Coil component

Patent metadata

Field	Value
Publication number	US-11752549-B2
Application number	US-202117150979-A
Country	US
Kind code	B2
Filing date	Jan 15, 2021
Priority date	Dec 9, 2016
Publication date	Sep 12, 2023
Grant date	Sep 12, 2023

Abstract

A coil component includes: a magnetic body part and a cover part covering one side of a magnetic layer part; and a coil part embedded in the magnetic body part. The magnetic body part is comprised of the following two types of layers: (A) an oblate soft magnetic grain-containing layer, and (B) a spherical grain-containing layer, wherein layer (A) extends over the entire range of the magnetic body part except for a portion including the coil part in a direction perpendicular to an axis direction of the coil part, layer (B) adjoins layer (A) in the axis direction. The cover part is constituted by multiple layers including one or more of layer(s) (A) and one or more of layer(s) (B) and extending over the entire range of the magnetic body part in the direction perpendicular to the axis direction.

First claim

We claim:

1. A coil component comprising:
a magnetic body part comprising first and second magnetic layers stacked together alternately in a preset axis direction, and a cover part covering one side of a magnetic layer part composed of the first and second magnetic layers from the preset axis direction; and
a coil part having conductor patterns provided in the second magnetic layers;
wherein the magnetic body part including the first and second magnetic layers is comprised of the following two types of layers:
(A) an oblate soft magnetic grain-containing layer formed with oblate soft magnetic grains which are flattened in a thickness direction oriented in the preset axis direction, and
(B) a spherical grain-containing layer formed with insulative spherical grains,
wherein, in the magnetic layer part, the first magnetic layer is constituted by the type (A) layer which extends over the entire range of the magnetic body part except for a portion including the coil part in a direction perpendicular to the preset axis direction, and is exposed in the direction perpendicular to the preset axis direction; and the second magnetic layer is constituted by the type (B) layer which adjoins the type (A) layer in the preset axis direction,
wherein the cover part is constituted by multiple layers including one or more of the type (A) layer(s) and one or more of the type (B) layer(s) and extending over the entire range of the magnetic body part in the direction perpendicular to the preset axis direction.

2. The coil component according to claim 1 , wherein each first magnetic layer is constituted by the type (A) layer.

3. The coil component according to claim 2 , wherein:
each first magnetic layer contains first spherical grains which are insulative and arranged in gaps between the oblate soft magnetic grains, and whose average size is smaller than the size of the oblate soft magnetic grains in the thickness direction, and
each second magnetic layer is constituted by the type (B) layer.

4. The coil component according to claim 3 , wherein, in the first magnetic layers, the quantity of the first spherical grains relative to the total quantity of the oblate soft magnetic grains and the first spherical grains is 5 percent by volume or more, but 15 percent by volume or less.

5. The coil component according to claim 2 , wherein the magnetic body part further comprises spherical grain-containing layers interposed between the first magnetic layers and the conductor patterns, and formed with second spherical grains which are insulative and whose average size is smaller than the size of the oblate soft magnetic grains in the thickness direction.

6. The coil component according to claim 2 , wherein the thickness of each of the first magnetic layers is less than 10 μm.

7. The coil component according to claim 1 , wherein the cover part is constituted by a first cover layer being the type (B) layer adjoining the outer side of one of the first or second magnetic layers in the preset axis direction, and a second cover layer being the type (A) layer adjoining the outer side of the first cover layer in the preset axis direction.

8. The coil component according to claim 7 , wherein the cover part is constituted further by a third cover layer adjoining the outer side of the second cover layer in the preset axis direction.

9. The coil component according to claim 8 , wherein the third cover layer is formed with third spherical grains which are insulative and whose average size is smaller than the size of the oblate soft magnetic grains in the thickness direction.

10. The coil component according to claim 1 , wherein, in the type (A) layer, a ratio of the longest size in the direction perpendicular to the thickness direction, to the size in the thickness direction, of the oblate soft magnetic grains, is 4 or greater.

11. The coil component according to claim 1 , wherein at least either one of the oblate soft magnetic grains of the type (A) layer or the spherical grains of the type (B) layer are iron alloy grains containing iron, silicon, and at least one of chromium and aluminum.

12. The coil component according to claim 11 , wherein an oxide film is formed on surfaces of the iron alloy grains, and the iron alloy grains are bonded to each other via the oxide film.

13. The coil component according to claim 12 , wherein the thickness of the oxide film is 0.6 μm or less.

14. The coil component according to claim 12 , wherein the oxide film has a multilayer structure that includes a first oxide film and a second oxide film formed on the outer side of the first oxide film.

15. The coil component according to claim 14 , wherein the first oxide film has, as a primary component, an oxide that contains at least one of chromium and aluminum, and the second oxide film has, as a primary component, an oxide that contains iron and at least one of chromium and aluminum, and is thicker than the first oxide film.

16. The coil component according to claim 11 , wherein the magnetic body part further comprises a resin covering the iron alloy grains.

17. The coil component according to claim 1 , wherein at least either one of the oblate soft magnetic grains of the type (A) layer or the spherical grains of the type (B) layer are at least either one of amorphous alloy grains or ferrite grains.

18. The coil component according to claim 1 , wherein the oblate soft magnetic grains of the type (A) layer and the spherical grains of the type (B) layer in the magnetic body part are constituted by soft magnetic grains covered with a resin, and the soft magnetic grains are insulated from each other by the resin.

19. The coil component according to claim 1 , wherein the size of the coil component in the preset axis direction is 1 mm or less.

20. The coil component according to claim 1 , wherein the cover part is a first cover part, and the magnetic body further comprises a second cover part covering another side of the magnetic layer part from the preset axis direction, wherein the second cover part has a layer structure equivalent to that of the first cover part.

Assignees

• Taiyo Yuden Kk

Inventors

• Hachiya Masahiro
• Matsuura Hitoshi
• Arai Takayuki
• Kurahashi Shuhei
• Machida Hideo
• Teshigawara Hidekazu
• Honmo Naoya

Classifications

• B22F1/08 Primary

  Metallic powder characterised by particles having an amorphous microstructure · CPC title

• H01F1/24

  the particles being insulated · CPC title

• H01F1/36

  in the form of particles {(H01F1/346, H01F1/348 and H01F1/38 take precedence)} · CPC title

• H01F17/04

  with magnetic core · CPC title

• H01F27/292

  Surface mounted devices · CPC title