Hybrid inductor and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2016293315-A1
Application number	US-201615009125-A
Country	US
Kind code	A1
Filing date	Jan 28, 2016
Priority date	Apr 1, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

A hybrid inductor includes an inductor body having a core part in which a coil part is disposed, and first and second cover parts having the core part interposed therebetween. The core part includes magnetic metal layers, and the first and second cover parts include ferrite layers.

First claim

What is claimed is:

1 . A hybrid inductor comprising:
an inductor body having a core part in which a coil part is disposed, and first and second cover parts having the core part interposed therebetween, wherein the core part comprises magnetic metal layers, and each of the first and second cover parts comprises a ferrite layer.

2 . The hybrid inductor of claim 1 , wherein each of the first and second cover parts further comprises a magnetic metal layer disposed on a surface of the ferrite layer.

3 . The hybrid inductor of claim 2 , wherein a thickness of the magnetic metal layer in the first and second cover parts is 20% to 100% of a thickness of the ferrite layer in the first and second cover parts, respectively.

4 . The hybrid inductor of claim 1 , wherein at least one of the magnetic metal layers comprises an iron (Fe)-based alloy including iron (Fe) and at least one selected from the group consisting of silicon (Si), boron (B), chromium (Cr), aluminum (Al), copper (Cu), niobium (Nb), and nickel (Ni).

5 . The hybrid inductor of claim 1 , wherein at least one of the magnetic metal layers includes magnetic metal particles having a saturation magnetization value of 100 emu/g to 250 emu/g.

6 . The hybrid inductor of claim 1 , wherein at least one of the magnetic metal layers includes magnetic metal particles having a surface on which a metal oxide film is formed.

7 . The hybrid inductor of claim 1 , wherein at least one of the ferrite layers comprises ferrite including at least one element selected from the group consisting of nickel (Ni) and zinc (Zn).

8 . The hybrid inductor of claim 1 , wherein at least one of the ferrite layers comprises a glass including at least one oxide selected from the group consisting of silicon (Si) oxide, lithium (Li) oxide, boron (B) oxide, potassium (K) oxide, calcium (Ca) oxide, and aluminum (Al) oxide.

9 . The hybrid inductor of claim 1 , wherein the coil part comprises a plurality of coil patterns connected to each other by vias penetrating the magnetic metal layers, the coil patterns being formed on the plurality of magnetic metal layers.

10 . The hybrid inductor of claim 4 , wherein the iron (Fe)-based alloy includes 87 wt % or more of iron (Fe), 4 to 6 wt % of chromium (Cr), and residual silicon, based on a total weight of the iron (Fe)-based alloy.

11 . A manufacturing method of a hybrid inductor comprising steps of:
preparing a plurality of magnetic metal sheets and forming coil patterns on the magnetic metal sheets; forming a core part by stacking the magnetic metal sheets on which the coil patterns are formed; forming first and second cover parts by stacking ferrite sheets on an upper surface and below a lower surface of the core part; and forming an inductor body by sintering a laminate including the core part and the first and second cover parts.

12 . The manufacturing method of claim 11 , wherein in the step of forming the first and second cover parts, magnetic metal sheets are further stacked after stacking the ferrite sheets.

13 . The manufacturing method of claim 12 , wherein in the step of forming the first and second cover parts, a thickness of the stacked magnetic metal sheets is 20% to 100% of a height of the stacked ferrite sheets.

14 . The manufacturing method of claim 11 , wherein magnetic metal particles included in the magnetic metal sheets have a saturation magnetization value of 100 emu/g to 250 emu/g.

15 . The manufacturing method of claim 11 , wherein the ferrite sheet includes ferrite including at least one element selected from the group consisting of nickel (Ni) and zinc (Zn) .

16 . The manufacturing method of claim 11 , wherein the ferrite sheet includes a glass containing at least one oxide selected from the group consisting of silicon (Si) oxide, lithium (Li) oxide, boron (B) oxide, potassium (K) oxide, calcium (Ca) oxide, and aluminum (Al) oxide.

17 . The manufacturing method of claim 11 , wherein in the step of sintering the laminate, the core part and the first and second cover parts are co-sintered at between 750° C. and 800° C.

18 . The manufacturing method of claim 11 , wherein the magnetic metal sheets comprise an iron (Fe)-based alloy including iron (Fe) and at least one selected from the group consisting of silicon (Si), boron (B), chromium (Cr), aluminum (Al), copper (Cu), niobium (Nb), and nickel (Ni).

19 . The manufacturing method of claim 18 , wherein the iron (Fe)-based alloy includes 87 wt % or more of iron (Fe), 4 to 6 wt % of chromium (Cr), and residual silicon, based on a total weight of the iron (Fe)-based alloy.

Assignees

• Samsung Electro Mech

Inventors

• Kim Ho Yoon
• Choi Yu Jin
• Son Soo Hwan
• Cheon Min Kyoung

Classifications

• H01F27/255

  made from particles (H01F27/26 takes precedence) · CPC title

• H01F27/2804

  Printed windings · CPC title

• H01F27/245 Primary

  made from sheets, e.g. grain-oriented (H01F27/26 takes precedence) · CPC title

• H01F41/041

  Printed circuit coils (apparatus or processes for manufacturing printed circuits in general H05K3/00) · CPC title

• H01F41/0233

  Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16) · CPC title