JP6614207B2 - Coil component assembly, coil component and manufacturing method thereof - Google Patents

Description

  The present invention relates to a coil component such as an inductor.

  An inductor, which is one of coil components, is a typical passive element that removes noise by forming an electronic circuit together with a resistor and a capacitor. For example, the power inductor can be used in a power supply circuit or a converter circuit in which a large current flows.

  On the other hand, a coil type having a relatively simple manufacturing method is often used for the coil component. In general, a winding-type coil component is manufactured by using a molding method in which a winding coil is arranged in a mold mold, and after being filled with a sealing material, it is cured.

  In the recent parts market, thinning and downsizing have been promoted, and there is a limit in stably mounting coils when manufacturing small coil parts by a molding method. Moreover, since coil parts must be manufactured individually, productivity falls.

  One of the various objects of the present invention is to solve the above-mentioned problem. Even when a small coil component is manufactured, the coil can be stably mounted and mass production is possible. Providing a simple coil component.

  One of various solutions proposed by the present invention is to manufacture a coil component by a new method using a support member having a plurality of processed spaces.

  For example, according to the present invention, a support member, a plurality of processed spaces penetrating the support member, a plurality of coils respectively disposed in the plurality of processed spaces, the support member, and the plurality of the plurality of spaces A coil component assembly is provided that includes a magnetic material covering the coil.

  According to the invention, the support member, the plurality of processed spaces penetrating the support member, the plurality of coils respectively disposed in the plurality of processed spaces, and the support member and the plurality of coils are provided. A coil component formed by cutting a coil component assembly including a magnetic material to be covered along a boundary line between the plurality of processed spaces, the coil component including a coil and a magnetic body covering the coil. Provided.

  According to the present invention, the step of forming a plurality of spaces penetrating the support member, the step of disposing each of the plurality of coils in the plurality of spaces, and forming a magnetic substance on at least one surface of the support member And a method of manufacturing a coil component assembly.

  According to the present invention, the step of forming a plurality of spaces penetrating the support member, the step of disposing each of the plurality of coils in the plurality of spaces, and forming a magnetic substance on at least one surface of the support member. Forming a coil component assembly, and cutting the coil component assembly to form a coil component.

  As one of the various effects of the present invention, a coil component assembly, a coil component, and a coil component assembly that can stably mount a coil, have excellent productivity, and can reduce the cost of a mold mold, and the efficiency thereof It is possible to provide a method that can be manufactured automatically.

It is a schematic perspective view which shows an example of a coil component. It is sectional drawing which follows the AA 'line of the coil components of FIG. (A)-(c) is drawing for demonstrating a supporting member and the processed space. (A) And (b) is drawing which shows the various processed space of a supporting member. (A) And (b) is drawing which shows the various lead terminals of a coil. It is a top view which shows an example of a coil component assembly. It is a top view which shows the other example of a coil component assembly. It is a top view which shows the further another example of a coil components assembly. It is a top view which shows the further another example of a coil components assembly. It is a schematic process flowchart which shows one manufacture example of the coil components using a coil component assembly. It is a schematic process flowchart which shows one manufacture example of the coil components using a coil component assembly. It is a schematic process flowchart which shows one manufacture example of the coil components using a coil component assembly. It is a schematic process flowchart which shows one manufacture example of the coil components using a coil component assembly. It is a schematic process flowchart which shows one manufacture example of the coil components using a coil component assembly. It is a schematic perspective view which shows an example of a coil component. It is a schematic sectional view showing an example of a coil component. It is a schematic sectional view showing an example of a coil component. It is a schematic sectional view showing an example of a coil component. It is drawing for demonstrating the other example of manufacture of a coil component. (A) And (b) is drawing for demonstrating the press-fit process of a magnetic material sheet. It is drawing for demonstrating another example of manufacture of a coil component. It is drawing for demonstrating another example of manufacture of a coil component. It is drawing for demonstrating another example of manufacture of a coil component. (A)-(c) is drawing for demonstrating a fixed frame. (A)-(c) is drawing which shows various examples of a fixed frame. (A)-(c) is drawing for demonstrating the shift | offset | difference of the coil after a cutting | disconnection. (A)-(c) is drawing which shows the internal structure of the coil components after a cutting | disconnection. (A)-(c) is drawing which shows the other internal structure | tissue of the coil components after a cutting | disconnection. (A)-(d) is drawing which shows other internal structure of the coil components after a cutting | disconnection. (A) And (b) is drawing for demonstrating the size of a fixed frame. (A)-(c) is drawing which shows a schematic example of a magnetic main body. It is drawing which shows a schematic example of the cut surface of a magnetic main body.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. However, the embodiments of the present invention can be modified in various other forms, and the scope of the present invention is not limited to the embodiments described below. In addition, the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art. Accordingly, the shape and size of elements in the drawings may be exaggerated for a clearer description.

  FIG. 1 is a schematic perspective view showing an example of a coil component.

  Referring to FIG. 1, a coil component 100-1 according to an example includes a coil (not shown), a magnetic body 130, and an external electrode 140. The magnetic main body 130 fills the inside of the coil component 100-1 and forms the outer shape of the component, and fills the space around the coil (not shown).

  The magnetic body 130 may be formed of a magnetic resin composite in which a metal magnetic powder and a resin mixture are mixed, but is not limited thereto. The metal magnetic powder includes Fe, Cr, or Si as a main component, and can include, for example, Fe—Ni, Fe, Fe—Cr—Si, and the like. The resin mixture may include an epoxy, a polyimide, a liquid crystal polymer (LCP), and the like.

  The magnetic body 130 may be filled with a metal magnetic powder having at least two particle sizes. In this case, since the magnetic resin composite can be filled by pressure bonding using bimodal metal magnetic powders of different sizes, the filling rate can be increased.

  The external electrode 140 is electrically connected to a coil (not shown). Although the drawing shows that the external electrodes 140 are arranged on opposite sides of the coil component 100-1, this is only an example, and the arrangement form of the external electrodes 140 is the type of the coil component 100-1. Various modifications can be made according to design and process requirements. The external electrode 140 includes a metal such as Ag, Ag—Pd, Ni, or Cu, and a Ni plating layer and a Sn plating layer can be selectively formed on the surface of the external electrode 140.

  2 is a cross-sectional view taken along the line AA ′ of the coil component of FIG.

  Referring to FIG. 2, the space around the coil 120 is filled with the magnetic body 130, and the lead terminals 121 a and 121 b of the coil 120 are connected to the external electrode 140. As shown in the figure, the coil 120 can be positioned at the center of the magnetic body 130, but is not limited to this, and the upper end of the magnetic body 130 according to the type, design, and process of the coil component 100-1. Alternatively, it can be located at the lower end. The coil 120 may be a winding coil formed by a winding method, but is not limited thereto.

  As will be described in detail below, the coil 120 is mounted in a processed space (not shown) of a support member (not shown), and the space around the coil 120 can be filled with the magnetic body 130. . Thereby, not only can the coil 120 be stably mounted in the magnetic main body 130, but also the coil component 100-1 can be miniaturized. However, depending on the case, the support member (not shown) may be completely removed by the cutting process, and the support member (not shown) may not remain in the individual parts as shown in the drawing.

  Since a core is formed in the middle hole of the coil 120 and the core can be filled with a magnetic material, a high-capacity coil component can be provided.

  FIG. 3 is a view for explaining the support member and the processed space.

  Referring to FIG. 3A, the support member 110 has a plurality of processed spaces 111. As the support member 110, a copper clad laminate (CCL), a rolled copper plate, a NiFe rolled copper plate, a Cu alloy plate, a ferrite substrate, a flexible substrate, or the like can be used. When a ferrite substrate is used instead of the PCB substrate, the inductance capacity characteristic can be improved by increasing the magnetic permeability. Further, the coil 120 can be fixed more stably.

  Referring to FIG. 3B, each processed space 111 is formed in such a manner that the coil 120 can be stably mounted. The processed space 111 may have a horizontal length larger than a vertical length based on the drawing. Formed sheets are stacked in the processed space 111, and the stacked sheets are pressure-bonded and cured to prevent displacement of the coil 120 disposed at a fixed position, and the bar (Bar) due to the flow of the sheet is prevented. Control deformation. “Processing” at least a part of the support member 110 not only forms a space by physically or optically or chemically deforming or removing at least a part of the support member, but also two or more support members. It also includes forming a space by a structure constituted by using.

  Referring to FIG. 3 (c), the coil 120 is disposed in each processed space 111. The machined space 111 can have a sufficiently large size to accommodate the coil 120. When the coil 120 is accommodated in the processed space 111, a vacant space is generated, and the vacant space can be filled with a magnetic substance by a crimping process of the molded magnetic sheet.

  FIG. 4 is a view illustrating various processed spaces of the support member.

  Referring to FIG. 4, at least a partially processed space 111 formed in the support member 110 has a space in which the coil 120 is disposed as shown in FIG. As shown in FIG. 4B, the shape is an ellipse similar to that of the coil 120. However, it is not limited to this, and other shapes may be used. A mounting space can be formed in which the coil 120 is disposed and the lead terminals 121a and 121b of the coil 120 are separately disposed.

  FIG. 5 is a view showing various lead terminals of the coil.

  Referring to FIG. 5, the at least partially processed space 111 of the support member 110 can also accommodate the lead terminals 121 a and 121 b of the coil 120. At this time, the space for accommodating the extraction terminals 121a and 121b has a bent shape, which increases the area of the support member 110 corresponding to the space for accommodating the two extraction terminals as compared with the straight shape. Can do.

  The lead terminals 121a and 121b may have a shape bent in the same direction, or may have a shape bent in a different direction. Therefore, the space for accommodating the lead terminals 121a and 121b may have a shape bent in the same direction as shown in FIG. 5A or a shape bent in a different direction as shown in FIG. 5B. it can.

  FIG. 6 is a plan view showing an example of a coil component assembly.

  Referring to FIG. 6, the coil component assembly 100 includes a support member 110 having a plurality of processed spaces 111, a plurality of coils 120 disposed in the plurality of processed spaces 111, and the support members 110 and the above. A magnetic material (not shown) covering the coil 120 is included. In one example, since the lead terminal of the coil 120 is bent in the same direction, the machined space 111 is machined accordingly. Each of the plurality of processed spaces 111 has protruding portions on both sides in the first direction, and any two processed spaces adjacent in the first direction among the plurality of processed spaces 111 are respectively The protruding parts are processed so as to be displaced from each other. Each of the plurality of coils 120 has a lead terminal projecting on both sides in the first direction, and among the plurality of coils 120, any two coils adjacent to each other in the first direction have their lead terminals shifted from each other. Has been placed.

  On the other hand, any two processed spaces adjacent to each other in the first direction among the plurality of processed spaces 111 with respect to the plane of the support member 110 are in relation to the intermediate point C1 of the boundary line L1 between them. They are point-symmetric with each other. Thus, when satisfying the point symmetry with respect to the intermediate point C1 of the boundary line L1, the space of the support member 110 can be utilized to the maximum, and the coil component 100-1 can be substantially reduced despite the downsizing of the coil component 100-1. Since the same processed space 111 is repeated, the loading of the coil 120 becomes easier and simpler, so that the accuracy of the arrangement of the coil 120 can be further improved.

  In this case, any two coils adjacent in the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110 are also the boundary line L1 between them. Are symmetrical with respect to the intermediate point C1. Since the coil 120 is also arranged point-symmetrically with respect to the intermediate point C1 of the boundary line L1 in accordance with the processed space 111, the above-described effect can be substantially obtained.

  Also, any two processed spaces adjacent to the second direction inclined by 45 ° with respect to the first direction among the plurality of processed spaces 111 with respect to the plane of the support member 110 are between these two spaces. Are mutually symmetrical with respect to the intersection C2 of the boundary lines L1 and L2 perpendicular to each other. As described above, when the point C2 is symmetrical with respect to the intersection C2 between the perpendicular boundaries L1 and L2, the space of the support member 110 can be utilized to the maximum, and the coil component 100-1 can be miniaturized. Regardless, since the substantially identical processed space 111 is repeated, the loading of the coil 120 becomes easier and simpler, so that the accuracy of the arrangement of the coil 120 can be further improved.

  In this case, any two adjacent to the second direction inclined by 45 ° with respect to the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110. The two coils are also point-symmetric with respect to each other with respect to the intersection C2 between the perpendicular boundaries L1 and L2 between them. By arranging the coil 120 in point symmetry with respect to the intersection C2 between the boundary lines L1 and L2 in accordance with the processed space 111, the above-described effects can be substantially obtained.

  In the present invention, the term “symmetry” is a concept including being completely symmetric and being substantially symmetric in consideration of an error that may be caused by a process or facility limitation.

  FIG. 7 is a plan view showing another example of the coil component assembly.

  The coil component assembly according to another example of FIG. 7 is different from the coil component assembly according to the example of FIG. 6 in that the lead terminal of the coil 120 is bent in a different direction, and the processed space 111 is processed accordingly. ing. Each of the plurality of processed spaces 111 has protruding portions on both sides in the first direction, and any two processed spaces adjacent in the first direction among the plurality of processed spaces 111 are respectively The protruding parts are processed so as to be displaced from each other. Each of the plurality of coils 120 has a lead terminal projecting on both sides in the first direction, and among the plurality of coils 120, any two coils adjacent to each other in the first direction have their lead terminals shifted from each other. Has been placed.

  Even when the lead terminal of the coil 120 is bent in different directions, and the processed space 111 is processed accordingly, the first of the plurality of processed spaces 111 based on the plane of the support member 110. Any two processed spaces adjacent to each other in the direction of are point-symmetric with respect to the intermediate point C1 of the boundary line L1 between them. In this case, any two coils adjacent in the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110 are also the boundary line L1 between them. Are symmetrical with respect to the intermediate point C1.

  Also, any two processed spaces adjacent to the second direction inclined by 45 ° with respect to the first direction among the plurality of processed spaces 111 with respect to the plane of the support member 110 are between these two spaces. Are mutually symmetrical with respect to the intersection C2 of the boundary lines L1 and L2 perpendicular to each other. In this case, any two adjacent to the second direction inclined by 45 ° with respect to the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110. The two coils are also point-symmetric with respect to each other with respect to the intersection C2 between the perpendicular boundaries L1 and L2 between them.

  Similarly to the above, the space of the support member 110 can be utilized to the maximum, and the substantially same processed space 111 is repeated despite the downsizing of the coil component 100-1. Since the loading of the coil 120 becomes easier and simpler, the accuracy of the arrangement of the coil 120 can be further improved.

  FIG. 8 is a plan view showing still another example of the coil component assembly.

  Referring to FIG. 8, the coil component assembly 100 includes a support member 110 having a plurality of processed spaces 111, a plurality of coils 120 disposed in the plurality of processed spaces 111, and the support members 110 and the above. A magnetic material (not shown) covering the coil 120 is included. In another example, the lead terminal of the coil 120 is bent in the same direction, and the processed space 111 is processed accordingly. Each of the plurality of processed spaces 111 has protruding portions on both sides in the first direction, and any two processed spaces adjacent in the first direction among the plurality of processed spaces 111 are respectively The protruding parts are processed so as to be displaced from each other. Each of the plurality of coils 120 has a lead terminal projecting on both sides in the first direction, and among the plurality of coils 120, any two coils adjacent to each other in the first direction have their lead terminals shifted from each other. Has been placed.

  On the other hand, any two processed spaces adjacent to each other in the first direction among the plurality of processed spaces 111 with respect to the plane of the support member 110 are in relation to the intermediate point C1 of the boundary line L1 between them. They are point-symmetric with each other. Thus, when satisfying the point symmetry with respect to the intermediate point C1 of the boundary line L1, the space of the support member 110 can be utilized to the maximum, and the coil component 100-1 can be substantially reduced despite the downsizing of the coil component 100-1. Since the same processed space 111 is repeated, the loading of the coil 120 becomes easier and simpler, so that the accuracy of the arrangement of the coil 120 can be further improved.

  In this case, any two coils adjacent in the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110 are also the boundary line L1 between them. Are symmetrical with respect to the intermediate point C1. Since the coil 120 is also arranged point-symmetrically with respect to the intermediate point C1 of the boundary line L1 in accordance with the processed space 111, the above-described effect can be substantially obtained.

  However, unlike the example shown in FIGS. 6 and 7, an arbitrary adjacent to the third direction inclined by 90 ° with respect to the first direction among the plurality of processed spaces 111 with respect to the plane of the support member 110. The two processed spaces 111 are point-symmetric with respect to the intermediate point C3 of the boundary line L2 between them. Thus, even in the case of point symmetry with respect to the intermediate point C3 of the boundary line L2, the space of the support member 110 can be utilized to the maximum, and the coil component 100-1 is miniaturized. Since the substantially identical processed space 111 is repeated, the loading of the coil 120 becomes easier and simpler, so that the accuracy of the arrangement of the coil 120 can be further improved.

  In this case, any two adjacent to the third direction inclined by 90 ° with respect to the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110. The two coils 120 are also point-symmetric with respect to the intermediate point C3 of the boundary line L2 between them. Since the coil 120 is also arranged point-symmetrically with respect to the intermediate point C3 of the boundary line L2 in accordance with the processed space 111, the above-described effect can be substantially obtained.

  FIG. 9 is a plan view showing still another example of the coil component assembly.

  Compared with the coil component assembly according to the other example of FIG. 8, the coil component assembly according to the other example of FIG. 9 has the lead terminal of the coil 120 bent in a different direction, and the processed space 111 is adjusted accordingly. Has been processed. Each of the plurality of processed spaces 111 has protruding portions on both sides in the first direction, and any two processed spaces adjacent in the first direction among the plurality of processed spaces 111 are respectively The protruding parts are processed so as to be displaced from each other. Each of the plurality of coils 120 has a lead terminal projecting on both sides in the first direction, and among the plurality of coils 120, any two coils adjacent to each other in the first direction have their lead terminals shifted from each other. Has been placed.

  Even when the lead terminal of the coil 120 is bent in different directions, and the processed space 111 is processed accordingly, the first of the plurality of processed spaces 111 based on the plane of the support member 110. Any two processed spaces adjacent to each other in the direction of are point-symmetric with respect to the intermediate point C1 of the boundary line L1 between them. In this case, any two coils adjacent in the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110 are also the boundary line L1 between them. Are symmetrical with respect to the intermediate point C1.

  In addition, any two processed spaces 111 adjacent to the third direction inclined by 90 ° with respect to the first direction among the plurality of processed spaces 111 on the basis of the plane are boundary lines between them. They are symmetrical with respect to the intermediate point C3 of L2. In this case, any two adjacent to the third direction inclined by 90 ° with respect to the first direction among the plurality of coils 120 respectively disposed in the plurality of processed spaces 111 with respect to the plane of the support member 110. The two coils 120 are also point-symmetric with respect to the intermediate point C3 of the boundary line L2 between them.

  Similarly to the above, the space of the support member 110 can be utilized to the maximum, and the substantially same processed space 111 is repeated despite the downsizing of the coil component 100-1. Since the loading of the coil 120 becomes easier and simpler, the accuracy of the arrangement of the coil 120 can be further improved.

  10a to 10e are schematic process flowcharts showing an example of manufacturing a coil component using a coil component assembly.

  Referring to FIG. 10a, a support member 110 having a plurality of processed spaces 111 is prepared. As the support member 110, a copper clad laminate (CCL), a rolled copper plate, a NiFe rolled copper plate, a Cu alloy plate, a ferrite substrate, a flexible substrate, or the like can be used. Each processed space 111 is formed in such a manner that the coil 120 can be stably mounted. The processed space 111 may have a horizontal length larger than a vertical length based on the drawing. The specific arrangement form of the processed space 111 may be the same as that described with reference to FIGS. The plurality of processed spaces 111 have a shape penetrating the support member 110.

  Referring to FIG. 10 b, the coil 120 is disposed in each processed space 111. That is, since the plurality of coils are loaded into the plurality of processed spaces 111 of the support member 110, it is advantageous for mass production. The specific arrangement form of the coil 120 may be the same as that described with reference to FIGS. Each machined space 111 can have a sufficiently large size to accommodate the coil 120. When the coil 120 is accommodated in the processed space 111, an empty space can be generated. The coil 120 may be a winding coil formed by a winding method, but is not limited thereto.

  Referring to FIG. 10 c, the first magnetic sheet 131 is pressure-bonded to one surface of the support member 110. The first magnetic sheet 131 is obtained by molding a magnetic resin composite into a sheet shape, and can be crimped in a semi-cured state. The magnetic resin composite is a mixture of a metal magnetic powder and a resin mixture. The metal magnetic powder contains Fe, Cr, or Si as a main component, and the resin mixture includes epoxy, polyimide ( Although it may be individual or combination, such as a polymer and a liquid crystal polymer (Liquid Crystal Polymer; LCP), it is not limited to this. By press-bonding the first magnetic sheet 131, a vacant space in the processed space 111 can be filled with a magnetic substance such as a magnetic resin composite. After the curing process, which is a subsequent process, it is possible to prevent displacement of the coil 120 arranged at a fixed position and to control deformation of the bar (Bar) due to the flow of the sheet.

  Referring to FIG. 10 d, the second magnetic sheet 132 is pressure-bonded to the other surface of the support member 110. The second magnetic sheet 132 is also formed by forming a magnetic resin composite into a sheet shape, and can be pressure-bonded in a semi-cured state. The magnetic resin composite is a mixture of a metal magnetic powder and a resin mixture. The metal magnetic powder contains Fe, Cr, or Si as a main component, and the resin mixture includes epoxy, polyimide ( Although it may be individual or combination, such as a polymer and a liquid crystal polymer (Liquid Crystal Polymer; LCP), it is not limited to this. After the curing process, which is a subsequent process, it is possible to prevent displacement of the coil 120 arranged at a fixed position and to control deformation of the bar (Bar) due to the flow of the sheet. The curing process of the first magnetic sheet 131 and the second magnetic sheet 132 can be performed simultaneously or individually.

  Referring to FIG. 10E, the support member 110 and the magnetic sheets 131 and 132 stacked on both sides thereof are cut along the boundary surfaces of the plurality of processed spaces 111. Cutting can be done to a pre-designed size. As a result, an individual coil component 100-1 is provided. At the time of cutting, it can be cut into individual coil parts using a cutting equipment, and other cutting methods such as a blade and a laser can also be used.

  On the other hand, if the support member 110 and / or the fixed frame (not shown) is designed to be smaller than the area that is not cut by the width of the dicing blade (dicing blade area) (dicing kerf area), The support member 110 and / or the fixed frame (not shown) may not remain in the coil component 100-1. That is, the support member 110 and / or the fixed frame (not shown) are for stable mounting of the coil 120 and may or may not remain in the final part. However, when the support member 110 is substantially close to the coil 120 in order to improve the position fixing accuracy of the coil 120, a part of the support member 110 and / or the fixing frame (not shown) remains in the coil 120. May be.

  Although not shown, after the cutting process, a polishing process can be performed to polish the corners of the individual coil components 100-1. The magnetic body 130 of the coil component 100-1 can be rounded by the polishing process, and an insulating material can be further printed on the surface of the magnetic body 130 to prevent plating. The insulating layer thus formed may include one or more of a glass-based material containing Si, an insulating resin, and plasma.

  Further, by minimizing the unevenness of the surface of the magnetic body 130 that is cut to prevent the diffusion of plating, current concentration can be prevented when a plating current is applied. That is, the magnetic main body 130 has a hemispherical shape in which the exposed surface of the metal magnetic powder is flattened or a shape in which a part of the sphere is cut off, and has a flat surface, thereby applying a plating current. In this case, current concentration can be prevented.

  In addition, after an insulating layer is formed on the magnetic body 130, a metal material can be pre-plated on the lead terminal of the coil 120 on which the insulating layer is not formed. The pre-plating layer (not shown) can be formed of a metal material, for example, Cu plating. An external electrode (not shown) is formed by applying at least one of Ni and Sn to a pre-plated layer (not shown), or after applying at least one of Ag and Cu, Ni, The external electrode 140 may be formed by applying at least one of Sn.

  For example, adding an application for forming an external electrode (not shown) by forming an electrode lead-out terminal portion exposed to the outside not coated with an insulating material to a predetermined thickness or more by Cu plating. Ni and Sn plating can be performed. Therefore, it is not necessary to further apply Ag, Cu or the like for increasing the contact force between the external electrode (not shown) terminals and forming the external electrode 140.

  On the other hand, when forming an external electrode (not shown) by further applying at least one of Ag and Cu on a pre-plated layer (not shown), ensure a wider internal / external contact area. Thus, a lower resistance can be obtained.

  11a to 11d are a schematic perspective view and a cross-sectional view showing an example of a coil component.

  FIG. 11a shows a schematic perspective view of an individual coil component 100-1 manufactured by the above-described process (see FIGS. 10a to 10e). Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to FIG. 11 a, an individual coil component 100-1 according to an example includes a coil 120, a magnetic body 130, and an external electrode 140. The coil component 100-1 is used in an electronic / electric device as an inductor, and in particular, can be used as a power inductor for a large current.

  The external electrode 140 is electrically connected to the lead terminals 121 a and 121 b of the coil 120. Although the drawing shows that the external electrodes 140 are arranged on opposite sides of the coil component 100-1, this is only an example, and the arrangement form of the external electrodes 140 is the type of the coil component 100-1. Various modifications can be made according to design and process requirements.

  11b to 11d are cross-sectional views taken along line II ′ of the individual coil component 100-1 shown in FIG. 11a. Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to FIGS. 11b and 11c, the support member 110 is a base member for manufacturing the inductor 100, and may remain in the coil component 100-1 after the cutting process. At this time, the support members 110 may remain only on both sides in the first direction as shown in FIG. 11b, and the support members 110 remain in all of the first direction and the third direction as shown in FIG. 11c. Also good.

  The coil 120 may be a winding coil formed by a winding method. The space at least partially processed in the support member 110 can accommodate the main body of the coil 120 and the two lead terminals 121a and 121b. The lead terminals 121a and 121b of the coil 120 can be connected to the external electrode 140, respectively.

  The coil 120 is disposed in the at least partially processed space of the support member 110 and is stably mounted in the magnetic body 130. In order to provide a high-capacity coil component, a core is formed in the middle hole of the coil 120, which can be filled with a magnetic material.

  The magnetic main body 130 fills the inside of the coil component and forms an outer shape, and fills the space around the support member 110 and / or the coil 120. The magnetic body 130 is made of a magnetic resin composite in which a metal magnetic powder and a resin mixture are mixed, and the support member 110 and the coil 120 can be embedded.

  Referring to FIG. 11d, the support member 110 is a base member for manufacturing the inductor 100, and may not remain in the coil component 100-1 after the cutting process.

  The coil 120 may be a winding coil formed by a winding method. The lead terminals 121a and 121b of the coil 120 can be connected to the external electrode 140, respectively.

  The coil 120 is disposed in the at least partially processed space of the support member 110 and is stably mounted in the magnetic body 130. However, the support member 110 does not remain in the coil component 100-1 due to the cutting process. Also good. Similarly to the above, a core is formed in the middle hole of the coil 120 to provide a high capacity coil component, which can be filled with a magnetic material.

  The magnetic main body 130 fills the inside of the coil component and forms an outer shape, and fills the space around the coil 120. Similarly to the above, the magnetic body 130 is made of a magnetic resin composite in which a metal magnetic powder and a resin mixture are mixed, and the coil 120 can be embedded.

  FIG. 12 is a drawing for explaining another example of manufacturing a coil component.

  The coil component manufacturing process shown in FIG. 12 schematically shows the process described with reference to FIGS. 10a to 10e. Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to FIG. 12A, first, the support member 110 has a space 111 that is at least partially processed. The at least partially processed space 111 of the support member may be a mounting space in which the coil 120 is disposed, and the coil 120 and the support member 110 may be formed to have a space gap.

  Referring to FIG. 12B, the coil 120 is mounted in the space 111 that is already manufactured and is at least partially processed. Here, the coil 120 may be a winding coil formed by a winding method. The at least partially machined space of the support member 110 can accommodate the main body of the coil 120 and the two lead terminals. The space that accommodates the two lead terminals has a bent shape, and this can increase the area of the support member 110 corresponding to the space that accommodates the two lead terminals compared to the straight shape. The lead terminal of the coil 120 accommodated in the space can be connected to an external electrode.

  Meanwhile, in the stage of attaching the coil 120, a fixing frame (not shown) that is disposed in at least one direction of the coil 120 and fixes the position of the coil 120 may be formed on the support member 110. The position of the coil 120 can be fixed by a fixing frame (not shown) formed in the space 111 at least partially processed of the support member. The fixed frame (not shown) can be formed by processing using the same material as the support member 110.

  Referring to FIG. 12C, in order to form the magnetic body 130 of the coil component, a magnetic resin composite is added to the space around the support member 110 and the coil 120 to embed the support member 110 and the coil 120. The magnetic resin composite is cured after being pressed. That is, the magnetic main body 130 can be formed by adding a magnetic resin composite in which a metal magnetic powder and a resin mixture are mixed to the space around the support member 110 and the coil 120 and embedding the support member 110 and the coil 120. it can.

  As described above, by using the magnetic sheet method for manufacturing the coil component, the productivity can be improved and the cost of the mold can be reduced as compared with the existing winding coil method.

  FIG. 13 is a drawing for explaining a step of pressing a magnetic sheet.

  Referring to FIG. 13A, a primary pressure bonding process is performed by laminating a first magnetic sheet 131 on one surface of the support member 110 and the coil 120.

  Referring to FIG. 13B, the vertical direction of the primary pressure-bonded structure is changed (rotated by 180 degrees), and the first magnetic sheet 131 is not formed in the support member 110 and the coil 120 in the first direction. Two magnetic sheets 132 are laminated to perform the secondary pressure bonding process. At this time, the coil 120 may be arranged in the center of the chip by adjusting the number of stacked sheets to be pressed and cured on the second magnetic sheet 132 and the first magnetic sheet 131. it can.

  For example, as shown in the figure, one magnetic sheet can be laminated on the primary pressure-bonding sheet, and three second magnetic sheets 132 can be laminated and pressure-bonded, followed by curing. At this time, the magnetic sheet can be pressure-bonded under the same hydrostatic pressure condition. As a result, the coil 120 can be positioned in the center with respect to the thickness direction of the coil component. Thereafter, the resin can be cured by vacuum pressurization to produce a bar type.

  FIG. 14 is a drawing for explaining still another example of manufacturing the coil component.

  FIG. 14 shows a manufacturing process of the coil component in which the space around the upper part of the coil is filled with the filler. Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to step 1010, at least a part of the space of the support member 1011 is processed as a cavity 1012. The above processing can be performed by physical, optical, or chemical means. Also, the size and shape of the cavity 1012 are variously determined according to the design and manufacturing process needs, and the horizontal length of the cavity 1012 in the first direction is processed to be larger than the vertical length of the second direction. be able to. Referring to step 1020, a coil 1013 (for example, a winding coil) is mounted inside the cavity 1012. After the coil 1013 is mounted, a space around the coil 1013 is filled with a filler. In this case, the filler can be filled by pressing one or more magnetic composite sheets.

  FIG. 15 is a drawing for explaining still another example of manufacturing the coil component.

  FIG. 15 shows a manufacturing process of the coil component in which the space around the upper part of the coil is filled with the filler after the specific material is added to the lower part of the support member. Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to step 1110, at least a part of the space of the support member 1111 is processed as a cavity 1112. Referring to step 1120, a specific material 1113 may be added to the lower portion of the cavity 1112. For example, a material such as an adhesive and an adhesive tape can be added to the lower portion of the cavity 1112. Referring to step 1130, a coil 1114 (eg, a winding coil) is mounted inside the cavity 1112. Referring to step 1140, the space around the coil 1114 is filled with a filler after the coil 1114 is mounted. Referring to step 1150, the specific material added to the bottom of the cavity 1112 is removed.

  FIG. 16 is a drawing for explaining still another example of manufacturing the coil component.

  FIG. 16 shows a manufacturing process of the coil component in which the space around the upper part of the coil and the space around the lower part are filled with the filler after the specific material is added to the lower part of the support member. Here, the overlapping contents are omitted to the maximum, and the main configuration will be mainly described.

  Referring to step 1210, at least a part of the space of the support member 1211 is processed as a cavity 1212. Referring to step 1220, a specific material 1213 may be added to the lower portion of the cavity 1212. For example, a material such as an adhesive and an adhesive tape can be added to the lower portion of the cavity 1212. Referring to step 1230, a coil 1214 (eg, a winding coil) is mounted inside the cavity 1212. Referring to step 1240, a space around the upper portion of the coil 1214 is filled with a filler after the coil 1214 is mounted. It is. Referring to step 1250, the specific material added to the bottom of the cavity 1212 is removed. Referring to step 1260, the space around the lower portion of the coil 1214 is filled with filler.

  FIG. 17 is a view for explaining a fixed frame.

  Referring to FIG. 17, whether or not the fixed frame 112 exists and the shape of the coil component depending on the shape of the fixed frame 112, and each coil component is cut in the first direction (Length) and the third direction (Width). The cross sections can be compared. Here, the fixed frame 112 is formed on the support member 110 and fixes the position of the coil 120 by physically supporting the coil 120. Depending on the shape of the fixed frame 112, the shape of the at least partially processed space formed in the support member 110 can also be changed.

  The coil component shown in FIG. 17A does not include the fixed frame 112 that fixes the position of the coil 120. In this coil component, since the coil 120 can be freely positioned in the mounting space, the designer can position the coil 120 with high positioning accuracy. However, since the variation of the size and form of the coil 120 may be relatively large, the failure rate of loading or insertion of the coil 120 may be relatively high.

  The coil components shown in FIGS. 17B and 17C include a fixed frame 112 that fixes the position of the coil 120. In this coil component, since the variation in the size and form of the coil 120 can be relatively small, the failure rate of loading or insertion of the coil 120 can be relatively low.

  FIG. 18 is a diagram illustrating various examples of the fixed frame.

  Referring to FIG. 18, in the coil component, a space 111 that is at least partially processed is formed inside the support member 110, and the coil 120 disposed in the processed space, and the support member 110 and the coil 120 are arranged. An embedded magnetic body 130 is included.

  A space 111 that is at least partially processed is formed inside the support member 110 and the coil 120 is disposed, and a fixing frame 112 is formed inside the space that is processed to fix the position of the coil 120. it can. The fixed frame 112 is formed by processing the support member 110 and can have various shapes. This will be described below with an example.

  Referring to FIG. 18A, the fixed frame 112 may be formed for stable mounting of the coil 120. In particular, in order to fix the position of the coil 120, a bar-shaped fixed frame 112 is formed on the top of the coil 120, and two protruding fixed frames 112 are formed on the bottom of the coil 120. Can. Here, the shape of the fixed frame 112 is not limited, but the fixed frame 112 is formed to be spaced apart from the coil 120 by a certain distance, and the end is curved or inclined along the coil so that the elliptical shape of the coil 120 can be guided. Can be formed.

  At this time, when the support member 110 inserted in the center or the fixed frame 112 of the support member 110 is designed to be smaller than a region (dicing kerf region) that is not cut by a dicing blade (dicing blade) width or the like, It does not have to remain in the manufactured coil component. However, when the support member 110 is close to the coil 120 in order to improve the position fixing accuracy of the coil 120, the support member 110 or a part of the fixing frame 112 of the support member 110 may remain inside the coil 120. Good.

  In FIG. 18B, as another example of the fixed frame 112, two rod-shaped fixed frames 112 projecting above the coil 120 on a plane are formed so that the position of the coil 120 can be fixed. In addition, two rod-shaped fixed frames 112 protruding at the lower part of the coil 120 may be formed. Here, the fixed frame 112 may be spaced apart from the coil 120 by a predetermined distance, and may have a curved surface or a sloped end along the coil 120 so that the elliptical shape of the coil 120 can be guided.

  Similarly to the above, when the support member 110 inserted in the center or the fixed frame 112 of the support member 110 is designed to be smaller than a region (Dicing Kerf) that is not cut by the width of the dicing blade, etc. , It does not have to remain in the manufactured coil component. However, when the support member 110 is close to the coil 120 in order to improve the position fixing accuracy of the coil 120, the support member 110 or a part of the fixing frame 112 of the support member 110 remains inside or outside the coil 120. May be.

  FIG. 18C shows an example of a coil component in which the fixed frame 112 is not separately formed.

  FIG. 19 is a view for explaining the shift of the coil after cutting.

  After the magnetic material sheet is pressed and cured around the support member 110 and the coil 120, the generated bulk structure can be diced to generate individual coil components. Specifically, the bulk structure includes a bar in which a large number of coils 120 are regularly arranged and the periphery of the coil 120 is filled with a magnetic sheet made of a magnetic resin composite. Is. A cutting process can be performed by cutting such a bulk structure into the size of the designed coil component in the horizontal and vertical directions to form individual coil components. For example, it can cut into the form of individual chips using a cutting equipment using SAW, and other cutting methods such as blades and lasers can also be used. On the other hand, such a cutting may cause a shift phenomenon of the coil 120 disposed on the support member 110. An example for confirming this will be shown below.

  In FIG. 19A, the at least partially processed space of the support member 110 includes a fixed frame 112 that protrudes from the processed space. That is, two fixed frames 112 are arranged on the top of the coil 120 on a plane and spaced apart by a certain distance. In FIG. 19 (b), two fixed frames 112 that are formed to protrude are arranged on the top and bottom of the coil 120 at a certain distance from each other on the plane. In FIG. 19 (c), the fixed frame 112 is disposed on the upper part of the coil 120 in a horizontal bar shape.

  In each case, after the bulk structure was cut into individual coil parts, the positional accuracy of the coil 120 in the magnetic resin composite was confirmed by NDT. In addition, since there is no coil 120 exposed on the side surface, an individual coil component with no appearance defect and excellent quality was obtained.

  FIG. 20 is a drawing showing the internal structure of the coil component after cutting.

  FIG. 21 is a drawing showing another internal structure of the coil component after cutting.

  FIG. 22 is a drawing showing still another internal structure of the coil component after cutting.

  FIG. 20A and FIG. 21A show a cross section in a first direction (Length) and a cross section in a third direction (Width) of a coil component having the same structure as FIG. That is, in FIGS. 20A and 21A, a bar-shaped fixed frame 112 is formed on the upper portion of the coil 120 so that the position of the coil 120 can be fixed, and the lower portion of the coil 120 protrudes. 2 shows a cross section in a first direction (Length) and a cross section in a third direction (Width) of the coil component in which the two fixed frames 112 are formed. Referring to the cross section in the third direction (width) in FIG. 21A, it can be confirmed that the bar-shaped fixed frame 112 exists at the upper right end of the coil.

  FIGS. 20B and 21B show a cross section in the first direction (Length) and a cross section in the third direction (Width) of the coil component having the same structure as that in FIG. 18B. That is, in FIG. 20B and FIG. 21B, two fixed frames 112 having a shape protruding from the top of the coil 120 are formed so that the position of the coil 120 can be fixed. A cross section in a first direction (Length) and a cross section in a third direction (Width) of a coil component in which two fixed frames 112 having the same protruding shape are also formed in the lower part are shown.

  FIG. 20C and FIG. 21C show a cross section in the first direction (Length) and a cross section in the third direction (Width) of the coil component having the same structure as FIG. That is, FIGS. 20C and 21C show a cross section in the first direction (Length) and a cross section in the third direction (Width) of the coil component in which the separate fixing frame 112 is not formed.

  FIG. 22 is an enlarged view of a cross section in the third direction (Width) of the coil component having the same structure as that of FIGS. 20 (c) and 21 (c).

  Referring to FIG. 22, after the magnetic sheet is pressure-bonded and cured around the support member 110 and the coil 120 in this way, the generated structure can be diced to generate individual coil parts. The deformation of the coil 120 after the cutting process according to the form of the coil component can be confirmed from the example of the coil component structure.

  As a result, there is almost no deformation of the coil 120 due to the crimping pressure, and the phenomenon that the magnetic metal (Metal) permeates into the insulating layer that insulates the coil 120 and lowers the insulation resistance does not occur. Further, there is no crack or the like that affects the strength of the magnetic main body 130 and the heat resistance of the solder due to the reaction with the material of the resin-based magnetic main body 130.

  In addition, it has the characteristics of a coil component that has a high metal filling factor that affects the inductance value, and the breakdown of the insulation layer does not occur, so that the breakdown voltage breakdown voltage (BDV) is improved. Can do.

  FIG. 23 is a diagram for explaining the size of the fixed frame.

  Fig.23 (a) is drawing which shows schematic structure of a coil component, FIG.23 (b) is the perspective view by which a part of coil component after a process was cut | disconnected.

  Referring to FIGS. 23 (a) and 23 (b), in the space 111 that is at least partially processed in the support member 110, an unnecessary processed portion due to the fixing of the coil 120 is increased or a capacity loss is generated. It can have a minimum fixed frame 112 to prevent. For this, the ratio of the fixed frame 112 can be expressed by Equation 1 below.

[Formula 1]
0.01 <(a1 + a2 + ... + an) / A <0.6

  Here, a1, a2,..., An indicate the length of each of the fixed frames in the first direction (Length), and A indicates the length of the coil component in the first direction (Length). When the value of the equation is 0.01 or less, the position of the coil 120 becomes unstable, and when it is 0.6 or more, the capacity may be reduced. At this time, the shape of the fixed frame 112 can be realized in various shapes such as a circle and a rectangle. Thus, if the ratio of the length of the support member 110 in the first direction (Length) is set, high-accuracy mounting is possible with a high rated current and a low DC resistance. Depending on the design, the ratio may be greater than 0.01 and less than 0.06.

  FIG. 24 is a drawing showing a schematic example of a magnetic body.

  Referring to FIG. 24, different types of sheets are used for the magnetic body 130, and the support body 110 and the coil 120 can be embedded in the magnetic body 130.

  FIG. 24 (a) shows a shape in which acicular powder is inserted into an external cover sheet (Cover Sheet). Inside the coil 120 is arranged, fine powder and coarse powder are mixed, and the acicular powder is arranged horizontally. Can be formed.

  FIG. 24 (b) shows a shape in which needle-like powder is inserted into the portion where the coil 120 is arranged. The needle-like powder is formed in a vertical arrangement inside the coil 120, and the cover sheet is made of fine powder and coarse powder. The powder can be mixed and formed.

  FIG. 24 (c) shows a shape in which needle-like powder is inserted in the whole, needle-like powder is formed in a vertical arrangement inside the coil 120, and needle-like powder is formed in a horizontal arrangement on the cover sheet. Can.

  By adjusting the ratio of the acicular powder, the efficiency of the magnetic field can be maximized within a limited size (Size).

  FIG. 25 is a drawing showing a schematic example of a cut surface of a magnetic body.

  After performing the cutting process, a metal (Metal) containing Fe as a main component can be used as the metal magnetic powder in the magnetic resin composite that is the material of the magnetic body 130. There is a possibility that the diffusion of the plating may occur when performing.

  At this time, current concentration can be prevented when applying a plating current by minimizing the unevenness of the surface of the magnetic body 130 in order to prevent the diffusion of the plating. That is, as shown in FIG. 25, the magnetic body 130 has a hemispherical shape in which the exposed surface of the metal magnetic powder is flattened or a shape in which a part of the sphere is cut out, and the surface is flat. Due to the structure, current concentration can be prevented when a plating current is applied.

  In order to prevent the diffusion of plating, an insulating layer can be applied to the surface of the magnetic main body 130 (a portion excluding a portion corresponding to the external electrode). The insulating layer may be formed of at least one of a glass-based material containing Si, an insulating resin, and plasma. A glass-based material containing Si or an insulating resin may be applied by printing and dipping, and a plasma treatment may be performed on the insulating material. Specifically, the spreading of the plating can be prevented by applying an insulating polymer to the side, top and bottom surfaces of the magnetic main body 130 and curing the coating.

  Although the embodiment of the present invention has been described in detail above, the scope of the right of the present invention is not limited to this, and various modifications and modifications can be made without departing from the technical idea of the present invention described in the claims. It will be apparent to those skilled in the art that variations are possible.

DESCRIPTION OF SYMBOLS 100 Coil component assembly 100-1 Coil component 110 Support member 111 Processed space 112 Fixed frame 120 Coil 121a, 121b Lead terminal 130 Magnetic main body 131 1st magnetic material sheet 132 2nd magnetic material sheet 140 External electrode L1, L2 Boundary lines C1, C3 Intermediate point C2 Intersection

Claims (6)

A coil component assembly including a support member, a plurality of processed spaces penetrating the support member, a plurality of coils respectively disposed in the plurality of processed spaces, and a magnetic material covering the support member and the plurality of coils A coil component formed by cutting along a boundary line between the plurality of processed spaces,
Look including a coil and a magnetic body covering the coil,
The coil component further comprising a plurality of fixed frames protruding from the support member and respectively facing the plurality of processed spaces .   The coil component according to claim 1, wherein the support member remains on both sides in a first direction.   The coil component according to claim 1, further comprising one or more fixing frames arranged in at least one direction of the coil and fixing the position of the coil.   2. The coil component according to claim 1, wherein the cut surface of the magnetic body includes metal magnetic powder having a hemispherical shape or a shape in which a part of a sphere is cut off. The coil has one or more lead terminals;
The coil component according to claim 1, wherein a pre-plated layer containing copper is formed on the lead terminal. Forming a plurality of spaces penetrating the support member;
Disposing each of a plurality of coils in the plurality of spaces;
Forming a coil material assembly by forming a magnetic material on at least one surface of the support member;
Cutting the coil component assembly to form a coil component;
Including
The method of manufacturing a coil component, wherein the support member is formed with a plurality of fixed frames that protrude from the support member and respectively go to the plurality of spaces.