outside, but embodiments are not limited thereto.

[0180] When the first coil pattern 210 and the second coil pattern 310 have the above-described shapes, the number of turns in a limited interval of the body 100 may be easily increased, thereby improving inductance capacity.

[0181] Fig. 20 It is shown Fig.18 5000" is a diagram of another modified example.

[0182] Reference Fig. 20According to the modified example of the coil component 5000", the first coil pattern 210 and the second coil pattern 310 can be formed into a circular shape in a cross section parallel to the first direction T (for example, a cross section from the length direction L to the thickness direction T). Therefore, the insulating film IF that insulates the surface of the first coil pattern 210 and the second coil pattern 310 can also be formed into a circular shape in a cross section parallel to the first direction T (for example, a cross section from the length direction L to the thickness direction T).

[0183] When the first coil pattern 210 and the second coil pattern 310 have the above-described shapes, the number of turns of the coil can be easily increased in the limited space of the body 100, thereby improving the inductance capacity. In addition, since the number of turns and the stretching direction of the first coil 200 and the second coil 300 have a high degree of design freedom, the coupling coefficient can be easily adjusted to a desired coupling coefficient.

[0184] According to the aforementioned embodiment, a desired coupling coefficient k can be achieved by providing an intermediate layer having a low magnetic permeability between two coils of a coupled inductor and adjusting the thickness and position of the intermediate layer.

[0185] According to another aspect of the present disclosure, by properly maintaining the spacing distance between the two coils in the coupled inductor, the saturation current I that occurs when the two coils are close together can be reduced. sat The degradation of characteristics or the increase in the fluctuation of the coupling coefficient k due to process errors.

[0186] While 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 body including an intermediate layer, the body having a first surface and a second surface opposite to each other in a first direction and a plurality of side surfaces connecting the first surface to the second surface; a first coil disposed in the body, and comprising a first coil pattern having at least one turn; a second coil disposed in the body and spaced apart from the first coil, and comprising a second coil pattern having at least one turn; a first external electrode and a second external electrode disposed on the body and connected to the first coil; as well as a third external electrode and a fourth external electrode, disposed on the body and connected to the second coil, The intermediate layer has a lower magnetic permeability than other regions of the body except the intermediate layer, the intermediate layer is disposed between the first coil and the second coil, and the intermediate layer is spaced apart from each of the first coil and the second coil.

2. The coil assembly according to claim 1, wherein: At least one of the first coil pattern and the second coil pattern is formed as a single layer.

3. The coil assembly according to claim 1, wherein: At least a portion of the intermediate layer extends to at least one of the plurality of side surfaces of the body.

4. The coil assembly according to claim 3, wherein: A coupling coefficient k between the first coil and the second coil is greater than or equal to 0.495 and less than or equal to 0.

605.

5. The coil assembly according to claim 4, wherein: The intermediate layer has a relative magnetic permeability of 3 or less.

6. The coil assembly according to claim 4, wherein: The relative magnetic permeability of the intermediate layer is 9, and the thickness of the intermediate layer in the first direction is 26 μm or less.

7. The coil assembly according to claim 4, wherein: The relative magnetic permeability of the intermediate layer is 18, and the thickness of the intermediate layer in the first direction is 10 μm or less.

8. The coil assembly according to claim 4, wherein: The relative magnetic permeability of the intermediate layer is 36, and the thickness of the intermediate layer in the first direction is 4 μm or less.

9. The coil assembly according to claim 3, in, The body further includes a first core filling a central area of ​​the first coil pattern and a second core filling a central area of ​​the second coil pattern, The intermediate layer includes through holes formed along a region where the first core and the second core overlap each other in the first direction.

10. The coil assembly according to claim 9, wherein: The first core and the second core each include a first region in which the first core and the second core overlap each other in the first direction and a second region in which the first core and the second core do not overlap each other in the first direction.

11. The coil assembly according to claim 1, wherein: At least a portion of the intermediate layer is spaced apart from the plurality of side surfaces of the body.

12. The coil assembly according to claim 11, in, The body further includes a first core filling a central area of ​​the first coil pattern and a second core filling a central area of ​​the second coil pattern, The intermediate layer includes through holes formed along a region where the first core and the second core overlap each other in the first direction.

13. The coil assembly according to claim 1, in, The first coil includes a first lead-out portion extending from the first coil pattern and connected to the first external electrode, a first connection pattern spaced apart from the first coil pattern and connected to the second external electrode, and a first via hole connecting an inner end of the first coil pattern to the first connection pattern. The second coil includes a second lead-out portion extending from the second coil pattern and connected to the third external electrode, a second connection pattern spaced apart from the second coil pattern and connected to the fourth external electrode, and a second via connecting an inner end of the second coil pattern to the second connection pattern.

14. The coil assembly according to claim 13, wherein: Each of the first via hole and the second via hole penetrates the middle layer.

15. The coil assembly according to claim 1, in, The body includes magnetic particles, and The filling rate of the magnetic particles in the intermediate layer is lower than the filling rate of the magnetic particles in the other regions of the main body.

16. The coil assembly according to claim 1, wherein: The other region of the body comprises two or more types of magnetic particles having different sizes of D50.

17. A coil assembly, comprising: a body including an intermediate layer, the body having a first surface and a second surface opposite to each other in a first direction and a plurality of side surfaces connecting the first surface to the second surface; a first coil disposed in the body, and comprising a first coil pattern having at least one turn and formed as a single layer; a second coil disposed in the body and spaced apart from the first coil, and comprising a second coil pattern having at least one turn and formed as a single layer; a first external electrode and a second external electrode disposed on the body and connected to the first coil; as well as a third external electrode and a fourth external electrode, disposed on the body and connected to the second coil, wherein the body includes an Fe-based alloy, and the Fe-based alloy included in the intermediate layer in the body and the Fe-based alloy included in other regions of the body except the intermediate layer have different compositions, and The intermediate layer is disposed between the first coil and the second coil, and the intermediate layer is spaced apart from each of the first coil and the second coil.

18. The coil assembly according to claim 17, wherein: The Fe content of the Fe-based alloy included in the intermediate layer is lower than the Fe content of the Fe-based alloy included in the other regions of the body.

19. The coil assembly according to claim 17, wherein: The Fe-based alloy included in the body is a Fe—Si-based alloy, and a Si content of the Fe—Si-based alloy included in the intermediate layer is lower than a Si content of the Fe—Si-based alloy included in the other regions of the body.

20. The coil assembly according to claim 19, wherein The Si content in the Fe-Si based alloy included in the intermediate layer is less than 6.5 wt %, and the Si content in the Fe-Si based alloy included in the other regions of the body is 6.5 wt % or more.

21. The coil assembly according to claim 20, wherein: The content of Si in the Fe-Si based alloy included in the intermediate layer is greater than or equal to 1 wt % and less than or equal to 5 wt %.

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