KR20160052467A - Sheet type inductor - Google Patents

Abstract

The present invention relates to an inductor, and a manufacturing method thereof. The inductor comprises: a spirally wound coil; a body unit receiving the coil; and an external electrode arranged in an outer surface of the body unit, and connected to an extraction terminal of the coil. The body unit includes: a metal magnetic material, and a resin. An outer surface having the external electrode connected to the extraction terminal of the coil among outer surfaces of the body unit is formed as a cutting surface.

Description

Sheet type inductor {SHEET TYPE INDUCTOR}

The following embodiments relate to an inductor and a manufacturing method thereof, and more particularly to an inductor stably mounting a coil and a manufacturing method thereof.

Due to miniaturization, thinning, and multifunctionality of electronic products, chip components may also require high current components.

In addition, inductors are used in a variety of electronic and electrical devices. In particular, the power inductor can be used in a power circuit or a converter circuit in which a large current flows.

Embodiments describe an inductor in which a coil is stably mounted and a method of manufacturing the same. More specifically, a support member is at least partially processed to form a cavity, and a coil is mounted on the cavity. Technology. Further, the embodiments can press the molded magnetic resin composite around the coil.

According to an embodiment of the present invention, the inductor includes a spiral wound coil, a body for receiving the coil, and an external electrode disposed on an outer surface of the body and connected to a lead terminal of the coil, And the outer surface of the outer surface of the body portion where the outer electrode connected to the lead terminal of the coil is formed may be a cut surface.

A method of manufacturing an inductor according to another embodiment includes the steps of: preparing a spirally wound coil; Pressing and curing a magnetic sheet including a magnetic metal and a resin on the upper and lower surfaces of the coil to form a body for receiving the coil; Cutting the outer surface of the body portion so that the lead-out terminal of the coil is exposed; And forming an outer electrode on the outer surface formed by the cut surface, the outer electrode being connected to the lead terminal of the coil; . ≪ / RTI >

1 is a perspective view illustrating an inductor according to an embodiment.
2 is a view schematically showing a BB 'cut plane shown in FIG.
3 is a view for explaining a cavity formed by processing at least a part of the support member.
FIG. 4 is a plan view of a support member having a cavity shown in FIG. 3. FIG.
5 is a diagram showing a schematic structure of an inductor according to an embodiment.
6 is a view for explaining an inductor according to an embodiment.
7 is a view for explaining a mounting space of an inductor according to an embodiment.
8 is a view for explaining a coil of an inductor according to an embodiment.
9-11 illustrate a process for fabricating an inductor in accordance with various embodiments.
12 is a view for explaining an example of a fixed frame of an inductor according to an embodiment.
13 is a view for explaining a fixed frame of an inductor according to an embodiment.
FIG. 14 is a view for explaining coil dislocation after dicing according to an embodiment. FIG.
15 to 17 are views showing the internal structure of a chip after dicing according to an embodiment.
18 is a view schematically showing a method of manufacturing an inductor according to an embodiment.
19 is a view for explaining sheet compression according to an embodiment.
20 is a diagram showing a part of a process for mass-producing an inductor according to an embodiment.
21 is a view showing the surface of the body part by cutting according to an embodiment.
22 is a view for explaining the size of a fixed frame according to an embodiment.
23 is a view for explaining a structure of a body part according to another embodiment.

Hereinafter, embodiments will be described with reference to the accompanying drawings. However, the embodiments described may be modified in various other forms, and the scope of the present invention is not limited by the embodiments described below. In addition, various embodiments are provided to more fully describe the present invention to those skilled in the art. The shape and size of elements in the drawings may be exaggerated for clarity.

1 is a perspective view illustrating an inductor according to an embodiment.

Referring to FIG. 1, an inductor 10 that can be used as a power inductor includes a body portion 11, external electrodes 12 and 13, and a coil (not shown). The body portion 11 fills the space around the coil 120 by filling the inside of the inductor 10 and forming a chip outer shape. The body part 130 may be made of a magnetic resin composite in which a metal magnetic material and a resin mixture are mixed.

Each of the two ends of the coil is connected to each of the external electrodes 12 and 13. 1 shows that the external electrodes 12 and 13 are disposed at both ends of the inductor 10, the position of each of the external electrodes 12 and 13 may be designed according to the needs of the process. Can be variously determined.

FIG. 2 is a schematic view of a section taken along the line B-B 'shown in FIG. 1. FIG.

2, the space around the coil 14 is filled with the body part 11, and both ends of the coil 14 are connected to the external electrodes 12 and 13. [ 2, the coil 14 may be located at the center of the body portion 11 and may be located at the top or bottom of the body portion 11, depending on design or manufacturing process needs.

As will be described in detail below, according to embodiments of the present invention, the coil 14 is seated in a cavity formed using at least a portion of a support member (not shown) comprising a substrate, Lt; / RTI > The coil 14 can be stably mounted in the body part 11, and the inductor 10 can be downsized.

3 is a view for explaining a cavity formed by processing at least a part of the support member.

3, the supporting member 110 may be a copper clad laminate (CCL), a rolled copper plate, a NiFe rolled copper plate, a Cu alloy plate, a ferrite substrate, or a flexible substrate. Here, instead of the PCB substrate, a ferrite substrate can be used as the support member 110, and the ferrite substrate can improve the inductance capacity characteristics by increasing the permeability. Further, not only the ferrite magnetic permeability is increased but also the coil can be fixed more stably.

The lead-out terminal and the coil of the coil may be disposed in the cavity 111 formed by processing at least a part of the support member 110. At this time, the "machining" of at least a portion of the support member 110 to form a cavity may include not only forming a cavity by physically, optically, or chemically deforming or removing at least a portion of the support member, To form a cavity through a structure that is constructed using the same.

As will be described below, the embodiments of the present invention not only can stably maintain the position of the coil by arranging the coil in the cavity formed by processing at least a part of the support member 110, but also the inductor can be further downsized. In addition, using a material having a desired characteristic such as a ferrite substrate as the support member 110 can help to increase the permeability and to keep the position of the coil stable.

FIG. 4 is a plan view of a support member having a cavity shown in FIG. 3. FIG.

Referring to FIG. 4 (a), a cavity 111 is formed in a space of at least a part of the support member 110. Referring to Fig. 4 (b), the cavity 111 formed by processing at least a part of the space of the support member 110 has a sufficient size to accommodate the coil. At this time, the illustrated lateral width of the cavity may be larger than the longitudinal length of the cavity.

The cavity 111 shown in FIGS. 4 (a) and 4 (b) has a space for accommodating not only the coil but also the lead-out terminal of the coil, It is not necessary to have a space for accommodating the lead-out terminal. In addition, the size and shape of the cavity 111 according to the embodiments of the present invention may vary according to design needs in the manufacturing process.

5 is a diagram showing a schematic structure of an inductor according to an embodiment.

5, the inductor 100 includes a support member 110, a coil 120, and a body portion 130. [ The inductor 100 can be used as an inductor in electronic / electrical devices, and in particular, as a power inductor for large currents.

The support member 110 is a base member for manufacturing the inductor 100. The support member 110 may be a copper clad laminate (CCL), a rolled copper plate, a NiFe rolled copper plate, a Cu alloy plate, a ferrite substrate , A flexible substrate, and the like.

As described with reference to Figs. 1 to 4, at least a partially machined space is formed in the support member 110, and the space has a sufficient size to accommodate the coil 120. [ At this time, the "machining" of at least a portion of the support member 110 to form a cavity may include not only forming a cavity by physically, optically, or chemically deforming or removing at least a portion of the support member, To form a cavity through a structure that is constructed using the same.

At this time, various substrates may be used for the support member 110. The supporting member 110 can be easily cut and machined and can be mounted without displacement of the coil 120. The position of the coil 120 due to the deformation of the sheet during the pressing of the sheet, It is possible to use a material for preventing deformation. For example, the support member 110 may be 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. Here, instead of the PCB substrate, a ferrite substrate can be used as the support member 110, and the ferrite substrate can improve the inductance capacity characteristics by increasing the permeability. Further, not only the ferrite magnetic permeability is increased but also the coil can be fixed more stably.

On the other hand, the at least partially machined space of the support member 110 is made up of a mounting space whose width is longer than the longitudinal length, so that the coil 120 can be stably placed in the machined space.

In addition, the at least partially machined space of the support member 110 may accommodate both the body of the coil 120 and two outgoing terminals. The space for accommodating the two lead terminals can have a bent shape, which can increase the area of the support member 110 corresponding to the space accommodating the two lead terminals compared to the straight shape.

The coil 120 is disposed in the at least partially machined space of the support member 110 and stably seats within the body portion 130. Here, the coil 120 may be a winding coil formed by a winding method, but is not limited thereto.

A core may be formed in an intermediate hole of the coil 120 to provide a high capacity inductor.

The body part 130 fills the space around the support member 110 and the coil 120 by filling the inside of the inductor 100 and forming the outer shape of the chip. The body part 130 is made of a magnetic resin composite in which a metal magnetic material and a resin mixture are mixed, and the supporting member 110 and the coil 120 are embedded.

At this time, the metal magnetic material may contain Fe, Cr or Si as a main component, and more specifically, it may be a powder including amorphous Fe, Fe-Ni, Fe and Fe-Cr-Si. Also, the resin mixture may include at least one of epoxy, polyimide, and Liquid Crystal Polymer (LCP) or a combination thereof.

The body portion 130 may be filled with a metal magnetic body having at least two particle sizes. Embodiments can fill the magnetic resin composite by pressing using different sizes of bimodal metal magnetic material, thereby increasing the filling rate.

In particular, the magnetic-substance-resin composite can be cured after the metal magnetic body and the resin mixture are molded into a sheet form and stacked on at least one side of the support member and pressed. For example, the body part 130 may include a high magnetic property of the coil inductor and a material for obtaining the DC-Bias, and in particular, the metal magnetic body as the metal magnetic body and the resin mixture may include a coarse powder containing Fe, Cr, And an epoxy resin can be used as the resin mixture. Whereby a sheet having a predetermined thickness can be formed.

The coil 120 and the support member 110 are arranged to have a space gap with each other and the coil 120 and the support member 110 are arranged to have a space gap with each other, The space between the support member 120 and the support member 110 is filled with the filling member constituting the body part 130.

In addition, the inductor 100 may further include an external electrode, and the external electrode is connected to a lead-out terminal exposed to the outside from the coil 120. The external electrode is electrically connected to each of the lead terminals of the coil 120 and is formed at a position corresponding to both ends of the body part 130. At this time, the external electrode may include a metal such as Ag, Ag-Pd, Ni, Cu, etc., and a Ni plating layer and a Sn plating layer may selectively be formed on the surface of the external electrode.

6 is a view for explaining an inductor according to an embodiment.

Referring to Fig. 6 (a), the large supporting member 110 includes a plurality of unit supporting members 110-1.

6B shows one unit supporting member 110-1. The unit supporting member 110-1 can be at least partially processed to form a cavity 111 for the coil and coil lead-out terminals have. Here, in the cavity 111 for the lead-out terminals of the coil and the coil, the formed sheets are laminated, and the laminated sheets are squeezed and cured. This prevents positional deviation of the coil 120 disposed at a constant position and controls deformation of the bar due to the sheet flow.

Referring to FIG. 6 (c), the coil 120 is disposed in the cavity 111 formed in the unit support member 110-1. The cavity 111 may have a sufficiently large size to accommodate the coil 120 and a space gap may be formed between the cavity 111 and the coil 120 when the coil 120 is accommodated in the cavity 111. [ Can occur.

On the support members 110-1 and the coils 120, a magnetic sheet formed by molding a magnetic resin composite can be laminated, and the laminated magnetic sheet can be cured at a curing temperature of the resin through heating and pressing. At this time, due to the applied pressure, a space gap between the coils 120, on which the magnetic substance sheet is mounted, and the processed space of the support member 110-1 can be filled. Meanwhile, another fixing means may be used to increase the fixing force of the coil 120. [ The coil 120 is fixed while filling the space gap, and then, when the filling of the magnetic sheet is completed, the coil 120 can be fixed by the magnetic sheet and its position can be fixed.

Subsequently, a magnetic sheet having a magnetic resin composite molded thereon is laminated on the surface of the support member 110-1 on which the magnetic sheet is not laminated, and is pressed and adhered to the back surface of the previously laminated sheet. That is, the magnetic member sheet is laminated on both sides of the support member 110 in which the coil 120 is embedded, and then the magnetic member is pressed and cured to form a bar shape. Then, the individual chips can be formed by cutting to a designed size. Here, the chip may be cut into individual chips using a dicing facility, and other cutting methods such as a blade or a laser may be applied.

7 is a view for explaining a mounting space of an inductor according to an embodiment.

Referring to FIG. 7, at least a partially processed space 111 is formed in the support member 110 constituting the inductor 100, so that the coil 120 can be stably mounted.

Here, the at least partially processed space 111 formed in the support member 110 may be variously embodied by a polygonal shape such as a rectangular shape or an elliptical shape similar to the shape of the coil 120, The mounting space may be formed so that the two lead-out terminals are disposed. At this time, the coil 120 disposed in the at least partially processed space 111 of the support member 110 may be formed to have a space gap with the support member 110. That is, since the coil 120 and the support member 110 are arranged so as to have a space gap with each other, a space gap between the coil 120 and the support member 110 is formed by a space gap between the coil 120 and the support member 110, And can be filled with a filling member. As the space between the coil 120 and the support member 110 is filled with the filling member, the position of the coil 120 can be more stably fixed.

8 is a view for explaining a coil of an inductor according to an embodiment.

Referring to Figure 8, the coil 120 is disposed in an at least partially machined space of the support member. Here, the coil 120 may be a winding coil formed by a winding method, but is not limited thereto.

In addition, the at least partially machined space of the support member 110 may accommodate both the body of the coil 120 and two outgoing terminals. The space for accommodating the two lead terminals can have a bent shape, which can increase the area of the support member 110 corresponding to the space accommodating the two lead terminals compared to the straight shape.

Further, the two lead terminals may have a bent shape in the same direction, and may have a bent shape in the other direction. For example, one of the two lead terminals can be bent upward, and the other one can be bent downward. In addition, the lead terminals may have a symmetrical shape as shown in FIG. 8, or may have an asymmetrical shape.

9-11 illustrate a process for fabricating an inductor in accordance with various embodiments.

9 shows fabrication steps of the inductor in which the upper peripheral space of the coil is filled with the filler. Referring to step 1010 of FIG. 9, at least a portion of the space of the support member 1011 is processed as a cavity 1012. Such processing may be performed by physical, optical, or chemical means. In addition, the size and shape of the cavity 1012 can be variously determined according to the needs of the fabrication process in design, and in particular, the width in the L direction of the cavity 1012 can be larger than the length in the W direction.

Referring to the process 1020, a coil 1013 (e.g., a coil) can be placed inside the cavity 1012, and the space around the coil 1013 is filled with the filler after the coil 1013 is seated. At this time, the filling material can be filled by pressing one or more magnetic composite sheets, as will be described below.

Fig. 10 shows the manufacturing processes of the inductor in which the space around the upper portion of the coil is filled with the filling material by the filling material after the specific material is added to the lower portion of the supporting member. 10, at least a part of the space of the support member 1111 is processed as a cavity 1112. [

10, a specific material 1113 may be added to the bottom of the cavity 1112. [ For example, a material such as an adhesive, an adhesive tape, or the like may be added to the lower portion of the cavity 1112.

10, a coil 1114 (e.g., a winding coil) may be seated inside the cavity 1112, and after the coil 1114 is seated in the process 1140, The space around the coil 1114 is filled.

Also, referring to process 1150, the specific material added to the bottom of cavity 1112 is removed.

11 shows fabrication processes of an inductor in which a filler material is filled with filler material in the upper and lower peripheral spaces of the coil, after a specific material is added to the lower part of the support member. Referring to step 1210 of FIG. 11, at least a portion of the space of the support member 1211 is processed as a cavity 1212.

11, a specific material 1213 may be added to the lower portion of the cavity 1112. In this case, For example, a material such as an adhesive, an adhesive tape or the like may be added to the lower portion of the cavity 1212.

11, a coil 1214 (e.g., a winding coil) may be seated within the cavity 1212, and after the coil 1214 is seated in the process 1240, The upper peripheral space of the coil 1214 is filled.

Also referring to process 1250, the specific material added to the bottom of cavity 1212 is removed.

11, the lower peripheral space of the coil 1214 is filled with the filling material.

12 is a view for explaining an example of a fixed frame of an inductor according to an embodiment.

12, it is determined whether or not the fixed frame 112 exists and the shape of the inductor 100 according to the shape of the fixed frame 112 and the shape of each inductor 100 in the L direction Length and the W direction ) Can be compared. Here, the stationary frame 112 is formed on the support member 110, and the position of the coil 120 is fixed 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 supporting member 110 can also be changed.

The inductor shown in FIG. 12 (a) does not include a fixed frame 112 that fixes the position of the coil 120. In such an inductor, 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 scattering of the size and shape of the coil 120 may be relatively large, the failure rate of loading or inserting the coil 120 may be relatively high.

12 (b) and 12 (c), the fixed frame 112 for fixing the position of the coil 120 is included. In such an inductor, the coil 120 can be positioned less freely than the case of Fig. 9 (a) in the mounting space, so that the designer can position the coil 120 with a relatively low positioning accuracy. However, since the scattering of the size and shape of the coil 120 may be relatively smaller than that of the case of FIG. 9A, the failure rate for loading or inserting the coil 120 may be relatively low.

13 is a view for explaining a fixed frame of an inductor according to an embodiment.

Referring to FIG. 13, the inductor 100 includes at least a partially processed space 111 inside the support member 110, as illustrated in FIG. 1, and includes coils 120, And a body part 130 for burying the support member 110 and the coil 120.

At least a partially processed space 111 may be formed inside the support member 110 so that the coil 120 may be disposed and a fixing frame 112 May be formed. The fixed frame 112 is formed by processing the supporting member 110, and various shapes are possible and will be described below by way of example.

Referring to FIG. 13 (a), a stationary frame 112 may be formed for stable mounting of the coil 120. In particular, a bar-shaped fixed frame 112 is formed on an upper portion of the coil 120 to fix the position of the coil 120, and two fixed frames 112 protruding from the lower portion of the coil 120, Can be formed. Although the shape of the stationary frame 112 is not limited, the stationary frame 112 may be formed to be spaced apart from the coil 120 by a predetermined distance, and the end may be formed as a curved surface or a beveled surface along the coil so as to guide the elliptical shape of the coil 120 have.

In this case, when the supporting frame 110 or the fixing frame 112 of the supporting member 110 is designed to be smaller than a dicing Kerf area which is cut off due to a dicing blade width or the like, When the support member 110 is in close proximity to the coil 120 in order to improve the position fixing accuracy of the coil 120, the support member 110 or the support member 110 of the support member 110 may not remain in the inductor 100, A portion of the coil 112 may remain within the coil 120. [

13B shows another example of the fixed frame 112 in which two fixed frames 112 protruding from the top of the coil 120 are formed on the plane so as to fix the position of the coil 120 And two fixed frames 112 protruding from the bottom of the coil 120 may be formed. Here, the stationary frame 112 is spaced apart from the coil 120 by a predetermined distance, and the end of the stationary frame 112 may be curved or beveled along the coil 120 so as to guide the elliptical shape of the coil 120.

Likewise, when the fixing frame 112 of the supporting member 110 or the supporting member 110 inserted in the middle is designed to be smaller than a dicing Kerf area that is cut off due to the width of the dicing blade or the like, 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 frame 110 or the support frame 110 of the support member 110 May remain in the coil 120 or outside.

13C shows an example of the inductor 100 in which the fixed frame 112 is not separately formed.

FIG. 14 is a view for explaining coil dislocation after dicing according to an embodiment. FIG.

Referring to FIG. 14, a magnetic sheet may be pressed and cured around the support member 110 and the coil 120, and then the resulting bulk structure may be diced to produce individual chips. Specifically, the bulk structure includes a plurality of coils 120 arranged regularly, and is formed in the form of a bar filled with the periphery of the coil 120 by a magnetic material sheet made of a magnetic resin composite. Such a bulk structure can be cut in the longitudinal and lateral directions by the designed chip size to form individual chips, thereby performing the cutting process. For example, it is possible to cut into individual chips by applying a dicing apparatus using SAW, and it is also possible to apply other cutting methods such as a blade or a laser.

Such cutting may cause the coil 120 disposed on the supporting member 110 to be twisted. Hereinafter, an example for confirming this is shown.

In Figure 14 (a), the at least partially processed space of the support member 110 includes a fixed frame 112 which is formed by projecting the fixed frame 112 into the processed space. In other words, two fixed frames 112 are arranged on the upper surface of the coil 120 on the plane at regular intervals. 14 (b), two projecting fixed frames 112 are arranged on the upper and lower sides of the coil 120 at regular intervals, and FIG. 14 (c) shows the fixed frame 112 Are arranged on the top of the coil 120 in the form of bars in the transverse direction.

In each case, after the bulk structure was cut into individual chips, the position accuracy of the coil 120 in the magnetic resin composite was confirmed by NDT. As a result, it was found that the coil 120 was in good condition Since there is no coil 120 exposed to the side, individual chips having excellent quality without defective appearance can be obtained.

15 to 17 are views showing the internal structure of a chip after dicing according to an embodiment.

Figs. 15 and 16A show cross sections in the L direction and the W direction of the inductor having the same structure as that of Fig. 13A. 15 and 16 (a), a bar-shaped fixed frame 112 is formed on an upper portion of the coil 120 so as to fix the position of the coil 120, Sectional view of the inductor in which two fixed frames 112 of a protruding shape are formed. 15 (a), it can be seen that a bar-shaped stationary frame 112 exists on the upper right side of the coil.

Figs. 15 and 16 (b) show cross sections in the L direction and the W direction of the inductor having the same structure as that of Fig. 13 (b). 15 and 16 (b) show two fixed frames 112 protruding from the top of the coil 120 to fix the position of the coil 120, Sectional view of the inductor in which two fixed frames 112 of the same protruding shape are formed.

Figs. 15 and 16C show a cross section in the L direction and a cross section in the W direction of the inductor having the same structure as that of Fig. 13C. Figs. 15 and 16 (b) show a directional section and a w-direction section of an inductor in which a separate fixed frame 112 is not formed.

Fig. 17 shows an enlarged view of a section in the W direction of the inductor having the same structure as Fig. 15 and Fig. 16 (c).

17, the magnetic material sheet is pressed and cured around the support member 110 and the coil 120, and then the individual structures are diced to produce individual chips. The deformation of the coil 120 after the cutting process can be confirmed by an example of the chip structure.

As a result, there is almost no deformation of the coil 120 due to the squeezing pressure, and no magnetic metal penetrates the insulating layer insulated from the coil 120 to lower the insulation resistance. Further, cracks and the like, which affect the strength of the body portion 130 and the heat resistance of the lead, are not found by reaction with the material of the resin-based inner body portion 130 inside.

Also, the metal filling factor that affects the inductance value also has a high inductor characteristic, and breakdown voltage (Breakdown Voltage) (BDV) can be improved because no breakdown of the insulation layer occurs.

18 is a view schematically showing a method of manufacturing an inductor according to an embodiment.

The processes for manufacturing the inductor shown in Fig. 18 show the processes described in Figs. 9 to 11 more simply. Here, the redundant description will be omitted and the main configuration will be mainly described.

As shown in Fig. 18 (a), first, the support member 110 has at least a partially processed space 111. [ The at least partially processed space 111 of the support member may be a mounting space for disposing the coil 120 and the coil 120 and the support member 110 may be formed to have a space gap with each other .

The coil 120 is seated in the at least partially machined space 111 of the preformed support member 110, as shown in Fig. 18 (b). Here, the coil 120 may be a winding coil formed by a winding method.

In addition, the at least partially machined space of the support member 110 may accommodate both the body of the coil 120 and two outgoing terminals. The space for accommodating the two lead terminals can have a bent shape, which can increase the area of the support member 110 corresponding to the space accommodating the two lead terminals compared to the straight shape. The lead terminals of the coil 120 accommodated in this space may be connected to the external electrode.

In addition, in the step of seating the coil 120, a stationary frame 112 may be formed on the support member 110, which is disposed at least one direction of the coil 120 to fix the position of the coil 120. [ That is, the position of the coil 120 can be fixed by the fixed frame 112 formed in the at least partially processed space 111 of the support member. Here, the fixed frame 112 can be formed by processing the same material as that of the supporting member 110.

18 (c), a magnetic resin composite is added to the space around the support member 110 and the coil 120 to form the body portion 130 of the inductor 100, (110) and the coil (120) are buried, and these magnetic resin composites are pressed and cured. That is, the body part 130 is formed by embedding the support member 110 and the coil 120 by adding the magnetic resin composite in which the metal magnetic material and the resin mixture are mixed in the space around the support member 110 and the coil 120 .

In particular, the magnetic resin composite can be formed by forming the metal magnetic body and the resin mixture into a sheet, stacking the same on at least one surface of the support member 110, pressing them, and curing them. Here, the body portion 130 can be filled with metal magnetic bodies having at least two particle sizes. By pressing the metal magnetic bodies using different sizes of metal magnetic bodies, the magnetic body resin composite can be filled, thereby increasing the filling rate.

More specifically, in order to press and cure the magnetic resin composite additionally, a first magnetic substance sheet 131 formed by molding a magnetic substance resin composite in which a metal magnetic substance and a resin mixture are mixed is formed on the upper surface of the support member 110 It can be pressed and cured. Thereafter, the second magnetic body sheet 132 formed by molding the magnetic body resin composite into a sheet can be pressed on the lower surface of the support member 110 and cured.

The number of stacked sheets to be pressed and cured on the second magnetic substance sheet 132 and the first magnetic substance sheet 131 is controlled in the step of pressing and curing the second magnetic substance sheet 132 on the lower surface of the support member 110 So that the coil 120 can be disposed centrally in the chip.

As described above, the productivity of the inductor 100 can be improved and the mold mold ratio can be reduced as compared with the conventional winding coil method using the magnetic substance sheet method.

Although not shown, it is possible to add a step of cutting the support member and the magnetic-substance-resin composite into individual chip units to produce individual chips (inductors 100).

In addition, after performing the above-described cutting step, an insulating layer may be formed on the surface of the magnetic resin composite constituting the body part 130 to prevent plating blur. Here, the insulating layer may be formed of at least one of a glass-based material containing Si, an insulating resin, and a plasma.

Further, the surface of the cut body 130 may be minimized to prevent the concentration of current during application of the plating current to prevent plating smearing. That is, the body part 130 has a hemispherical shape in which the exposed and exposed surface of the metal magnetic body is flattened, or a part of the spherical shape is cut out, and the surface is flat. Thus, the current concentration can be prevented when the plating current is applied.

After the insulating layer is formed on the body part 130, Cu lead plating can be performed on the lead terminal of the coil 120 on which the insulating layer is not formed. At least one of Ni and Sn may be applied to the pre-plating layer to form an external electrode, or at least one of Ag and Cu may be applied, and then at least one of Ni and Sn may be applied to form an external electrode.

Specifically, a portion of the electrode lead-out terminal (external electrode forming terminal) exposed to the outside without applying an insulating material is formed to a thickness of at least a predetermined thickness by Cu plating, and Ni, Sn plating . Accordingly, it is not necessary to separately apply Ag, Cu, or the like for increasing the contact force between the terminals of the external electrode 140 and forming the external electrode 140.

On the other hand, when at least one of Ag and Cu is further applied on the Cu line plating layer to form the external electrode 140, a lower resistance can be obtained by securing a wider inner and outer contact areas.

19 is a view for explaining sheet compression according to an embodiment.

19 (a), a first magnetic sheet 131 is laminated on the support member 110 and the coil 120 to perform a primary pressing process.

19 (b) shows a state in which the first pressed body is vertically switched (rotated 180 degrees) so that the first magnetic body sheet 131 is not formed in the supporting member 110 and the coil 120 And the second magnetic substance sheet 132 are laminated to perform a secondary pressing process. At this time, the number of stacked sheets to be pressed and cured on the second magnetic material sheet 132 and the first magnetic material sheet 131 may be adjusted so that the coil 120 is centrally disposed in the chip.

For example, as shown in the figure, one sheet of magnetic material may be laminated on the outside of the first squeezed surface, and three sheets of the second magnetic material sheets 132 may be laminated and cured after pressing. At this time, it is preferable that the magnetic sheet is filled under the same hydrostatic pressure.

Therefore, the coil sheet 120 can be positioned at the center by applying the molded sheet downward or upward, respectively, so that the coil 120 is positioned in the center of the chip T direction. Thereafter, the curing of the resin is performed under a vacuum pressurization, so that it can be manufactured into a bar type.

20 is a diagram showing a part of a process for mass-producing an inductor according to an embodiment.

20 shows a configuration in which a plurality of coils 120 are formed on a support member 110 and then the entire body of the assembly 200 is filled with a magnetic resin composite to form the body part 130. [ A plurality of individual inductors 100 can be obtained by dicing the bulk-shaped assembly 200 filled with the magnetic material-resin composite.

In another embodiment, a plurality of coils 120 may be formed on the support member 110, and then the magnetic resin composite may be individually filled in units of the inductor 100 to be obtained. In this case, only a plurality of inductors can be obtained by dicing the supporting member 110 only.

21 is a view showing the surface of the body part by cutting according to an embodiment.

The surface of the body part 130 is coated with silica or insulation resin or the like so as to prevent plating blur caused by the conductivity of the magnetic material resin composite which is the material of the inductor body part 130, An external electrode material (Cu, Ag, Ni) may be applied to the inner and outer lead terminals of the semiconductor device.

After the cutting process is performed, an insulating layer may be formed on the body part 130 to prevent plating blur. For example, as a metal magnetic material of the magnetic body resin composite material, which is a material of the body part 130, a metal containing Fe as a main component may be used, which may cause plating smear during plating after forming the external electrode.

Accordingly, the irregularities on the surface of the body part 130 can be minimized to prevent the plating current from concentrating when the plating current is applied. That is, as shown in FIG. 21, the body part 130 has a hemispherical shape in which the exposed and exposed surface of the metal magnetic body is flattened, or a part of the spherical shape is cut out, and the surface is flat. Current concentration can be prevented.

In addition, an insulating layer may be applied to the surface of the body portion 130 (excluding the portion corresponding to the external electrode) in order to prevent plating smearing. The insulating layer may be formed of at least one of a glass-based material containing Si, an insulating resin, and a plasma, and specifically, a glass-based or insulating resin containing Si may be printed and dipped And the insulating material is also subjected to plasma treatment. For example, it is possible to prevent the plating blur by applying an insulating polymer on the side and upper and lower surfaces of the body part 130 and curing the same.

A part of the coil 120 is drawn out to form a lead plating layer of Cu plating on the lead terminal. Particularly, the Cu plating plated layer is formed by forming an insulating layer on the body portion 130 and then performing Cu plating on the exposed portion of the electrode lead-out terminal (external electrode forming terminal) to which the insulating material is not applied . Specifically, in order to increase the contact force between the external electrode terminals and not separately apply Ag, Cu, or the like for forming the external electrode, the lead-out terminal portion of the coil is plated with a predetermined thickness or more, It is possible to perform Ni and Sn plating without adding external electrode coating.

On the other hand, when at least one of Ag and Cu is coated on the Cu line plating layer to form an external electrode, a wider inner and outer contact areas can be ensured and a lower resistance can be obtained.

22 is a view for explaining the size of a fixed frame according to an embodiment.

FIG. 22A is a diagram showing a schematic structure of an inductor, and FIG. 22B is a diagram showing a partially cut-away perspective view of the inductor after machining.

22 (a) and 22 (b), the at least partially machined space of the support member may cause an unnecessary machining portion due to the fixing of the coil 120 to increase or a capacity loss to occur, Can be used. For this, the ratio of the fixed frame 112 can be expressed by the following equation.

0.01> (a1 + a2 + ... + an) / A> 0.6

Here, a1, a2, ..., an represent the length of the fixed frame 112, and A may represent the total length of the inductor 100. When the value of the above equation is 0.01, the position of the coil 120 may become unstable, and when it is 0.06, the capacity may decrease. At this time, the shape of the fixed frame 112 may be variously shaped like a circle, a square, or the like.

Thus, by setting the length ratio of the support member 110, high-precision mounting can be achieved with a high rated current and a low DC resistance.

23 is a view for explaining a structure of a body part according to another embodiment.

23, the inductor 100 includes a coil 120 having a space 111 formed at least partially inside the support member 110, a coil 120 disposed in the space, A body part 130 for embedding the coil 120 and an external electrode 140 formed on both sides of the body part 130 connected to the coil 120. [ Here, the body part 130 may be coated with a different kind of sheet, and the body part 130 to which the dissimilar sheet is applied may be embedded with the supporting member 110 and the coil 120.

23 (a) shows a state in which an acupuncture powder is inserted into an outer cover sheet. Inside the coils 120 are arranged, powders of fine powder and coarse powder are mixed, and acicular powder is formed in a horizontal array .

23 (b) shows a state in which needle-shaped powder is inserted into a portion where the coil 120 is disposed. In the inside where the coil 120 is disposed, the needle-shaped powder is arranged in a vertical array, May be mixed and formed.

FIG. 23C shows a state in which the needle-shaped powder is inserted into the entire body. In the interior where the coil 120 is disposed, the needle-like powder is formed in a vertical array, and the cover sheet is formed in a transverse array in the needle-shaped powder.

By adjusting the ratio of the needle powder, it is possible to maximize the magnetic field efficiency within a limited size.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. For example, it is to be understood that the techniques described may be performed in a different order than the described methods, and / or that components of the described systems, structures, devices, circuits, Lt; / RTI > or equivalents, even if it is replaced or replaced.

Therefore, other implementations, other embodiments, and equivalents to the claims are also within the scope of the following claims.

Claims (22)

And an external electrode disposed on an outer surface of the body and connected to a lead-out terminal of the coil, wherein the coil is wound in a spiral manner,
Wherein the body portion includes a metal magnetic substance and a resin,
And an outer side surface of the outer side surface of the body portion where the outer electrode connected to the lead-out terminal of the coil is formed is a cut surface.
The method according to claim 1,
And an outer side surface formed on a radially outer side of the wound coil is formed as a cut surface.
The method according to claim 1,
Further comprising a support member having an at least partially machined space,
Said at least partially worked space penetrating said support member,
Wherein the coil is disposed in the at least partially machined space.
The method of claim 3,
And the lead-out terminal of the coil is disposed in the at least partly machined space.
The method of claim 3,
Wherein the support member is a copper clad laminate (CCL), a rolled copper plate, a NiFe rolled copper plate, a Cu alloy plate, a ferrite substrate, or a flexible substrate.
The method of claim 3,
Wherein the coil is disposed so as to have a space gap with the support member,
And the bottom surface of the coil is not in contact with the support member.
The method according to claim 1,
A lead plating layer formed on the lead terminal; Further comprising:
And the lead terminal is connected to the external electrode through the pre-plating layer.
8. The method of claim 7,
The external electrode may be formed by applying at least one of nickel (Ni) and tin (Sn) to the pre-plating layer, or silver (Ag) or copper ) And then applying at least one of nickel (Ni) or tin (Sn) thereon.
The method according to claim 1,
Wherein the body portion is filled with the metal magnetic substance having at least two particle sizes.
The method according to claim 1,
Wherein the body is formed by molding a magnetic resin composite including the metal magnetic material and the resin into a sheet shape and pressing and curing on the upper and lower surfaces of the coil.
The method according to claim 1,
And a metal magnetic body, at least a portion of which is cut off, is disposed on a side surface of the body portion.
12. The method of claim 11,
Wherein the metal magnetic body, at least a portion of which is cut off, has a shape in which a portion of a planarized hemispherical or planarized sphere is cut out.
12. The method of claim 11,
Wherein the side surface of the body on which the metal magnetic body at least partially cut is disposed is flat.
12. The method of claim 11,
And a side surface of the body where the metal magnetic body at least partially cut is disposed has an empty space.
The method according to claim 1,
An insulating layer disposed on a surface of the body; Further comprising an inductor.
16. The method of claim 15,
Wherein the insulating layer comprises at least one of a glass-based material containing silicon (Si), an insulating resin, and a plasma.
The method according to claim 1,
Wherein the inductor is a power inductor.
Preparing a spirally wound coil;
Pressing and curing a magnetic sheet including a magnetic metal and a resin on the upper and lower surfaces of the coil to form a body for receiving the coil;
Cutting the outer surface of the body portion so that the lead-out terminal of the coil is exposed; And
Forming an outer electrode on the outer surface formed by the cut surface, the outer electrode being connected to a lead terminal of the coil; Wherein the inductor is made of a metal.
19. The method of claim 18,
The step of cutting the outer surface of the body part comprises:
And cutting the outer surface formed on the radially outer side of the wound coil.
19. The method of claim 18,
Placing the coil in an at least partially machined space of a support member; Further comprising:
Wherein the at least partially processed space passes through the support member.
19. The method of claim 18,
The step of forming the body part comprises:
Pressing and curing a first magnetic sheet, which is formed into a sheet form, on a top surface of the coil, the magnetic resin composite comprising a metal magnetic material and a resin mixture; And
Pressing and curing a second magnetic sheet formed by molding a magnetic resin composite including a metal magnetic material and a resin mixture into a sheet on the lower surface of the coil; Wherein the inductor is made of a metal.
22. The method of claim 21,
The step of pressing and hardening the second magnetic material sheet comprises:
Wherein the number of stacked layers of the second magnetic material sheet and the magnetic sheet further stacked on the first magnetic material sheet is adjusted so that the coil is disposed in the center of the inductor.

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