Coil component and method of manufacturing the same

A coil component and a method of manufacturing the same are provided. The coil component may include a body part containing a magnetic material, a coil part disposed in the body part, and an electrode part disposed on the body part. The coil part includes a support member, a coil disposed on a surface of the support member and having a terminal exposed to at least one outer surface of the body part, and a conductive via connected to the terminal of the coil and penetrating through at least one end portion of the support member to thereby be exposed to the at least one outer surface of the body part.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority and benefit of Korean Patent Application No. 10-2015-0181757, filed on Dec. 18, 2015 with the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.

BACKGROUND

The present disclosure relates to a coil component and a method of manufacturing the same.

In parallel with the miniaturization and slimming of electronic devices such as digital TVs, mobile phones, laptop PCs, and the like, there has also been a demand for miniaturization and slimming of coil components used in these electronic devices. In order to satisfy this demand, research into winding type or thin film type coil components having various shapes has been actively conducted.

In general, a thin film type coil component may be manufactured by forming a coil on an insulating substrate, embedding the insulating substrate and the coil formed on the insulating substrate with a magnetic material, grinding an outer surface of a formed magnetic body, and forming electrodes on the outer surface of the magnetic body.

In a case of manufacturing the coil component using the method as described above, an end portion of the insulating substrate is exposed to the outer surface of the magnetic body together with a terminal of the coil. However, it is difficult to form a plating layer on the insulating substrate, and the resulting device may thus include defects such as a contact defects or the like. Such defects may occur even when a subsequent process, such as application of a conductive paste or the like, is performed after plating for forming the electrodes.

SUMMARY

An aspect of the present disclosure may provide a coil component capable of decreasing a defect when plating is performed, or the like, due to a novel structure in which an insulating substrate is not exposed to an outer surface of a body on which electrodes are formed.

According to an aspect of the present disclosure, a coil component may include a conductive via formed on an end portion of an insulating substrate exposed to an outer surface of a body on which an electrode is formed, and thus the insulating substrate may not be exposed to the outer surface of the body.

In detail, in accordance with one aspect of the disclosure, a coil component includes a body part containing a magnetic material, a coil part disposed in the body part, and an electrode part disposed on the body part. The coil part includes a support member, a coil disposed on a surface of the support member and having a terminal exposed to at least one outer surface of the body part, and a conductive via connected to the terminal of the coil and penetrating through at least one end portion of the support member to thereby be exposed to the at least one outer surface of the body part.

In accordance with another aspect of the disclosure, a method of manufacturing a coil component includes forming a coil part by providing a support member, forming a coil having a terminal on at least one surface of the support member, and forming a conductive via connected to the terminal of the coil and penetrating through at least one end portion of the support member. A body part is then formed by embedding the coil part with a magnetic material. In turn, an electrode part is formed by forming, on the body part, an electrode connected to the terminal of the coil and to the conductive via. The terminal of the coil and the conductive via are exposed to at least one outer surface of the body part, and the electrode is connected to the terminal of the coil and the conductive via on the at least one outer surface of the body part.

In accordance with a further aspect of the disclosure, a coil component includes a support member, a coil disposed in a planar coil pattern on a surface of the support member, and a body part containing a magnetic material and enclosing the coil and the support member. The coil includes at least one coil terminal exposed to an outer surface of the body part, and the support member is spaced apart from all outer surfaces of the body part.

In accordance with another aspect of the disclosure, a method includes forming a coil disposed in a planar coil pattern on a surface of a support member, and forming a conductive via connected to the coil and penetrating through the support member. A body part containing a magnetic material is formed to enclose the coil, the conductive via, and the support member. The body part enclosing the coil, the conductive via, and the support member is then diced along a dicing line that extends through the conductive via.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present disclosure will be described with reference to schematic views illustrating embodiments of the present disclosure. In the drawings, components having ideal shapes are shown. However, variations from these shapes, for example due to variability in manufacturing techniques and/or tolerances, also fall within the scope of the disclosure. Thus, embodiments of the present disclosure should not be construed as being limited to the particular shapes of regions shown herein, but should more generally be understood to include changes in shape resulting from manufacturing methods and processes. The following embodiments may also be constituted by one or a combination thereof.

The present disclosure describes a variety of configurations, and only illustrative configurations are shown herein. However, the disclosure is not limited to the particular illustrative configurations presented herein, but extends to other similar/analogous configurations as well.

Electronic Device

FIG. 1schematically illustrates an example of a coil component used in an electronic device. Referring toFIG. 1, it may be appreciated that various kinds of electronic components are used in the electronic device. For example, the electronic device ofFIG. 1includes, in addition to various coil components, one or more of an application processor, a direct current (DC) to DC converter, a communications processor, one or more transceivers configured for communication using a wireless local area network (WLAN), Bluetooth (BT), wireless fidelity (Wi-Fi), frequency modulation (FM), global positioning system (GPS), and/or near field communications (NFC) standard, a power management integrated circuit (PMIC), a battery, a switch-mode battery charger (SMBC), a liquid crystal display (LCD) and/or active matrix organic light emitting diode (AMOLED) display, an audio codec, a universal serial bus (USB) 2.0/3.0 interface and/or a high definition multimedia interface (HDMI), or a conditional access module (CAM), or the like. In this case, in order to remove noise, or the like, various kinds of coil components may be appropriately used between these electronic components and/or in the electronic device depending on the use. For example, the coil components can include power inductors1, high-frequency (HF) inductors2, general beads3, high frequency or GHz beads4, common mode filters5, or the like.

In detail, the power inductors1may be used for stabilizing power by storing electricity in a form of a magnetic field to maintain an output voltage, etc. Further, the HF inductors2may be used for matching impedance to secure a frequency to be required, or blocking noise and alternating current component, etc. In addition, the general beads3may be used for removing noise in power and signal lines or removing high frequency ripples, etc. Further, the high frequency or GHz beads4may be used for removing high-frequency noise in power and signal lines associated with audio, etc. In addition, the common mode filters5may be used for passing a current in a differential mode and removing only common mode noise, etc.

A representative example of the electronic device may be a smartphone, but is not limited thereto. For example, the electronic device may be a personal digital assistant, a digital video camera, a digital still camera, a network system, a computer, a monitor, a television, a video game console, or a smart watch. In addition, various other electronic devices and the like may use coil components such as those described herein.

Coil Component

Hereinafter, a coil component according to the present disclosure will be described in more detail. For convenience, a structure of an inductor will be described by way of example, but the coil component may be used as other types of components for various purposes as described above. Meanwhile, hereinafter, the term “side portion” is used to indicate a portion located toward a first (lateral) or second (lateral) direction, the term “upper portion” is used to indicate a portion located toward a third (upward) direction, and the term “lower portion” is used to indicate a portion locate in a (downward) direction opposite to the third (upward) direction. In addition, the term “positioned to the side portion, the upper portion, or the lower portion” may include a case in which a target component is disposed in the corresponding direction but does not directly contact a component located in the side, upper, or lower portion, as well as a case in which the target component directly contacts the corresponding component in the corresponding direction. However, the directions detailed above are defined only for convenience of explanation, and the scope of the present disclosure is not particularly limited by the description of the directions as described above.

FIG. 2is a schematic perspective view illustrating an example of the coil component.FIG. 3illustrates a schematic cross-section of the coil component ofFIG. 2taken along line I-I′. Referring toFIGS. 2 and 3, a coil component100A according to the example may include a body part10, a coil part70disposed in the body part10, and one or more electrode part(s)80disposed on the body part10. The coil part70may include a support member20, a first coil31and32and a second coil41and42disposed on respective surfaces of the support member20, first and second conductive vias33and43penetrating through respective end portions of the support member20, a through via51connecting the first coil31and32and the second coil41and42to each other while penetrating through the support member20, and first and second insulating films34and44respectively covering the first coil31and32and the second coil41and42. The one or more electrode part(s)80may include first and second electrodes81and82disposed on the body part10to be spaced apart from each other.

Meanwhile, as described above, in accordance with miniaturization and slimming of electronic devices, there has also been a demand for miniaturization and slimming of coil components used in these electronic devices. In order to satisfy this demand, research into a thin film type coil component has been actively conducted. In such devices, an end portion of an insulating substrate is generally exposed to an outer surface of a magnetic body together with a terminal of a coil. The end portion of the insulating substrate is exposed to the outer surface of the substrate due to characteristics of a method of manufacturing the thin film type coil component. As a result of the insulating substrate being exposed, a problem such as a plating defect or the like may occur when an electrode is formed on the outer surface of the substrate on which the insulating substrate is exposed.

In contrast, in the coil component100A according to the example, the first and second conductive vias33and43may completely penetrate through a dicing surface of the support member20contacting first and second surfaces of the body part10. As a result, the support member20may not be substantially exposed to the first and second surfaces of the body part10. Therefore, since the electrode(s)80are formed of a conductive material, the plating defects or other problems resulting from the exposed substrate may not occur. Here, the term “substantially” is used to indicate that a situation in which a small portion of the support member20remains unintentionally exposed to the outer surface of the body part10due to a process limitation, or the like, can fall within the scope of the structure ofFIGS. 2 and 3.

Hereinafter, the configurations of the coil component100A according to the example will be described in more detail.

The body part10may form an exterior of the coil component100A and have first and second (end) surfaces opposing each other in the first (length) direction, third and fourth (side) surfaces opposing each other in the second (width) direction, and fifth (upper) and sixth (lower) surfaces opposing each other in the third (height/vertical) direction. The body part10may have a hexahedral shape as described above. However, a shape of the body part10is not limited thereto. The body part10may contain a magnetic material. The magnetic material is not particularly limited as long as it has magnetic properties. Examples of the magnetic material may include pure iron powder; Fe alloys such as Fe—Si based alloy powder, Fe—Si—Al based alloy powder, Fe—Ni based alloy powder, Fe—Ni—Mo based alloy powder, Fe—Ni—Mo—Cu based alloy powder, Fe—Co based alloy powder, Fe—Ni—Co based alloy powder, Fe—Cr based alloy powder, Fe—Cr—Si based alloy powder, Fe—Ni—Cr based alloy powder, Fe—Cr—Al based alloy powder, or the like; amorphous alloys such as an Fe based amorphous alloy, a Co based amorphous alloy, or the like; spinel type ferrites such as a Mg—Zn based ferrite, a Mn—Zn based ferrite, a Mn—Mg based ferrite, a Cu—Zn based ferrite, a Mg—Mn—Sr based ferrite, a Ni—Zn based ferrite, or the like; hexagonal ferrites such as a Ba—Zn based ferrite, a Ba—Mg based ferrite, a Ba—Ni based ferrite, a Ba—Co based ferrite, a Ba—Ni—Co based ferrite, or the like; or garnet ferrites such as an Y based ferrite, or the like.

The coil part70may provide the coil characteristics to the coil component100A. The coil part70may include the support member20, the first coil31and32disposed on one surface of the support member20and having a first terminal32led (or exposed) to the first surface of the body part10, the second coil41and42disposed on another surface of the support member20opposite to the one surface and having a second terminal42led (or exposed) to the second surface of the body part10, the first conductive via33penetrating through a first end portion of the support member20and connected to the first terminal32of the first coil31and32to thereby be led (or exposed) to the first surface of the body part10, and the second conductive via43penetrating through a second end portion of the support member20and connected to the second terminal42of the second coil41and42to thereby be led (or exposed) to the second surface of the body part10. Further, the coil part70may include the through via51connecting the first coil31and32and the second coil41and42to each other while penetrating through the support member20. Further, the coil part70may include the first insulating film34covering the first coil31and32and the second insulating film44covering the second coil41and42.

The support member20is used to more easily form the coils31,32,41, and42to be thin. The support member20may be an insulating substrate formed of an insulating resin. In this case, as the insulating resin, a thermosetting resin such as an epoxy resin, a thermoplastic resin such as polyimide, resins in which a reinforcement material, such as a glass fiber or an inorganic filler, is impregnated in the thermosetting resin and the thermoplastic resin, such as pre-preg, an Ajinomoto build-up film (ABF), FR-4, a bismaleimide triazine (BT) resin, a photo imageable dielectric (PID) resin, or the like, may be used. In a case in which the glass fiber is contained in the support member20, rigidity may be further improved.

The through via51may electrically connect the first coil31and32and the second coil41and42to each other, thereby forming a single coil having two windings rotating in the same direction. The through via51may be a plating pattern formed by a general plating method after forming a through hole extending through the support member20, but is not limited thereto. In some cases, the first coil31and32and/or the second coil41and42and the through via51may be simultaneously formed to thereby be integrated with each other, but are not limited thereto. The through via51may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

A shape of a horizontal cross section of the through via51(e.g., in a plane extending along the first and second directions) is not particularly limited, but may be, for example, a circular shape, an oval shape, a polygonal shape, or the like. A shape of a perpendicular cross section of the through via51(e.g., in a plane extending along the first and third directions, or along the second and third directions) is not particularly limited, but may be, for example, a tapered shape, a reversely tapered shape, an hourglass shape, a pillar shape, or the like. Generally, a substrate containing glass fiber and an insulating resin, such as pre-preg, or the like, may be used as the support member20. In this case, the through via51may have the hourglass shape, but is not necessarily limited thereto.

The first coil31and32may have a first plating pattern31having a planar coil shape disposed on the one surface of the support member20. The first plating pattern31having the planar coil shape may be a plating pattern formed by a general isotropic plating method, but is not limited thereto. The first plating pattern31having the planar coil shape may have at least two turns, thereby implementing high inductance while having a reduced thickness. The first plating pattern31having the planar coil shape may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The first coil31and32may include the first terminal32led (or exposed) to the first surface of the body part10. The first terminal32may also be a plating pattern formed by a general isotropic plating method, but is not limited thereto. The first terminal32is electrically connected to the first plating pattern31. The first terminal32may be exposed to the first surface of the body part10to thereby be connected to the first electrode81. The first terminal32may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The first conductive via33may be connected to the first terminal32of the first coil31and32and led (or exposed) to the first surface of the body part10together with the first terminal32. The first conductive via33may be a plating pattern formed by a general plating method after forming a via hole extending through the support member20, but is not limited thereto. In some cases, the first coil31and32and the first conductive via33may be simultaneously formed to thereby be integrated with each other, but are not limited thereto. The first conductive via33may be exposed to the first surface of the body part10to thereby be connected to the first electrode81together with the first terminal32. The first conductive via33may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The first insulating film34, the purpose of which is to protect and insulate the first coil31and32(e.g., insulate the first coil31and32from the material of the body part10), may contain an insulating material. Any of a wide range of insulating materials may be contained in the first insulating film34without particular limitation. The first insulating film34may enclose a surface of the first coil31and32, and a thickness, or the like, of the first insulating film34is not particularly limited. The first insulating film34may further extend between windings of the first coil31and32and insulate adjacent windings from each other.

The second coil41and42may have a second plating pattern41having a planar coil shape disposed on the other surface of the support member20(opposite to the one surface). The second plating pattern41having the planar coil shape may be a plating pattern formed by a general isotropic plating method, but is not limited thereto. The second plating pattern41having the planar coil shape may have at least two turns, thereby implementing high inductance while having a reduced thickness. The second plating pattern41having the planar coil shape may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The second coil41and42may include the second terminal42led (or exposed) to the second surface of the body part10. The second terminal42may also be a plating pattern formed by a general isotropic plating method, but is not limited thereto. The second terminal42is electrically connected to the second plating pattern41. The second terminal42may be exposed to the second surface of the body part10(opposite to the first surface) to thereby be connected to the second electrode82. The second terminal42may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The second conductive via43may be connected to the second terminal42of the second coil41and42and led (or exposed) to the second surface of the body part10together with the second terminal42. The second conductive via43may be a plating pattern formed by a general plating method after forming a via hole extending through the support member20, but is not limited thereto. In some cases, the second coil41and42and the second conductive via43may be simultaneously formed to thereby be integrated with each other, but are not limited thereto. The second conductive via43may be exposed to the second surface of the body part10to thereby be connected to the second electrode82together with the second terminal42. The second conductive via43may be composed of a seed layer and a plating layer. As a material of the seed layer and the plating layer, a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), alloys thereof, or the like, which is a general plating material, may be used.

The second insulating film44, the purpose of which is to protect and insulate the second coil41and42(e.g., insulate the second coil41and42from the material of the body part10), may contain an insulating material. Any of a wide range of insulating materials may be contained in the second insulating film44without particular limitation. The second insulating film44may enclose a surface of the second coil41and42, and a thickness, or the like, of the second insulating film44is not particularly limited. The second insulating film44may further extend between windings of the second coil41and42and insulate adjacent windings from each other.

The one or more electrode part(s)80may serve to electrically connect the coil component100A to an electronic device (or to other electronic components, wires, or circuit traces) when the coil component100A is mounted in the electronic device. The one or more electrode part(s)80may include the first and second electrodes81and82disposed on the body part10to be spaced apart from each other. If necessary, as described below, each electrode part80may include a pre-plating layer (not illustrated) between the coil part70and the electrode part80in order to improve electrical reliability.

The first electrode81may be extended to portions of third, fourth, fifth, and sixth surfaces of the body part10while covering the first surface of the body part10. The first electrode81may be connected to the first terminal32of the first coil31and32and the first conductive via33which are led (or exposed) to the first surface of the body part10. The first electrode81may include, for example, a conductive resin layer and a conductor layer formed on the conductive resin layer. The conductive resin layer may be formed by printing a paste, or the like, and may contain any one or more conductive metals selected from the group consisting of copper (Cu), nickel (Ni), silver (Ag), and a thermosetting resin. The conductor layer may contain any one or more selected from the group consisting of nickel (Ni), copper (Cu), and tin (Sn). For example, a nickel (Ni) layer and a tin (Sn) layer may be sequentially formed by plating.

The second electrode82may be extended to portions of third, fourth, fifth, and sixth surfaces of the body part10while covering the second surface of the body part10. The second electrode82may be connected to the second terminal42of the second coil41and42and the second conductive via43which are led (or exposed) to the second surface of the body part10. The second electrode82may include, for example, a conductive resin layer and a conductor layer formed on the conductive resin layer. The conductive resin layer may contain any one or more conductive metals selected from the group consisting of copper (Cu), nickel (Ni), silver (Ag), and a thermosetting resin. The conductor layer may contain any one or more selected from the group consisting of nickel (Ni), copper (Cu), and tin (Sn). For example, a nickel (Ni) layer and a tin (Sn) layer may be sequentially formed by plating.

FIGS. 4A and 4Billustrate schematic examples of the body part10of the coil component ofFIG. 2viewed in the A and B directions, respectively, identified inFIG. 2. Here,FIG. 4Aschematically illustrates the first surface of the body part10. In addition,FIG. 4Bschematically illustrates the second surface of the body part10. Referring toFIGS. 4A and 4B, the first terminal32of the first coil31and32, the first conductive via33connected to the first terminal32, and the first insulating film34covering the first coil31and32may be exposed to the first surface of the body part10. That is, the support member20may not be exposed to the first surface of the body part10. Therefore, when the first electrode81is formed on the first surface of the body part10, a problem such as a plating defect, or the like, may not occur. Further, the second terminal42of the second coil41and42, the second conductive via43connected to the second terminal42, and the second insulating film44covering the second coil41and42may be exposed to the second surface of the body part10. That is, the support member20may not be exposed to the second surface of the body part10. Therefore, when the second electrode82is formed on the second surface of the body part10, a problem such as a plating defect, or the like, may not occur.

FIGS. 5A and 5Bschematically illustrate other examples of the body part10of the coil component ofFIG. 2viewed in the A and B directions, respectively. Here,FIG. 5Aschematically illustrates the first surface of the body part10. In addition,FIG. 5Bschematically illustrates the second surface of the body part10. Referring toFIGS. 5A and 5B, only the first terminal32of the first coil31and32, and the first conductive via33connected to the first terminal32may be exposed to the first surface of the body part10. That is, the first insulating film34and the support member20may not be exposed to the first surface of the body part10in the example ofFIG. 5A. The example ofFIG. 5Amay illustrate a case in which the first insulating film34is not formed, or a case in which the first insulating film34does not cover an end portion of the first terminal32of the first coil31and32. In addition, only the second terminal42of the second coil41and42, and the second conductive via43connected to the second terminal42may be exposed to the second surface of the body part10. That is, the second insulating film44and the support member20may not be exposed to the second surface of the body part10in the example ofFIG. 5B. The example ofFIG. 5Billustrates a case in which the second insulating film44is not formed, or a case in which the second insulating film44does not cover an end portion of the second terminal42of the second coil41and42.

FIG. 6illustrates a schematic example of the coil part70of the coil component ofFIG. 2viewed in a C direction.FIG. 7illustrates a schematic example of the coil part70of the coil component ofFIG. 2viewed in a D direction. Referring toFIGS. 6 and 7, the first plating pattern31of the first coil31and32may have a planar coil shape with a plurality of turns. The second plating pattern41of the second coil41and42may also have a planar coil shape with a plurality of turns. The first conductive via33may be connected to the first terminal32of the first coil31and32, may penetrate through the first end portion of the support member20, and may completely penetrate through an end surface of the support member20contacting the first surface of the body part10. The second conductive via43may be connected to the second terminal42of the second coil41and42, may penetrate through the second end portion of the support member20, and may completely penetrate through an end surface of the support member20contacting the second surface of the body part10.

Meanwhile, although a case in which the one or more electrode part(s)80are formed on the first and second surfaces of the body part10is illustrated in the accompanying drawings, unlike this, the electrode part80may be formed on another surface depending on the kind of coil component. Alternatively, the electrode part80may be formed on three or more surfaces. In this case, a terminal of the coil and a conductive via of the coil part70may be added in accordance therewith. Further, the coil of the coil part70may be formed on only one surface of the support member or may be composed of a plurality of coil layers. Besides, the coil part70may be modified in various forms.

FIG. 8is a schematic process flow chart showings steps of an illustrative method for forming the coil component ofFIG. 2. Referring toFIG. 8, a method of manufacturing the coil component100A according to the example may include forming a plurality of coil parts by forming a plurality of coils and a plurality of conductive vias on a support member; forming a plurality of body parts by stacking magnetic sheets on top of and below the plurality of coil parts; dicing the plurality of body parts; and forming one or more electrode part(s) on each of the individual body parts. A plurality of coil components may be manufactured by a single process through a series of operations.

FIGS. 9, 10, 12, 13, 14, and 15illustrate examples of schematic process steps of methods for manufacturing or forming the coil component ofFIG. 2.FIGS. 11A through 11Dillustrate a schematic enlarged cross-section of part P of the coil component ofFIG. 10. Hereinafter, a description overlapping the description above will be omitted, and each of the processes in the method of manufacturing the coil component will be described in more detail with reference toFIGS. 9, 10, 11A through 11D, 12, 13, 14, and 15.

Referring toFIG. 9, a support member20may be prepared. In some examples, unlike the support member illustrated inFIG. 9, a plurality of metal layers (not illustrated) may be disposed on both opposing main surfaces of the support member20. In such examples, the plurality of metal layers (not illustrated) may be used as seed layers when a coil is formed on the support member20, or the like. In one example, the support member20may be a portion of a general copper clad laminate (CCL), but is not limited thereto.

Referring toFIG. 10, the plurality of coil parts70may be formed by forming a plurality of first coils31and32and a plurality of second coils41and42on respective surfaces of the support member20, and forming a plurality of first conductive vias33and a plurality of second conductive vias43penetrating through the support member20. The plurality of coil parts70may be formed, for example, by forming a dry film, patterning the dry film by a photolithography method, and filling a patterned portion using a plating method. However, the formation method of the coil parts70is not limited thereto. The plating method may be an electrolytic copper plating method, an electroless copper plating method, or the like. In more detail, the plurality of coil parts70may be formed using a chemical vapor deposition (CVD) method, a physical vapor deposition (PVD) method, a sputtering method, a subtractive method, an additive method, a semi-additive process (SAP), a modified semi-additive process (MSAP), or the like, but are not limited thereto. Via holes for the first and second conductive vias33and43may be formed using a mechanical drill, a laser drill, and/or the like, before plating. The plurality of coil parts70may be connected to each other by a support pattern300, and may be separated from each other by dicing the plurality of coil parts70along each dicing line200.

Referring toFIGS. 11A through 11D, the conductive vias33and43may have any shape as long as they penetrate through an end portion of the support member20so as to not be exposed to an outer surface of a body10after the support member20is diced along the dicing line200. For example, as illustrated inFIG. 11A, a horizontal cross-sectional shape of the conductive vias33and43may be a circle, and a diameter thereof may be larger than a line width of the terminals32and42of the coils31,32,41, and42. Further, as illustrated inFIG. 11B, the horizontal cross-sectional shape of the conductive vias33and43may be a circle, and a diameter thereof may be equal to the line width of the terminals32and42of the coils31,32,41, and42. In addition, as illustrated inFIG. 11C, the horizontal cross-sectional shape of the conductive vias33and43may be a tetragon, and a width thereof may be larger than the line width of the terminals32and42of the coils31,32,41, and42. Further, as illustrated inFIG. 11D, the horizontal cross-sectional shape of the conductive vias33and43may be a tetragon, and a width thereof may be equal to the line width of the terminals32and42of the coils31,32,41, and42. However, the conductive vias illustrated inFIGS. 11A through 11Dare provided by way of example, and the conductive vias may have different shapes or sizes, or the like. Portions of the conductive vias33and43formed on connection portions301, and the like, of the support pattern300may be removed during dicing of the support member20along the dicing line200, and thus the portions may not remain after the individual coil component100A is manufactured.

Referring toFIG. 12, in a region expanded to be wider than an area enclosed by each of the dicing lines200, the other regions of the support member20except for a region of the support member20on which each of the coil parts70is formed may be removed by a trimming method, and thus regions21from which the support member20is removed may be formed. As the trimming method, any method may be used without particular limitation as long as it may selectively remove the support member20as described above. In addition, the removal method is not limited thereto, and the support member20may also be selectively removed by another method in addition to the trimming method.

Referring toFIG. 13, a plurality of body parts10embedding the plurality of coil parts70may be formed by filling the regions in which the support member20is removed by the trimming method, or the like, with a magnetic material13. This may be performed by compressing and curing magnetic sheets (not illustrated). For example, the plurality of body parts10may be formed by compressing the magnetic sheets on top of and below the plurality of coil parts70, respectively, and then curing the compressed magnetic sheets. However, the plurality of body parts10are not limited thereto, and may be formed by providing the magnetic material13using a different method.

Referring toFIG. 14, individual body parts10may be obtained by dicing the plurality of body parts10along the dicing line(s)200. The dicing may be performed in accordance with a size designed in advance, and as a result, a plurality of body parts10in which the coil part70is disposed may be provided. The dicing may be performed using dicing equipment. In addition, another dicing method such as a blade method, a laser method, or the like, may be used. After dicing, although not illustrated in detail in the drawings, edges of the body part10may be formed in a round shape by polishing the edges of the body part10, and in order to prevent plating, an insulator (not illustrated) for insulation may be printed on an outer surface of the body part10.

Referring toFIG. 15, a coil component may be obtained by forming one or more electrode(s)80on each of the individual body parts10. The electrode(s)80may be first and second electrodes81and82and formed using a suitable method. For example, the electrodes80may be formed by printing a paste containing a metal having excellent conductivity using a dipping method, or the like, and then plating a metal having excellent conductivity using a plating method, but a formation method of the electrodes80is not limited thereto. If necessary, a pre-plating layer (not illustrated) may be formed by a plating method before forming the electrodes80.

FIG. 16illustrates another example of the schematic cross-section of the coil component taken along line I-I′ ofFIG. 2.FIG. 17illustrates a schematic enlarged cross-section of part Q of the coil component ofFIG. 16. Referring toFIGS. 16 and 17, in a coil component100B according to another example, a magnetic material of a body part10may be a magnetic material-resin composite in which magnetic metal powders11and12and a resin mixture13are mixed with each other. The magnetic metal powders11and12may contain iron (Fe), chromium (Cr), or silicon (Si) as a main ingredient. For example, the magnetic metal powders11and12may contain iron (Fe)-nickel (Ni), iron (Fe), iron (Fe)-chromium (Cr)-silicon (Si), or the like, but are not limited thereto. The resin mixture13may contain epoxy, polyimide, a liquid crystal polymer (LCP), or the like, but is not limited thereto. As the magnetic metal powders11and12, magnetic metal powders11and12having at least two average particle sizes D1and D2different from each other may be used. In this case, the magnetic material-resin composite may be fully filled by using bimodal magnetic metal powders11and12having different sizes and compressing the bimodal magnetic metal powders11and12, and thus a filling rate may be increased. Since other configurations are the same as those described above, a description thereof will be omitted.

FIG. 18illustrates another example of the schematic cross-section of the coil component taken along line I-I′ ofFIG. 2.FIG. 19illustrates a schematic enlarged cross-section of part R of the coil component ofFIG. 18. Referring toFIGS. 18 and 19, in a coil component100C according to another example, coils31,32,41, and42may be formed by applying an anisotropic plating technology. In this case, the coils31,32,41, and42may be composed of a plurality of plating patterns31a,31b,32a,32b,41a,41b,42a, and42b, respectively, and thus, a high aspect ratio (AR), which is a ratio of a height H to a line width W, may be implemented. In this case, the height H may be measured orthogonally to a main surface of the support member20, and the line width W may be measured across the width of the coil plating pattern31along a plane parallel to the main surface of the support member20. As a result, high inductance may be implemented. Since other configurations are the same as those described above, a description thereof will be omitted.

FIG. 20illustrates another example of the schematic cross-section of the coil component taken along line I-I′ ofFIG. 2. Referring toFIG. 20, one or more electrode part (s)80may include pre-plating layers86and87provided in order to improve electrical reliability of the electrical connection between the coil part70and each electrode part80. The pre-plating layers86and87may include a first pre-plating layer86disposed on a first terminal32of a first coil31and32and a first conductive via33to connect the first terminal32and the first conductive via33to a first electrode81, and a second pre-plating layer87disposed on a second terminal42of a second coil41and42and a second conductive via43to connect the second terminal42and the second conductive via43to a second electrode82. Since other configurations are the same as those described above, a description thereof will be omitted.

The first pre-plating layer86may be disposed on the first terminal32of the first coil31and32and the first conductive via33exposed to a first surface of a body part10. In some cases, a portion of the first pre-plating layer86may be disposed inwardly of the first surface of the body part10. The first pre-plating layer86may be formed of a conductive material, such as copper (Cu) plating. The first electrode81may be formed by applying at least one of nickel (Ni) and tin (Sn) to the first pre-plating layer86, or may be formed by applying at least one of silver (Ag) and copper (Cu) to the first pre-plating layer86and then applying at least one of nickel (Ni) and tin (Sn) thereto. Therefore, contact force of the first electrode81may be increased, and silver (Ag), copper (Cu), and the like, for forming the first electrode81do not need to be separately applied.

The second pre-plating layer87may be disposed on the second terminal42of the second coil41and42and the second conductive via43exposed to a second surface of the body part10. In some cases, a portion of the second pre-plating layer87may be disposed inwardly of the second surface of the body part10. The second pre-plating layer87may be formed of a conductive material, such as copper (Cu) plating. The second electrode82may be formed by applying at least one of nickel (Ni) and tin (Sn) to the second pre-plating layer87, or may be formed by applying at least one of silver (Ag) and copper (Cu) to the second pre-plating layer87and then applying at least one of nickel (Ni) and tin (Sn) thereto. Therefore, contact force of the second electrode82may be increased, and silver (Ag), copper (Cu), and the like, for forming the second electrode82do not need to be separately applied.

FIG. 21illustrates another example of the schematic cross-section of the coil component taken along line I-I′ ofFIG. 2. Referring toFIG. 21, one or more electrode part(s)80may include pre-plating layers86and87in order to improve electrical reliability of the electrical connection between the coil part70and the electrode part80. In this case, the pre-plating layers86and87do not entirely cover first and second surfaces of a body part10but may cover only terminals32and42of coils31,32,41, and42and conductive vias33and43, unlike the pre-plating layers illustrated inFIG. 20. However, a disposition form of the pre-plating layers86and87is not limited thereto, and the pre-plating layers86and87may also be disposed in another form as long as the pre-plating layers86and87cover only the terminals32and42of the coils31,32,41, and42and the conductive vias33and43. Since other configurations are the same as those described above, a description thereof will be omitted.

As set forth above, in accordance with the exemplary embodiments described herein, the coil component having a novel structure capable of decreasing plating defects, or the like, by allowing the insulating substrate not to be exposed to the outer surface of the body on which the electrode is formed, and the method of manufacturing the same capable of efficiently manufacturing the coil component are provided.

Meanwhile, in the present disclosure, a word ‘electrically connected’ includes both a case in which one component is physically connected to another component and a case in which a component is not physically connected to another component.

In addition, a term ‘examples’ used in the present disclosure does not mean the same exemplary embodiment, but is provided in order emphasize and describe different unique features. However, each of the above suggested examples may also be implemented to be combined with a feature of another example. For example, even though a content described in a specific example is not described in another example, it may be understood as a description related to another example unless explicitly described otherwise.

Further, terms used in the present disclosure are used only in order to describe an example rather than limiting the present disclosure. Here, singular forms include plural forms unless a context clearly indicates otherwise.