Coil component and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11322291-B2
Application number	US-201816126554-A
Country	US
Kind code	B2
Filing date	Sep 10, 2018
Priority date	Feb 9, 2018
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A coil component includes a magnetic body and a coil portion embedded in the magnetic body. The coil portion includes an internal insulating layer, coil patterns disposed on opposite surfaces of the internal insulating layer, an insulating wall disposed between turns of a coil pattern, an external insulating layer disposed on the insulating wall and the coil pattern, and a connection portion including a first conductive layer and a second conductive layer having a melting point lower than a melting point of the first conductive layer, and penetrating through the internal insulating layer to connect the coil patterns disposed on the opposite surfaces of the internal insulating layer to each other.

First claim

What is claimed is:

1. A coil component comprising:
a magnetic body; and
a coil portion embedded in the magnetic body,
wherein the coil portion includes:
an internal insulating layer;
first and second coil patterns respectively disposed on opposite surfaces of the internal insulating layer;
a first insulating wall disposed between turns of the first coil pattern;
a second insulating wall disposed between turns of the second coil pattern;
a first external insulating layer covering the first insulating wall and the first coil pattern;
a second external insulating layer covering the second insulating wall and the second coil pattern; and
a connection portion disposed in the internal insulating layer to connect the first coil pattern and the second coil pattern to each other, and

wherein the first insulating wall includes:
a first protrusion protruding from an upper surface of the first coil pattern and extending in the first external insulating layer; and
a second protrusion protruding from a lower surface of the first coil pattern, opposing the upper surface, and extending in the internal insulating layer,

wherein a surface roughness of one surface of the first insulating wall facing the internal insulating layer is different from a surface roughness of another surface of the first insulating wall facing the first external insulating layer.

2. The coil component of claim 1 , wherein the connection portion includes a first conductive layer and a second conductive layer having a melting point lower than a melting point of the first conductive layer.

3. The coil component of claim 1 , wherein each of the first and second coil patterns is an electroplating layer.

4. The coil component of claim 1 , wherein the internal insulating layer includes a photosensitive resin.

5. The coil component of claim 2 , wherein the connection portion further includes a first intermetallic compound layer disposed between the first conductive layer and the second conductive layer.

6. The coil component of claim 5 , wherein the second conductive layer is disposed between the first conductive layer and one of the first and second coil patterns, and
the connection portion further includes a second intermetallic compound layer between the one of the first and second coil patterns and the second conductive layer.

7. The coil component of claim 1 , wherein the magnetic body includes a core penetrating through the coil portion.

8. The coil component of claim 2 , wherein the first conductive layer includes copper (Cu).

9. The coil component of claim 8 , wherein the second conductive layer includes tin (Sn).

10. The coil component of claim 2 , wherein the second conductive layer includes tin (Sn).

11. The coil component of claim 2 , wherein a width of the second conductive layer is greater than a width of the first conductive layer.

12. The coil component of claim 1 , wherein a surface of the first coil pattern facing the first external insulating layer is flat, and
the flat surface of the first coil pattern, facing the first external insulating layer, extends from side surfaces of the first coil pattern.

13. The coil component of claim 1 , wherein no seed layer is disposed between the first coil pattern and the internal insulating layer.

14. The coil component of claim 1 , wherein no seed layer is disposed between the second coil pattern and the internal insulating layer.

15. The coil component of claim 1 , wherein no seed layer is disposed between the first coil pattern and the internal insulating layer, and between the second coil pattern and the internal insulating layer.

16. The coil component of claim 1 , wherein the second insulating wall includes a third protrusion protruding from a lower surface of the second coil pattern and extending in the second external insulating layer.

17. The coil component of claim 1 , wherein the second insulating wall includes a fourth protrusion protruding from an upper surface of the second coil pattern and extending in the internal insulating layer.

18. The coil component of claim 1 , wherein the second insulating wall includes:
a third protrusion protruding from a lower surface of the second coil pattern and extending in the second external insulating layer; and
a fourth protrusion protruding from an upper surface of the second coil pattern and extending in the internal insulating layer.

19. The coil component of claim 1 , wherein the first and second coil patterns are respectively disposed directly on the opposite surfaces of the internal insulating layer.

Assignees

• Samsung Electro Mech

Inventors

• Cho Seong Min
• Shin Chang Hyun
• Kim Sang Seob

Classifications

• H01F41/26

  using electric currents {, e.g. electroplating} · CPC title

• H01F41/12

  Insulating of windings ({impregnating or encapsulating of transformers H01F41/005} ; of conductors in general H01B13/06) · CPC title

• H01F27/2804 Primary

  Printed windings · CPC title

• H01F17/0013 Primary

  with stacked layers · CPC title

• H01F17/04

  with magnetic core · CPC title