Coil component

Abstract

To enhance inductance of an embedded type coil component.SOLUTION: A coil component 100 includes conductor layers L1 to L6 which are embedded in a magnetic element assembly 110 and are stacked through an insulation resin layer 120. The conductor layers L1 to L6 have coil patterns, and first and second connection patterns, respectively. In the conductor layer L6, the outer peripheral end of the coil pattern 60 is connected to the connection pattern 62 through a lead-out pattern 63. In at least the one layer of the conductor layers L1 to L5, the magnetic element assembly 110 is arranged in separation regions D1 to D5 overlapped with the lead-out pattern 63 in plan view when being viewed from a stacking direction.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a coil component, and more particularly to a coil component having a structure in which a plurality of conductor layers laminated with insulating resin layers interposed therebetween are embedded in a magnetic body. [Background technology]

[0002] Patent Document 1 discloses a coil component having a structure in which multiple conductor layers are laminated with insulating resin layers interposed between them and embedded in a magnetic body, and each conductor layer includes a coil pattern and a pair of connection patterns exposed from the magnetic body. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-152043 A Summary of the Invention [Problem to be solved by the invention]

[0004] In order to increase the inductance of a coil component, it is effective to increase the volume of the magnetic body.

[0005] This disclosure describes a technology for increasing the inductance of a coil component having a structure in which multiple conductor layers stacked with insulating resin layers interposed between them are embedded in a magnetic body by increasing the volume of the magnetic body. [Means for solving the problem]

[0006] A coil component according to one aspect of the present disclosure includes a magnetic body having a mounting surface, and a plurality of conductor layers embedded in the magnetic body and stacked via insulating resin layers, each of the plurality of conductor layers including a coil pattern whose coil axis direction is parallel to the mounting surface, and first and second connection patterns exposed from the mounting surface of the magnetic body, the first connection patterns included in each of the plurality of conductor layers overlap each other in a planar view seen from the stacking direction, and the second connection patterns included in each of the plurality of conductor layers overlap each other in a planar view seen from the stacking direction, and the plurality of conductor layers include a first conductor layer located at one end in the stacking direction, a second conductor layer located at the other end in the stacking direction, and a first conductor layer and a second conductor layer. and one or more third conductor layers located between the first and second conductor layers, wherein in the first conductor layer, an outer peripheral end of the coil pattern is connected to the first connection pattern and the second connection pattern is separated from the coil pattern in-plane, in the second conductor layer, an outer peripheral end of the coil pattern is connected to the second connection pattern via an extension pattern and the first connection pattern is separated from the coil pattern in-plane, and in the third conductor layer, both the first and second connection patterns are separated from the coil pattern in-plane, and in at least one of the first and third conductor layers, a magnetic body is arranged in a separation region that overlaps with the extension pattern in a planar view seen from the stacking direction. Effect of the Invention

[0007] According to the present disclosure, a technology is provided for increasing the inductance of a coil component having a structure in which multiple conductor layers stacked with insulating resin layers interposed between them are embedded in a magnetic base body by increasing the volume of the magnetic base body. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic perspective view showing the appearance of a coil device 100 according to an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a schematic plan view for explaining the structure of the conductor layers L1 to L6. [Diagram 3]3(a) to 3(c) are schematic cross-sectional views taken along lines AA, BB and CC shown in FIG. 2, respectively. [Figure 4] FIG. 4 is a schematic perspective view showing the appearance of a coil device 100A according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, embodiments of the technology according to the present disclosure will be described in detail with reference to the accompanying drawings.

[0010] FIG. 1 is a schematic perspective view showing the appearance of a coil device 100 according to an embodiment of the present disclosure.

[0011] 1, the coil component 100 according to this embodiment includes a magnetic body 110 made of a composite material of a resin binder and a magnetic filler made of a metal magnetic material or the like, and a plurality of conductor layers L1-L6 embedded in the magnetic body 110 and laminated via an insulating resin layer 120. The conductor patterns provided on the conductor layers L1-L6 and the magnetic body 110 are insulated by the insulating resin layer 120. The conductor patterns provided on the conductor layers L1-L6 are made of a good conductor such as Cu (copper). The insulating resin layer 120 is made of a non-magnetic insulating resin.

[0012] The coil component 100 according to the present embodiment is an embedded coil component having a structure in which the insulating resin layer 120 and the conductor layers L1 to L6 are embedded in the magnetic base body 110, and has a different structure from a laminated coil component in which magnetic sheets made of ceramic or the like and coil patterns are laminated alternately. For example, in a laminated coil component, a magnetic sheet is interposed between coil patterns adjacent in the lamination direction, but in the coil component 100 according to the present embodiment, the coil patterns adjacent in the lamination direction are insulated by the insulating resin layer 120, and the magnetic base body 110 is not interposed between them. The structure is also different from a sheet coil of a type in which a coil pattern is formed on a printed circuit board.

[0013] The magnetic body 110 has surfaces 111 and 112 which form an XZ plane and are located opposite each other, surfaces 113 and 114 which form a YZ plane and are located opposite each other, and surfaces 115 and 116 which form an XY plane and are located opposite each other. Surface 111 forms a mounting surface which faces the surface of a circuit board during actual use. The Z direction is the lamination direction of the conductor layers L1 to L6. That is, in the coil component 100 according to this embodiment, the mounting surface is parallel to the lamination direction.

[0014] Fig. 2 is a schematic plan view for explaining the structure of the conductor layers L1 to L6, and Figs. 3(a) to 3(c) are schematic cross-sectional views taken along lines AA, BB, and CC shown in Fig. 2, respectively.

[0015] As shown in FIG. 2 and FIG. 3(a) to (c), the conductor layer L1 has a coil pattern 10 and connection patterns 11 and 12. A magnetic element 110 is disposed in an inner diameter region surrounded by the coil pattern 10 and an outer region located radially outward of the coil pattern 10, with an insulating resin layer 120 interposed therebetween. The coil pattern 10 winds about two turns, and adjacent turns are insulated by the insulating resin layer 120. The outer peripheral end of the coil pattern 10 is connected to the connection pattern 11. The connection pattern 12 is not connected to the coil pattern 10 within the plane, and is independent within the plane. The coil pattern 10 and the connection pattern 12 are separated not only by the insulating resin layer 120 but also by the magnetic element 110. A portion of the magnetic element 110 located on the conductor layer L1 that separates the coil pattern 10 and the connection pattern 12 constitutes a separation region D1.

[0016] The conductor layer L2 has a coil pattern 20 and connection patterns 21 and 22. A magnetic base body 110 is disposed in an inner diameter region surrounded by the coil pattern 20 and an outer region located radially outward of the coil pattern 20 via an insulating resin layer 120. The coil pattern 20 winds about two turns, and adjacent turns are insulated by the insulating resin layer 120. The inner peripheral end of the coil pattern 20 is connected to the inner peripheral end of the coil pattern 10 via a via hole 71 provided in the insulating resin layer 120. The connection patterns 21 and 22 are not connected to the coil pattern 20 in the plane, are independent in the plane, and are connected to the connection patterns 11 and 12 via via holes 81 and 91 provided in the insulating resin layer 120, respectively. The coil pattern 20 and the connection pattern 21 are separated by the insulating resin layer 120. In contrast, the coil pattern 20 and the connection pattern 22 are separated not only by the insulating resin layer 120 but also by the magnetic base body 110. Of the magnetic body 110 located on the conductor layer L2, the portion that separates the coil pattern 20 and the connection pattern 22 constitutes a separation region D2.

[0017] The conductor layer L3 has a coil pattern 30 and connection patterns 31 and 32. A magnetic base body 110 is disposed in an inner diameter region surrounded by the coil pattern 30 and an outer region located radially outward of the coil pattern 30, with an insulating resin layer 120 interposed therebetween. The coil pattern 30 winds about two turns, and adjacent turns are insulated by the insulating resin layer 120. The outer peripheral end of the coil pattern 30 is connected to the outer peripheral end of the coil pattern 20 through a via hole 72 provided in the insulating resin layer 120. The connection patterns 31 and 32 are not connected to the coil pattern 30 within the plane, are independent within the plane, and are connected to the connection patterns 21 and 22 through via holes 82 and 92 provided in the insulating resin layer 120, respectively. The coil pattern 30 and the connection pattern 31 are separated by the insulating resin layer 120. In contrast, the coil pattern 30 and the connection pattern 32 are separated not only by the insulating resin layer 120 but also by the magnetic base body 110. Of the magnetic body 110 located on the conductor layer L3, the portion that separates the coil pattern 30 and the connection pattern 32 constitutes a separation region D3.

[0018] The conductor layer L4 has a coil pattern 40 and connection patterns 41, 42. A magnetic element 110 is disposed in an inner diameter region surrounded by the coil pattern 40 and an outer region located radially outward of the coil pattern 40 via an insulating resin layer 120. The coil pattern 40 winds about two turns, and adjacent turns are insulated by the insulating resin layer 120. The inner peripheral end of the coil pattern 40 is connected to the inner peripheral end of the coil pattern 30 via a via hole 73 provided in the insulating resin layer 120. The connection patterns 41, 42 are not connected to the coil pattern 40 in the plane, are independent in the plane, and are connected to the connection patterns 31, 32 via via holes 83, 93 provided in the insulating resin layer 120, respectively. The coil pattern 40 and the connection pattern 41 are separated by the insulating resin layer 120. In contrast, the coil pattern 40 and the connection pattern 42 are separated not only by the insulating resin layer 120 but also by the magnetic element 110. The portion of the magnetic body 110 located on the conductor layer L4 that separates the coil pattern 40 and the connection pattern 42 constitutes a separation region D4.

[0019] The conductor layer L5 has a coil pattern 50 and connection patterns 51 and 52. A magnetic element 110 is disposed in an inner diameter region surrounded by the coil pattern 50 and an outer region located radially outward of the coil pattern 50 via an insulating resin layer 120. The coil pattern 50 winds about two turns, and adjacent turns are insulated by the insulating resin layer 120. The outer peripheral end of the coil pattern 50 is connected to the outer peripheral end of the coil pattern 40 via a via hole 74 provided in the insulating resin layer 120. The connection patterns 51 and 52 are not connected to the coil pattern 50 in the plane, are independent in the plane, and are connected to the connection patterns 41 and 42 via via holes 84 and 94 provided in the insulating resin layer 120, respectively. The coil pattern 50 and the connection pattern 51 are separated by the insulating resin layer 120. In contrast, the coil pattern 50 and the connection pattern 52 are separated not only by the insulating resin layer 120 but also by the magnetic element 110. Of the magnetic body 110 located on the conductor layer L5, the portion that separates the coil pattern 50 and the connection pattern 52 constitutes a separation region D5.

[0020] The conductor layer L6 has a coil pattern 60 and connection patterns 61 and 62. In the inner diameter region surrounded by the coil pattern 60 and the outer region located radially outward of the coil pattern 60, the magnetic element 110 is disposed via the insulating resin layer 120. The coil pattern 60 winds about 1.5 turns, and adjacent turns are insulated by the insulating resin layer 120. The outer peripheral end of the coil pattern 60 is connected to the connection pattern 62 via the lead pattern 63. The inner peripheral end of the coil pattern 60 is connected to the inner peripheral end of the coil pattern 50 via a via hole 75 provided in the insulating resin layer 120. The connection pattern 61 is not connected to the coil pattern 60 within the plane, and is independent within the plane. The connection patterns 61 and 62 are connected to the connection patterns 51 and 52 via via holes 85 and 95 provided in the insulating resin layer 120, respectively. The coil pattern 60 and the connection pattern 61 are separated not only by the insulating resin layer 120 but also by the magnetic element 110.

[0021] 1, the connection patterns 11, 21, 31, 41, 51, and 61 overlap each other in a plan view seen from the Z direction, and are all exposed from two surfaces, 111 and 113, of the magnetic body 110, to form one terminal electrode of the coil component 100 according to this embodiment. Also, the connection patterns 12, 22, 32, 42, 52, and 62 overlap each other in a plan view seen from the Z direction, and are all exposed from two surfaces, 111 and 114, of the magnetic body 110, to form the other terminal electrode of the coil component 100 according to this embodiment.

[0022] The lead pattern 63 of the coil pattern 60 located on the conductor layer L6 is a portion located near the outer circumferential end of the coil pattern 60, and extends in the -Y direction away from the turns located on the inner circumferential side. In other words, the lead pattern 63 is a portion of the coil pattern 60 that is sandwiched by the magnetic body 110 from both sides in the width direction (X direction) with the insulating resin layer 120 interposed therebetween.

[0023] The extension pattern 63 overlaps with the separation regions D1 to D5 located on the conductor layers L1 to L5 in plan view seen from the Z direction, which is the lamination direction. This increases the volume of the magnetic body 110 located on the conductor layers L1 to L5, making it possible to obtain high inductance, compared to a case in which the separation regions D1 to D5 are embedded in a conductor pattern or an insulating resin layer 120. Furthermore, the increased volume of the magnetic body 110 also reduces leakage magnetic flux.

[0024] When actually manufacturing the coil component 100 according to this embodiment, the insulating resin layers 120 and the conductor layers L1 to L6 are alternately laminated in this order, and then the magnetic body 110 is filled into the space not containing the insulating resin layers 120 and the conductor layers L1 to L6 to complete the coil component 100. In this case, the conductor layer L5 located below the extension pattern 63 requires some kind of base for forming the extension pattern 63, but by forming a sacrificial pattern in the portion corresponding to the separation regions D1 to D5, which is to be removed before filling with the magnetic body 110, this sacrificial pattern can be used as the base.

[0025] Furthermore, when a composite material made of a magnetic filler and a resin binder is used as the material for the magnetic body 110, it is preferable to use a blend of multiple types of magnetic fillers with different particle size distributions. This makes it possible to efficiently fill the narrow separation regions D1 to D5 with small-diameter magnetic fillers. As a result, the average particle size of the magnetic fillers filled in the separation regions D1 to D5 is smaller than the average particle size of the magnetic fillers filled in other regions of the magnetic body 110, making it difficult for voids to occur in the separation regions D1 to D5.

[0026] As described above, in the coil component 100 of this embodiment, the coil pattern 60 located on the top layer is connected to the connection pattern 62 via the draw-out pattern 63, and the magnetic base body 110 is arranged in the separation regions D1 to D5 that overlap with the draw-out pattern 63 in a planar view. This increases the volume of the magnetic base body 110, and as a result, makes it possible to obtain a high inductance.

[0027] The above describes embodiments of the technology related to the present disclosure. However, the technology related to the present disclosure is not limited to the above embodiments, and various modifications are possible without departing from the spirit of the technology, and it goes without saying that these modifications are also included within the scope of the technology related to the present disclosure.

[0028] For example, in the above embodiment, the magnetic body 110 is disposed in all of the separation regions D1 to D5, but this is not essential to the present invention, and it is sufficient that the magnetic body 110 is disposed in at least one of the separation regions D1 to D5.

[0029] Furthermore, in the above embodiment, six conductor layers L1 to L6 are laminated, but the number of conductor layers is not particularly limited, and a four-layer structure may be used, for example.

[0030] Furthermore, in the above embodiment, the connection patterns 11, 21, 31, 41, 51, 61 exposed from the surface of the magnetic body 110 are used as one terminal electrode, and the connection patterns 12, 22, 32, 42, 52, 62 exposed from the surface of the magnetic body 110 are used as the other terminal electrode, but as in a coil component 100A according to a modification shown in Fig. 4, a terminal electrode 131 in contact with the connection patterns 11, 21, 31, 41, 51, 61 may be provided on the surface 111 of the magnetic body 110, and a terminal electrode 132 in contact with the connection patterns 12, 22, 32, 42, 52, 62 may be provided. This allows the terminal electrodes 131, 132 to have any shape.

[0031] The technology according to the present disclosure includes the following configuration examples, but is not limited to these.

[0032] A coil component according to one aspect of the present disclosure includes a magnetic body having a mounting surface, and a plurality of conductor layers embedded in the magnetic body and stacked via insulating resin layers, each of the plurality of conductor layers including a coil pattern whose coil axis direction is parallel to the mounting surface, and first and second connection patterns exposed from the mounting surface of the magnetic body, the first connection patterns included in each of the plurality of conductor layers overlap each other in a planar view seen from the stacking direction, and the second connection patterns included in each of the plurality of conductor layers overlap each other in a planar view seen from the stacking direction, and the plurality of conductor layers include a first conductor layer located at one end in the stacking direction, a second conductor layer located at the other end in the stacking direction, and a first conductor layer and a second conductor layer. and one or more third conductor layers located between the first and second conductor layers, wherein in the first conductor layer, an outer peripheral end of the coil pattern is connected to the first connection pattern and the second connection pattern is separated from the coil pattern in the plane, in the second conductor layer, an outer peripheral end of the coil pattern is connected to the second connection pattern via an extension pattern and the first connection pattern is separated from the coil pattern in the plane, and in the third conductor layer, both the first and second connection patterns are separated from the coil pattern in the plane, and in at least one of the first and third conductor layers, a magnetic element is arranged in a separation region that overlaps with the extension pattern in a plan view seen from the stacking direction. This increases inductance by the magnetic element arranged in the separation region.

[0033] In the coil component, a magnetic body may be disposed in both of the isolation regions located in the first and third conductor layers, thereby making it possible to increase the volume of the magnetic body.

[0034] In the coil component, the magnetic body is made of a composite magnetic material containing a magnetic filler and a binder resin, and the average particle size of the magnetic filler located in the separation region may be smaller than the average particle size of the magnetic filler located in other regions of the magnetic body, which makes it difficult for voids to occur in the separation region.

[0035] The coil component may further include a first terminal electrode in contact with the first connection pattern exposed from the mounting surface, and a second terminal electrode in contact with the second connection pattern exposed from the mounting surface, which allows the first and second terminal electrodes to have any shape. [Explanation of symbols]

[0036] 10,20,30,40,50,60 coil patterns 11,12,21,22,31,32,41,42,51,52,61,62 Connection patterns 63 Drawer Pattern 71~75,81~85,91~95 Beer Hall 100,100A coil parts 110 Magnetic element 111~116 Surface of magnetic body 120 Insulating resin layer 131,132 Terminal electrode D1~D5 Separation area L1~L6 conductor layer

Claims

1. a magnetic body having a mounting surface; A plurality of conductor layers embedded in the magnetic body and laminated with insulating resin layers interposed therebetween; Equipped with each of the plurality of conductor layers includes a coil pattern whose coil axis direction is parallel to the mounting surface, and first and second connection patterns exposed from the mounting surface of the magnetic body; the first connection patterns included in each of the plurality of conductor layers overlap each other in a plan view seen from a stacking direction, the second connection patterns included in each of the plurality of conductor layers overlap each other in a plan view seen from the stacking direction, the plurality of conductor layers include a first conductor layer located at one end in the stacking direction, a second conductor layer located at the other end in the stacking direction, and one or more third conductor layers located between the first conductor layer and the second conductor layer; In the first conductor layer, an outer peripheral end of the coil pattern is connected to the first connection pattern, and the second connection pattern is separated from the coil pattern in a plane, In the second conductor layer, an outer peripheral end of the coil pattern is connected to the second connection pattern via an extraction pattern, and the first connection pattern is separated from the coil pattern in a plane, In the third conductor layer, the first and second connection patterns are both separated from the coil pattern in a plane, In at least one of the first and third conductor layers, the magnetic body is disposed in an isolation region overlapping with the lead pattern in a plan view seen from the stacking direction. Coil parts.

2. the magnetic element is disposed in each of the isolation regions located in the first and third conductor layers; The coil component according to claim 1 .

3. the magnetic body is made of a composite magnetic material containing a magnetic filler and a binder resin; the average particle size of the magnetic filler located in the separation region is smaller than the average particle size of the magnetic filler located in other regions of the magnetic body; The coil component according to claim 1 .

4. a first terminal electrode in contact with the first connection pattern exposed from the mounting surface; a second terminal electrode in contact with the second connection pattern exposed from the mounting surface, The coil component according to claim 1 .

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