This application claims benefit of priority to Korean Patent Application No. 10-2015-0107021 filed on Jul. 29, 2015, and Korean Patent Application No. 10-2016-0035328 filed on Mar. 24, 2016 in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference in their entireties.
1. Field
The present disclosure relates to a coil component and a method of manufacturing the same.
2. Description of Related Art
In accordance with the miniaturization and thinning of electronic devices such as digital televisions (TV), mobile phones, laptop computers, and the like, coil components used in such electronic devices correspondingly need to be miniaturized and thinned. In order to demand for such components, research into and development of various winding type or thin film type coil components have been actively conducted.
As part of the miniaturization and the thinning of coil components, miniaturized and thinned coil components need to provide characteristics equal to the characteristics of existing coil components in spite of the miniaturization and the thinning. In order to satisfy this demand, a core in which a magnetic material is filled and which has a low direct current (DC) resistance Rdc having a sufficient size needs to be secured. To achieve this end, coil components having coil patterns with increased aspect ratios and coil parts having increased cross-sectional areas have been developed using, for example, an anisotropic plating technology.
However, when coil components are manufactured using the anisotropic plating technology in a limited space due to the requirements for miniaturization and thinning, the risks of defects are increased including defects resulting from a decrease in uniformity of plating growth, the occurrence of short-circuits between coil parts, and the like, due to an increase in an aspect ratio.
An aspect of the present disclosure provides a coil component in which a risk of occurrence of a defect, such as a short-circuit or the like, may be decreased and uniformity of coils and a low direct current (DC) resistance Rdc may be secured. A method of manufacturing the same provides similar advantages.
One of several solutions presented includes increasing the number of coil turns or windings in a stacking direction of a plurality of stacked coil layers by stably forming the plurality of coil layers using insulating layers on a support member.
According to an aspect of the present disclosure, a coil component may include a body part containing a magnetic material, a coil part disposed in the body part, and an electrode part disposed on the body part. The coil part includes a support member, a first coil layer disposed on at least one surface of the support member, a first insulating layer stacked on at least one surface of the support member and covering the first coil layer, and a second coil layer disposed on the first insulating layer. The first and second coil layers are electrically connected to each other, and the second coil layer has a larger number of coil turns than the first coil layer.
According to another aspect of the present disclosure, a method of manufacturing a coil component may include forming a coil part, forming a body part accommodating the coil part therein, and forming an electrode part on the body part. The coil part is formed by forming a first coil layer on at least one surface of a support member by plating, stacking a first insulating layer on at least one surface of the support member so as to cover the first coil layer, and forming a second coil layer on the first insulating layer by plating. The first and second coil layers are electrically connected to each other, and the second coil layer has a larger number of coil turns than the first coil layer.
According to a further aspect of the present disclosure, a coil component includes a body part containing a magnetic material, a coil part disposed in the body part, and an electrode part disposed on the body part. The coil part includes a support member, a first coil layer disposed on one surface of the support member, a first insulating layer stacked on the one surface of the support member and covering the first coil layer, and a second coil layer disposed on the first insulating layer. The first and second coil layers are electrically connected to each other, and a conductor of the first coil layer has an aspect ratio h1/w1 less than 1 where a thickness h1 is measured orthogonally to the one surface of the support member on which the first coil layer is disposed and a width w1 is measured parallel to the one surface of the support member.
The above and other aspects, features, and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
Hereinafter, embodiments of the present disclosure will be described as follows with reference to the attached drawings.
The present disclosure may, however, be exemplified in many different forms and should not be construed as being limited to the specific embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
Throughout the specification, it will be understood that when an element, such as a layer, region or wafer (substrate), is referred to as being “on,” “connected to,” or “coupled to” another element, it can be directly “on,” “connected to,” or “coupled to” the other element or other elements intervening therebetween may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element, there may be no elements or layers intervening therebetween. Like numerals refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be apparent that though the terms first, second, third, etc. may be used herein to describe various members, components, regions, layers, and/or sections, these members, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one member, component, region, layer, or section from another member, component, region, layer, or section. Thus, a first member, component, region, layer, or section discussed below could be termed a second member, component, region, layer, or section without departing from the teachings of the exemplary embodiments.
Spatially relative terms, such as “above,” “upper,” “below,” “lower,” and the like, may be used herein for ease of description to describe one element's positional relationship relative to one or more other elements as shown in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “above” or “upper” relative to other elements would then be oriented “below” or “lower” relative to the other elements or features. Thus, the term “above” can encompass both the above and below orientations depending on a particular direction of the devices, elements, or figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may be interpreted accordingly.
The terminology used herein is for describing particular illustrative embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, members, elements, and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, members, elements, and/or groups.
Hereinafter, embodiments of the present disclosure will be described with reference to schematic views illustrating embodiments. In the drawings, components having ideal shapes are shown. However, variations from these ideal shapes, for example due to variability in manufacturing techniques and/or tolerances, also fall within the scope of the disclosure. Thus, embodiments of the present disclosure should not be construed as being limited to the particular shapes of regions shown herein, but should more generally be understood to include changes in shape resulting from manufacturing methods and processes. The following embodiments may also be constituted by one or a combination thereof.
The present disclosure describes a variety of configurations, and only illustrative configurations are shown herein. However, the disclosure is not limited to the particular illustrative configurations presented herein, but extends to other similar/analogous configurations as well.
Electronic Device
Referring to
In detail, the power inductors 1 may be used to store electricity in magnetic field form to maintain an output voltage, thereby stabilizing power. In addition, the high frequency (HF) inductors 2 may be used to perform impedance matching to secure a required frequency or cut off noise and an alternating current (AC) component. Further, the general beads 3 may be used to remove noise of power and signal lines or remove a high frequency ripple. Further, the beads 4 for high frequency (e.g., GHz) applications may be used to remove high frequency noise of a signal line and a power line related to an audio. Further, the common mode filters 5 may be used to pass a current therethrough in a differential mode and remove only common mode noise.
A representative example of the electronic device may be a smart phone, but is not limited thereto. The electronic device may also be, for example, a personal digital assistant, a digital video camera, a digital still camera, a network system, a computer, a monitor, a television, a video game, a smart watch, or the like. The electronic device may also be various other electronic devices in addition to the devices described above.
Coil Component
Hereinafter, a coil component according to the present disclosure, particularly an inductor, will be described for convenience of explanation. However, the coil component may alternatively take the form of any of the other coil components described above.
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The body part 100 may form an exterior of the coil component 10A. The body part 100 may have first and second surfaces opposing each other in a first direction, third and fourth surfaces opposing each other in a second direction, and fifth and sixth surfaces opposing each other in a third direction. The body part 100 may have an approximately hexahedral shape, but is not limited thereto. Six corners at which the first to sixth surfaces meet each other may be rounded by grinding, or the like. The body part 100 may contain a magnetic material having magnetic properties. For example, the body part 100 may be formed by mixing ferritic and/or magnetic metal particles in a resin. The ferrite may be a material such as Mn—Zn based ferrite, Ni—Zn based ferrite, Ni—Zn—Cu based ferrite, Mn—Mg based ferrite, Ba based ferrite, Li based ferrite, or the like. The magnetic metal particles may contain one or more selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), aluminum (Al), and nickel (Ni). For example, the magnetic metal particles may be Fe—Si—B—Cr based amorphous metal particles, but are not necessarily limited thereto. The magnetic metal particles may have diameters of about 0.1 μm to 30 μm. The body part 100 may have a form in which the ferrites and/or the magnetic metal particles are dispersed in a thermosetting resin such as an epoxy resin, a polyimide resin, or the like. A thickness T of the body part 100 (and other dimensions of the body part 100) may be changed depending on characteristics of an electronic device in which the coil component is used, and may be approximately 500 μm to 900 μm, but is not limited thereto.
The coil part 200 may perform various functions in the electronic device through a property appearing in a coil of the coil component 10A. For example, the coil component 10A may be a power inductor. In this case, the coil part 200 may serve to store electricity in a magnetic field form to maintain an output voltage, thereby stabilizing power. The plurality of coil layers 211, 212, 221, and 222 respectively stacked on surfaces of the support member 230 may be electrically connected to each other through a via 234 penetrating through the support member 230. The coil layers 211 and 221 disposed in the inner portion among the plurality of coil layers 211, 212, 221, and 222 and the coil layers 212 and 222 disposed in the outer portion among the plurality of coil layers 211, 212, 221, and 222 may be electrically connected to each other through vias 214 and 224 penetrating through the insulating layers 213 and 223 disposed between the coil layers 211 and 221 and the coil layers 212 and 222. As a result, the plurality of coil layers 211, 212, 221, and 222 may be electrically connected to each other to form a single coil. A through-hole 105 may be formed in a central portion of the coil part 200. The through-hole 105 may be filled with the magnetic material constituting the body part 100. The coil part 200 may include the first coil layers 211 and 221 formed on respective opposing surfaces of the support member 230, that is, stacked in the inner portion, and the second coil layers 212 and 222 formed on the insulating layers 213 and 223, that is, stacked in the outer portion on top of and below the first coil layers 211 and 221, respectively. The insulating layers 213 and 223 may be disposed between the first coil layers 211 and 221 and the second coil layers 212 and 222, respectively. The second coil layers 212 and 222 may be covered by insulating films 215 and 225, respectively.
Cross sections of the conductors of the coil patterns of the first coil layers 211 and 221 may have an aspect ratio (AR), which is a ratio (h1/w1) of a thickness h1 to a width w1, less than 1 (where h1 is measured orthogonally to the opposing surfaces of the support member 230 on which the first coil layers 211 and 221 are disposed, and w1 is measured parallel to the opposing surfaces). Cross sections of the conductors of the coil patterns of the second coil layers 212 and 222 may have an aspect ratio (AR), which is a ratio (h2/w2) of a thickness h2 to a width w2, exceeding 1 (where h2 is measured orthogonally to the opposing surfaces of the support member 230 on which the first coil layers 211 and 221 are disposed, and w2 is measured parallel to the opposing surfaces). That is, in the coil component 10A according to an example, the aspect ratios of the cross sections of the conductors of the coil patterns of the first coil layers 211 and 221 and the second coil layers 212 and 222 may be different from each other. For example, the conductors of the coil patterns of the first coil layers 211 and 221 may have a width w1 of about 160 μm to 190 μm and a thickness h1 of about 60 μm to 90 μm, and the conductors of the coil patterns of the second coil layers 212 and 222 may have a width w2 of about 60 μm to 90 μm and a thickness h2 of about 90 μm to 120 μm.
Meanwhile, direct current (DC) resistance Rdc characteristics, among main characteristics of the coil component such as the inductor, may be reduced as a cross-sectional area of the coil part 200 is increased. In addition, an inductance may become large as an area of a magnetic region in the body part 100 through which a magnetic flux passes is increased. Therefore, in order to decrease the DC resistance Rdc and increase the inductance, the cross-sectional area of the coil part 200 needs to be increased and the area of the magnetic region needs to be increased. As a method of increasing the cross-sectional area of the coil part 200, there are a method of increasing widths (e.g., w1 and w2) of the conductors of the coil patterns and a method of increasing thicknesses (e.g., h1 and h2) of the conductors of the coil patterns. However, in a case of simply increasing the width of the conductors of the coil patterns, there is a risk that short-circuits between adjacent coil patterns will occur. In addition, a limitation is generated in the number of turns of coil patterns that may be implemented, and an area occupied by the magnetic region is decreased, such that efficiency is decreased, and a limitation is also generated in implementing a high inductance product. In order to overcome these limitations, implementation of a coil pattern conductor having a high aspect ratio obtained by increasing a thickness of the coil pattern conductor without increasing a width of the coil pattern conductor has been demanded.
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On the other hand, in a case in which the aspect ratio of the conductors of the coil patterns of the first coil layers 211 and 221 is less than 1 as in the coil component 10A according to an example, a height and a width of the coil patterns may be freely adjusted within a dispersion allowed by a process technology used for forming the coil patterns, such that uniformity of the coil pattern conductors may be excellent, and the coil pattern conductors are wide in the width direction, such that the cross-sectional area of the conductors of the coil part is increased, whereby low DC resistance Rdc characteristics may be implemented. In addition, in a case in which the aspect ratio of the coil pattern conductors of the second coil layers 212 and 222 exceeds 1, the coil patterns of the second coil layers 212 and 222 may each have a number of turns (or windings) higher than that of the coil patterns of the first coil layers 211 and 221 on the same plane. That is, the cross-sectional area of the conductor forming each winding of the coil part is decreased, but the number of turns (or windings) may be further increased, which is particularly useful for implementing a high inductance.
In addition, in the coil component 10A according to an example, the aspect ratios of the coil pattern conductors of the first coil layers 211 and 221 may be less than 1, such that thicknesses of the coil pattern conductors of the first coil layers 211 and 221 may be basically thin, and the aspect ratios of the coil pattern conductors of the second coil layers 212 and 222 may exceed 1, but line widths themselves of the coil pattern conductors of the second coil layers 212 and 222 may be thinly implemented, such that widths of the coil pattern conductors of the second coil layers 212 and 222 may not be very thick. In addition, in order to have a sufficient number of turns (or windings), the respective coil layers 211, 221, 212, and 222 may be formed to utilize spaces as much as possible in horizontal directions, that is, a first direction and/or a second direction (e.g., directions parallel to the opposing surfaces of the support member 230 on which the first coil layers 211 and 221 are disposed). That is, the first coil layers 211 and 221 and the second coil layers 212 and 222 stacked in a vertical direction may have overlapped regions. Therefore, a coil component that is thin and has sufficient coil characteristics may be implemented.
The coil pattern conductors of the first coil layers 211 and 221 may have the aspect ratio, which is the ratio (h1/w1) of the thickness h1 to the width w1, less than 1, as described above. In addition, the number of turns (or windings) of the coil patterns of the first coil layers 211 and 221 may be one. Here, the meaning that the number of turns is one is that the number of turns is 1 or less (e.g., an incomplete turn). On the other hand, the coil pattern conductors of the second coil layers 212 and 222 may have the aspect ratio, which is the ratio (h2/w2) of the thickness h2 to the width w2, exceeding 1, as described above. In addition, the number of turns (or windings) of the coil patterns of the second coil layers 212 and 222 may be plural. Here, the meaning that the number of turns is plural is that the number of turns exceeds 1. Therefore, as described above, the cross-sectional area of the coil part is decreased, but the number of turns may be further increased, which is particularly useful for implementing the high inductance.
When the number of turns of the coil patterns of the first coil layers 211 and 221 is x and the number of turns of the coil patterns of the second coil layers 212 and 222 is y, a ratio (y/x) of y to x may be 2 or more. For example, the ratio (y/x) of y to x may be about 2 to 3 (or within the range of 2 to 3). In this case, disadvantages of the isotropic plating technology and the anisotropic plating technology may be countered, and the number of turns may be increased, such that a higher degree of inductance may be implemented.
Only the first coil layers 211 and 221 and the second coil layers 212 and 222 are illustrated in the drawings, but additional coil layers may be further formed on (e.g., stacked on and/or below) the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the second coil layers 212 and 222, such that the additional coil layers and the second coil layers 212 and 222 may be electrically connected to each other. In this case, the same contents or materials as the first coil layers 211 and 221 or the second coil layers 212 and 222 may be applied to the additional coil layers. In addition, additional coil layers may be further formed between the first coil layers 211 and 221 and the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222, such that the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222 may be electrically connected to each other. In this case, the same contents or materials as the first coil layers 211 and 221 or the second coil layers 212 and 222 may also be applied to the additional coil layers.
A material or a kind of the support member 230 is not particularly limited as long as the support member 230 may support the plurality of coil layers 211, 212, 221, and 222. For example, the support member 230 may be a copper clad laminate (CCL), a polypropylene glycol (PPG) substrate, a ferrite substrate, a metal based soft magnetic substrate, or the like. In addition, the support member 230 may be an insulating substrate formed of an insulating resin. The insulating resin may be a thermosetting resin such as an epoxy resin, a thermoplastic resin such as a polyimide resin, a resin having a reinforcing material such as a glass fiber or an inorganic filler impregnated in the thermosetting resin and the thermoplastic resin, such as pre-preg, Ajinomoto Build up Film (ABF), FR-4, a Bismaleimide Triazine (BT) resin, a photo-imageable dielectric (PID) resin, or the like. An insulating substrate containing a glass fiber and an epoxy resin may be used in terms of maintenance of rigidity, but is not limited thereto. A thickness T of the support member 230 (e.g., the smallest dimension of the support member 230) may be 80 μm or less, preferably 60 μm or less, more preferably, 40 μm or less, but is not limited thereto.
When a thickness of the support member 230 is H and a thickness of the body part 100 is T, a ratio (H/T) of H to T may be 0.15 or less, for example, about 0.05 to 0.10. In a case in which a ratio occupied by the thickness of the support member 230 in the body part 100 exceeds 0.15, thicknesses of magnetic materials disposed in upper and lower portion of the coil part 200 may become comparatively thin, which may cause a decrease in an inductance. In addition, as the thickness of the support member 230 is increased, a thickness of the via 234 formed in the support member 230 and extending through the support member 230 is increased, such that a current path between the plurality of coil layers 211, 212, 221, and 222 stacked on opposing surfaces of the support member 230 is increased. As a result, an inductance, a DC resistance Rdc, and the like, may be decreased. However, in order to maintain rigidity, it may be disadvantageous that the thickness of the support member 230 is excessively thin.
A shape or a material of the via 234 penetrating through the support member 230 is not particularly limited as long as the via 234 may electrically connect the first coil layers 211 and 221 disposed on opposing surfaces of the support member 230. That is, the first coil layer 211 may be disposed in the upper surface or portion of the support member 230 and the first coil layer 221 may be disposed in the lower surface or portion of the support member 230, and the first coil layers 211 and 221 may be electrically connected to each other by the via 234. Here, the upper portion and the lower portion are decided in relation to a third direction as indicated in the drawings. The via 234 may have any of a variety of different shapes. For example, the via 234 may have any shape, such as a taper shape of which a diameter is reduced or increased from an upper surface toward a lower surface, a cylindrical shape of which a diameter is substantially constant from an upper surface toward a lower surface, an hourglass shape, and the like. In addition, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, or the like, may be used as a material of the via 234.
The insulating layers 213 and 223 may serve to insulate the first coil layers 211 and 221 and the second coil layers 212 and 222 from each other, respectively. The insulating layers 213 and 223 may be a build-up film containing an insulating material. For example, a thermosetting resin such as an epoxy resin, a thermoplastic resin such as a polyimide resin, a resin having a reinforcing material such as an inorganic filler impregnated in the thermosetting resin and the thermoplastic resin, such as ABF, or the like, may be used as the insulating layers 213 and 223. Alternatively, the insulating layers 213 and 223 may be an insulating film containing a photo-imageable dielectric (PID) resin. The insulating layers 213 and 223 may have a thickness greater than that of the first coil layers 211 and 221 to be sufficient to insulate the first coil layers 211 and 221 from the second coil layers 212 and 222 while covering the first coil layers 211 and 221, respectively. An insulation distance between the first coil layers 211 and 221 and the second coil layers 212 and 222 by the insulating layers 213 and 223 may be, for example, about 3 μm to 20 μm, but is not limited thereto.
Shapes or materials of the vias 214 and 224 penetrating through the insulating layers 213 and 223 are not particularly limited as long as the vias 214 and 224 may respectively electrically connect the first coil layers 211 and 221 and the second coil layers 212 and 222 to each other. The vias 214 and 224 may have any of a variety of different shapes. For example, the vias 214 and 224 may have any shape, such as the taper shape, the cylindrical shape, and the like, as described above. In addition, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, or the like, may be used as the materials of the vias 214 and 224. A thickness (e.g., measured in the third direction) of the insulating layers 213 and 223 may be generally thinner than that of the support member 230.
The insulating films 215 and 225 may serve to protect the second coil layers 212 and 222, respectively. Any material containing an insulating material may be used as materials of the insulating films 215 and 225. Materials of the insulating films 215 and 225 may be an insulating material used for general insulation coating, for example, an epoxy resin, a polyimide resin, a liquid crystalline polymer resin, or the like, or may be a photo-imageable dielectric (PID) resin, or the like, but are not limited thereto. The insulating films 215 and 225 may be integrated with the insulating layers 213 and 223, respectively, depending on a manufacturing method, but are not limited thereto.
The electrode part 300 may include first and second external electrodes 301 and 302 disposed on the body part 100 so as to be spaced apart from each other and each electrically connected to a lead terminal of a respective one of the second coil layers 212 and 222. The external electrodes 301 and 302 may serve to electrically connect the coil part 200 in the coil component 10A to the electronic device when the coil component 10A is mounted in the electronic device. The external electrodes 301 and 302 may include, for example, conductive resin layers and plating layers formed on the conductive resin layers. The conductive resin layer may contain one or more conductive metal(s) selected from the group consisting of copper (Cu), nickel (Ni), and silver (Ag), and a thermosetting resin. The plating layer may contain one or more selected from the group consisting of nickel (Ni), copper (Cu), and tin (Sn). For example, a nickel (Ni) layer and a tin (Sn) layer may be sequentially formed in the plating layer.
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When the support member 230 is used, the plurality of coil parts 200 may be simultaneously formed, and the plurality of body parts 100 may be simultaneously formed using the plurality of coil parts 200. Then, a plurality of coil components may be simultaneously manufactured by a singulation process such as a dicing process, or the like. That is, the process of manufacturing the coil component described above may be advantageous in mass production. The plurality of coil parts 200 may be formed using one surface or two opposing surfaces of the support member 230. In a case in which the plurality of coil parts 200 are formed using two opposing surfaces of the support member 230, the vias 234 may be formed by forming through-holes penetrating through the support member 230 by a method such as mechanical drilling, laser drilling, or the like, and then filling the through-holes by plating. A more detailed description for a method of forming the coil part 200 will be provided below.
The plurality of body parts 100 may be formed by stacking, compressing, and hardening the magnetic sheets on and beneath the plurality of coil parts 200 after the plurality of coil parts 200 are formed. The magnetic sheets may contain the magnetic material as described above, and may be manufactured in a sheet shape by mixing magnetic metal particles, a binder resin, a solvent, and the like, with each other to prepare slurry and applying and then drying the slurry at a thickness of several ten micrometers (e.g., 10, 20, 50, or 90 micrometers) on a carrier film by a doctor blade method.
The electrode part 300 may be formed by forming the external electrodes 301 and 302 on the outer surfaces of the body part 100 so as to be connected to a respective lead cross section of the coil part 200 exposed to respective surfaces of the body part 100. The external electrodes 301 and 302 may be formed of a paste containing a metal having excellent electrical conductivity, for example, a conductive paste containing nickel (Ni), copper (Cu), tin (Sn), or silver (Ag), or alloys thereof, or the like In addition, the external electrodes 301 and 302 may further include a plating layer formed on the paste layer. The plating layer may contain one or more selected from the group consisting of nickel (Ni), copper (Cu), and tin (Sn). For example, a nickel (Ni) layer and a tin (Sn) layer may be sequentially formed in the plating layer.
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Cross sections of the conductors of the coil patterns of the first coil layers 211 and 221 may have an aspect ratio (AR), which is a ratio (h1/w1) of a thickness h1 to a width w1, less than 1 (where h1 is measured orthogonally to the opposing surfaces of the support member 230 on which the first coil layers 211 and 221 are disposed, and w1 is measured parallel to the opposing surfaces). Cross sections of the conductors of the coil patterns of the second coil layers 212 and 222 may also have an aspect ratio (AR), which is a ratio (h2/w2) of a thickness h2 to a width w2, less than 1 (where h2 is measured orthogonally to the opposing surfaces of the support member 230 on which the first coil layers 211 and 221 are disposed, and w2 is measured parallel to the opposing surfaces). That is, in the coil component 10B according to another example, coil pattern conductors of the coil layers 211, 212, 221, and 222 may have an aspect ratio less than 1. For example, the coil pattern conductors of the first coil layers 211 and 221 may have a width w1 of about 160 μm to 190 μm and a thickness h1 of about 60 μm to 90 μm, and the coil pattern conductors of the second coil layers 212 and 222 may have a width w2 of about 160 μm to 190 μm and a thickness h2 of about 60 μm to 90 μm.
In a case in which the aspect ratios of the coil pattern conductors of the coil layers 211, 212, 221, and 222 are less than 1, a height and a width of the coil patterns may be freely adjusted within a dispersion allowed by a process technology of forming coil patterns such that uniformity of the coil patterns may be excellent. Additionally, the coil pattern conductors are wide in the width direction such that a cross-sectional area of the coil part is increased, whereby low DC resistance Rdc characteristics may be provided. In addition, since an interval between the coil pattern turns or windings does not need to be forcibly adjusted, the probability of occurrence of a defect such as short-circuits between the coil patterns, or the like, may be decreased. In addition, since the coil layers 211, 212, 221, and 222 may have the same rotation direction and may be electrically connected to each other through the vias 214, 224, and 234, the number of turns (or windings) of the coils in a stacking direction may be increased. Here, the stacking direction refers to the third direction in the drawings.
In addition, since the aspect ratios of all the coil pattern conductors of the coil layers 211, 212, 221, and 222 are less than 1, a thickness of the coil part (measured orthogonally to the opposing surfaces of the support member 230 on which the coil layers 211 and 221 are disposed) may be basically thin. Here, in order to have a sufficient number of turns (or windings) in the coil component 10B, the respective coil layers 211, 221, 212, and 222 may be formed to utilize spaces as much as possible in the horizontal directions, that is in the first direction and/or the second direction (e.g., directions parallel to the opposing surfaces of the support member 230 on which the coil layers 211 and 221 are disposed). That is, the first coil layers 211 and 221 and the second coil layers 212 and 222 stacked in the vertical direction may have overlapped regions. Therefore, a coil component that is thin and has sufficient coil characteristics may be implemented.
Conductors of the coil patterns of the first coil layers 211 and 221 may have an aspect ratio (AR), which is a ratio (h1/w1) of a thickness h1 to a width w1, less than 1. In addition, the coil patterns of the first coil layers 211 and 221 may each include only a single turn (or winding). Here, the single turn (or winding) may indicate that the number of turns (or windings) is 1 or less. Therefore, a risk of occurrence of a defect such as short-circuits between the coil patterns, or the like, may be decreased, and uniformity of coils and a low DC resistance Rdc may be provided. A conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, or the like, may be used as materials of the first coil layers 211 and 221.
Conductors of the coil patterns of the second coil layers 212 and 222 may also have an aspect ratio (AR), which is a ratio (h2/w2) of a thickness h2 to a width w2, less than 1. In addition, the coil patterns of the second coil layers 212 and 222 may each include only a single turn (or winding). Here, the single turn (or winding) may indicate that the number of turns (or windings) is 1 or less. Therefore, a risk of occurrence of a defect such as short-circuits between the coil patterns, or the like, may be decreased, and uniformity of coils and a low DC resistance Rdc may be provided. A conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, or the like, may be used as materials of the second coil layers 212 and 222.
Only the first coil layers 211 and 221 and the second coil layers 212 and 222 are illustrated in the drawings, but additional coil layers may be additionally formed on the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the second coil layers 212 and 222, such that the additional coil layers and the second coil layers 212 and 222 may be electrically connected to each other. In this case, the additional coil layers may have the same contents as the first coil layers 211 and 221 or the second coil layers 212 and 222. In addition, additional coil layers may be further formed between the first coil layers 211 and 221 and the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222, such that the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222 may be electrically connected to each other. In this case, the additional coil layers may have the same contents as the first coil layers 211 and 221 or the second coil layers 212 and 222.
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The coil part 200 may include a first coil layer 241, a second coil layer 242, a third coil layer 243, and a fourth coil layer 244 sequentially stacked in the third direction on one surface of the support member 230. A first insulating layer 245 covering the first coil layer 241, a second insulating layer 246 covering the second coil layer 242, and a third insulating layer 247 covering the third coil layer 243 may be disposed between the first coil layer 241 and the second coil layer 242, between the second coil layer 242 and the third coil layer 243, and between the third coil layer 243 and the fourth coil layer 244, respectively. The fourth coil layer 244 may be covered by an insulating film 248.
A coil pattern conductor of the first coil layer 241 may have an aspect ratio (AR), which is a ratio (h1/w1) of a thickness h1 to a width w1, less than 1 (where h1 is measured orthogonally to the surface of the support member 230 on which the first coil layers 241 is disposed, and w1 is measured parallel to the surface of the support member 230). A coil pattern conductor of the second coil layer 242 may also have an aspect ratio (AR), which is a ratio (h2/w2) of a thickness h2 to a width w2, less than 1 (where h2 is measured orthogonally to the surface of the support member 230 on which the first coil layers 241 is disposed, and w2 is measured parallel to the surface of the support member 230). Likewise, coil pattern conductors of the third coil layer 243 and the fourth coil layer 244 may also have an aspect ratio, which is a ratio of a thickness to a width, less than 1. That is, in the coil component 10C according to another example, coil pattern conductors of the coil layers 241, 242, 243, and 244 may each have an aspect ratio less than 1. In addition, the coil patterns of all the coil layers 241, 242, 243, and 244 may each include a single turn or winding. Here, the single turn or winding may indicate that the number of turns (or windings) is 1 or less.
Therefore, a height and a width of the coil pattern conductors may be freely adjusted within a dispersion allowed by a process technology of forming coil patterns, such that uniformity of the coil patterns may be excellent, and the coil patterns are wide in the width direction, such that a cross-sectional area of the coil part is increased, whereby low DC resistance Rdc characteristics may be implemented. In addition, since an interval between the coil pattern turns or windings does not need to be forcibly adjusted, the possibility that a defect such as short-circuits between the coil patterns, or the like, will occur may be decreased. In addition, since the coil layers 241, 242, 243, and 244 may have the same rotation direction and may be electrically connected to each other through the vias 261, 262, and 263, the number of turns of coils in a stacking direction may be increased. Here, the stacking direction refers to the third direction in the drawings.
In addition, since the aspect ratios of all the coil pattern conductors of the coil layers 241, 242, 244, and 244 are less than 1, a thickness of the coil part may basically be thin. Here, in order to have a sufficient number of turns (or windings), the respective coil layers 241, 242, 243, and 244 may be formed to utilize spaces as much as possible in the horizontal directions, that is, the first direction and/or the second direction. That is, overlapped regions may be present between the respective coil layers 241, 242, 243, and 244 stacked in the vertical direction. Therefore, a coil component that is thin and has sufficient coil characteristics may be implemented.
Only the first coil layer 241, the second coil layer 242, the third coil layer 243, and the fourth coil layer 244 are illustrated in the drawings, but additional coil layers may be further formed on the fourth coil layer 244, and an insulating layer in which a via is formed may be disposed between the additional coil layer and the fourth coil layer 244, such that the additional coil layer and the fourth coil layer 244 may be electrically connected to each other. In this case, the additional coil layers may have the same contents as the first coil layer 241, the second coil layer 242, the third coil layer 243, or the fourth coil layer 244.
In addition, additional coil layers may be further formed between the first coil layer 241, the second coil layer 242, the third coil layer 243, and the fourth coil layer 244, and insulating layers in which vias are formed may be disposed between the additional coil layers and the first coil layer 241, the second coil layer 242, the third coil layer 243, and the fourth coil layer 244, such that the additional coil layers and the first coil layer 241, the second coil layer 242, the third coil layer 243, and the fourth coil layer 244 may be electrically connected to each other. In this case, the additional coil layers may have the same contents as the first coil layer 241, the second coil layer 242, the third coil layer 243, or the fourth coil layer 244.
Meanwhile, in some cases, coil patterns of one or more of the first coil layer 241, the second coil layer 242, the third coil layer 243, and the fourth coil layer 244 may have an aspect ratio exceeding 1, as described above in relation to the coil component 10A according to an example, and may have multiple turns. That is, aspects or characteristics of the coil components 10A to 10C may be combined with each other.
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Coil patterns of the first coil layers 211 and 221 may include both of a coil pattern conductor (or a portion of a coil pattern conductor) having an aspect ratio (AR), which is a ratio (h1/w1) of a thickness h1 to a width w1, exceeding 1, and a coil pattern conductor (or a portion of a coil pattern conductor) having an aspect ratio (AR), which is a ratio (h1/w2) of a thickness h1 to a width w2, less than 1. Most of coil pattern conductors of the second coil layers 212 and 222 may have an aspect ratio (AR), which is a ratio (h2/w3) of a thickness h2 to a width w3, exceeding 1. For example, the coil pattern conductors of the first coil layers 211 and 221 may have a width w1 of about 30 μm to 50 μm, a width w2 of about 90 μm to 150 μm, and a thickness h1 of about 40 μm to 60 μm. The coil pattern conductors of the second coil layers 212 and 222 may have a width w3 of about 40 μm to 60 μm and a thickness h2 of about 40 μm to 70 μm.
Both of the coil patterns of the first coil layers 211 an 221 and the second coil layers 212 and 222 may have plural turns or windings. Here, since the first coil layers 211 and 221 and the second coil layers 212 and 222 are configured of coil patterns having a thin line width, the turns (or windings) of coil patterns of the first coil layers 211 and 221 and the second coil layers 212 and 222 in the horizontal directions, that is, the first direction and/or the second direction, may be basically large. In addition, since the coil layers 211, 212, 221, and 222 may have the same rotation direction and may be electrically connected to each other through vias 214, 224, and 234, the number of turns of coils in the stacking direction, that is, the third direction, may be increased. The number of turns of coil patterns may also be larger or smaller than the number of turns illustrated in
Since most of the coil layers 211, 221, 212, and 222 are formed of coil patterns having a thin line width, a thickness of the coil part may be thin. Here, in order to have a sufficient number of turns, the respective coil layers 211, 221, 212, and 222 may be formed to utilize spaces as much as possible in the horizontal directions, that is, the first direction and/or the second direction. That is, the first coil layers 211 and 221 and the second coil layers 212 and 222 stacked in the vertical direction may have overlapped regions. Therefore, a coil component that is thin and has sufficient coil characteristics (e.g., sufficient inductance) may be implemented.
A line width w2 of coil patterns disposed in the outermost portion (measured from a center of the coil windings) of the first coil layers 211 and 221 may be wider than a line width w1 of coil patterns disposed in an inner portion of the first coil layers 211 and 221. That is, the coil patterns disposed in the inner portion may be implemented to have a relatively thin line width w1, such that the number of turns (or windings) of coil patterns disposed in the inner portion is high, and the coil patterns disposed in the outer portion may be implemented to have a relatively thick line width w2, such that low DC resistance Rdc characteristics may be secured. In addition, an interval L1 between adjacent turns (or windings) of the coil patterns of the first coil layers 211 and 221 may be wider than an interval L2 between adjacent turns of the coil patterns of the second coil layers 212 and 222. That is, the interval L1 between the coil patterns of the first coil layers 211 and 221 formed in the inner portion may be relatively wide to decrease a risk of a defect such as occurrence of short-circuits between the coil patterns, or the like, and make the insulating layers 213 and 223 covering the first coil layers 211 and 221 flat, whereby uniformity of coils of the second coil layers 212 and 222 formed in the outer portion may be improved. In addition, the interval L2 between the coil patterns of the second coil layers 212 and 222 formed in the outer portion may be relatively narrow, such that the number of turns of coil part 200 may be generally increased.
Only the first coil layers 211 and 221 and the second coil layers 212 and 222 are illustrated in the drawings, but additional coil layers may be further formed on the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the second coil layers 212 and 222, such that the additional coil layers and the second coil layers 212 and 222 may be electrically connected to each other. In addition, additional coil layers may be further formed between the first coil layers 211 and 221 and the second coil layers 212 and 222, and insulating layers in which vias are formed may be disposed between the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222, such that the additional coil layers and the first coil layers 211 and 221 or the second coil layers 212 and 222 may be electrically connected to each other.
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Since a method of manufacturing the coil component 10D according to another example is similar to the methods of manufacturing the coil components 10A to 10C described above, a detailed description thereof will be omitted.
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The coil component to which the isotropic plating technology is applied may be manufactured by, for example, forming coil patterns 1021 and 1022 having a planar coil shape on both surfaces of a support member 1030 by the isotropic plating technology, embedding the coil patterns 1021 and 1022 using a magnetic material to form a body part 1010, and forming external electrodes 1041 and 1042 electrically connected to the coil patterns 1021 and 1022 on outer surfaces of the body part 1010. The isotropic plating technology has a limitation in implementing a high aspect ratio as illustrated in
The coil component to which the anisotropic plating technology is applied may be manufactured by, for example, forming coil patterns 2021 and 2022 having a planar coil shape on both surfaces of a support member 2030 by the anisotropic plating technology, embedding the coil patterns 2021 and 2022 using a magnetic material to form a body part 2010, and forming external electrodes 2041 and 2042 electrically connected to the coil patterns 2021 and 2022 on outer surfaces of the body part 2010. In the case of applying the anisotropic plating technology, a high aspect ratio may be implemented, but uniformity of plating growth may be decreased due to an increase in an aspect ratio, and a dispersion of a plating thickness is wide, such that short-circuits between the coil patterns may easily occur.
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As set forth above, according to the exemplary embodiment, a new coil component in which a risk of a defect such as occurrence of short-circuits, or the like, is decreased and uniformity of coils and a low DC resistance Rdc are secured, and thinness is implemented, and a method of manufacturing the same may be provided.
Meanwhile, a phrase ‘electrically connected’ includes both of a case in which one component is physically connected to another component and a case in which one component is not physically connected to another component.
In addition, a term ‘example’ used in the present disclosure does not mean the same exemplary embodiment, but is provided in order to emphasize and describe different unique features. However, the above suggested examples may also be implemented to be combined such that a feature from one example can be included in another example. For example, even though particulars described in a specific example are not described in another example, it may be understood such particulars can be incorporated in the other example unless described otherwise.
In addition, terms used in the present disclosure are used only in order to describe an example rather than limit the present disclosure. Here, singular forms include plural forms unless interpreted otherwise in a context.
While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations could be made without departing from the scope of the present invention as defined by the appended claims.
Number | Date | Country | Kind |
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10-2015-0107021 | Jul 2015 | KR | national |
10-2016-0035328 | Mar 2016 | KR | national |