Coil component and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-2024203639-A1
Application number	US-202318537468-A
Country	US
Kind code	A1
Filing date	Dec 12, 2023
Priority date	Dec 14, 2022
Publication date	Jun 20, 2024
Grant date	—

Abstract

Disclosed herein is a coil component that includes a magnetic element body having a mounting surface, a coil pattern embedded in the magnetic element body, a conductor post embedded in the magnetic element body, the conductor post having a first end connected to the coil pattern and a second end, and a terminal electrode connected to the second end of the conductor post through an opening formed in the cover insulating film. The second end of the conductor post is flush with a surface of the cover insulating film.

First claim

What is claimed is:

1 . A coil component comprising:
a magnetic element body having a mounting surface; a coil pattern embedded in the magnetic element body; a conductor post embedded in the magnetic element body, the conductor post having a first end connected to the coil pattern and a second end; and a terminal electrode connected to the second end of the conductor post through an opening formed in the cover insulating film, wherein the second end of the conductor post is flush with a surface of the cover insulating film.

2 . The coil component as claimed in claim 1 , further comprising a post protective film provided between the conductor post and the magnetic element body.

3 . The coil component as claimed in claim 2 , wherein an end surface of the post protective film is flush with the second end of the conductor post and the surface of the cover insulating film.

4 . The coil component as claimed in claim 3 , wherein the cover insulating film and the post protective film contact each other.

5 . The coil component as claimed in claim 1 ,
wherein the cover insulating film contains a filler, and wherein a plurality of recesses which are drop marks of the filler are generated in the surface of the cover insulating film.

6 . A method of manufacturing a coil component, the method comprising:
embedding, in a magnetic element body, a coil pattern and a conductor post having a first end connected to the coil pattern and a second end exposed from a mounting surface of the magnetic element body; forming a cover insulating film on the second end of the conductor post and the mounting surface of the magnetic element body and making the second end of the conductor post protrude from the mounting surface of the magnetic element body; polishing a surface of the cover insulating film to such a degree that the second end of the conductor post is exposed and that the cover insulating film covering the mounting surface is left; and forming a terminal electrode on the second end of the conductor post.

7 . The method of manufacturing a coil component as claimed in claim 6 , wherein the forming the cover insulating film is carried out by removing the magnetic element body by a predetermined depth from the mounting surface to make the second end of the conductor post protrude from the mounting surface of the magnetic element body and then forming the cover insulating film.

8 . The method of manufacturing a coil component as claimed in claim 6 , wherein the forming the cover insulating film is carried out by forming the cover insulating film and then pressing the magnetic element body to make the second end of the conductor post protrude from the mounting surface of the magnetic element body.

Assignees

• Tdk Corp

Inventors

• Kawaguchi Yuuichi
• Sato Hironori
• Satoh Azuma
• Chen Liyi

Classifications

• H01F41/125

  Other insulating structures; Insulating between coil and core, between different winding sections, around the coil · CPC title

• H01F41/00

  Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties · CPC title

• H01F27/2804

  Printed windings · CPC title

• H01F27/29

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

• H01F27/324 Primary

  Insulation between coil and core, between different winding sections, around the coil; Other insulation structures · CPC title