KR20160018615A - Coil component and manufacturing method for the same - Google Patents

Abstract

The present invention relates to a coil component and a manufacturing method thereof. More specifically, the coil component is manufactured in a thin film type to maintain a thin thickness and enable miniaturization, prevents an efficiency lowering due to magnetic loss under a high frequency and a high current, and increases density to show high permeability, high efficiency and a high Isat value.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a coil component,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil component, and more particularly, to an inductor capable of removing noise from an IT device or the like.

An inductor is a passive element that removes noise by forming an electronic circuit together with a resistor and a capacitor. The inductor is a resonant circuit that amplifies a signal of a specific frequency band by combining with a capacitor using electromagnetic characteristics, a filter ) Circuit and the like.

On the other hand, as electronic devices such as mobile phones, notebook PCs, and multimedia products have become smaller and lighter and thinner, various inductors have been rapidly converted to chips capable of automatic surface mounting with a small size and high density. A thin film type inductor formed by mixing a magnetic powder with a resin on a coiled lead wire by plating has been developed.

A high inductance (L) or fine capacitance, a high quality factor (Q), a high self resonant frequency (SRF), a low direct current resistance (Rdc) and a high inductance A product having a rated current is required.

 In order to obtain a high inductance at a predetermined unit volume, a material having a high permeability is required. Normally, a magnetic substance having a large grain size is used in order to obtain such a high magnetic permeability.

However, such a large particle has a problem that the efficiency according to the magnetic loss (core loss) deteriorates when the frequency and the used current become large. Therefore, it is necessary to reduce the particle size in order to prevent the decrease in the efficiency at high frequencies.

However, when small particles are used, there is a problem that the inductance is reduced because the permeability is lower than that of the large particles, so it is essential to increase the permeability by increasing the filling rate. FIG. 1 is a cross-sectional view of a conventional thin-film type inductor. Since a uniform magnetic particle is used, the filling rate is low and a sufficient permeability can not be obtained.

The following Patent Document 1 discloses a coil device using a magnetic layer of a metallic magnetic powder having a particle size distribution of 5 to 30 탆. However, since the invention of Patent Document 1 is composed of magnetic particles having a uniform particle size, a sufficient filling rate can not be ensured and there is a limitation in improving the permeability.

Japanese Patent Application Laid-Open No. 2008-166455

An object of one embodiment according to the present invention is to provide an inductor having a high permeability, a high efficiency and a high Isat value by improving the packing ratio while maintaining a thin thickness and miniaturization, and a manufacturing method thereof.

In order to solve the above-described problems, according to one embodiment of the present invention,

Wherein a coil portion including a support member and a coil pattern disposed on at least one surface of the support member is disposed in the body, the body having a length of a major axis of 15 占 퐉 or more and a first magnetic And a second magnetic particle having a particle length of 5 탆 or less and a metal containing an iron (Fe) component, wherein a cross-sectional area occupied by the first magnetic particle in the thickness and width direction cross- Sectional area of the second magnetic particle, and the number of the second magnetic particles is larger than the number of the first magnetic particles.

The coil part according to one embodiment of the present invention can be manufactured in a thin film shape to maintain a thin thickness and can be downsized. In addition, it is possible to prevent a decrease in efficiency due to magnetic loss even at high frequency and high current. By improving the filling rate, high permeability, Value.

1 is a cross-sectional view of a conventional coil component.
2 is a perspective view of a coil component according to an embodiment of the present invention.
3 is a sectional view taken along the line II 'shown in FIG.
Fig. 4 is a view for schematically explaining a method of manufacturing the coil component of Fig. 2;
Fig. 5 is a photograph of a coil component according to an embodiment of the present invention, observed at a magnification of 2,000 times in a scanning electron microscope (SEM) by the cross section in the W-T direction.
Fig. 6 is a photograph of a coil part according to an embodiment of the present invention, which is observed at an enlarged size of 2,000 times in an SEM (Scanning Electron Microscope) section in the WT direction.

Hereinafter, embodiments of the present invention will be described with reference to specific embodiments and the accompanying drawings. However, the embodiments of the present invention can be modified into various other forms, and the scope of the present invention is not limited to the embodiments described below. The embodiments of the present invention are provided to enable those skilled in the art to more fully understand the present invention.

The same reference numerals are used to designate the same components in the same reference numerals in the drawings of the embodiments.

Coil parts

FIG. 2 is a schematic perspective view of a coil part according to an embodiment of the present invention, and FIG. 3 is a sectional view taken along a line I-I 'shown in FIG.

Referring to Figs. 2 and 3, a thin film coil component 10 for use in a power supply line of a power supply circuit as an example of a coil component is disclosed. The coil component may be suitably applied to chip beads, chip filters, etc. in addition to chip coil components.

The thin film coil component (10) comprises a body (50) and a support member (23). Coil patterns 42 and 44, and an external electrode 80. [

The body 50 may be in the form of a hexahedron, and L, W, and T in FIG. 2 denote the longitudinal direction, the width direction, and the thickness direction, respectively.

The body 50 may include both end faces in the thickness direction, both end faces in the longitudinal direction, and both end faces in the width direction. The body 50 may have a rectangular parallelepiped shape whose length in the longitudinal direction is greater than the length in the width direction.

The supporting member 23 formed inside the body 50 is not particularly limited as long as it can be formed by electroplating to form the coil patterns 42 and 44. For example, So that it can be formed into a thin film.

A coil pattern 42 having a coil-shaped pattern may be formed on one surface of the support member 23 and a coil pattern 44 having a coil-shaped pattern may be formed on the opposite surface of the support member 23 . One end of the coil pattern 42 formed on one side of the support member 23 may be exposed at one end in the longitudinal direction of the body 50 and a coil pattern formed on the opposite side of the support member 23 44 may be exposed at the other end surface in the longitudinal direction of the body 50.

The coil patterns 42 and 44 formed on the opposite surface of the support member 23 may be electrically connected through the via electrode 46 formed on the support member 23.

A hole may be formed in the center of the support member 23 to penetrate the support member. The hole may be filled with a magnetic material such as a metal soft magnetic material forming the body to form the core portion 71. The inductance can be improved by forming the core portion 71 filled with the magnetic substance.

External electrodes 80 may be formed on both end faces in the longitudinal direction of the body 50 to be connected to the exposed coil patterns 42 and 44. The coil patterns 42 and 44, the via electrode 46 and the external electrode 80 may be formed of a metal having excellent electrical conductivity. For example, silver (Ag), copper (Cu), nickel (Ni) , Aluminum (Al), an alloy thereof, or the like.

The body 50 includes a first magnetic particle 52 and a second magnetic particle 53. The first magnetic particle 52 and the second magnetic particle are made of iron Wherein the first magnetic particle has a major axis length of at least 15 mu m and the second magnetic particle has a minor axis length of at most 5 mu m.

3, which is a cross-sectional view of the thin-film coil component 10 of one embodiment of the present invention, the body 50 includes first magnetic particles 52 And the second magnetic particles 53 are mixed and formed.

The filling efficiency is improved by mixing the first magnetic particles 52 and the second magnetic particles 53 having different particle size distributions in this manner by forming the body 50. The magnetic permeability is thus remarkably improved and the inductance and the Isat value Can be improved.

The first magnetic particles 52 and the second magnetic particles 53 may be amorphous metals including at least three or more metals in addition to iron (Fe).

As well as the first magnetic particles 52 of the coarse particles and the second magnetic particles 53 of the fine particles are also formed of amorphous metal, the effect is advantageous for improving the performance such as inductance. When the amorphous metal is used, It can also be effective for improvement.

The first magnetic particles 52 and the second magnetic particles 53 may be formed of at least one of iron (Fe), silicon (Si), boron (B), chromium (Cr), nickel (Ni), cobalt Al), and may be an amorphous metal including at least three metals selected from the group consisting of Fe-Si-B-Cr amorphous metals.

The first magnetic particles 52 and the second magnetic particles 53 may be the same kind of amorphous metal or different kinds of amorphous metals may be selected.

The first particle size distribution D ₅₀ of the magnetic particle elements 52 may be larger second 4 to 13.5-fold compared to the particle size distribution D ₅₀ of the magnetic particles (53).

Here, the particle size distribution D ₅₀ is When the area per field of view of the SEM (Scanning Eletron Microscope) photograph taken at 1,000 times was taken as 12.5 占 퐉 ² , the particle sizes of the magnetic particles corresponding to 50 fields of view were obtained and the particle sizes were listed in ascending order of size, The particle size of the order of 50% of the total was defined as the particle size distribution D ₅₀ in that field of view.

When the first distribution D ₅₀ particle size of the magnetic particles 52 to the second magnetic particles larger 53 4 to 13.5 times the size compared with the distribution D ₅₀ of the filling rate is remarkably improved, and the permeability is increased by an effect of the inductance is remarkably improved have. (See Table 3)

More specifically, the first particle size distribution D ₅₀ of the magnetic particle 52 may be a second 15 particle size distribution than the D ₅₀ of the magnetic particle 53 to 18 ㎛ large. If the difference between the particle size distribution D ₅₀ of the first magnetic particles 52 and the second magnetic particles 53 is less than 15 탆 or exceeds 18 탆, the effect of improving the filling factor is insufficient and the improvement of the inductance can be reduced.

The first magnetic particles 52 may have a particle size distribution D ₅₀ of 18 to 22 μm. When the particle size distribution D ₅₀ of the first magnetic particles 52 is in the range of 18 to 22 탆, a high magnetic permeability can be ensured with a small magnetic loss at a high frequency. If the particle size distribution D ₅₀ of the first magnetic particles 52 is less than 18 탆, a sufficient magnetic permeability can not be secured. If the particle size distribution exceeds ₅₀ 탆, the efficiency at a high frequency and at a high current may be significantly reduced.

In addition, the second magnetic particles 53 may have a particle size distribution D ₅₀ of 2 to 4 탆. When the particle size distribution D ₅₀ of the second magnetic particles 53 is in the range of 2 to 4 탆, the second magnetic particles 53 are mixed with the first magnetic particles 52, and the filling ratio can be remarkably improved and the magnetic permeability can be remarkably improved. If the particle size distribution D ₅₀ of the second magnetic particles 53 is less than 2 탆 or more than 4 탆, there is a problem that the improvement of the filling ratio is insufficient and the permeability is decreased.

The first magnetic particles and the second magnetic particles may be mixed at a weight ratio of 6: 4 to 8: 2 to form the body 50.

At this time, when the body 50 is broken and one end surface is observed, the cross-sectional area ratio occupied by the first magnetic particles 52 and the second magnetic particles 53 may be 10: 1 to 18: 1. When the cross-sectional area ratios of the first magnetic particles 52 and the second magnetic particles 53 within the above range are shown, the filling rate can be remarkably improved and high permeability can be exhibited.

The body 50 according to an embodiment of the present invention can satisfy a density of 80% or more.

Particle size distribution D ₅₀ According to one embodiment of the present invention, the first magnetic particles having a particle size distribution D ₅₀ of 20 탆 and the particle size distribution (particle size distribution) When the second magnetic particles having a distribution D ₅₀ of 3 탆 were mixed and formed at a weight ratio of 7: 3 (Example 5), the packing density was improved to 76.1% by about 14% or more. (See Table 1)

Accordingly, the thin film coil component 10 according to one embodiment of the present invention can realize high permeability, high efficiency, and high Isat value. (See Table 2)

Manufacturing method of coil parts

Fig. 4 is a view for schematically explaining a method of manufacturing the coil component of Fig. 2;

4 (a), coil patterns 42 and 44 are formed on one surface and the opposite surface of the support member 23, respectively. The coil patterns 42 and 44 may be formed by plating, etching, printing, transfer, or the like, which are used in the production process of the printed wiring board. In order to form the coil patterns 42 and 44 thicker Plating is preferred. The coil patterns 42 and 44 may be formed of a metal having excellent electrical conductivity and may be formed of silver (Ag), copper (Cu), nickel (Ni), aluminum (Al) .

A via hole is formed in a part of the support member 23 and a conductive material is filled to form a via electrode 46. The via hole 46 is formed on the opposite surface of the support member 23 The coil patterns 42 and 44 can be electrically connected.

A hole 70 may be formed at the center of the support member 23 to penetrate the support member. The hole 70 may be formed by performing a drill, laser, sand blast, punching, or the like, but is not limited thereto.

Referring to FIG. 4 (b), the coil patterns 42 and 44 formed on one surface and the opposite surface of the support member 23 can be covered with the insulating layer 27.

4 (c), the body 50 may be formed by stacking magnetic layers on the upper and lower surfaces of the support member 23 on which the coil patterns 42 and 44 are formed. The body layer 50 can be formed by laminating the magnetic layer on both surfaces of the support member 23 and pressing them through a laminating method or a hydrostatic pressing method. At this time, the core portion 71 can be formed by allowing the hole 70 to be filled with a magnetic material.

The body 50 includes a first magnetic particle and a second magnetic particle, and the first magnetic particle and the second magnetic particle are amorphous metals including iron (Fe), and the first magnetic particle has a long axis And the length of the second magnetic particle is a fine particle having a major axis length of 5 占 퐉 or less.

The detailed description of the first magnetic particles and the second magnetic particles, which are equally applicable to the method of manufacturing a coil component according to one embodiment of the present invention, will be omitted herein.

Finally, referring to FIG. 4 (d), a thin film coil component 10 can be manufactured by forming external electrodes 80 on both end faces of the body 50 in the longitudinal direction. The external electrode 80 is connected to the ends of the coil patterns 42 and 44 and may be formed by dipping or the like. The external electrode may be formed of a metal having excellent electrical conductivity. For example, the external electrode may be formed of silver (Ag), copper (Cu), nickel (Ni), aluminum (Al)

The following Tables 1 and 2 show the results of the filling factor, the permeability and the inductance value of the thin film coil component according to the mixing weight ratio of the first magnetic particles and the second magnetic particles which are Fe-Si-B-Cr amorphous metals.

Mixing weight ratio Filling rate (%)
Permeability (μ)
The first magnetic particle
(D ₅₀ = 20 탆) The second magnetic particle
(D ₅₀ = 3 탆) Example 1 3 7 67.7 17.6 Example 2 5 5 72.9 23.8 Example 3 6 4 76.0 27.7 Example 4 6.6 3.4 75.6 27.7 Example 5 7 3 76.1 30.2 Example 6 7.6 2.4 75.0 27.6 Comparative Example 1 0 10 62.7 13.3 Comparative Example 2 10 0 67.4 20.7

1MHz 3MHz 9MHz Ls (uH) Q Rs Ls (uH) Q Rs Ls (uH) Q Rs Example 1 0.78 41.00 0.12 0.78 58.33 0.24 0.78 45.53 1.01 Example 2 0.97 48.20 0.13 0.97 53.54 0.34 0.96 27.55 2.02 Example 3 1.09 51.99 0.14 1.09 48.13 0.41 1.09 22.84 2.73 Example 4 1.11 50.89 0.14 1.10 46.25 0.43 1.10 22.14 2.83 Example 5 1.18 54.93 0.14 1.18 47.15 0.47 1.18 20.33 3.34 Example 6 1.1 51.85 0.13 1.09 45.71 0.45 1.09 21.18 2.96 Comparative Example 1 0.63 31.20 0.12 0.62 61.41 0.19 0.62 87.97 0.41 Comparative Example 2 0.92 45.12 0.13 0.91 45.18 0.38 0.91 24.03 2.18

Table 3 below is a table showing the results of the filling factor, the magnetic permeability and the inductance value according to the particle size ratio of the first magnetic particles and the second magnetic particles which are Fe-Si-B-Cr amorphous metals.

The first magnetic particle (D ₅₀ ) / the second magnetic particle (D ₅₀ ) Mixing weight ratio
(First magnetic particles: second magnetic particles) Filling rate (%) Permeability (μ) Ls (uH) Example 7 8.0 7: 3 80 33 1.15 Example 8 6.0 7: 3 75 30 1.0 Example 9 4.0 7: 3 74 28 0.9 Example 10 6.7 7: 3 76 28 0.9 Example 11 13.3 7: 3 84 33 1.15 Example 12 4.6 7: 3 65 25 0.75 Example 13 9.3 7: 3 78 29 0.95 Example 14 7.3 7: 3 76 28 0.9 Comparative Example 3 3μm alone - 63 13 0.6 Comparative Example 4 4μm alone - 64 15 0.65 Comparative Example 5 5μm alone - 64 17 0.68 Comparative Example 6 11μm alone - 65 18 0.70 Comparative Example 7 14μm alone - 66 19 0.75 Comparative Example 8 20μm alone - 67 20 0.78 Comparative Example 9 24㎛ alone - 68 23 0.8

The present invention is not limited to the above-described embodiment and the accompanying drawings, but is intended to be limited by the appended claims.

It will be apparent to those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. something to do.

10: Thin film coil component 46: Via electrode
50: Body 27: Insulating layer
52: first magnetic particle 70: hole
53: second magnetic particle 71: core part
23: support member 80: external electrode
42, 44: Coil pattern

Claims (13)

A coil part in which a coil part including a support member inside a body and a coil pattern disposed on at least one side of the support member,
The body includes a first magnetic particle having a major axis length of 15 mu m or more and being a metal containing an iron (Fe) component, and a second magnetic particle having a major axis length of 5 mu m or less and containing an iron (Fe) and,
In view of the thickness and width direction of the body,
Sectional area occupied by the first magnetic particles is larger than a sectional area occupied by the second magnetic particles,
Wherein the number of the second magnetic particles is larger than the number of the first magnetic particles.
The method according to claim 1,
Wherein the first magnetic particles and the second magnetic particles are metals including at least three or more metals in addition to iron (Fe).
The method according to claim 1,
Wherein the first magnetic particles and the second magnetic particles are made of a material selected from the group consisting of iron (Fe) and silicon (Si), boron (B), chromium (Cr), nickel (Ni), cobalt (Co) And a metal comprising at least three selected metals.
The method according to claim 1,
Wherein the first magnetic particles and the second magnetic particles are Fe-Si-B-Cr-based metals.
The method according to claim 1,
In view of the thickness and width direction of the body,
The ratio of the first magnetic particles and the second magnetic particles Wherein the cross-sectional area ratio is 10: 1 to 18: 1.
The method according to claim 1,
The first particle size distribution D ₅₀ of the magnetic particle has a second particle size distribution D ₅₀ compared to 4 to 13.5 times the coil component of the magnetic particles.
The method according to claim 1,
The first particle size distribution D ₅₀ is larger than the coil component 15 to 18 ㎛ particle size distribution D ₅₀ of the second magnetic particles of the magnetic particles.
The method according to claim 1,
And the first magnetic particle has a particle size distribution D ₅₀ of 18 to 22 μm.
The method according to claim 1,
And the second magnetic particle has a particle size distribution D ₅₀ of 2 to 4 탆.
The method according to claim 1,
Wherein the first magnetic particles and the second magnetic particles are mixed at a weight ratio of 6: 4 to 8: 2.
The method according to claim 1,
Wherein the body has a density of at least 80%.
Forming a coil pattern on at least one surface of the support member; And
Forming a body for embedding the support member and the coil pattern; / RTI >
The body includes a first magnetic particle having a major axis length of 15 mu m or more and being a metal containing an iron (Fe) component, and a second magnetic particle having a major axis length of 5 mu m or less and containing an iron (Fe) and,
In view of the thickness and width direction of the body,
Sectional area occupied by the first magnetic particles is larger than a sectional area occupied by the second magnetic particles,
Wherein the number of the second magnetic particles is larger than the number of the first magnetic particles.
13. The method of claim 12,
Wherein the step of forming the body includes laminating and pressing the magnetic layer including the first and second magnetic particles on the upper and lower surfaces of the support member on which the coil pattern is formed.

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