Magnetic composite sheet and coil component

Patent metadata

Field	Value
Publication number	US-11657950-B2
Application number	US-202016901501-A
Country	US
Kind code	B2
Filing date	Jun 15, 2020
Priority date	Jan 22, 2020
Publication date	May 23, 2023
Grant date	May 23, 2023

Abstract

A coil component includes a body and a coil portion embedded in the body, wherein the body comprises a first magnetic metal powder particle comprising a core represented by Formula 1 below, and an oxide film comprising at least one of silicon (Si) and chromium (Cr) and formed on a surface of the core, a second magnetic metal powder particle having a larger diameter than the first magnetic metal powder particle, and a third magnetic metal powder particle having a larger diameter than the second magnetic metal powder particle:

Fe a Si b Cr c   [Formula 1]
where 3 atom %≤b≤6 atom %, 2.65 atom %≤c≤3.65 atom %, and a+b+C=100.

First claim

What is claimed is:

1. A coil component, comprising
a body and a coil portion embedded in the body,
wherein the body comprises:
a first magnetic particle comprising a core comprising a compound represented by Formula 1 below, and an oxide film comprising at least one of silicon (Si) or chromium (Cr) and directly deposited on a surface of the core;
a second magnetic particle having a larger diameter than the first magnetic particle; and
a third magnetic particle having a larger diameter than the second magnetic particle:
Fe a Si b Cr c   [Formula 1]

where 3 atom %≤b≤6 atom %, 2.65 atom %≤c≤3.65 atom %, and a+b+C=100,
wherein each of the second and third magnetic particles comprises a metal particle and an insulating coating layer directly disposed on a surface of the second and third metal particles, wherein the insulating coating layer comprises an insulating resin.

2. The coil component of claim 1 , wherein the diameter of the first magnetic particle is less than 1 μm.

3. The coil component of claim 1 , wherein the diameter of the first magnetic particle is 0.1 μm to 0.2 μm.

4. The coil component of claim 1 , wherein:
the diameter of the second magnetic particle is 1 μm to 2 μm, and
the diameter of the third magnetic particle is 25 μm to 30 μm.

5. The coil component of claim 1 , wherein a thickness of the coil component is 0.85 mm or less.

6. The coil component of claim 1 , wherein each of the metal particles of the second and third magnetic particles comprises an iron(Fe)-silicon(Si)-boron(B)-copper(Cu)-base alloy powder.

7. The coil component of claim 1 , further comprising first and second external electrodes spaced apart on an outer surface of the body, and connected to both ends of the coil portion exposed to the outer surface of the body.

8. The coil component of claim 1 , wherein the coil component further comprises an insulating substrate embedded in the body,
wherein the coil portion comprises first and second coil pattern disposed respectively on one surface and the other surface of the insulating substrate facing each other.

9. The coil component of claim 8 , wherein each of the first and second coil patterns comprises a first conductive layer formed on the insulating substrate and a second conductive layer formed on the first conductive layer.

10. The coil component of claim 9 , wherein
each of the first and second conductive layers comprises copper (Cu),
and a density of the copper of the first conductive layer is lower than a density of the copper of the second conductive layer.

11. The coil component of claim 9 , wherein a side surface of the first conductive layer is exposed by the second conductive layer.

12. The coil component of claim 9 , wherein the second conductive layer covers a side surface of the first conductive layer and contacts the insulating substrate.

13. The coil component of claim 1 , wherein the insulating resin comprises an epoxy resin.

14. The coil component of claim 1 , wherein the insulating resin comprises an polyamide resin.

15. The coil component of claim 1 , wherein a thickness of the insulating coating layers of the second and third magnetic particles is greater than 0.01 μm and less than 1 μm.

16. A magnetic composite sheet, comprising:
a first magnetic particle comprising a core comprising a compound represented by Formula 1 below, and an oxide film comprising at least one of silicon (Si) or chromium (Cr) and directly formed on a surface of the core,
a second magnetic particle having a larger diameter than the first magnetic particle,
a third magnetic particle having a larger diameter than the second magnetic particle; and
an insulating resin:
Fe a Si b Cr c   [Formula 1]

where 3 atom %≤b≤6 atom %, 2.65 atom %≤c≤3.65 atom %, and a+b+C=100,
wherein each of the second and third magnetic particles comprises a metal particle and an insulating coating layer directly disposed on a surface of the second and third metal particles, wherein the insulating coating layer comprises an insulating resin.

17. The magnetic composite sheet of claim 16 , wherein the diameter of the first magnetic particle is 0.1 μm to 0.2 μm.

18. The magnetic composite sheet of claim 16 , wherein:
the diameter of the second magnetic particle is 1 μm to 2 μm, and
the diameter of the third magnetic particle is 25 μm to 30 μm.

Assignees

• Samsung Electro Mech

Inventors

• Jeon Jong Ok
• Lim Jeong Ho
• Park Il Jin
• Kwon Soon Kwang
• Hwang Gwang Hwan

Classifications

• H01F10/12 Primary

  being metals or alloys (intermetallic compounds H01F10/18) · CPC title

• H01F1/26

  by macromolecular organic substances · CPC title

• H01F2017/048

  with encapsulating core, e.g. made of resin and magnetic powder · CPC title

• H01F27/29

  Terminals; Tapping arrangements {for signal inductances} · CPC title

• H01F17/0013

  with stacked layers · CPC title