Method of manufacturing electronic component

A method of manufacturing an electronic component having high inductance (L) and an excellent quality (Q) factor and direct current (DC)-bias characteristics includes forming a magnetic body in which internal coil parts are embedded, and forming a cover part including a magnetic metal plate on at least one of upper and lower portions of the magnetic body.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims benefit of priority to Korean Patent Application No. 10-2014-0189117 filed on Dec. 24, 2014, with the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a method of manufacturing an electronic component.

BACKGROUND

An inductor, an electronic component, is a representative passive element configuring an electronic circuit, together with a resistor and a capacitor, to remove noise therefrom.

Inductors are manufactured by forming an internal coil part in a magnetic body including a magnetic material and forming external electrodes on external surfaces of the magnetic body.

SUMMARY

An aspect of the present disclosure may provide a method of manufacturing an electronic component having high inductance (L) and an excellent quality (Q) factor, and direct current (DC)-bias characteristics (change characteristics in inductance, depending on the application of a current).

According to an aspect of the present disclosure, a method of manufacturing an electronic component may include forming a magnetic metal plate on at least one of an upper portion and a lower portion of a magnetic body in which internal coil parts are embedded.

According to another aspect of the present disclosure, a method of manufacturing an electronic component may include stacking a magnetic metal plate and thermosetting resin layers on at least one of upper and lower portions of the magnetic metal plate to form a laminate, compressing the laminate to pulverize the magnetic metal plate into a plurality of metal fragments, and forming the laminate in which the magnetic metal plate is pulverized, on at least one of upper and lower portions of a magnetic body in which internal coil parts are embedded.

According to another aspect of the present disclosure, a method of manufacturing an electronic component may include forming a magnetic body embedded with internal coil parts and forming a cover part including a pulverized magnetic metal plate on at least one of upper and lower portions of the magnetic body.

DETAILED DESCRIPTION

Hereinafter, an electronic component manufactured according to an exemplary embodiment in the present disclosure, for example, a thin film type inductor, will be described. However, the electronic component according to exemplary embodiments in the present disclosure is not limited thereto.

FIG. 1is a perspective view schematically illustrating an internal coil part of an electronic component manufactured according to an exemplary embodiment in the present disclosure.

Referring toFIG. 1, as an example of the electronic component, a thin film type inductor used in a power line of a power supply circuit is illustrated.

An electronic component100according to an exemplary embodiment in the present disclosure may include a magnetic body50, internal coil parts41and42embedded in the magnetic body50, and first and second external electrodes81and82disposed on external surfaces of the magnetic body50and connected to the internal coil parts41and42.

In the electronic component100according to an exemplary embodiment in the present disclosure, a ‘length’ direction refers to an ‘L’ direction ofFIG. 1, a ‘width’ direction refers to a ‘W’ direction ofFIG. 1, and a ‘thickness’ direction refers to a ‘T’ direction ofFIG. 1.

The electronic component100according to the exemplary embodiment in the present disclosure may include a first internal coil part41having a flat coil shape and formed on one surface of an insulating substrate20and a second internal coil part42having a flat coil shape and formed on the other surface of the insulating substrate20opposing the one surface thereof.

The first and second internal coil parts41and42may have a spiral shape, and the first and second internal coil parts41and42formed on one surface and the other surface of the insulating substrate20, respectively, may be electrically connected to each other by a via (not shown) penetrating through the insulating substrate20.

The insulating substrate20may have a through-hole formed in a central portion thereof to penetrate therethrough, in which the through-hole may be filled with a magnetic material to form a core part55. The core part55may be filled with the magnetic material to improve an inductance (L).

However, the insulating substrate20is not necessarily included. The internal coil part may also be formed of a metal wire without including the insulating substrate.

One end portion of the first internal coil part41formed on one surface of the insulating substrate20may be exposed to one end surface of the magnetic body50in the length (L) direction thereof, and one end portion of the second internal coil part42formed on the other surface of the insulating substrate20may be exposed to the other end surface of the magnetic body50in the length (L) direction thereof.

However, one end portions of the respective first and second internal coil parts41and42are not limited to being exposed as described above, but one end portion of each of the first and second internal coil parts41and42may be exposed to at least one surface of the magnetic body50.

The first and second external electrodes81and82may be formed on the external surfaces of the magnetic body50to be connected to the first and second internal coil parts41and42exposed to the end surfaces of the magnetic body50, respectively.

Referring toFIG. 2, the magnetic body50of the electronic component100manufactured according to the exemplary embodiment in the present disclosure may include magnetic metal powder particles51. However, the magnetic body50is not limited to including the magnetic metal powder particles51, and may include any magnetic powder particles exhibiting magnetic properties.

The electronic component100manufactured according to the exemplary embodiment in the present disclosure may include a cover part70including a magnetic metal plate71disposed on at least one of upper and lower portions of the magnetic body50including the magnetic metal powder particles51.

A boundary between the magnetic body50and the cover part70may be able to be confirmed using a scanning electron microscope (SEM), but the magnetic body50and the cover part70may not necessarily be differentiated from each other by the boundary observed by the scanning electron microscope (SEM). For example, a region thereof in which magnetic metal plate71is included may be differentiated as the cover part70.

The cover part70including the magnetic metal plate71may have a degree of permeability greater than that of the magnetic body50including the magnetic metal powder particles51. Further, the cover part70including the magnetic metal plate71may serve to prevent a magnetic flux from leaking to the outside.

Accordingly, the electronic component100manufactured according to the exemplary embodiment in the present disclosure may implement relatively high inductance and excellent DC-bias characteristics.

The magnetic metal powder particles51may be spherical powder particles or plate-shaped, for example, flake powder particles.

The magnetic metal powder particles51may be formed of crystalline metal or amorphous metal including at least one or more selected from the group consisting of iron (Fe), silicon (Si), boron (B), chromium (Cr), aluminum (Al), copper (Cu), niobium (Nb), and nickel (Ni).

For example, the magnetic metal powder particles51may be Fe—Si—B—Cr-based spherical amorphous metal particles.

The magnetic metal powder particles51may be included in a thermosetting resin such as an epoxy resin and a polyimide resin in a form in which they are dispersed in the thermosetting resin.

Permeability of the magnetic metal plates71may be about two to ten times greater than that of the magnetic metal powder particles51, and the magnetic metal plates71may be disposed above and below the magnetic body50to prevent a magnetic flux from leaking to the outside.

The magnetic metal plates71may be formed of a crystalline metal or an amorphous metal including at least one selected from the group consisting of iron (Fe), silicon (Si), boron (B), chromium (Cr), aluminum (Al), copper (Cu), niobium (Nb), and nickel (Ni).

The magnetic metal plates71according to the exemplary embodiment in the present disclosure may be formed of a plurality of pulverized metal fragments71a.

When the magnetic metal plates are used in plate form without being pulverized, permeability of the magnetic metal plates may be about two to ten times as high as that of the magnetic metal powder particles51, but a core loss of the magnetic metal plates may be greatly increased due to an eddy current and thus a Q factor thereof may deteriorate.

Therefore, according to the exemplary embodiment in the present disclosure, the magnetic metal plates71may be pulverized to form the plurality of metal fragments71a, thereby implementing the high permeability and reducing the core loss.

Accordingly, the electronic component100manufactured according to the exemplary embodiment in the present disclosure may improve permeability, thereby securing high inductance and satisfying the requirement for an excellent Q factor.

The cover part70may further include thermosetting resin layers72disposed on at least one or both of the upper and lower portions of the magnetic metal plates71.

The thermosetting resin layers72may include a thermosetting resin such as the epoxy resin and the polyimide resin.

A thermosetting resin72amay be disposed in a space between adjacent metal fragments71aof the pulverized magnetic metal plates71.

The thermosetting resin72adisposed in the space between the adjacent metal fragments71amay insulate the adjacent metal fragments71afrom each other.

As a result, core loss of the metal magnetic plate71may be reduced and the Q factor thereof may be improved.

FIG. 3is a cross-sectional view of an electronic component manufactured according to another exemplary embodiment in the present disclosure, taken in L-T directions.

Referring toFIG. 3, the cover part70of the electronic component100manufactured according to another exemplary embodiment in the present disclosure may include a plurality of the magnetic metal plates71.

The cover part70may include the magnetic metal plates71stacked in a plurality of layers.

The cover part70may have the plurality of magnetic metal plates71and the thermosetting resin layers72alternately stacked therein.

The thermosetting resin layers72may be formed between the plurality of magnetic metal plates71to insulate the adjacently stacked magnetic metal plates71from each other.

The thermosetting resin72amay be disposed in the space between the adjacent metal fragments71aof each pulverized magnetic metal plate71and the thermosetting resin72adisposed in the space between the adjacent metal fragments71amay insulate the adjacent metal fragments71afrom each other.

The cover part70may include the plurality of magnetic metal plates71, thereby further improving permeability and securing a relatively high degree of inductance.

For instance, the cover part70may include the magnetic metal plates71in an amount of four or more.

FIGS. 4A and 4Bare views illustrating a manufacturing process of an electronic component according to an exemplary embodiment in the present disclosure.

Referring toFIG. 4A, first, the magnetic body50in which the internal coil parts41and42are embedded may be formed.

The magnetic body50may include the magnetic metal powder particles51.

A method of forming magnetic body50is not particularly limited, but any method of forming a magnetic metal powder-resin composite in which the internal coil parts are embedded may be used.

The magnetic body50may include a mixture of magnetic metal powder particles having a relatively large average particle size and magnetic metal powder particles having a relatively small average particle size.

The magnetic metal powder particles having a relatively large average particle size may allow for relatively high permeability, and the magnetic metal powder particles having a relatively small average particle size may be mixed with the magnetic metal powder particles having a relatively large average particle size to improve a filling rate. As the filling rate thereof is increased, the permeability thereof may be improved.

Further, using the magnetic metal powder particles having a relatively large average particle size may implement the high permeability but increase the core loss. On the other hand, the magnetic metal powder particles having a relatively small average particle size are a low core loss material, and thus, mixing the magnetic metal powder particles having a relatively small average particle size with the magnetic metal powder particles having a relatively large average particle size may offset the core loss increasing due to the use of the magnetic metal powder particles having a relatively large average particle size to improve the Q factor.

Accordingly, the magnetic body50may include the mixture of the magnetic metal powder particles having a relatively large average particle size with the magnetic metal powder particles having an average particle size smaller than that of the magnetic metal powder particles having the relatively large average particle size, to improve the inductance and the Q factor.

However, permeability may not be greatly improved through only the mixing of the magnetic metal powder particles having a relatively large average particle size with the magnetic metal powder particles having a relatively small average particle size.

According to the exemplary embodiment in the present disclosure, the magnetic metal plates71may be further formed to more improve permeability.

Referring toFIG. 4B, the cover parts70including the magnetic metal plates71may be formed above and below the magnetic body50.

The magnetic body50and the cover parts70including the magnetic metal plates71may be integrated by being compressed and hardened by a laminate method or an isostatic pressing method.

When a thickness of the magnetic body50including the magnetic metal powder particles51is t1and a thickness of the cover part70including the magnetic metal plates71is t2, the thickness t2of each of the cover parts70may range from 10% to 30% of the thickness t1of the magnetic body50.

When the thickness t2of the cover part70is less than 10% of the thickness t1of the magnetic body50, the effect of improving permeability and reducing the leakage magnetic flux may be degraded and when the thickness t2of the cover part70exceeds 30% of the thickness t1of the magnetic body50, the core loss may be increased and the Q factor may deteriorate.

FIGS. 4A and 4Billustrate that the magnetic metal plates71are disposed above and below the magnetic body50to form the cover parts70, but the formation of the cover part70is not limited thereto. For example, any method capable of achieving the effect of the present disclosure by forming the magnetic metal plate of at least one layer may be used.

For example, the cover parts70including the magnetic metal plates71may also be formed on side surfaces of the magnetic body50, or may also be formed in the magnetic body50, instead of being disposed above and below the magnetic body50.

FIGS. 5A and 5Bare views illustrating a process of forming a magnetic body of an electronic component according to an exemplary embodiment in the present disclosure.

Referring toFIG. 5A, the first and second internal coil parts41and42may be formed on one surface and the other surface of the insulating substrate20.

A via hole (not illustrated) may be formed in the insulating substrate20, a plating resist having an opening may be formed on the insulating substrate20, and the via hole and the opening may be filled with a conductive metal by the plating to form the first and second internal coil parts41and42and a via (not shown) connecting the first and second internal coil parts41and42to each other.

The first and second internal coil parts41and42and the via may be formed using a conductive metal having excellent electrical conductivity, for example, silver (Ag), palladium (Pd), aluminum (Al), nickel (Ni), titanium (Ti), gold (Au), copper (Cu), platinum (Pt), or an alloy thereof, etc.

However, a method of forming internal coil parts41and42is not limited to the above-mentioned plating, and the internal coil parts may also be formed by a metal wire.

An insulating film (not shown) coating the first and second internal coil parts41and42may be formed on the first and second internal coil parts41and42.

The insulating film (not shown) may be formed by a method well-known in the art such as a screen printing method, a photo-resist (PR) exposure and development method, a spray application method, or the like.

The first and second internal coil parts41and42may be coated with the insulating film (not shown), such that the first and second internal coil parts41and42may not directly contact magnetic materials forming the magnetic body50.

The insulating substrate20may be, for example, a polypropylene glycol (PPG) substrate, a ferrite substrate, a metal-based soft magnetic substrate, or the like.

In a region of the insulating substrate20in which the first and second internal coil parts41and42are not formed, a central portion thereof may be removed to thus form a core part hole55′ in the central portion of the insulating substrate20.

A partial removal of the insulating substrate20may be carried out by mechanical drilling, laser drilling, sand blasting, punching, or the like.

Referring toFIG. 5B, magnetic sheets50′ may be stacked on the upper and lower portions of the first and second internal coil parts41and42.

The magnetic sheets50′ may be manufactured by mixing the magnetic metal powder particles51with organic materials such as a thermosetting resin, a binder and a solvent to prepare slurry, applying the slurry to a carrier film at a thickness of several tens of micrometers using the doctor blade method, and drying the slurry.

The magnetic metal powder particles51may be the spherical powder particles or the plate-shaped, for example, flake powder particles.

The magnetic sheets50′ may be manufactured by mixing the magnetic metal powder particles having a relatively large average particle size with the magnetic metal powder particles that have an average particle size smaller than that of the magnetic metal powder particles having the relatively large average particle size.

The magnetic sheets50′ may be manufactured by dispersing the magnetic metal powder particles51in the thermosetting resin such as an epoxy resin and a polyimide resin.

The magnetic body50in which the internal coil parts41and42are embedded may be formed by stacking, compressing, and hardening the magnetic sheets50′.

Here, the core part hole55′ may be filled with magnetic materials to form the core part55.

However,FIG. 5Billustrates that the magnetic sheets50′ are stacked to form the magnetic body50, but the formation of the magnetic body50is not limited thereto. For example, any method capable of forming the magnetic metal powder-resin composite in which the internal coil parts are embedded may be used.

FIGS. 6A through 6Eare views illustrating a process of forming a cover part of the electronic component including a magnetic metal plate according to the exemplary embodiment in the present disclosure.

Referring toFIG. 6A, magnetic metal plates71′ and the thermosetting resin layers72may be alternately stacked on a support film91to form a laminate70′.

The support film91may not particularly be limited as long as it may support the laminate70′. For example, a polyethylene terephthalate (PET) film, a polyimide film, a polyester film, a polyphenylene sulfide (PPS) film, a polypropylene (PP) film, a fluorine resin-based film such as polyterephthalate (PTFE), or the like may be used.

A thickness of the support film91may range from 20 μm to 50 μm.

The magnetic metal plates71′ may be formed of crystalline metal or amorphous metal including at least one selected from the group consisting of iron (Fe), silicon (Si), boron (B), chromium (Cr), aluminum (Al), copper (Cu), niobium (Nb), and nickel (Ni).

A thickness taof the magnetic metal plate71′ may range from 5 μm to 50 μm.

When the thickness taof the magnetic metal plate71′ is less than 5 μm, the effect of improving permeability and reducing leakage magnetic flux may deteriorate. When the thickness taof the magnetic metal plate71′ exceeds 50 μm, the magnetic metal plate71′ may not be properly pulverized and a Q factor of the magnetic metal plate71′ may be degraded due to the increase in the core loss.

The thermosetting resin layers72may include the thermosetting resin such as the epoxy resin, the polyimide resin, and the like.

A thickness tbof the thermosetting resin layer72may be 1.0 to 2.5 times the thickness taof the magnetic metal plate71′.

When the thickness tbof the thermosetting resin layer72is less than 1.0 times the thickness taof the magnetic metal plate71′, the insulating effect between the adjacent magnetic metal plates71′ and the adjacent metal fragments71amay be degraded. When the thickness tbof the thermosetting resin layer72exceeds 2.5 times the thickness taof the magnetic metal plate71′, the effect of improving permeability may be degraded.

For example, the thickness taof the thermosetting resin layer72may be 1.5 to 2.0 times the thickness taof the magnetic metal plate71′.

FIG. 6Aillustrates the laminate70′ in which the magnetic metal plates71′ of four layers are stacked, but the laminate70′ is not limited thereto. The laminate70′ in which the magnetic metal plate71′ of at least one layer and the thermosetting resin layer72which is stacked on at least one of the upper and lower portions of the magnetic metal plate71′ are stacked may be formed.

In further detail, the magnetic metal plates71′ of four or more layers may be stacked.

Referring toFIG. 6B, a cover film92may be formed on the laminate70′.

The cover film92may serve to fix the laminate70′ so that the magnetic metal plate71′ may be pulverized while being formed as one layer as it is during the pulverization of the magnetic metal plates71′ by compressing the laminate70′.

The cover film92may not be particularly limited as long as it may fix the laminate70′. For example, a polyethylene terephthalate (PET) film, a polyimide film, a polyester film, a polyphenylene sulfide (PPS) film, a polypropylene (PP) film, a fluorine resin-based film such as polyester terephthalate (PTFE), an epoxy resin film, or the like may be used.

A thickness of the cover film92may range from 10 μm to 25 μm.

Referring toFIG. 6C, the magnetic metal plates71′ may be pulverized by compressing the laminate70′ on which the support film91and the cover film92are formed.

When the magnetic metal plates are used in a plate form without being pulverized, the permeability of the magnetic metal plates may be two to ten times higher than that of the magnetic metal powder particles51, but the core loss of the magnetic metal plate may be greatly increased due to the eddy current and thus the Q factor thereof may deteriorate.

Therefore, according to the exemplary embodiment in the present disclosure, the magnetic metal plates71′ may be pulverized to form the plurality of metal fragments71a, thereby implementing relatively high permeability and reducing core loss.

When the plurality of metal fragments71aare formed by pulverizing the magnetic metal plates71′, permeability thereof may be slightly reduced, but the high permeability may be still exhibited, and the core loss due to the eddy current may be significantly reduced as compared to the degree of reduction in permeability.

A method of pulverizing the magnetic metal plates71′ may be performed, for example, by pulverizing the magnetic metal plates71into the plurality of metal fragments71aby forming the laminate70′ and then passing the laminate70′ through rollers210and220disposed at upper and lower portions of the laminate70′, as illustrated inFIG. 6C.

The magnetic metal plates71′ may be formed using crystalline metal or amorphous metal, but may be more effectively pulverized when the magnetic metal plates71′ are heat-treated to form a crystalloid.

The rollers210and220may be a metal roller, a rubber roller, etc., and a roller having a plurality of protrusions formed on external surfaces thereof may be used.

The method of pulverizing magnetic metal plates71′ is not limited thereto, but any method capable of pulverizing the magnetic metal plates71′ into the plurality of metal fragments71ato achieve the effect of the present disclosure may be used.

Referring toFIG. 6D, the magnetic metal plates71may be pulverized to form the plurality of metal fragments71a.

The magnetic metal plates71may be pulverized so that adjacent metal fragments71amay have shapes corresponding to each other.

The metal fragments71aformed by pulverizing the magnetic metal plates are not irregularly dispersed but are positioned to form one layer in the pulverized state in which the adjacent metal fragments71ahave shapes corresponding to each other.

For instance, the corresponding shapes of the adjacent metal fragments71adoes not mean that the adjacent metal fragments71aexactly match each other but means a degree to which it may be confirmed that the metal fragments71aare positioned while forming one layer in the pulverized state.

The thermosetting resin72amay be disposed in the space between the adjacent metal fragments71aof the pulverized magnetic metal plates71.

The thermosetting resin72amay be formed by the thermosetting resin of the thermosetting resin layers72permeated into the space between the adjacent metal fragments71aduring the pulverization of the magnetic metal plates by compressing the laminate70′.

The thermosetting resin72adisposed in the space between the adjacent metal fragments71amay insulate the adjacent metal fragments71afrom each other.

As a result, the core loss of the magnetic metal plate71may be reduced and the Q factor thereof may be improved.

Referring toFIG. 6E, the compressed laminates70″ including the pulverized magnetic metal plates71may be formed on the upper and lower portions of the magnetic body50.

The compressed laminates70″ including the pulverized magnetic metal plates71may be disposed on the upper and lower portions of the magnetic body50, and the magnetic body50and the cover parts70including the magnetic metal plates71may be integrated by being compressed and hardened by the laminate method or the isostatic pressing method.

FIGS. 7A and 7Bare perspective views schematically illustrating the pulverized form of the magnetic metal plate according to an exemplary embodiment in the present disclosure.

Referring toFIG. 7A, the magnetic metal plate71according to the exemplary embodiment in the present disclosure may be pulverized to have lattice-shaped metal fragments71a.

FIG. 7Aillustrates the magnetic metal plate71pulverized to have the lattice-shaped metal fragments71a, but the magnetic metal plates71are not limited thereto. For example, any magnetic metal plate71which may be regularly pulverized may be used.

The number, volume, shape, or the like of metal fragments71aformed by regularly pulverizing the magnetic metal plates71are not particularly limited and the metal fragments71ahaving any structure capable of implementing the effect of the present disclosure may be applied.

For example, an area ‘a’ of a cross section of the metal fragment71ain a length-width (L-W) direction of the metal fragment71aformed by regularly pulverizing the magnetic metal plate71, for instance, an upper surface or a lower surface of the metal fragment71amay range from 20 μm2to 5,000 μm2.

When the area ‘a’ of the upper surface or the lower surface of the metal fragment71ais less than 20 μm2, permeability may be significantly reduced. When the area ‘a’ of the upper surface or the lower surface of the metal fragment71aexceeds 5,000 μm2, the loss due to the eddy current may be increased and the Q factor may deteriorate.

Referring toFIG. 7B, the magnetic metal plate71according to another exemplary embodiment in the present disclosure may be pulverized to have atypical metal fragments71a.

The magnetic metal plates71are not necessarily be pulverized regularly and as illustrated inFIG. 7B, the magnetic metal plates71may be atypically pulverized within the range in which the effect of the present disclosure may be implemented.

An average of the area ‘a’ of the cross section of the metal fragment71ain the length-width (L-W) direction of the metal fragment71aformed by atypically pulverizing the magnetic metal plate, for instance, the upper surface or the lower surface of the metal fragment71amay range from 20 μm2to 5,000 μm2.

The thermosetting resin72amay be disposed in the space between the adjacent metal fragments71aof the pulverized magnetic metal plates71and the thermosetting resin72adisposed in the space between the adjacent metal fragments71amay insulate the adjacent metal fragments71afrom each other.

FIGS. 8A through 8Dare views illustrating a process of forming a cover part of an electronic component including a magnetic metal plate according to another exemplary embodiment in the present disclosure.

Referring toFIG. 8A, the magnetic body50in which the internal coil parts41and42are embedded may be formed.

The method of forming the magnetic body50is not particularly limited, but for example, the magnetic body50may be formed by stacking the magnetic sheets50′ as illustrated inFIGS. 5A and 5B.

Referring toFIG. 8B, the magnetic metal plates71′ may be stacked on the upper and lower portions of the magnetic body50.

In this case, the thermosetting resin layer72may be stacked on at least one of the upper and lower portions of the magnetic metal plate71′.

FIG. 8Billustrates that the magnetic metal plate71′ of one layer is stacked above and below the magnetic body50, respectively, but the magnetic metal plate71′ is not limited thereto. For example, the magnetic metal plate71′ may be stacked on at least one of the upper and lower portions of the magnetic body50and the magnetic metal plates71′ of two or more layers may be stacked on the magnetic body50. When the magnetic metal plates71′ of two or more layers are stacked, the magnetic metal plates71′ and the thermosetting resin layers72may be alternately stacked on the magnetic body50.

Referring toFIG. 8C, the magnetic metal plates71′ stacked on the magnetic body50may be pulverized by being compressed.

For instance, as illustrated inFIGS. 6A through 6E, the magnetic metal plates71′ may be first pulverized such that the magnetic metal plates71′ have the plurality of metal fragments71a, and the magnetic metal plates71′ formed of the plurality of metal fragments71amay be formed on the magnetic body50, but as illustrated inFIGS. 8A through 8D, the non-pulverized magnetic metal plates71′ according to another exemplary embodiment in the present disclosure may be formed on the magnetic body50and then may be pulverized into the plurality of metal fragments71aby the compression.

Referring toFIG. 8D, the cover parts70including the magnetic metal plates71pulverized to have the plurality of metal fragments71amay be formed on the upper and lower portions of the magnetic body50.

For instance, the non-pulverized magnetic metal plates71′ may be formed on the magnetic body50and then the magnetic metal plates may be pulverized by being compressed and hardened by the laminate method or the isostatic pressing method into the plurality of metal fragments71aand the magnetic body50and the cover parts70including the magnetic metal plates71may be integrated.

The thermosetting resin72amay be disposed in the space between the adjacent metal fragments71aof the pulverized magnetic metal plates71.

The thermosetting resin72amay be formed by the thermosetting resin of the thermosetting resin layers72permeated into the space between the adjacent metal fragments71aduring the pulverization of the magnetic metal plates by the compression.

The thermosetting resin72adisposed in the space between the adjacent metal fragments71amay insulate the adjacent metal fragments71afrom each other.

A surface roughness of the cover part70including the magnetic metal plate71of the electronic component100manufactured according to the exemplary embodiment in the present disclosure may be equal to or less than 0.5 μm.

In the case of another example in which the cover parts including the magnetic metal plates are not formed on the top portion and the bottom portion of the magnetic body, the surface roughness thereof may be relatively large, exceeding 4 μm. In detail, as the magnetic metal powder particles having a relatively large average particle size are used to improve permeability, the surface roughness is getting larger.

The magnetic metal powder particles having a relatively large average particle size may protrude on the surface of the magnetic body, and an insulating coating layer of a protruding portion may be peeled off during a polishing process of the magnetic body cut into individual electronic components, such that defects such as plating spread, or the like, may occur at the time of forming the plating layer on the external electrodes.

However, according to the exemplary embodiment in the present disclosure, the cover parts70including the magnetic metal plates71may be formed such that the surface roughness may be 0.5 μm or less, and thus, a plating solution spread phenomenon may be prevented.

The magnetic metal plates71may be pulverized to have the plurality of metal fragments71a, and the metal fragments71aare not irregularly dispersed after the magnetic metal plates71are pulverized, but are positioned while forming one layer as the pulverized state, such that the surface roughness thereof may be 0.5 μm or less unlike the case of the magnetic metal powder particles.

As set forth above, according to exemplary embodiments in the present disclosure, the electronic component having the high inductance and the excellent Q factor and DC-bias characteristics may be manufactured.