JP2022130064A - Coil component - Google Patents

Abstract

To improve reliability of a coil component having magnetic members.SOLUTION: A coil component 1 comprises: a coil pattern C disposed between magnetic members M1, M2; insulation members 70 to 76 covering the surface of the coil pattern C; a magnetic member M3 which is disposed in an inner diameter region of the coil pattern C via the insulation members 71 to 76 so as to form a first magnetic path between the magnetic members M1, M2; and a magnetic member M4 which is disposed in an outside region of the coil pattern C via the insulation members 71 to 76 so as to form a second magnetic path between the magnetic members M1, M2. The first magnetic path has such a structure that the magnetic member M3 and the insulation members 70 to 76 are alternately laminated, and the second magnetic path has such a structure that the magnetic member M4 and the insulation members 70 to 76 are alternately laminated. In this way, the coil pattern C does not come into direct contact with the magnetic members M1 to M4 because the surface of the coil pattern C is covered with the insulation members 70 to 76. This improves product reliability.SELECTED DRAWING: Figure 1

Description

The present invention relates to a coil component, and more particularly to a chip-type coil component having a structure in which a spiral coil pattern is covered with a magnetic member.

A chip-type coil component having a spiral coil pattern is sometimes covered with a magnetic member in order to increase inductance. For example, Patent Literature 1 discloses a coil component having a structure in which a spiral coil pattern is covered with a magnetic member. The coil component described in Patent Document 1 has a structure in which a magnetic gap layer is provided between a plurality of laminated coil patterns.

WO2008/007705

However, in the coil component described in Patent Document 1, since the coil pattern and the magnetic member are in direct contact with each other, if the magnetic member contains a conductive material such as a metal magnetic material, the parasitic capacitance increases. Therefore, there is a problem that the resonance frequency and the Q value are lowered.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to prevent a decrease in Q value in a coil component having a structure in which a coil pattern is covered with a magnetic member.

A coil component according to the present invention includes first and second magnetic members, a coil pattern disposed between the first magnetic member and the second magnetic member, an insulating member covering the surface of the coil pattern, and an insulating member. A third magnetic member disposed in the inner diameter region of the coil pattern via and constituting a first magnetic path between the first magnetic member and the second magnetic member, and the outside of the coil pattern via an insulating member a fourth magnetic member disposed in the region and forming a second magnetic path between the first magnetic member and the second magnetic member, the first magnetic path being insulated from the third magnetic member It has a structure in which members are alternately laminated, and the second magnetic path has a structure in which a fourth magnetic member and an insulating member are alternately laminated.

According to the present invention, since the surface of the coil pattern is covered with the insulating member, the coil pattern and the magnetic member do not come into direct contact with each other. This makes it possible to improve product reliability.

In the present invention, the coil pattern may include a spiral pattern wound in a spiral for a plurality of turns, and an insulating member may be embedded between adjacent turns of the spiral pattern. According to this, it is possible to suppress a decrease in resonance frequency and Q value due to an increase in parasitic capacitance.

In the present invention, the coil pattern has a structure in which a plurality of spiral patterns are laminated between the first magnetic member and the second magnetic member, and includes the third or fourth coil pattern included in the first or second magnetic path. The number of layers of the magnetic member may be the same as the number of layers of the plurality of spiral patterns. According to this, it becomes easy to manufacture the coil component.

In the present invention, a magnetic gap may be provided in the first or second magnetic member. According to this, the characteristics can be adjusted by the magnetic gap, and the magnetic permeability between the adjacent turns is suppressed, so that minor loops of the magnetic flux passing between the adjacent turns are reduced.

In the present invention, two of the third or fourth magnetic members that are adjacent in the stacking direction may have a portion that is connected without an insulating member interposed therebetween. According to this, it becomes possible to adjust the characteristics by the portion connected without the interposition of the insulating member.

In the present invention, at least the third and fourth magnetic members may contain metal magnetic bodies.

Thus, according to the present invention, it is possible to improve the reliability of a coil component having a structure in which a coil pattern is covered with a magnetic member.

FIG. 1 is a schematic cross-sectional view for explaining the structure of a coil component 1 according to a first embodiment of the invention. FIG. 2 is a schematic plan view of the conductor layer 10. FIG. FIG. 3 is a schematic plan view of the conductor layers 20 and 40. FIG. FIG. 4 is a schematic plan view of the conductor layers 30 and 50. FIG. FIG. 5 is a schematic plan view of the conductor layer 60. FIG. FIG. 6 is a graph showing the relationship between frequency and alternating current resistance (ACR). FIG. 7 is a graph showing the relationship between frequency and Q value. FIG. 8 is a schematic cross-sectional view for explaining the structure of the coil component 2 according to the second embodiment of the invention. FIG. 9 is a schematic cross-sectional view for explaining the structure of the coil component 3 according to the third embodiment of the invention. FIG. 10 is a schematic cross-sectional view for explaining the structure of the coil component 4 according to the fourth embodiment of the invention.

Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

FIG. 1 is a schematic cross-sectional view for explaining the structure of a coil component 1 according to a first embodiment of the invention.

The coil component 1 according to the first embodiment is a surface-mounted chip component suitable for use as an inductor for a power supply circuit such as a DCDC converter. and a coil pattern C embedded in the members M1 to M4. Although the configuration of the coil pattern C will be described later, in this embodiment, it is composed of spiral patterns SP1 to SP6 wound in a spiral for a plurality of turns.

The magnetic members M1 to M4 are composite members containing a metal magnetic filler made of iron (Fe) or permalloy-based material and a resin binder, and constitute a magnetic path for magnetic flux generated by applying an electric current to the coil pattern C. A liquid or powder epoxy resin is preferably used as the resin binder. The materials forming the magnetic members M1 to M4 may be the same or different. Here, the magnetic member M1 covers the coil pattern C from one side in the axial direction (lower side shown in FIG. 1), and the magnetic member M2 covers the coil pattern C from the other side in the axial direction (upper side shown in FIG. 1). The magnetic member M3 is a portion embedded in the inner diameter region of the coil pattern C, and the magnetic member M4 is a portion located in the outer region of the coil pattern C in the radial direction. The magnetic member M1 may be a magnetic substrate made of ferrite or the like.

As shown in FIG. 1, the insulating members 70 to 76 and the conductor layers 10, 20, 30, 40, 50, 60 are alternately laminated in the axial direction. The planar shape of conductor layer 10 is shown in FIG. 2, the planar shape of conductor layers 20 and 40 is shown in FIG. 3, the planar shape of conductor layers 30 and 50 is shown in FIG. It is shown in FIG. The conductor layers 10, 20, 30, 40, 50, 60 have spiral patterns SP1-SP6, respectively, and the upper or lower surfaces of the spiral patterns SP1-SP6 are covered with insulating members 70-76. The side surfaces of the spiral patterns SP1-SP6 are covered with portions of the insulating members 71-76, respectively. Here, the upper and lower surfaces of the spiral patterns SP1 to SP6 refer to surfaces substantially perpendicular to the coil axis, and the side surfaces of the spiral patterns SP1 to SP6 refer to surfaces substantially perpendicular to the radial direction.

The spiral patterns SP1-SP6 are connected to each other via through-holes formed in the insulating members 71-75 to form one coil conductor. Copper (Cu) is preferably used as the material for the conductor layers 10, 20, 30, 40, 50, and 60. FIG. All of the insulating members 70 to 76 are made of a resin material. Of the insulating members 70-76, at least the insulating members 71-75 are made of a non-magnetic material. The insulating member 70 located at the bottom layer and the insulating member 76 located at the top layer may have magnetism.

The conductor layer 10 is the first conductor layer formed on the upper surface of the magnetic member M1 via the insulating member 70. As shown in FIG. , has two electrode patterns 11 and 12 . The lower surface of the spiral pattern SP1 is covered with an insulating member 70, and the side and upper surfaces of the spiral pattern SP1 are covered with an insulating member 71. As shown in FIG. Thus, the insulating member 71 is interposed between the spiral pattern SP1 and the magnetic members M3 and M4. The electrode pattern 11 is connected to the outer peripheral end of the spiral pattern SP1. The electrode pattern 12 is provided independently of the spiral pattern SP1.

The conductor layer 20 is a second conductor layer formed on the upper surface of the conductor layer 10 via an insulating member 71. As shown in FIG. , has two electrode patterns 21 and 22 . The lower surface of the spiral pattern SP2 is covered with an insulating member 71, and the side and upper surfaces of the spiral pattern SP2 are covered with an insulating member 72. As shown in FIG. Thus, the insulating member 72 is interposed between the spiral pattern SP2 and the magnetic members M3 and M4. Both the electrode patterns 21 and 22 are provided independently of the spiral pattern SP2.

The conductor layer 30 is a third conductor layer formed on the upper surface of the conductor layer 20 via an insulating member 72, and as shown in FIG. , has two electrode patterns 31 and 32 . The lower surface of the spiral pattern SP3 is covered with an insulating member 72, and the side and upper surfaces of the spiral pattern SP3 are covered with an insulating member 73. As shown in FIG. Thus, the insulating member 73 is interposed between the spiral pattern SP3 and the magnetic members M3 and M4. Both the electrode patterns 31 and 32 are provided independently of the spiral pattern SP3.

The conductor layer 40 is a fourth conductor layer formed on the upper surface of the conductor layer 30 via an insulating member 73. As shown in FIG. , has two electrode patterns 41 and 42 . The lower surface of the spiral pattern SP4 is covered with an insulating member 73, and the side and upper surfaces of the spiral pattern SP4 are covered with an insulating member 74. As shown in FIG. Thus, the insulating member 74 is interposed between the spiral pattern SP4 and the magnetic members M3 and M4. Both the electrode patterns 41 and 42 are provided independently of the spiral pattern SP4.

The conductor layer 50 is a fifth conductor layer formed on the upper surface of the conductor layer 40 via an insulating member 74. As shown in FIG. , has two electrode patterns 51 and 52 . The lower surface of the spiral pattern SP5 is covered with an insulating member 74, and the side and upper surfaces of the spiral pattern SP5 are covered with an insulating member 75. As shown in FIG. Thus, the insulating member 75 is interposed between the spiral pattern SP5 and the magnetic members M3 and M4. Both the electrode patterns 51 and 52 are provided independently of the spiral pattern SP5.

The conductor layer 60 is a sixth conductor layer formed on the upper surface of the conductor layer 50 via an insulating member 75, and as shown in FIG. It has SP6 and two electrode patterns 61 and 62 . The lower surface of the spiral pattern SP6 is covered with an insulating member 75, and the side and upper surfaces of the spiral pattern SP6 are covered with an insulating member . Thus, the insulating member 76 is interposed between the spiral pattern SP6 and the magnetic members M3 and M4. The electrode pattern 62 is connected to the outer peripheral edge of the spiral pattern SP6. The electrode pattern 61 is provided independently of the spiral pattern SP6.

The inner peripheral end of the spiral pattern SP1 and the inner peripheral end of the spiral pattern SP2 are connected via a via conductor 81 that is a part of the conductor layer 20 and provided through the insulating member 71 . The outer peripheral end of the spiral pattern SP2 and the outer peripheral end of the spiral pattern SP3 are connected via a via conductor 82 which is a part of the conductor layer 30 and provided to penetrate the insulating member 72 . The inner peripheral end of the spiral pattern SP3 and the inner peripheral end of the spiral pattern SP4 are connected via a via conductor 83 which is a part of the conductor layer 40 and is provided through the insulating member 73 . The outer peripheral end of the spiral pattern SP4 and the outer peripheral end of the spiral pattern SP5 are connected via a via conductor 84 which is a part of the conductor layer 50 and is provided through the insulating member 74 . The inner peripheral end of the spiral pattern SP5 and the inner peripheral end of the spiral pattern SP6 are connected via a via conductor 85 which is a part of the conductor layer 60 and is provided through the insulating member 75 . As a result, the spiral patterns SP1 to SP6 are connected in series to form a coil conductor consisting of multiple turns. The electrode patterns 11, 21, 31, 41, 51, 61 are exposed from the magnetic members M1 to M4 and used as one external terminal. The electrode patterns 12, 22, 32, 42, 52, 62 are exposed from the magnetic members M1 to M4 and used as the other external terminals.

As shown in FIG. 1, the magnetic members M3 and M4 are separated in the stacking direction by insulating members 70-76. Thus, the magnetic member M3 constitutes a magnetic path between the magnetic members M1 and M2, and the low magnetic permeability portion composed of the insulating members 70 to 76 functions as a magnetic gap. Similarly, the magnetic member M4 constitutes a magnetic path between the magnetic member M1 and the magnetic member M2, and the low magnetic permeability portion composed of the insulating members 70 to 76 functions as a magnetic gap. Thus, in the present embodiment, since the magnetic members M3 and M4 are separated, the effective magnetic permeability is lowered and the area of the hysteresis loop is reduced. This reduces the iron loss (hysteresis loss) represented by the area of the hysteresis loop, resulting in an improvement in the Q value.

6 and 7 are graphs for explaining the effect of this embodiment, FIG. 6 shows the relationship between frequency and AC resistance (ACR), and FIG. 7 shows the relationship between frequency and Q value. The solid lines in FIGS. 6 and 7 show the characteristics of the coil component 1 according to the present embodiment, and the broken lines in FIGS. 6 and 7 show the characteristics of the coil component according to the comparative example. The coil component according to the comparative example has a structure in which the magnetic members M3 and M4 are not separated in the stacking direction by the insulating members 70 to 76, and are integrated with each other.

As shown in FIG. 6, it can be seen that the coil component 1 according to the present embodiment has improved AC resistance (ACR) particularly in a high frequency region due to the iron loss reduction effect compared to the coil component according to the comparative example. Moreover, as shown in FIG. 7, it can be seen that the peak of the Q value of the coil component 1 according to the present embodiment moves to the high frequency region due to the iron loss reduction effect compared to the coil component according to the comparative example.

As described above, in the coil component 1 according to the present embodiment, the magnetic members M3 and M4 forming the magnetic path between the magnetic member M1 and the magnetic member M2 are divided by the insulating members 70 to 76 for each conductor layer. , it is possible to improve the AC resistance (ACR) and the Q value due to the iron loss reduction effect. In addition, since it can be manufactured by alternately repeating the formation of the conductor layer and the magnetic member and the formation of the insulating member, it is not necessary to use a complicated manufacturing process. Moreover, since the spiral patterns SP1 to SP6 are not in direct contact with the magnetic members M1 to M4 and the surfaces thereof are covered with the insulating members 70 to 76, the reliability of the product is enhanced and the parasitic capacitance is reduced. is also possible. Furthermore, since the spiral patterns SP1 to SP6 have a structure in which the insulating members 71 to 76 are embedded between two radially adjacent turns, minor loops of magnetic flux passing between adjacent turns are also reduced. be.

FIG. 8 is a schematic cross-sectional view for explaining the structure of the coil component 2 according to the second embodiment of the invention.

As shown in FIG. 8, in the coil component 2 according to the second embodiment, the magnetic member M3 located on the conductor layer 10 and the magnetic member M3 located on the conductor layer 20 are integrated without being separated by the insulating member 71. , the magnetic member M3 located on the conductor layer 30 and the magnetic member M3 located on the conductor layer 40 are integrated without being separated by the insulating member 73, and the magnetic member M3 located on the conductor layer 50 and the magnetic member M3 located on the conductor layer 60 are integrated. It is different from the coil component 1 according to the first embodiment in that the magnetic member M3 is integrated without being separated by the insulating member 75 . Since other basic configurations are the same as those of the coil component 1 according to the first embodiment, the same elements are denoted by the same reference numerals, and overlapping descriptions are omitted.

As exemplified by the coil component 2 according to the present embodiment, it is not necessary to divide the magnetic member M3 by the insulating members 70 to 76 for each conductor layer. . . 76 may be integrated without being divided. According to this, the characteristics can be adjusted by the number and positions of the integrated magnetic members M3. Although not shown, the magnetic member M4 does not need to be separated for each conductor layer by the insulating members 70 to 76, and the magnetic members M4 located in some conductor layers may be integrated.

FIG. 9 is a schematic cross-sectional view for explaining the structure of the coil component 3 according to the third embodiment of the invention.

As shown in FIG. 9, the coil component 3 according to the third embodiment differs from the coil component 2 according to the second embodiment in that magnetic gaps are provided between the magnetic members M1 and M2. Since other basic configurations are the same as those of the coil component 2 according to the second embodiment, the same elements are denoted by the same reference numerals, and overlapping descriptions are omitted.

A magnetic gap provided in the magnetic member M1 is composed of an insulating member 91 provided so as to separate the magnetic path between the magnetic member M3 and the magnetic member M4. Similarly, the magnetic gap provided in the magnetic member M2 consists of an insulating member 92 provided so as to separate the magnetic path between the magnetic members M3 and M4. As exemplified by the coil component 3 according to the present embodiment, it is also possible to adjust the characteristics by providing magnetic gaps in the magnetic members M1 and M2.

FIG. 10 is a schematic cross-sectional view for explaining the structure of the coil component 4 according to the fourth embodiment of the invention.

As shown in FIG. 10, in the coil component 4 according to the fourth embodiment, via holes 70a to 76a are provided in the insulating members 70 to 76 at positions overlapping the magnetic member M3, and via holes 70a to 76a are provided at positions overlapping the magnetic member M4. 76 are provided with via holes 70b to 76b, whereby the magnetic members M3 and M4 both have portions to be connected without interposing the insulating members 70 to 76, which is the coil component according to the first embodiment. is different from 1. Since other basic configurations are the same as those of the coil component 1 according to the first embodiment, the same elements are denoted by the same reference numerals, and overlapping descriptions are omitted.

As exemplified by the coil component 4 according to the present embodiment, the magnetic members M3 and M4 are not completely separated by the insulating members 70 to 76, but by partially connecting the upper and lower magnetic members M3 and M4. can also be adjusted.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention. Needless to say, it is included within the scope.

1 to 4 coil parts 10, 20, 30, 40, 50, 60 conductor layers 11, 21, 31, 41, 51, 61, 12, 22, 32, 42, 52, 62 electrode patterns 70 to 76, 91, 92 Insulating members 70a to 76a, 70b to 76b Via holes 81 to 85 Via conductors C Coil patterns M1 to M4 Magnetic members SP1 to SP6 Spiral patterns

Claims (6)

first and second magnetic members;
a coil pattern disposed between the first magnetic member and the second magnetic member;
an insulating member covering the surface of the coil pattern;
a third magnetic member disposed in the inner diameter region of the coil pattern via the insulating member and forming a first magnetic path between the first magnetic member and the second magnetic member;
a fourth magnetic member disposed outside the coil pattern via the insulating member and forming a second magnetic path between the first magnetic member and the second magnetic member;
The first magnetic path has a structure in which the third magnetic member and the insulating member are alternately laminated,
A coil component, wherein the second magnetic path has a structure in which the fourth magnetic member and the insulating member are alternately laminated. The coil pattern includes a spiral pattern wound in a spiral for multiple turns,
2. The coil component according to claim 1, wherein said insulating member is embedded between adjacent turns of said spiral pattern. The coil pattern has a structure in which a plurality of the spiral patterns are laminated between the first magnetic member and the second magnetic member,
3. The coil according to claim 2, wherein the number of layers of said third or fourth magnetic member included in said first or second magnetic path is the same as the number of layers of said plurality of spiral patterns. parts. 4. The coil component according to claim 1, wherein a magnetic gap is provided in said first or second magnetic member. 5. The magnetic member according to any one of claims 1 to 4, wherein two of said third and fourth magnetic members which are adjacent in the stacking direction have a portion connected without said insulating member interposed therebetween. Coil parts described in the item. The coil component according to any one of claims 1 to 5, wherein at least the third and fourth magnetic members contain a metal magnetic material.

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