Coil components
The coil component with embedded conductor layers and insulating resin prevents magnetic filler detachment by ensuring structural integrity and reliability even with enlarged coil patterns.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TDK CORP
- Filing Date
- 2025-01-10
- Publication Date
- 2026-07-23
Smart Images
Figure 2026121075000001_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a coil component, and particularly to a coil component having a structure in which a coil pattern is embedded in a magnetic element body.
Background Art
[0002] Patent Document 1 discloses a coil component having a structure in which a coil pattern is embedded in a magnetic element body.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In this type of coil component, when the outer diameter size of the coil pattern is increased while maintaining the size of the magnetic element body, a thin portion occurs in the magnetic element body, and there is a problem that the magnetic filler contained in the magnetic element body is likely to drop off in this portion.
[0005] The present disclosure describes a technique for suppressing the dropout of magnetic filler even when the outer diameter size of the coil pattern is increased in a coil component having a structure in which a coil pattern is embedded in a magnetic element body.
Means for Solving the Problems
[0006] A coil component according to one aspect of this disclosure comprises a magnetic element having a mounting surface, a top surface located opposite the mounting surface, and first and second sides perpendicular to the mounting surface and the top surface and located opposite each other; a coil portion consisting of a plurality of conductor layers embedded in the magnetic element and laminated in a stacking direction parallel to the mounting surface, the top surface, and the first and second sides; and an insulating resin located between the magnetic element and the coil portion. The plurality of conductor layers include a first conductor layer, a second conductor layer, and one or more third conductor layers located between the first and second conductor layers. The first conductor layer includes a first coil pattern whose outer peripheral end exposed from the mounting surface constitutes one end of the coil portion, and a first terminal pattern exposed from the mounting surface. The second conductor layer includes a second coil pattern whose outer peripheral end exposed from the mounting surface constitutes the other end of the coil portion, and a second terminal pattern exposed from the mounting surface. The third conductor layer includes a third coil pattern, one end of which is connected to one end of the coil portion via the first coil pattern and the other end of which is connected to the other end of the coil portion via the second coil pattern, and third and fourth terminal patterns exposed from the mounting surface. The insulating resin includes a first exposed portion exposed from the region located between the outer periphery of the first coil pattern, the second terminal pattern, and the third terminal pattern, and the outer periphery of the second coil pattern, the first terminal pattern, and the fourth terminal pattern on the mounting surface, a second exposed portion exposed from the top surface, a third exposed portion exposed from the first side surface, and a fourth exposed portion exposed from the second side surface. [Effects of the Invention]
[0007] According to this disclosure, in a coil component having a structure in which a coil pattern is embedded in a magnetic element, it is possible to suppress the detachment of the magnetic filler even when the outer diameter size of the coil pattern is increased. [Brief explanation of the drawing]
[0008] [Figure 1] Figures 1(a) and 1(b) are schematic perspective views showing the appearance of a coil component 100 according to one embodiment of the technology described herein, and depict the state as viewed from different directions. [Figure 2]Figure 2 is a schematic perspective view showing the coil component 100 with the terminal electrodes 121 and 122 removed. [Figure 3] Figure 3 is a schematic cross-sectional view illustrating the structure of the conductor layer L1 in the coil component 100. [Figure 4] Figure 4 is a schematic cross-sectional view illustrating the structure of the conductor layer L2 in the coil component 100. [Figure 5] Figure 5 is a schematic cross-sectional view illustrating the structure of the conductor layer L3 in the coil component 100. [Figure 6] Figure 6 is a schematic cross-sectional view illustrating the structure of the conductor layer L4 in the coil component 100. [Figure 7] Figure 7 is a schematic cross-sectional view illustrating the structure of the conductor layer L5 in the coil component 100. [Figure 8] Figure 8 is a schematic cross-sectional view illustrating the structure of the conductor layer L6 in the coil component 100. [Figure 9] Figure 9 is a schematic perspective view of coil component 100A in a modified form. [Figure 10] Figure 10 is a schematic cross-sectional view illustrating the structure of the conductor layer L1 in the coil component 100A. [Figure 11] Figure 11 is a schematic cross-sectional view illustrating the structure of the conductor layer L2 in coil component 100A. [Figure 12] Figure 12 is a schematic cross-sectional view illustrating the structure of the conductor layer L3 in coil component 100A. [Figure 13] Figure 13 is a schematic cross-sectional view illustrating the structure of the conductor layer L4 in coil component 100A. [Figure 14] Figure 14 is a schematic cross-sectional view illustrating the structure of the conductor layer L5 in coil component 100A. [Figure 15] Figure 15 is a schematic cross-sectional view illustrating the structure of the conductor layer L6 in coil component 100A. [Modes for carrying out the invention]
[0009] Hereinafter, embodiments of the technology according to the present disclosure will be described in detail with reference to the accompanying drawings.
[0010] FIGS. 1(a) and (b) are schematic perspective views showing the appearance of the coil component 100 according to an embodiment of the technology according to the present disclosure, and show states viewed from different directions.
[0011] As shown in FIGS. 1(a) and (b), the coil component 100 according to the present embodiment includes a magnetic element 110 and a pair of terminal electrodes 121 and 122 provided on the mounting surface 111 of the magnetic element 110. As will be described later, a coil portion composed of conductor layers L1 to L6 is embedded in the magnetic element 110, one end of the coil portion is connected to the terminal electrode 121, and the other end of the coil portion is connected to the terminal electrode 122.
[0012] The magnetic element 110 may be made of a composite magnetic material in which a magnetic filler made of a high magnetic permeability material such as ferrite or permalloy is hardened with a resin binder. In order to further increase the inductance of the coil component 100, it is advantageous to use a magnetic filler having a large diameter. The magnetic element 110 has a mounting surface 111 and an upper surface 112 that form the XZ plane and are located on opposite sides, side surfaces 113 and 114 that form the YZ plane and are located on opposite sides, and side surfaces 115 and 116 that form the XY plane and are located on opposite sides. Therefore, the mounting surface 111 and the upper surface 112, the side surfaces 113 and 114, and the side surfaces 115 and 116 are orthogonal to each other.
[0013] The terminal electrode 121 is provided at the end of the mounting surface 111 in the -X direction. The terminal electrode 122 is provided at the end of the mounting surface 111 in the +X direction. The width of the terminal electrodes 121 and 122 in the Z direction may be the same as the width of the mounting surface 111 in the Z direction. Also, a part of the terminal electrode 121 may extend around the side surfaces 115 and 116 of the magnetic element 110, or may extend around the side surface 113 of the magnetic element
[0014] FIG. 2 is a schematic perspective view showing a state in which the terminal electrodes 121 and 122 are removed from the coil component 100.
[0015] As shown in FIG. 2, from the mounting surface 111 of the magnetic element 110, the outer peripheral end 10A of the coil pattern located in the conductor layer L1 and the terminal patterns 21, 31, 41, 51, 61 located in the conductor layers L2 to L6 are exposed. The outer peripheral end 10A of the coil pattern and the terminal patterns 21, 31, 41, 51, 61 are arranged in the Z direction on the mounting surface 111. The terminal electrode 121 is provided so as to contact the outer peripheral end 10A of the coil pattern and the terminal patterns 21, 31, 41, 51, 61. Further, from the mounting surface 111 of the magnetic element 110, the terminal patterns 12, 22, 32, 42, 52 located in the conductor layers L1 to L5 and the outer peripheral end 60A of the coil pattern located in the conductor layer L6 are exposed. The terminal patterns 12, 22, 32, 42, 52 and the outer peripheral end 60A of the coil pattern are arranged in the Z direction on the mounting surface 111. The terminal electrode 122 is provided so as to contact the terminal patterns 12, 22, 32, 42, 52 and the outer peripheral end 60A of the coil pattern.
[0016] An exposed portion 131 of the insulating resin is exposed from the region located between the outer peripheral end 10A of the coil pattern and the terminal patterns 21, 31, 41, 51, 61 and the terminal patterns 12, 22, 32, 42, 52 and the outer peripheral end 60A of the coil pattern. Similarly, an exposed portion 132 of the insulating resin is exposed from the upper surface 112, an exposed portion 133 of the insulating resin is exposed from the side surface 113, and an exposed portion 134 of the insulating resin is exposed from the side surface 114.
[0017] In the examples shown in FIGS. 1(a) and 1(b), the exposed portion 131 is located at a substantially central portion in the X direction of the mounting surface 111. Similarly, the exposed portion 132 is located at a substantially central portion in the X direction of the upper surface 112, the exposed portion 133 is located at a substantially central portion in the Y direction of the side surface 113, and the exposed portion 134 is located at a substantially central portion in the Y direction of the side surface 114.
[0018] As shown in Figure 1(a), the terminal electrodes 121 and 122 may have regions 121a and 122a that cover the exposed portion 131. When the terminal electrodes 121 and 122 have regions 121a and 122a that cover the exposed portion 131, the area of the terminal electrodes 121 and 122 is increased, thereby improving mounting reliability when the coil component 100 is mounted on the circuit board using solder or the like. The width of regions 121a and 122a in the Z direction may be the same as the width of the exposed portion 131 in the Z direction, or it may be larger than the width of the exposed portion 131 in the Z direction, so that a part of regions 121a and 122a covers the mounting surface 111 of the magnetic element 110. In the latter case, the boundary between the mounting surface 111 of the magnetic element 110 and the exposed portion 131 of the insulating resin is covered by the regions 121a and 122a of the terminal electrodes 121 and 122, thereby suppressing the shedding of magnetic filler particles in this portion. Such regions 121a and 122a may be formed by flowing paste-like terminal electrodes 121 and 122 onto the exposed portion 131. The flow width of the terminal electrodes 121 and 122 onto the exposed portion 131 can be adjusted by the surface roughness of the exposed portion 131, and the smaller the surface roughness of the exposed portion 131, the larger the flow. The surface roughness of the exposed portion 131 may be smaller than the surface roughness of the magnetic element 110.
[0019] The coil component 100 according to this embodiment has a configuration in which six conductive layers L1 to L6 constituting the coil portion are embedded in a magnetic element 110. These conductive layers L1 to L6 are stacked in the Z direction, which is the stacking direction parallel to the mounting surface 111.
[0020] Figures 3 to 8 are schematic cross-sectional views illustrating the structure of the conductor layers L1 to L6, respectively.
[0021] The conductor layer L1 is a conductor layer located at the end in the -Z direction and is formed first during manufacturing. In the example shown in Figure 3, the conductor layer L1 includes a coil pattern 10 that makes approximately two turns and a terminal pattern 12 that is provided separately from the coil pattern 10 in the plane. The outer peripheral end 10A of the coil pattern 10 and the terminal pattern 12 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductor layer L1 and the magnetic element 110, thereby preventing contact between the conductor layer L1 and the magnetic element 110. The insulating resin 130 may be made of a material in which an inorganic filler made of an insulating material such as silica is solidified with a resin binder.
[0022] The conductor layer L2 is the second conductor layer from the edge in the -Z direction, and is formed after the conductor layer L1 via the insulating resin 130 during manufacturing. In the example shown in Figure 4, the conductor layer L2 includes a coil pattern 20 that makes approximately two turns and terminal patterns 21 and 22 that are provided separately from the coil pattern 20 in the plane. The inner circumferential end of the coil pattern 20 is connected to the inner circumferential end of the coil pattern 10 located in the conductor layer L1 via vias provided in the insulating resin 130. The terminal patterns 21 and 22 are connected to the outer circumferential end 10A and terminal pattern 12 of the coil pattern 10, respectively, via vias provided in the insulating resin 130. The terminal patterns 21 and 22 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductive layer L2 and the magnetic element 110, and between the conductive layer L1 and the conductive layer L2. This separates the conductive layer L2 and the conductive layer L1, and prevents contact between the conductive layer L2 and the magnetic element 110.
[0023] Conductor layer L3 is the third conductor layer from the edge in the -Z direction, and is formed after conductor layer L2 via the insulating resin 130 during manufacturing. In the example shown in Figure 5, conductor layer L3 includes a coil pattern 30 that makes approximately two turns and terminal patterns 31 and 32 that are provided separately from the coil pattern 30 in the plane. The outer peripheral end of the coil pattern 30 is connected to the outer peripheral end of the coil pattern 20 located in conductor layer L2 via vias provided in the insulating resin 130. Terminal patterns 31 and 32 are connected to terminal patterns 21 and 22 of conductor layer L2, respectively, via vias provided in the insulating resin 130. Terminal patterns 31 and 32 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductive layer L3 and the magnetic element 110, and between the conductive layer L2 and the conductive layer L3. This separates the conductive layer L3 and the conductive layer L2, and prevents contact between the conductive layer L3 and the magnetic element 110.
[0024] Conductor layer L4 is the fourth conductor layer from the edge in the -Z direction, and is formed after conductor layer L3 via the insulating resin 130 during manufacturing. In the example shown in Figure 6, conductor layer L4 includes a coil pattern 40 that makes approximately two turns and terminal patterns 41 and 42 that are provided separately from the coil pattern 40 in the plane. The inner circumferential end of the coil pattern 40 is connected to the inner circumferential end of the coil pattern 30 located in conductor layer L3 via vias provided in the insulating resin 130. Terminal patterns 41 and 42 are connected to terminal patterns 31 and 32 of conductor layer L3, respectively, via vias provided in the insulating resin 130. Terminal patterns 41 and 42 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductive layer L4 and the magnetic element 110, and between the conductive layer L3 and the conductive layer L4. This separates the conductive layer L4 and the conductive layer L3, and prevents contact between the conductive layer L4 and the magnetic element 110.
[0025] The conductor layer L5 is the fifth conductor layer from the edge in the -Z direction, and during manufacturing, it is formed after the conductor layer L4 via the insulating resin 130. In the example shown in Figure 7, the conductor layer L5 includes a coil pattern 50 that makes approximately two turns and terminal patterns 51 and 52 that are provided separately from the coil pattern 50 in the plane. The outer peripheral end of the coil pattern 50 is connected to the outer peripheral end of the coil pattern 40 located in the conductor layer L4 via vias provided in the insulating resin 130. The terminal patterns 51 and 52 are connected to the terminal patterns 41 and 42 of the conductor layer L4, respectively, via vias provided in the insulating resin 130. The terminal patterns 51 and 52 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductive layer L5 and the magnetic element 110, and between the conductive layer L4 and the conductive layer L5. This separates the conductive layer L5 and the conductive layer L4, and prevents contact between the conductive layer L5 and the magnetic element 110.
[0026] The conductor layer L6 is a conductor layer located at the end in the +Z direction, and during manufacturing, it is formed after the conductor layer L5 via the insulating resin 130. In the example shown in Figure 8, the conductor layer L6 includes a coil pattern 60 that makes approximately two turns and a terminal pattern 61 that is provided separately from the coil pattern 60 in the plane. The inner circumferential end of the coil pattern 60 is connected to the inner circumferential end of the coil pattern 50 located in the conductor layer L5 via vias provided in the insulating resin 130. The outer circumferential ends 60A of the terminal pattern 61 and the coil pattern 60 are connected to the terminal patterns 51 and 52 of the conductor layer L5, respectively, via vias provided in the insulating resin 130. The outer circumferential ends 60A of the terminal pattern 61 and the coil pattern 60 are exposed from the mounting surface 111 of the magnetic element 110. An insulating resin 130 is provided between the conductive layer L6 and the magnetic element 110, and between the conductive layer L5 and the conductive layer L6. This separates the conductive layer L6 and the conductive layer L5, and prevents contact between the conductive layer L6 and the magnetic element 110.
[0027] In this configuration, six coil patterns 10, 20, 30, 40, 50, and 60 are connected in series inside the magnetic element 110 to form a coil section. One end of coil pattern 10, outer edge 10A, is connected to terminal electrode 121, and the other end, outer edge 60A of coil pattern 60, is connected to terminal electrode 122. For coil patterns 20, 30, 40, and 50 located in conductor layers L2 to L5, one end is connected to terminal electrode 121 via coil pattern 10, and the other end is connected to terminal electrode 122 via coil pattern 60.
[0028] As shown in Figures 3 to 8, a portion of the insulating resin 130 constitutes an exposed portion 131 exposed from the mounting surface 111 of the magnetic element 110, an exposed portion 132 exposed from the upper surface 112 of the magnetic element 110, an exposed portion 133 exposed from the side surface 113 of the magnetic element 110, and an exposed portion 134 exposed from the side surface 114 of the magnetic element 110. As a result, in the plane shown in Figures 3 to 8, the magnetic element 110 is divided into five regions 110A to 110E. Region 110A is located in the region surrounded by coil patterns 10, 20, 30, 40, 50, and 60. Region 110B constitutes the mounting surface 111 and side surface 113 of the magnetic element 110. Region 110C constitutes the mounting surface 111 and side surface 114 of the magnetic element 110. Region 110D constitutes the upper surface 112 and side surface 113 of the magnetic element 110. Region 110E constitutes the upper surface 112 and side surface 114 of the magnetic element 110.
[0029] In the planes shown in Figures 3 to 8, the exposed portion 131 of the insulating resin 130 is located between the outer peripheral edge 10A of the coil pattern 10 and the terminal patterns 21, 31, 41, 51, 61, and the outer peripheral edge 60A of the terminal patterns 12, 22, 32, 42, 52 and the coil pattern 60. Also in the planes shown in Figures 3 to 8, the exposed portion 132 of the insulating resin 130 is located between regions 110D and 110E of the magnetic element 110, the exposed portion 133 of the insulating resin 130 is located between regions 110B and 110D of the magnetic element 110, and the exposed portion 134 of the insulating resin 130 is located between regions 110C and 110E of the magnetic element 110.
[0030] The exposed portion 131 of the insulating resin 130 encompasses the region where the distance in the Y direction between the coil patterns 10, 20, 30, 40, 50, 60 and the mounting surface 111 of the magnetic element 110 is shortest. The exposed portion 132 of the insulating resin 130 encompasses the region where the distance in the Y direction between the coil patterns 10, 20, 30, 40, 50, 60 and the upper surface 112 of the magnetic element 110 is shortest. The exposed portion 133 of the insulating resin 130 encompasses the region where the distance in the X direction between the coil patterns 10, 20, 30, 40, 50, 60 and the side surface 113 of the magnetic element 110 is shortest. The exposed portion 134 of the insulating resin 130 encompasses the region where the distance in the X direction between the coil patterns 10, 20, 30, 40, 50, 60 and the side surface 114 of the magnetic element 110 is shortest. Since these areas are thin, placing magnetic elements 110 in these areas would make it easy for magnetic fillers, especially those with a large diameter, to fall off. However, in this embodiment, since these areas are composed of exposed portions 131-134 of the insulating resin 130, even if the outer diameter size of the coil patterns 10, 20, 30, 40, 50, and 60 is large, magnetic filler detachment is less likely to occur.
[0031] Here, if we let W1 be the width of the exposed portion 131 in the X direction and W2 be the width of the exposed portion 132 in the X direction, W1>W2 This is acceptable. On the mounting surface 111 side of the magnetic element 110, not only the outer edges 10A of the coil pattern 10 and the outer edges 60A of the coil pattern 60 are exposed, but also the terminal patterns 12, 21, 22, 31, 32, 41, 42, 51, 52, and 61. Therefore, if the magnetic element 110 is placed between the outer edges 10A of the coil pattern 10 and the terminal patterns 21, 31, 41, 51, and 61, and the terminal patterns 12, 22, 32, 42, 52 and the outer edges 60A of the coil pattern 60, there is a risk that the magnetic filler may fall off in this area. Taking this into consideration, the width W1 in the X direction of the exposed portion 131 exposed on the mounting surface 111 of the magnetic element 110 may be set to be sufficiently large. The exposed portion 131 also has the effect of increasing the dielectric strength between the outer peripheral edge 10A of the coil pattern 10 and the terminal patterns 21, 31, 41, 51, 61, and the terminal patterns 12, 22, 32, 42, 52 and the outer peripheral edge 60A of the coil pattern 60. In contrast, since the coil pattern and terminal patterns are not exposed from the upper surface 112 side of the magnetic element 110, the width W2 of the exposed portion 132 in the X direction may be smaller than the width W1 of the exposed portion 131 in the X direction.
[0032] Furthermore, if the width of the exposed portion 133 in the Y direction is W3 and the width of the exposed portion 134 in the Y direction is W4, W2 > W3, and W2 > W4 That's fine, W3=W4 It may be so. In the present embodiment, since the outer diameters of the coil patterns 10, 20, 30, 40, 50, 60 have an elliptical shape in which the size in the X direction is larger than the size in the Y direction, among the coil patterns 10, 20, 30, 40, 50, 60, the curvature of the section S3 extending along the side surface 113 and the section S4 extending along the side surface 114 is smaller than the curvature of the section S1 extending along the mounting surface 111 and the section S2 extending along the upper surface 112. As a result, the length in the X direction of the region where the distance in the Y direction between the coil patterns 10, 20, 30, 40, 50, 60 and the upper surface 112 of the magnetic element 110 is short and the magnetic filler is likely to fall off is longer than the length in the Y direction of the region where the distance in the X direction between the coil patterns 10, 20, 30, 40, 50, 60 and the side surfaces 113, 114 of the magnetic element 110 is short and the magnetic filler is likely to fall off. Considering this point, the width W2 of the exposed portion 132 in the X direction may be set to be larger than each of the widths W3, W4 of the exposed portions 133, 134 in the Y direction.
[0033] Also, when the thickness of the exposed portion 131 in the Y direction is T1, the thickness of the exposed portion 132 in the Y direction is T2, the thickness of the exposed portion 133 in the X direction is T3, and the thickness of the exposed portion 134 in the X direction is T4, T1 < T3, T1 < T4, T2 < T3, and T2 < T4 This is acceptable. The thickness T1 to T4 decreases as the outer diameter size of the coil patterns 10, 20, 30, 40, 50, and 60 increases. Generally, parameters such as the inductance and DC superposition characteristics of the coil component 100 improve as the outer diameter size of the coil patterns 10, 20, 30, 40, 50, and 60 increases. However, if the outer diameter size of the coil patterns 10, 20, 30, 40, 50, and 60 is too large, the volume of region 110B to 110E of the magnetic element 110 becomes smaller than the volume of region 110A of the magnetic element 110, which can result in a decrease in inductance, for example. Taking this into consideration, by making the thicknesses T3 and T4 of the exposed parts 133 and 134, which have smaller widths W3 and W4 in the Y direction, larger than the thicknesses T1 and T2 of the exposed parts 131 and 132, which have larger widths W1 and W2 in the X direction, the outer diameter size of the coil patterns 10, 20, 30, 40, 50, and 60 can be increased while ensuring sufficient volume in the magnetic element region 110B to 110E. This makes it possible to set parameters such as the inductance and DC superposition characteristics of the coil component 100 to favorable values.
[0034] Furthermore, the heights of the exposed parts 131 to 134 in the Z direction may be the same.
[0035] Figure 9 is a schematic perspective view of coil component 100A in a modified form.
[0036] As shown in Figure 9, the modified coil component 100A differs from the coil component 100 in the above embodiment in that the center position in the X direction of the exposed portion 132 of the insulating resin 130 is offset to the -X direction side (side surface 113 side) rather than to the center position in the X direction of the upper surface 112 of the magnetic element 110. Since the other basic configurations are the same as those of the coil component 100 in the above embodiment, the same reference numerals are used for the same elements, and redundant explanations are omitted.
[0037] Figures 10 to 15 are schematic cross-sectional views illustrating the structure of the conductor layers L1 to L6 in the modified coil component 100A. As shown in Figures 10 to 15, in the modified coil component 100A, the width W2a in the X direction of the exposed portion 132 of the insulating resin 130 is wider than the width W2, and is offset towards the side surface 113.
[0038] As shown in the modified coil component 100A, by offsetting the exposed portion 132 of the insulating resin 130, the exposed portion 132 of the insulating resin 130 can be used as a directional mark.
[0039] While embodiments of the technology described herein have been explained above, it goes without saying that the technology described herein is not limited to the embodiments described above, and various modifications are possible without departing from its spirit, and these modifications are also included within the scope of the technology described herein.
[0040] For example, the coil component 100 according to the above embodiment has a configuration in which six conductor layers L1 to L6 are embedded in a magnetic element 110, but the number of layers of conductor layers embedded in the magnetic element is not limited to this.
[0041] The technology relating to this disclosure includes, but is not limited to, the following configuration examples.
[0042] A coil component according to one aspect of this disclosure comprises a magnetic element having a mounting surface, a top surface located opposite the mounting surface, and first and second sides perpendicular to the mounting surface and the top surface and located opposite each other; a coil portion consisting of a plurality of conductor layers embedded in the magnetic element and laminated in a stacking direction parallel to the mounting surface, the top surface, and the first and second sides; and an insulating resin located between the magnetic element and the coil portion. The plurality of conductor layers include a first conductor layer, a second conductor layer, and one or more third conductor layers located between the first and second conductor layers. The first conductor layer includes a first coil pattern whose outer peripheral end exposed from the mounting surface constitutes one end of the coil portion, and a first terminal pattern exposed from the mounting surface. The second conductor layer includes a second coil pattern whose outer peripheral end exposed from the mounting surface constitutes the other end of the coil portion, and a second terminal pattern exposed from the mounting surface. The third conductor layer includes a third coil pattern, one end of which is connected to one end of the coil section via the first coil pattern and the other end of which is connected to the other end of the coil section via the second coil pattern, and third and fourth terminal patterns exposed from the mounting surface. The insulating resin includes a first exposed portion exposed from the region located between the outer periphery of the first coil pattern, the second terminal pattern, and the third terminal pattern, and the outer periphery of the second coil pattern, the first terminal pattern, and the fourth terminal pattern on the mounting surface, a second exposed portion exposed from the top surface, a third exposed portion exposed from the first side surface, and a fourth exposed portion exposed from the second side surface. This makes it less likely for magnetic fillers contained in the magnetic material to fall off, even when the outer diameter size of the first to third coil patterns is designed to be large.
[0043] In the above coil component, the first exposed portion may include the region where the distance between the first, second, and third coil patterns and the mounting surface is shortest, the second exposed portion may include the region where the distance between the first, second, and third coil patterns and the top surface is shortest, the third exposed portion may include the region where the distance between the first, second, and third coil patterns and the first side surface is shortest, and the fourth exposed portion may include the region where the distance between the first, second, and third coil patterns and the second side surface is shortest. This makes it less likely for the magnetic filler contained in the magnetic element to fall off.
[0044] In the above coil component, the exposed width of the first exposed portion along the first direction perpendicular to the first and second side surfaces may be greater than the exposed width of the second exposed portion along the first direction. This makes it possible to suppress the detachment of the magnetic filler from the mounting surface side.
[0045] In the above coil component, the first, second, and third coil patterns include a first section extending along the top surface, a second section extending along the first side surface, and a third section extending along the second side surface, wherein the curvature of the first section is greater than the curvature of the second and third sections, and the exposed width of the second exposed portion along the first direction may be greater than the exposed width of the third exposed portion along the second direction perpendicular to the mounting surface and the top surface, as well as the exposed width of the fourth exposed portion along the second direction. This makes it possible to suppress the detachment of magnetic filler from the top side, where detachment of magnetic filler is more likely to occur.
[0046] In the above coil component, the thickness of the second exposed portion in the second direction may be thinner than the thicknesses of the third and fourth exposed portions in the first direction. This makes it possible to secure the volume of the magnetic element while suppressing the shedding of the magnetic filler.
[0047] In the above coil component, the second exposed portion may be offset to the first side. This makes it possible to use the second exposed portion as a directional mark.
[0048] The above coil component may further include a first terminal electrode provided on the mounting surface so as to contact the outer edge of the first coil pattern, the second terminal pattern, and the third terminal pattern, and a second terminal electrode provided on the mounting surface so as to contact the outer edge of the second coil pattern, the first terminal pattern, and the fourth terminal pattern. This makes surface mounting to a circuit board easier.
[0049] In the above-described coil component, parts of the first and second terminal electrodes may cover the first exposed portion. This increases the area of the first and second terminal electrodes. [Explanation of Symbols]
[0050] 10, 20, 30, 40, 50, 60 coil patterns 10A,60A outer edge Terminal patterns 12, 21, 22, 31, 32, 41, 42, 51, 52, 61 100, 100A coil components 110 Magnetic element 110A~110E area 111 Implementation aspects 112 Top surface 113-116 Side view 121,122 terminal electrode 121a,122a area 130 Insulating resin 131~134 Exposed part L1~L6 conductor layer Sections S1 to S4 T1~T4 Thickness W1~W4, W2a width
Claims
1. A magnetic element having a mounting surface, an upper surface located opposite to the mounting surface, and first and second side surfaces perpendicular to the mounting surface and the upper surface and located opposite to each other, A coil portion comprising a plurality of conductor layers embedded in the magnetic element and stacked in a stacking direction parallel to the mounting surface, the upper surface, and the first and second side surfaces, An insulating resin located between the magnetic element and the coil portion, Equipped with, The plurality of conductor layers include a first conductor layer, a second conductor layer, and one or more third conductor layers located between the first conductor layer and the second conductor layer. The first conductor layer includes a first coil pattern whose outer peripheral edge exposed from the mounting surface constitutes one end of the coil portion, and a first terminal pattern exposed from the mounting surface. The second conductor layer includes a second coil pattern whose outer peripheral end exposed from the mounting surface constitutes the other end of the coil portion, and a second terminal pattern exposed from the mounting surface. The third conductor layer includes a third coil pattern, one end of which is connected to the one end of the coil portion via the first coil pattern, and the other end of which is connected to the other end of the coil portion via the second coil pattern, and third and fourth terminal patterns exposed from the mounting surface. The insulating resin includes, on the mounting surface, a first exposed portion exposed from the region located between the outer peripheral end of the first coil pattern, the second terminal pattern, and the third terminal pattern, and the outer peripheral end of the second coil pattern, the first terminal pattern, and the fourth terminal pattern; a second exposed portion exposed from the upper surface; a third exposed portion exposed from the first side surface; and a fourth exposed portion exposed from the second side surface. Coil components.
2. The first exposed portion includes the region where the distance between the first, second, and third coil patterns and the mounting surface is shortest. The second exposed portion includes the region where the distance between the first, second and third coil patterns and the upper surface is shortest. The third exposed portion includes the region where the distance between the first, second and third coil patterns and the first side surface is shortest. The fourth exposed portion includes the region where the distance between the first, second, and third coil patterns and the second side surface is shortest. The coil component according to claim 1.
3. The exposed width of the first exposed portion along the first direction perpendicular to the first and second side surfaces is greater than the exposed width of the second exposed portion along the first direction. The coil component according to claim 2.
4. The first, second, and third coil patterns include a first section extending along the upper surface, a second section extending along the first side surface, and a third section extending along the second side surface. The curvature of the first section is greater than the curvature of the second and third sections. The exposed width of the second exposed portion along the first direction is greater than the exposed width of the third exposed portion along the second direction perpendicular to the mounting surface and the upper surface, and the exposed width of the fourth exposed portion along the second direction. The coil component according to claim 3.
5. The thickness of the second exposed portion in the second direction is thinner than the thicknesses of the third and fourth exposed portions in the first direction. The coil component according to claim 4.
6. The second exposed portion is positioned offset to the first side side, The coil component according to claim 1.
7. A first terminal electrode is provided on the mounting surface so as to be in contact with the outer peripheral end of the first coil pattern, the second terminal pattern, and the third terminal pattern, A second terminal electrode is provided on the mounting surface so as to be in contact with the outer peripheral end of the second coil pattern, the first terminal pattern, and the fourth terminal pattern, Furthermore, A coil component according to any one of claims 1 to 6.
8. A portion of the first and second terminal electrodes covers the first exposed portion. The coil component according to claim 7.