Coil component and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-2016314889-A1
Application number	US-201614995103-A
Country	US
Kind code	A1
Filing date	Jan 13, 2016
Priority date	Apr 24, 2015
Publication date	Oct 27, 2016
Grant date	—

Abstract

A coil component includes a body having a coil part disposed therein and an external electrode connected to the coil part. The body includes magnetic particles, and the magnetic particles include first magnetic particles, second magnetic particles, and third magnetic particles. A diameter of each of the first, second, and third magnetic particles is different from each other.

First claim

What is claimed is:

1 . A coil component, comprising:
a body having a coil part disposed therein; and external electrodes connected to the coil part, wherein the body includes magnetic particles, and wherein the magnetic particles include first magnetic particles, second magnetic particles, and third magnetic particles, of which diameters differ from one another.

2 . The coil component of claim 1 , wherein a diameter of the first magnetic particles ranges from 8 μm to 30 μm, a diameter of the second magnetic particles ranges from 2.5 μm to 5.0 μm, and a diameter of the third magnetic particles is 0 μm to 1.5 μm.

3 . The coil component of claim 1 , wherein, at a fractured plane of the body, when a sum of cross sectional areas occupied by the first magnetic particles is a, and a sum of cross sectional areas occupied by the second magnetic particles and the third magnetic particles is b, the first through third magnetic particles are mixed so that a:b corresponds to 5:5 through 9:1.

4 . The coil component of claim 1 , wherein, at a fractured plane of the body, the second magnetic particles and the third magnetic particles are mixed so that a ratio of a sum of cross sectional areas occupied by the second magnetic particles and a sum of cross sectional areas occupied by the third magnetic particles is 5:5 through 9:1.

5 . The coil component of claim 1 , wherein the magnetic particles of the body have grain size distribution including at least three peaks.

6 . The coil component of claim 1 , wherein the first through third magnetic particles include iron (Fe).

7 . The coil component of claim 1 , wherein the first magnetic particles include Fe-chromium (Cr)-silicon (Si)-boron (B)-carbon (C) based amorphous metal particles.

8 . The coil component of claim 1 , wherein the second magnetic particles include at least one of Fe—Cr—Si—B—C based amorphous metal particles and Fe metal particles, and the third magnetic particles include at least one of Fe—B-phosphorous (P) based amorphous metal particles and nickel (Ni) particles.

9 . The coil component of claim 1 , wherein when viewing one section of the body, a ratio of cross sectional areas occupied by the first magnetic particles:cross sectional areas occupied by the second magnetic particles:cross sectional areas occupied by the third magnetic particles is 5:4.5:0.5 through 9:0.9:0.1.

10 . The coil component of claim 1 , wherein the coil part includes a substrate layer and a coil pattern formed on at least one surface of the substrate layer.

11 . The coil component of claim 1 , wherein the body further includes a thermosetting resin.

12 . The coil component of claim 1 , wherein a magnetic particle density of the body is equal to or more than 70%.

13 . The coil component of claim 6 , wherein the Fe—Cr—Si—B—C based amorphous metal includes 72 to 80 wt % of Fe, 0.5 to 3.0 wt % of Cr, 4.5 to 8.5 wt % of Si, 0.5 to 2.0 wt % of B, and 0.5 to 2.0 wt % of C.

14 . The coil component of claim 7 , wherein the Fe—B—P based amorphous metal may include 87 to 93 wt % of Fe, 5 to 11 wt % of B, and 1 to 3 wt % of P.

15 . A coil component including a body having a coil part disposed therein, wherein the body includes a plurality of magnetic particles,
the magnetic particles included in the body have grain size distribution of a first peak, a second peak, and a third peak, and a grain size of the magnetic particles corresponding to the third peak is four through fifteen times larger than that of the magnetic particles corresponding to the second peak, and the grain size of the magnetic particles corresponding to the second peak is two through seven times larger than that of the magnetic particles corresponding to the first peak.

16 . The coil component of claim 15 , wherein the third peak in the grain size distribution ranges from 8 μm to 30 μm,
the second peak in the grain size distribution ranges from 2.5 μm to 6.0 μm, and
the first peak in the grain size distribution ranges from 0 μm to 1.5 μm.

17 . A method of manufacturing a coil component, comprising:
preparing a coil part by forming a coil pattern on at least one surface of a substrate layer; forming a body by stacking and compressing magnetic bodies on upper and lower portions of the coil part; and forming an external electrode on an outer surface of the body so that the external electrode is connected to the coil pattern, wherein the body includes magnetic particles, and the magnetic particles include first magnetic particles, second magnetic particles, and third magnetic particles, of which diameters differ from one another.

18 . The method of claim 17 , wherein a diameter of the first magnetic particles ranges from 8 μm to 30 μm, a diameter of the second magnetic particles ranges from 2.5 μm to 5.0 μm, and a diameter of the third magnetic particles ranges from 0 μm to 1.5 μm.

19 . The method of claim 18 , wherein the forming of the coil patterns includes forming an opening on the substrate layer and filling the opening part with an electro-conductive metal and forming an insulation layer to cover the coil patterns.

20 . The coil component of claim 18 , wherein the magnetic particles include Fe—Cr—Si—B—C based amorphous metal particles in the third peak, at least one of Fe—Cr—Si—B—C based amorphous metal particles and Fe metal particles in the second peak, and at least one of Fe—B—P based amorphous metal particles and nickel (Ni) particles in the first peak.

Assignees

• Samsung Electro Mech

Inventors

• Ryu Han Wool
• Lee Byoung Hwa

Classifications

• H01F27/255 Primary

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

• H01F1/15308

  based on Fe/Ni (H01F1/15325 takes precedence) · CPC title

• H01F17/0013

  with stacked layers · CPC title

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• H01F27/292

  Surface mounted devices · CPC title