WO2016039517A1 - 파워 인덕터 - Google Patents
파워 인덕터 Download PDFInfo
- Publication number
- WO2016039517A1 WO2016039517A1 PCT/KR2015/004137 KR2015004137W WO2016039517A1 WO 2016039517 A1 WO2016039517 A1 WO 2016039517A1 KR 2015004137 W KR2015004137 W KR 2015004137W WO 2016039517 A1 WO2016039517 A1 WO 2016039517A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- power inductor
- magnetic
- metal powder
- metal
- thermally conductive
- Prior art date
Links
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/02—Fixed inductances of the signal type without magnetic core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
Definitions
- the present invention relates to a power inductor, and more particularly, to a power inductor capable of increasing capacitance.
- Power inductors are mainly provided in power supply circuits such as DC-DC converters in portable devices. Such power inductors have been increasingly used in place of the conventional coiled choke coil patterns (Choke Coil) in accordance with the high frequency and miniaturization of the power circuit. In addition, power inductors are being developed in the direction of miniaturization, high current, and low resistance according to the size reduction and multifunction of portable devices.
- the power inductor may be manufactured in the form of a laminate in which ceramic sheets made of a plurality of ferrites or low dielectric constant dielectrics are stacked.
- a metal pattern is formed on the ceramic sheet in the form of a coil pattern, and the coil pattern formed on each ceramic sheet is connected by conductive vias formed in each ceramic sheet, and overlaps along the vertical direction in which the sheets are stacked. Can be achieved.
- the body constituting such a power inductor is conventionally manufactured using a magnetic material composed of quaternary systems of nickel (Ni) -zinc (Zn) -copper (Cu) -iron (Fe).
- the magnetic material may not implement the high current characteristic required by recent portable devices because the saturation magnetization value is lower than that of the metal material. Therefore, by manufacturing the body constituting the power inductor using metal powder, the saturation magnetization value can be relatively increased as compared with the case in which the body is made of magnetic material.
- the saturation magnetization value can be relatively increased as compared with the case in which the body is made of magnetic material.
- eddy current loss and hysteresis loss at high frequencies may increase, resulting in a serious loss of material.
- a structure insulating a polymer between metal powders is applied.
- a power inductor manufactured using a metal powder and a polymer has a problem in that inductance is lowered as the temperature increases. That is, the temperature of the power inductor increases due to the heat generation of the portable device to which the power inductor is applied, and as a result, the inductance decreases while the metal powder forming the body of the power inductor is heated.
- such a power inductor has a limit in increasing capacity because one substrate is provided inside the body and a coil pattern is formed on both sides of the substrate.
- the present invention provides a power inductor capable of improving stability to temperature and thus preventing a decrease in inductance.
- the present invention provides a power inductor capable of increasing capacitance.
- the present invention provides a power inductor capable of improving the permeability.
- a power inductor includes a body; At least two substrates provided in the body; And at least two coils each formed on the at least two substrates; And at least two external electrodes respectively connected to the at least two coils and formed outside the body.
- the body comprises a metal powder, a polymer and a thermally conductive filler.
- the metal powder includes a metal alloy powder including iron.
- the thermally conductive filler includes one or more selected from the group consisting of MgO, AlN, carbon-based materials.
- the thermally conductive filler is included in an amount of 0.5wt% to 3wt% with respect to 100wt% of the metal powder.
- the thermally conductive filler has a size of 0.5 ⁇ m to 100 ⁇ m.
- the substrate is bonded to the copper foil on both sides of the metal plate containing iron.
- the plurality of external electrodes are formed spaced apart from each other on the same side of the body, or formed on different sides of the body.
- the magnetic layer has a magnetic permeability higher than that of the body.
- the magnetic layer is formed including a thermally conductive filler.
- At least two or more substrates each having a coil pattern formed on at least one surface may be provided in a body to form a plurality of coils in one body, thereby increasing the capacity of the power inductor.
- a plurality of power inductors may be implemented in one body by connecting coils formed on at least two substrates in the body to different external electrodes. Therefore, the volume of the power inductor can be reduced to reduce the area occupied by the power inductor on the circuit.
- the body may be manufactured including a metal powder, a polymer, and a thermally conductive filler. Accordingly, the body may be discharged to the outside by heating the metal powder to prevent the temperature rise of the body, thereby reducing the inductance. You can prevent it.
- FIG. 1 is a perspective view of a power inductor according to an embodiment of the present invention.
- FIG. 2 and 3 are cross-sectional views taken along the line A-A 'and line B-B' of FIG.
- FIG. 4 is a perspective view of a power inductor according to another embodiment of the present invention.
- 5 to 7 are cross-sectional views of a power inductor according to other embodiments of the present invention.
- FIGS. 8 to 10 are cross-sectional views illustrating a method of manufacturing a power inductor according to an embodiment of the present invention.
- FIG. 1 is a perspective view of a power inductor according to an exemplary embodiment of the present invention
- FIG. 2 is a cross-sectional view taken along the line AA ′ of FIG. 1
- FIG. 3 is a cut along the line BB ′ of FIG. 2. It is a cross section.
- a power inductor includes a body 100, at least two substrates 210, 220, and 200 provided in the body 100, and at least two substrates.
- Coil patterns 310, 320, 330, and 340; 300 formed on at least one surface of each of the first and second surfaces of the body 200 are provided on two opposite sides of the body 100 and connected to the coil patterns 310 and 320, respectively.
- the second external electrodes 410 and 420 are provided to be spaced apart from the first external electrodes 410 and 420 on two opposite sides of the body 100 and connected to the coil patterns 330 and 340, respectively.
- Electrodes 510, 520; and 500 That is, two or more power inductors are implemented in one body 100 by connecting the coil patterns 300 formed on at least two substrates 200 by different external electrodes 400 and 500.
- the body 100 may be, for example, a hexahedral shape. However, the body 100 may have a shape of a polyhedron other than a hexahedron.
- the body 100 may include a metal powder 110 and a polymer 120, and may further include a thermally conductive filler 130. That is, the body 100 may include the metal powder 110 and the polymer 120, and may include the metal powder 110, the polymer 120, and the thermally conductive filler 130.
- the metal powder 110 may have an average particle diameter of 1 ⁇ m to 50 ⁇ m.
- the metal powder 110 may use a single particle or two or more kinds of particles of the same size, or may use a single particle or two or more kinds of particles having a plurality of sizes.
- the first metal particles having an average size of 30 ⁇ m and the second metal particles having an average size of 3 ⁇ m may be mixed and used.
- the filling rate of the body 100 may be increased to maximize the capacity.
- voids may occur between the metal powder of 30 ⁇ m, and thus the filling rate may be lowered.
- the filling rate can be increased by mixing a smaller 3 ⁇ m metal powder between the 30 ⁇ m metal powder.
- the metal powder 110 may use a metal including iron (Fe), for example iron-nickel (Fe-Ni), iron-nickel-silicon (Fe-Ni-Si), iron-aluminum-silicon It may include one or more metals selected from the group consisting of (Fe-Al-Si) and iron-aluminum-chromium (Fe-Al-Cr). That is, the metal powder 110 may be formed of a metal alloy having magnetic structure or magnetic properties including iron, and may have a predetermined permeability. In addition, the surface of the metal powder 110 may be coated with a magnetic material, and the metal powder 110 may be coated with a material having a different permeability.
- Fe iron
- Fe-Ni iron-nickel
- Fe-Si-Si iron-aluminum-silicon
- Fe-aluminum-silicon It may include one or more metals selected from the group consisting of (Fe-Al-Si) and iron-aluminum-chromium (
- the magnetic body may be formed of a metal oxide magnetic material, and may be formed of a nickel oxide magnetic material, a zinc oxide magnetic material, a copper oxide magnetic material, a manganese oxide magnetic material, a cobalt oxide magnetic material, a barium oxide magnetic material, and a nickel-zinc-copper oxide magnetic material.
- a metal oxide magnetic material may be formed of a nickel oxide magnetic material, a zinc oxide magnetic material, a copper oxide magnetic material, a manganese oxide magnetic material, a cobalt oxide magnetic material, a barium oxide magnetic material, and a nickel-zinc-copper oxide magnetic material.
- One or more oxide magnetic materials selected may be used. That is, the magnetic body coated on the surface of the metal powder 110 may be formed of a metal oxide containing iron, it is preferable to have a higher permeability than the metal powder (110). In addition, the metal powder 110 may have a surface coated with at least one insulator.
- the metal powder 110 may be coated with an oxide on a surface thereof, or may be coated with an insulating polymer material such as parylene.
- the oxide may be formed by oxidizing the metal powder 110, and may be formed of TiO 2 , SiO 2 , ZrO 2 , SnO 2 , NiO, ZnO, CuO, CoO, MnO, MgO, Al 2 O 3 , Cr 2 O 3 , Fe One selected from 2 O 3 , B 2 O 3 and Bi 2 O 3 may be coated.
- the surface of the metal powder 110 may be coated using various insulating polymer materials in addition to parylene.
- the metal powder 110 may be coated with an oxide having a dual structure, and may be coated with a dual structure of an oxide and a polymer material.
- the metal powder 110 may be coated with an insulating material after the surface is coated with a magnetic material.
- the surface of the metal powder 110 is coated with an insulator, it is possible to prevent a short due to contact between the metal powder 110.
- the polymer 120 may be mixed with the metal powder 110 to insulate between the metal powders 110. That is, the metal powder 110 may have a problem in that the loss of materials is increased due to high eddy current loss and hysteresis loss at a high frequency. 120).
- the polymer 120 may include one or more polymers selected from the group consisting of epoxy, polyimide, and liquid crystal crystalline polymer (LCP), but is not limited thereto.
- the polymer 120 may be formed of a thermosetting resin to provide insulation between the metal powders 110.
- thermosetting resins include Novolac Epoxy Resin, Phenoxy Type Epoxy Resin, BPA Type Epoxy Resin and BPF Type Epoxy Resin.
- the polymer 120 may be included in an amount of 2.0 wt% to 5.0 wt% with respect to 100 wt% of the metal powder.
- the content of the polymer 120 is increased, the volume fraction of the metal powder 110 is lowered, so that the effect of increasing the saturation magnetization value is not properly implemented, and the magnetic properties of the body 100, that is, the permeability may be reduced.
- the content of the polymer 120 decreases, a strong acid or strong base solution used in the manufacturing process of the inductor may penetrate into the inside, thereby reducing the inductance characteristic. Therefore, the polymer 120 may be included in a range not to lower the saturation magnetization value and inductance of the metal powder 110.
- the thermally conductive filler 130 is included to solve the problem that the body 100 is heated by external heat. That is, the metal powder 110 of the body 100 may be heated by external heat, and the heat conductive filler 130 may be included to release heat of the metal powder 110 to the outside.
- the thermally conductive filler 130 may include one or more selected from the group consisting of MgO, AlN, and carbon-based materials, but is not limited thereto.
- the carbon-based material may include carbon and have various shapes, for example, graphite, carbon black, graphene, graphite, or the like.
- the thermally conductive filler 130 may be included in an amount of 0.5 wt% to 3 wt% with respect to 100 wt% of the metal powder 110.
- the thermally conductive filler 130 may have, for example, a size of 0.5 ⁇ m to 100 ⁇ m. That is, the thermally conductive filler 130 may have a size larger or smaller than the metal powder 110.
- the body 100 may be manufactured by stacking a plurality of sheets made of a material including the metal powder 110, the polymer 120, and the thermally conductive filler 130. Here, when the body 100 is manufactured by stacking a plurality of sheets, the content of the thermally conductive filler 130 of each sheet may be different.
- the content of the thermally conductive filler 130 in the sheet may increase as it moves toward the upper side and the lower side with respect to the substrate 200.
- the body 100 is formed by printing a paste made of a material including the metal powder 110, the polymer 120, and the thermally conductive filler 130 to a predetermined thickness, or by pressing such paste into a mold and pressing the paste. If necessary, various methods may be applied and formed. In this case, the number of sheets laminated to form the body 100 or the thickness of the paste printed with a predetermined thickness may be determined to an appropriate number or thickness in consideration of electrical characteristics such as inductance required by the power inductor.
- At least two substrates 210, 220, and 200 may be provided inside the body 100.
- the at least two substrates 200 may be provided along the major axis direction of the body 100 inside the body 100 and spaced apart at a predetermined interval in the thickness direction of the body 100.
- the substrate 200 may be made of, for example, copper clad lamination (CCL) or a magnetic metal.
- CCL copper clad lamination
- the substrate 200 may be made of a magnetic metal to increase the effective permeability and facilitate the implementation of the capacity. That is, CCL is manufactured by bonding a copper foil to glass-reinforced fibers. Since CCL does not have a permeability, the permeability of the power inductor is reduced.
- the magnetic magnetic material has a magnetic permeability, so that the magnetic permeability of the power inductor is not lowered.
- Substrate 200 using such a magnetic metal material is a metal containing iron, for example iron-nickel (Fe-Ni), iron-nickel-silicon (Fe-Ni-Si), iron-aluminum-silicon (Fe-Al -Si) and iron-aluminum-chromium (Fe-Al-Cr) can be produced by bonding a copper foil to a plate of a predetermined thickness consisting of at least one metal selected from the group consisting of.
- the substrate 200 may be manufactured by manufacturing an alloy made of at least one metal including iron into a plate shape having a predetermined thickness, and bonding a copper foil to at least one surface of the metal plate.
- at least one conductive via (not shown) may be formed in a predetermined region of the substrate 200, and the coil patterns 310 and 320 formed at the upper side and the lower side of the substrate 200 by the conductive via may be electrically connected. Can be connected.
- the conductive via may be formed by forming a via (not shown) that penetrates the substrate 200 along the thickness direction, and then fills the via with a conductive paste.
- the coil patterns 310, 320, 330, 340; 300 may be formed on at least one side of each of the at least two substrates 200, preferably on both sides.
- the coil patterns 310 and 320 may be formed on the lower and upper portions of the first substrate 210, respectively, and may be electrically connected to each other by conductive vias formed in the first substrate 210.
- the coil patterns 330 and 340 may be formed on the lower and upper portions of the second substrate 220 and electrically connected to each other by conductive vias formed on the second substrate 220.
- the coil patterns 310 and 330 and the coil patterns 320 and 340 are formed to be exposed in opposite directions.
- the plurality of coil patterns 300 may be formed in a spiral shape in a predetermined area of the substrate 200, for example, from the center portion to an outward direction, and two coil patterns formed on each substrate 200 may be connected to one another. Coil can be achieved. That is, two or more coils may be formed in one body 100.
- the coil patterns 310 and 330 on the upper side of the substrate 200 and the coil patterns 320 and 340 on the lower side may be formed in the same shape.
- the plurality of coil patterns 300 may be formed to overlap each other, or the lower coil patterns 320 and 340 may be formed to overlap the region where the upper coil patterns 310 and 330 are not formed.
- the coil pattern 310 on the first substrate 210 and the coil pattern 330 on the second substrate 220 are exposed in the same direction but are formed to be spaced apart from each other without being overlapped with each other.
- the coil pattern 320 on the first substrate 210 and the coil pattern 340 on the second substrate 220 are exposed in the same direction but are formed to be spaced apart from each other without being overlapped with each other.
- the coil patterns 310 and 320 on the first substrate 210 and the coil patterns 330 and 340 on the second substrate 220 may be connected by the first and second external electrodes 400 and 500, respectively.
- the plurality of coil patterns 300 may be formed by, for example, thick film printing, coating, deposition, plating, and sputtering.
- the plurality of coil patterns 300 and the conductive vias may be formed of a material including at least one of silver (Ag), copper (Cu), and a copper alloy, but is not limited thereto.
- a plating process for example, a metal layer, for example, a copper layer may be formed on each substrate 200 by a plating process, and may be patterned by a lithography process. That is, the coil pattern 300 may be formed by forming a copper layer by a plating process using a copper foil formed on the surface of the substrate 200 as a seed layer and patterning it.
- the coil pattern 300 formed on the substrate 200 may be formed in a multilayer.
- a plurality of coil patterns may be further formed above the coil pattern 310 formed on the upper side of the first substrate 210, and the lower side of the coil pattern 320 formed on the lower side of the second substrate 210.
- a plurality of coil patterns may be further formed.
- an insulating layer may be formed between the lower layer and the upper layer, and conductive vias (not shown) may be formed in the insulating layer to connect the multilayer coil patterns.
- the first external electrodes 410, 420; 400 may be formed at both ends of the body 100.
- the external electrodes 400 may be formed on two side surfaces facing each other in the long axis direction of the body 100.
- the first external electrodes 410 and 420 may be electrically connected to the coil patterns 310 and 320 formed on the first substrate 210. That is, at least one end of the coil patterns 310 and 320 is exposed to the outside of the body 100 in a direction opposite to each other, and the first external electrodes 410 and 420 are connected to the ends of the coil patterns 310 and 320. Can be formed.
- the first external electrodes 410 and 420 may be formed by immersing the body 100 in a conductive paste, or by patterning and forming both ends of the body 100 through various methods such as printing, deposition, and sputtering.
- the first external electrodes 410 and 420 may be formed of a metal having electrical conductivity, for example, at least one metal selected from the group consisting of gold, silver, platinum, copper, nickel, palladium, and alloys thereof. Can be formed.
- the first external electrodes 410 and 420 may further have a nickel-plated layer (not shown) or a tin plating layer (not shown) on the surface thereof.
- the second external electrodes 510, 520; 500 may be formed at both ends of the body 100, and may be spaced apart from the first external electrodes 410, 420. That is, the first external electrodes 410 and 420 and the second external electrodes 510 and 520 may be formed on the same side of the body 100, and they are formed spaced apart from each other.
- the second external electrodes 510 and 520 may be electrically connected to the coil patterns 330 and 340 formed on the second substrate 220. That is, at least one end of the coil patterns 330 and 340 is exposed to the outside of the body 100 in a direction opposite to each other and the second external electrodes 510 and 520 are connected to the ends of the coil patterns 330 and 340. Can be formed.
- the coil patterns 330 and 340 may be exposed in the same direction as the coil patterns 310 and 320, but may be connected to the first and second external electrodes 400 and 500 by being exposed at a predetermined interval without being overlapped with each other.
- the second external electrodes 510 and 520 may be simultaneously formed in the same process as the first external electrodes 410 and 410. That is, the second external electrodes 510 and 520 may be formed by immersing the body 100 in the conductive paste, or by patterning and forming both ends of the body 100 through various methods such as printing, deposition, and sputtering. .
- the second external electrodes 510 and 520 may be formed of a metal having electrical conductivity, for example, at least one metal selected from the group consisting of gold, silver, platinum, copper, nickel, palladium, and alloys thereof. Can be formed.
- the first and second external electrodes 410 and 420 may further have a nickel-plated layer (not shown) or a tin plating layer (not shown) on their surfaces.
- an insulating layer 600 may be further formed between the plurality of coil patterns 300 and the body 100 to insulate the plurality of coil patterns 300 and the metal powder 110. That is, the insulating layer 600 may be formed on the upper and lower portions of the substrate 200 to cover the plurality of coil patterns 300, respectively.
- the insulating layer 600 may include one or more materials selected from the group consisting of epoxy, polyimide, and liquid crystal crystalline polymer. That is, the insulating layer 600 may be made of the same material as the polymer 120 forming the body 100.
- the insulating layer 600 may be coated with an insulating polymer material such as parylene on the coil pattern 300. That is, the insulating layer 600 may be coated with a uniform thickness along the step of the coil pattern 300.
- the insulating layer 600 may be formed on the coil pattern 300 using an insulating sheet.
- the body 100 As described above, in the power inductor according to the embodiment of the present invention, at least two or more substrates 200 having coil patterns 300 formed on at least one surface thereof are provided in the body 100, and a plurality of the inductors may be formed in one body 100. Coils may be formed, and they may be connected to different external electrodes 400 and 500 to implement a plurality of power inductors in one body 100. Therefore, the volume of the power inductor can be reduced to reduce the area occupied by the power inductor on the circuit. In addition, since two power inductors are implemented in one body 100, the capacity of the power inductor may be increased. In addition, the body 100 may be manufactured by including the metal powder 110, the polymer 120, and the thermally conductive filler 130.
- the heat of the body 100 due to the heating of the metal powder 110 can be released to the outside to prevent the temperature rise of the body 100, thereby preventing problems such as inductance lowering.
- the magnetic permeability of the power inductor by forming the substrate 200 inside the body 100 using a magnetic metal material.
- first external electrodes 410 and 420 and second external electrodes 510 and 520 are formed in different directions. That is, the first external electrodes 410 and 420 and the second external electrodes 510 and 520 may be formed on side surfaces of the body 100 that are perpendicular to each other. For example, the first external electrodes 410 and 420 may be formed on two side surfaces of the body 100 that face each other in the major axis direction, and the second external electrodes 510 and 520 may be arranged in the minor direction of the body 100. It can be formed on two opposite sides.
- FIG. 5 is a cross-sectional view of a power inductor according to another embodiment of the present invention.
- a power inductor may include a body 100, at least two substrates 210, 220, and 200 provided inside the body 100, and at least two substrates 200.
- Coil patterns 310, 320, 330, 340; 300 formed on at least one surface of each of the first and second external electrodes provided on two opposite sides of the body 100 and connected to the coil patterns 310, 320, respectively.
- 410, 420; 400, and second external electrodes 510 provided on the two opposite sides of the body 100, spaced apart from the first external electrodes 410, 420, and connected to the coil patterns 330, 340, respectively.
- the insulation layer 500 may be further formed on the coil pattern 300.
- the magnetic layers 710, 720; 700 may be provided in at least one region of the body 100. That is, the first magnetic layer 710 may be formed on the upper surface of the body 100, and the second magnetic layer 720 may be formed on the lower surface of the body 100.
- the first and second magnetic layers 710 and 720 are provided to increase the magnetic permeability of the body 100, and may be made of a material having a higher magnetic permeability than the body 100.
- the permeability of the body 100 is 20 and the first and second magnetic layers 710 and 720 may be provided to have permeability of 40 to 1000.
- the first and second magnetic layers 710 and 720 may be manufactured using, for example, magnetic powder and epoxy.
- the first and second magnetic layers 710 and 720 may be formed of a material having a higher magnetism than the magnetic body of the body 100 or have a higher content of the magnetic body so as to have a higher magnetic permeability than the body 100.
- the polymer may be added at 15 wt% with respect to 100 wt% of the metal powder.
- the magnetic powder is nickel magnetic (Ni Ferrite), zinc magnetic (Zn Ferrite), copper magnetic (Cu Ferrite), manganese magnetic (Mn Ferrite), cobalt magnetic (Co Ferrite), barium magnetic (Ba Ferrite) and nickel-zinc
- Ni Ferrite nickel magnetic
- Zn Ferrite zinc magnetic
- Cu Ferrite copper magnetic
- Mn Ferrite manganese magnetic
- Co Ferrite cobalt magnetic
- nickel-zinc nickel-zinc
- One or more or one or more oxide magnetic materials thereof selected from the group consisting of -Ni-Zn-Cu Ferrite can be used.
- the magnetic layer 600 may be formed using metal alloy powder containing iron or metal alloy oxide containing iron.
- the magnetic powder may be coated on the metal alloy powder to form the magnetic powder.
- one or more oxide magnetic materials selected from the group consisting of nickel oxide magnetic materials, zinc oxide magnetic materials, copper oxide magnetic materials, manganese oxide magnetic materials, cobalt oxide magnetic materials, barium oxide magnetic materials, and nickel-zinc-copper oxide magnetic materials, for example, iron It may be coated on the metal alloy powder to form a magnetic powder. That is, the magnetic oxide powder may be formed by coating the metal oxide including iron on the metal alloy powder.
- the first and second magnetic layers 710 and 720 may further include a thermally conductive filler in the metal powder and the polymer. The thermally conductive filler may be contained in an amount of 0.5 wt% to 3 wt% with respect to 100 wt% of the metal powder.
- the first and second magnetic layers 710 and 720 may be manufactured in the form of a sheet and may be provided on the upper and lower portions of the body 100 in which a plurality of sheets are stacked.
- the body 100 after forming a body 100 for printing a paste made of a material including the metal powder 110, the polymer 120 and the thermally conductive filler 130 to a predetermined thickness or by inserting the paste into a mold to press the body 100
- the first and second magnetic layers 710 and 720 may be formed on the top and the bottom of the bottom surface, respectively.
- the magnetic layers 710 and 720 may be formed using a paste, and the magnetic layers 710 and 720 may be formed by applying a magnetic material to the upper and lower portions of the body 100.
- third and fourth magnetic layers 730 and 740 are disposed on the upper and lower portions between the body 100 and the at least two substrates 200. Further, as shown in FIG. 7, fifth and sixth magnetic layers 750 and 760 may be further provided therebetween. That is, at least one magnetic layer 700 may be provided in the body 100.
- the magnetic layer 700 may be manufactured in the form of a sheet and may be provided between the bodies 100 in which a plurality of sheets are stacked. That is, at least one magnetic layer 700 may be provided between the plurality of sheets for manufacturing the body 100.
- a magnetic layer may be formed during printing.
- the magnetic layer can be pressed in between.
- the magnetic layer 700 may be formed using a paste.
- a soft magnetic material may be applied to form the magnetic layer 700 in the body 100.
- FIGS. 8 to 10 are cross-sectional views sequentially illustrating a method of manufacturing a power inductor according to an embodiment of the present invention.
- At least two substrates 210 and 220 may be provided, and coil patterns 310 and 320 having a predetermined shape on at least one surface, preferably, one surface and the other surface of each of the at least two substrates 210 and 220. , 330 and 340, respectively.
- the substrates 210 and 220 may be made of CCL or a magnetic metal, and the like, it is preferable to use a magnetic metal that can increase the effective permeability and facilitate capacity implementation.
- the substrates 210 and 220 may be manufactured by bonding a copper foil to one side and the other side of a metal plate having a predetermined thickness made of a metal alloy containing iron.
- the coil patterns 310, 320, 330, and 340 may be formed as coil patterns formed in a spiral shape from a predetermined region of the substrate 210, 220, for example, a central portion thereof.
- the coil patterns 310 and 330 are formed on one surface of the substrates 210 and 220, and the conductive vias are formed through the predetermined regions of the substrates 210 and 220 and the conductive material is filled.
- Coil patterns 320 and 340 may be formed on the other surface of 220.
- the conductive via may be formed by forming a via hole in the thickness direction of the substrates 210 and 220 by using a laser or the like, and then filling the via hole with a conductive paste.
- the coil patterns 310, 320, 330, and 340 may be formed by, for example, a plating process.
- a photosensitive film pattern having a predetermined shape is formed on one surface of the first substrate 210, and a plating process using a copper foil on the first substrate 210 as a seed is performed to expose the first substrate 210. It can form by growing a metal layer from the surface, and removing a photosensitive film.
- the coil pattern 320 may be formed on the other surface of the first substrate 210 in the same manner as the coil pattern 310.
- the coil patterns 330 and 340 may be formed on one surface and the other surface of the second substrate 220 in the same manner as the coil patterns 310 and 320.
- the coil patterns 310, 320, 330, and 340 may be formed in multiple layers.
- an insulating layer may be formed between the lower layer and the upper layer, and conductive vias (not shown) may be formed in the insulating layer to connect the multilayer coil patterns.
- the coil patterns 310, 320, 330, and 340 are formed on one surface and the other surface of the substrate 210 and 220, respectively, and then the insulating layer 600 is formed to cover the coil patterns 310, 320, 330, and 340. do.
- the insulating layer 600 may be formed by closely contacting the sheet including one or more materials selected from the group consisting of epoxy, polyimide, and liquid crystal crystalline polymer on the coil patterns 310, 320, 330, and 340.
- a plurality of sheets 100a to 100h made of a material including a metal powder 110 and a polymer 120 are prepared.
- the plurality of seeds 100a to 100i may be made of a material further including a thermally conductive filler 130.
- the metal powder 110 may use a metal material including iron (Fe), and the polymer 120 may use an epoxy, polyimide, or the like, which may insulate the metal powder 110 from each other.
- 130 may use MgO, AlN, a carbon-based material that can release the heat of the metal powder 110 to the outside.
- the surface of the metal powder 110 may be coated with a magnetic material, for example, a metal oxide magnetic material.
- the polymer 120 may be included in an amount of 2.0 wt% to 5.0 wt% with respect to 100 wt% of the metal powder, and the thermally conductive filler 130 may be 0.5 wt% to 3 wt% with respect to 100 wt% of the metal powder 110. It may be included in the content.
- the plurality of sheets 100a to 100i are disposed above and below and between at least two substrates 210 and 220 on which coil patterns 310, 320, 330, and 340 are formed.
- at least one sheet 100a is provided between at least two substrates 210 and 220, and a plurality of sheets 100b to 100e are provided above the substrate 210, and the substrate 220 is provided.
- a plurality of sheets 100f to 100i may be provided below.
- the plurality of sheets 100a to 100i may have different contents of the thermally conductive filler 130.
- the content of the thermally conductive filler 130 may increase from one side and the other side of the substrate 200 toward the upper side and the lower side. That is, the content of the thermally conductive fillers 130 of the sheets 100c and 100f positioned above and below the sheets 100b and 100e in contact with the substrates 210 and 220 is less than the thermally conductive fillers of the sheets 100b and 100e.
- the content of the thermally conductive fillers 130 of the sheets 100d and 100h which are higher than the content of 130 and positioned above and below the sheets 100c and 100f is greater than that of the thermally conductive fillers 130 of the sheets 100c and 100f. It may be higher than the content. As the distance from the substrates 210 and 220 increases, the content of the thermally conductive filler 130 may increase, thereby further improving heat transfer efficiency.
- a plurality of sheets 100a to 100i are stacked with at least two substrates 210 and 220 interposed therebetween, and then pressurized and molded to form a body 100.
- the first and second external electrodes 400 and 500 may be formed at both ends of the body 100 to be electrically connected to the drawn portions of the coil patterns 310, 320, 330, and 340.
- the first and second external electrodes 400 and 500 may be spaced apart from each other after immersing the body 100 in the conductive paste, printing the conductive paste on both ends of the body 10, or forming the paste in a manner such as deposition and sputtering. It can be formed by patterning.
- the conductive paste may be a metal material capable of imparting electrical conductivity to the first and second external electrodes 400 and 500.
- a nickel plating layer and a tin plating layer may be further formed on the surfaces of the first and second external electrodes 400 and 500 if necessary.
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Abstract
Description
Claims (12)
- 바디;상기 바디 내부에 마련된 적어도 둘 이상의 기재; 및상기 적어도 둘 이상의 기재 상에 각각 형성된 적어도 둘 이상의 코일; 및상기 적어도 둘 이상의 코일과 각각 연결되어 상기 바디 외측에 형성된 적어도 둘 이상의 외부 전극을 포함하는 파워 인덕터.
- 청구항 1에 있어서, 상기 바디는 금속 분말, 폴리머 및 열 전도성 필러를 포함하는 파워 인덕터.
- 청구항 2에 있어서, 상기 금속 분말은 철을 포함하는 금속 합금 분말을 포함하는 파워 인덕터.
- 청구항 3에 있어서, 상기 금속 분말은 표면에 자성체 및 절연체의 적어도 하나가 코팅된 파워 인덕터.
- 청구항 2에 있어서, 상기 열 전도성 필러는 MgO, AlN, 카본 계열의 물질로 구성된 군으로부터 선택된 하나 이상을 포함하는 파워 인덕터.
- 청구항 5에 있어서, 상기 열 전도성 필러는 상기 금속 분말 100wt%에 대하여 0.5wt% 내지 3wt%의 함량으로 포함되는 파워 인덕터.
- 청구항 6에 있어서, 상기 열 전도성 필러는 0.5㎛ 내지 100㎛의 크기를 갖는 파워 인덕터.
- 청구항 1에 있어서, 상기 기재는 철을 포함하는 금속판의 양면 상에 구리 포일이 접합된 파워 인덕터.
- 청구항 1에 있어서, 상기 복수의 외부 전극은 상기 바디의 동일 측면에 서로 이격되어 형성되거나, 상기 바디의 서로 다른 측면에 형성된 파워 인덕터.
- 청구항 1 내지 청구항 9 중 어느 한 항에 있어서, 상기 바디의 적어도 일 영역에 마련된 자성층을 포함하는 파워 인덕터.
- 청구항 10에 있어서, 상기 자성층은 상기 바디의 투자율보다 높은 투자율을 갖는 파워 인덕터.
- 청구항 11에 있어서, 상기 자성층은 열 전도성 필러를 포함하여 형성된 파워 인덕터.
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EP15839164.9A EP3196900A4 (en) | 2014-09-11 | 2015-04-27 | Power inductor |
CN201580048593.1A CN106688063B (zh) | 2014-09-11 | 2015-04-27 | 功率电感器 |
US15/509,850 US20170263367A1 (en) | 2014-09-11 | 2015-04-27 | Power inductor |
JP2017513226A JP2017528002A (ja) | 2014-09-11 | 2015-04-27 | パワーインダクター |
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KR10-2014-0120128 | 2014-09-11 | ||
KR20140120128 | 2014-09-11 | ||
KR1020150032403A KR101662207B1 (ko) | 2014-09-11 | 2015-03-09 | 파워 인덕터 |
KR10-2015-0032403 | 2015-03-09 |
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