Coil component

A coil component includes a body having one surface and the other surface opposing each other in one direction, and a plurality of walls each connecting the one surface to the other surface; a coil portion buried in the body, and having both ends exposing to one of the plurality of walls of the body; first and second external electrodes respectively including first and second terminal electrodes disposed on one surface of the body and spaced apart from each other, and first and second connection electrodes respectively connecting the first and second terminal electrodes to both ends of the coil portion; a first external insulating layer disposed on the other surface of the body; and a first shielding layer disposed on the external insulating layer.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of priority to Korean Patent Application No. 10-2018-0083387 filed on Jul. 18, 2018 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.

1. TECHNICAL FIELD

The present disclosure relates to a coil component.

An inductor, a coil component, is a representative passive electronic component used together with a resistor and a capacitor in electronic devices.

As electronic devices are designed to have higher performance and to be reduced in size, electronic components used in electronic devices have been increased in number and reduced in size.

Accordingly, there has been increasing demand for removing a factor causing noise such as electromagnetic interference (EMI) in electronic components.

A currently used EMI shielding technique is, after mounting electronic components on a substrate, to envelop the electronic components and the substrate using a shielding can.

SUMMARY

An aspect of the present disclosure is to provide a coil component having a reduced size and thickness.

Another aspect of the present disclosure is to provide a coil component in which an electrode structure may be easily formed on a lower surface.

Another aspect of the present disclosure is to provide a coil component in which a shielding structure capable of reducing a magnetic flux leakage may be easily formed.

According to an aspect of the present disclosure, a coil component includes a body having one surface and the other surface opposing each other in one direction, and a plurality of walls each connecting the one surface to the other surface; a coil portion buried in the body, and having both ends exposing to one of the plurality of walls of the body; first and second external electrodes respectively including first and second terminal electrodes disposed on one surface of the body and spaced apart from each other, and first and second connection electrodes respectively connecting the first and second terminal electrodes to both ends of the coil portion; a first external insulating layer disposed on the other surface of the body; and a first shielding layer disposed on the external insulating layer.

DETAILED DESCRIPTION

The terms used in the exemplary embodiments are used to simply describe an exemplary embodiment, and are not intended to limit the present disclosure. A singular term includes a plural form unless otherwise indicated. The terms used in the exemplary embodiments are used to simply describe an exemplary embodiment, and are not intended to limit the present disclosure. A singular term includes a plural form unless otherwise indicated. The terms, “include,” “comprise,” “is configured to,” etc. of the description are used to indicate the presence of features, numbers, steps, operations, elements, parts or combination thereof, and do not exclude the possibilities of combination or addition of one or more features, numbers, steps, operations, elements, parts or combination thereof. Also, the term “disposed on,” “positioned on,” and the like, may indicate that an element is positioned on or below an object, and does not necessarily mean that the element is positioned on the object with reference to a gravity direction.

The term “coupled to,” “combined to,” and the like, may not only indicate that elements are directly and physically in contact with each other, but also include the configuration in which the other element is interposed between the elements such that the elements are also in contact with the other component.

Sizes and thicknesses of elements illustrated in the drawings are indicated as examples for ease of description, and exemplary embodiments in the present disclosure are not limited thereto.

In the drawings, an L direction is a first direction or a length direction, a W direction is a second direction or a width direction, a T direction is a third direction or a thickness direction.

In electronic devices, various types of electronic components may be used, and various types of coil components may be used between the electronic components to remove noise, or for other purposes.

In other words, in electronic devices, a coil component may be used as a power inductor, a high frequency inductor, a general bead, a high frequency bead, a common mode filter, and the like.

First Embodiment

FIG.1is a schematic perspective diagram illustrating a coil component according to an exemplary embodiment.FIG.2is a diagram illustrating a coil component in which some of elements illustrated inFIG.1are omitted.FIG.3is a diagram illustrating a third surface of a body illustrated inFIG.2.FIG.4is a cross-sectional diagram taken along line I-I′ inFIG.1.FIG.5is a cross-sectional diagram taken along line II-II′ inFIG.1.FIG.6is a cross-sectional diagram taken along line III-III′ inFIG.4. With regard toFIG.2,FIG.2illustrates the coil component in which a cover insulating layer630, a third shielding layer730, and a cover layer800are omitted.

Referring toFIGS.1to6, a coil component1000according to the exemplary embodiment may include a body100, a coil portion200, external electrodes300,400, and500, external insulating layers610and640, shielding layers710and730, and a cover insulating layer640, and may further include an internal insulating layer IL.

The body100may form an exterior of the coil component1000, and may bury the coil portion200in the body100.

The body100may have a hexahedral shape.

Referring toFIG.2, the body100may include a first surface101and a second surface102opposing each other in a length direction L, a third surface103and a fourth surface104opposing each other in a width direction W, and a fifth surface105and a sixth surface106opposing each other in a thickness direction T. The first to fourth surfaces101,102,103, and104of the body100may be walls of the body100connecting the fifth surface105and the sixth surface106of the body100. In the description below, “both front and rear surfaces of the body” may refer to the first surface101and the second surface102, and “both side surfaces of the body” may refer to the third surface103and the fourth surface104of the body.

As an example, the body100may be configured such that the coil component1000on which the external electrodes300,400, and500are formed may have a length of 2.0 mm, a width of 1.2 mm, and a thickness of 0.65 mm, but an exemplary embodiment of the coil component1000is not limited thereto. In one embodiment, the length of the coil component1000is 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, or 1.5 mm. In one embodiment, the width of the coil component1000is 1.1 mm, 1.0 mm, 0.9 mm, 0.0 mm, 0.7 mm, or 0.6 mm. In one embodiment, the thickness of the coil component is 0.60 mm, 0.55 mm, 0.50 mm, 0.45 mm, 0.40 mm, 0.35 mm, or 0.30 mm.

The body100may include a magnetic material and a resin material. For example, the body100may be formed by layering one or more magnetic composite sheets including a magnetic material dispersed in a resin. Alternatively, the body100may have a structure different from the structure in which a magnetic material is dispersed in a resin. For example, the body100may be formed of a magnetic material such as a ferrite.

The magnetic material may be a ferrite or a magnetic metal powder.

The ferrite may include, for example, one or more materials among a spinel ferrite such as an Mg—Zn ferrite, an Mn—Zn ferrite, an Mn—Mg ferrite, a Cu—Zn ferrite, an Mg—Mn—Sr ferrite, an Ni—Zn ferrite, and the like, a hexagonal ferrite such as a Ba—Zn ferrite, a Ba—Mg ferrite, a Ba—Ni ferrite, a Ba—Co ferrite, a Ba—Ni—Co ferrite, and the like, a garnet ferrite such as an yttrium (Y) ferrite, and a lithium (Li) ferrite.

The magnetic metal powder may include one or more materials selected from a group consisting of iron (Fe), silicon (Si), chromium (Cr), cobalt (Co), molybdenum (Mo), aluminum (Al), niobium (Nb), copper (Cu), and nickel (Ni). For example, the magnetic metal powder may be one or more materials among a pure iron powder, a Fe—Si alloy powder, a Fe—Si—Al alloy powder, a Fe—Ni alloy powder, a Fe—Ni—Mo alloy powder, Fe—Ni—Mo—Cu alloy powder, a Fe—Co alloy powder, a Fe—Ni—Co alloy powder, a Fe—Cr alloy powder, a Fe—Cr—Si alloy powder, a Fe—Si—Cu—Nb alloy powder, a Fe—Ni—Cr alloy powder, and a Fe—Cr—Al alloy powder.

The magnetic metal powder may be amorphous or crystalline. For example, the magnetic metal powder may be a Fe—Si—B—Cr amorphous alloy powder, but an exemplary embodiment of the magnetic metal powder is not limited thereto.

The ferrite and the magnetic metal powder may have an average diameter of 0.1 μm to 30 μm, but an example of the average diameter is not limited thereto. In one embodiment, the average diameter of the ferrite or the magnetic metal powder is 0.5 μm, 1 μm, 5 μm, 10 μm, 15 μm, 20 μm, or 25 μm.

The body100may include two or more types of magnetic materials dispersed in a resin. The notion that types of the magnetic materials are different may indicate that one of an average diameter, a composition, crystallinity, and a form of one of magnetic materials is different from those of the other magnetic material.

The resin may include one of an epoxy resin, a polyimide, a liquid crystal polymer, or mixture thereof, but the example of the resin is not limited thereto.

The body100may include a core110penetrating through a coil portion200, which will be described later. The core110may be formed by filling a through hole of the coil portion200, but an exemplary embodiment thereof is not limited thereto.

The internal insulating layer IL may be buried in the body100. The internal insulating layer IL may support the coil portion200.

The internal insulating layer IL may be formed of an insulating material including a thermosetting insulating resin such as an epoxy resin, a thermoplastic insulating resin such as a polyimide, or a photosensitive insulating resin, or may be formed of an insulating material in which a reinforcing material such as a glass fiber or an inorganic filler is impregnated with such an insulating resin. For example, the internal insulating layer IL may be formed of an insulating material such as prepreg, ajinomoto build-up film (ABF), FR-4, a bismaleimide triazine (BT) resin, a photoimageable dielectric (PID), and the like, but an example of the material of the internal insulating layer is not limited thereto.

As an inorganic filler, one or more materials selected from a group consisting of silica (SiO2), alumina (Al2O3), silicon carbide (SiC), barium sulfate (BaSO4), talc, mud, a mica powder, aluminium hydroxide (Al(OH)3), magnesium hydroxide (Mg(OH)2), calcium carbonate (CaCO3), magnesium carbonate (MgCO3), magnesium oxide (MgO), boron nitride (BN), aluminum borate (AlBO3), barium titanate (BaTiO3), and calcium zirconate (CaZrO3) may be used.

When the internal insulating layer IL is formed of an insulating material including a reinforcing material, the internal insulating layer IL may provide improved stiffness. When the internal insulating layer IL is formed of an insulating material which does not include a glass fiber, the internal insulating layer IL may be desirable to reducing an overall thickness of the coil portion200. When the internal insulating layer IL is formed of an insulating material including a photosensitive insulating resin, the number of processes for forming the coil portion200may be reduced such that manufacturing costs may be reduced, and a fine via may be formed.

The coil portion200may be buried in the body100, and may embody properties of the coil component. For example, when the coil component1000is used as a power inductor, the coil portion200may store an electric field as a magnetic field such that an output voltage may be maintained, thereby stabilizing power of an electronic device.

The coil portion200may include first and second coil patterns211and212, first and second lead-out portions231and232, and a via220, and the first and second coil patterns211and212, the first and second lead-out portions231and232, and the via220may be connected to one another and may collectively function as one coil.

For example, referring toFIGS.1to5, the first coil pattern211and the first lead-out portion231may be disposed on a lower surface of the internal insulating layer IL opposing the sixth surface106of the body100, and the second coil pattern212and the second lead-out portion232may be disposed on an upper surface of the internal insulating layer IL opposing a lower surface of the internal insulating layer IL. The first and second lead-out portions231and232may respectively correspond to ends of the first and second coil patterns211and212, and may be in contact with and connected to the first and second connection electrodes310and410of the first and second external electrodes300and400. The via220may penetrate through the internal insulating layer IL and may respectively be in contact with the first coil pattern211and the second coil pattern212and may connect the first coil pattern211and the second coil pattern212to each other.

The first coil pattern211and the second coil pattern212each may have a planar spiral shape forming at least one turn centering on the core110as an axis. For example, the first coil pattern211may form at least one turn on a lower surface of the internal insulating layer IL centering on the core110as an axis.

The first and second lead-out portions231and232may extend to and be exposed to one of the plurality of walls of the body100from the first and second coil patterns211and212. For example, referring toFIGS.1to6, the first and second lead-out portions231and232may extend to the third surface103of the body100from the first and second coil patterns211and212, and may be exposed together to the third surface103of the body100while being spaced apart from each other. Thus, the structure in the exemplary embodiment may be different from a general coil structure in which the first and second lead-out portions231and232extend to two walls of a body opposing each other.

The first and second lead-out portions231and232each may include one or more silts. As an example, the first lead-out portion231may include two silts such that the first lead-out portion231may have a shape similar to a fork as illustrated inFIG.6and other diagrams. When the slits are formed in the first and second lead-out portions231and232, a contact area between the first and second lead-out portions231and232and the body100may increase. Accordingly, cohesion force between the coil portion200and the body100may improve.

At least one of the first and second coil patterns211and212, the via220, and the first and second lead-out portions231and232may include a conductive layer.

As an example, when the second coil pattern212and the via220are formed on the other surface of the internal insulating layer IL through a plating process, the second coil pattern212and the via220each may include a seed layer such as an electroless plating layer, and an electroplating layer, and the like. The electroplating layer may have a single-layer structure, or may have a multiple-layer structure. The electroplating layer having a multiple-layer structure may have a conformal film structure in which one of the electroplating layers is covered by the other electroplating layer, or may have a form in which one of the electroplating layers is disposed on one surface of the other plating layers. The seed layer of the second coil pattern212and the seed layer of the via220may be integrated with each other such that no boundary may be formed between the seed layers, but an exemplary embodiment thereof is not limited thereto.

As another example, referring toFIGS.1to5, when the first coil pattern211and the first lead-out portion231disposed on a lower surface of the internal insulating layer IL, and the second coil pattern212and the second lead-out portion232disposed on an upper portion of the internal insulating layer IL are formed independently, and the coil portion200is formed by layering the first coil pattern211, the first lead-out portion231, the second coil pattern212and the second lead-out portion232on the internal insulating layer IL, the via220may include a metal layer having a high melting point, and a metal layer having a low melting point relatively lower than the melting point of the metal layer having a high melting point. The metal layer having a low melting point may be formed of a solder including lead (Pb) and/or tin (Sn). The metal layer having a low melting point may have at least a portion melted due to pressure and temperature generating during the layer process, and an inter-metallic compound layer (IMC layer) may be formed between the metal layer having a low melting point and the second coil pattern212, for example.

Also, as an example, the first and second coil patterns211and212and the first and second lead-out portions231and232may respectively be formed on and protrude to a lower surface and an upper surface of the internal insulating layer IL as illustrated inFIGS.4and5. As another example, the first coil pattern211and the first lead-out portion231may be formed on and protrude to the lower surface of the internal insulating layer IL, and the second coil pattern212and the second lead-out portion232may be buried in the upper surface of the internal insulating layer IL, and the upper surfaces of the second coil pattern212and the second lead-out portion232may be exposed to the upper surface of the internal insulating layer IL. In this case, a concave portion may be formed on an upper surface of the second coil pattern212and/or an upper surface of the second lead-out portion232such that the upper surface of the internal insulating layer IL may not be coplanar with the upper surface of the second coil pattern212and/or the upper surface of the second lead-out portion232.

The first and second coil patterns211and212, the first and second lead-out portions231and232, and the via220each may be formed of a conductive material such as aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), titanium (Ti), or alloys thereof, but an example of the material is not limited thereto.

A lower insulating layer640and a first external insulating layer610may respectively be on one surface and the other surface of the body100, respectively. For example, referring toFIGS.1to5, the first external insulating layer610may be disposed on the fifth surface of the body100, and the lower insulating layer640may be disposed on the sixth surface of the body100. In one embodiment, the lower insulating layer640may be disposed on the entire surface of the one surface or the fifth surface of the body100. In one embodiment, the lower insulating layer640may be disposed on a part of the one surface or the fifth surface of the body100. In one embodiment, the first external insulating layer610may be disposed on the entire surface of the other surface or the sixth surface of the body100. In one embodiment, the first external insulating layer610may be disposed on a part of the other surface or the sixth surface of the body100.

The lower insulating layer640and the first external insulating layer610each may include a thermoplastic resin such as a polystyrene resin, a vinyl acetate resin, a polyester resin, a polyethylene resin, a polypropylene resin, a polyamide resin, a rubber resin, an acrylic resin, and the like, or a thermosetting resin such as a phenolic resin, an epoxy resin, a urethane resin, a melamine resin, an alkyd resin, and the like.

The lower insulating layer640and the external insulating layer610each may have a thickness of 10 nm to 100 μm. When thicknesses of the lower insulating layer640and the first external insulating layer610are lower than 10 nm, properties of the coil component such as a Q factor, and the like, may be reduced. When thicknesses of the lower insulating layer640and the first external insulating layer610are greater than 100 μm, an overall length, width, and thickness of the coil component may increase such that it may be difficult to reduce a size of the coil component. In one embodiment, the thickness of the lower insulating layer640is 50 nm, 100 nm, 500 nm, 1 μm, or 50 μm. In one embodiment, the thickness of the external insulating layer610is 50 nm, 100 nm, 500 nm, 1 μm, or 50 μm.

The lower insulating layer640and the first external insulating layer610each may be formed by layering an insulating film such as an Ajinomoto build-up film on the sixth surface106and the fifth surface105of the body100, but an exemplary embodiment thereof is not limited thereto. The lower insulating layer640and the first external insulating layer610each may also be formed by layering a photosensitive insulating material such as a dry film. As another example, the lower insulating layer640may be formed by disposing an intermediate material in which a metal film is formed, such as a resin coated copper (RCC), on one surface of an insulating film such that the other surface of the insulating film faces the sixth surface106of the body100, and layering the intermediate material. In this case, the metal film of the intermediate material may become first to third terminal electrodes320,420, and520of the first to third external electrodes300,400, and500after going through a selective removal process. Also, the first external insulating layer610may be formed by disposing an intermediate material in which a metal film is formed, such as a resin coated copper (RCC), on one surface of an insulating film such that the other surface of the insulating film faces the fifth surface105of the body100, and layering the intermediate material. In this case, the metal film of the intermediate material may become a first shielding layer710.

The first shielding layer710may be disposed on the first external insulating layer610disposed on the fifth surface105of the body100. In one embodiment, the first shielding layer710may be disposed on an entire surface of the first external insulating layer610. In one embodiment, the first shielding layer710may be partially disposed on the first external insulating layer610. The first shielding layer710may reduce a magnetic flux leakage leaking externally from the coil component according to the exemplary embodiment.

The first shielding layer710may include at least one of a conductive material and/or at least one of a magnetic material. For example, the conductive material may be a metal or an alloy including one or more materials selected from a group consisting of copper (Cu), aluminum (Al), iron (Fe), silicon (Si), boron (B), chromium (Cr), niobium (Nb), and nickel (Ni), or may be Fe—Si or Fe—Ni. Also, the first shielding layer710may include one or more materials selected from a group consisting of a ferrite, a permalloy, and an amorphous ribbon. The first shielding layer710may have a double-layer structure having a layer including the conductive material and a layer including a magnetic material, or may have a single-layer structure including the conductive material and/or a magnetic material.

The first shielding layer710may include two or more separate fine structures. For example, the first shielding layer710may be formed of an amorphous ribbon sheet divided into a plurality of pieces isolated from one another.

The first shielding layer710may be formed by layering an insulating film such as an Ajinomoto build-up film on the fifth surface105of the body100, but an exemplary embodiment thereof is not limited thereto. As an example, the first shielding layer710may be formed by layering an intermediate material in which a metal film is formed, such as a resin coated copper (RCC), on one surface of the insulating film such that the other surface of the insulating film faces the fifth surface105of the body100, or by layering an intermediate material in which a magnetic film is formed on one surface of the insulating film such that the other surface of the insulating film faces the fifth surface105of the body100, the first shielding layer710may be formed along with the first external insulating layer610. Alternatively, the first shielding layer710may also be formed on the first external insulating layer610by layering an insulating film such as an ABF on the fifth surface105of the body100and layering a shield film including a conductive material and/or a magnetic material.

The first shielding layer710may have a thickness of 10 nm to 100 μm. When thicknesses of the first shielding layer710are lower than 10 nm, properties of the coil component such as a Q factor, and the like, may be reduced. When thicknesses of the first shielding layer710are greater than 100 μm, an overall length, width, and thickness of the coil component may increase such that it may be difficult to reduce a size of the coil component. In one embodiment, the thickness of the first shielding layer710is 50 nm, 100 nm, 500 nm, 1 μm, or 50 μm.

The first and second external electrodes300and400may be connected to the coil portion200. The first external electrode300may be connected to the first lead-out portion231, and the second external electrode400may be connected to the second lead-out portion232. The first external electrode300may include the first terminal electrode320disposed on the sixth surface106of the body100, and a first connection electrode310disposed on the third surface103of the body100and connecting the first terminal electrode320to the first lead-out portion231. The second external electrode400may include the second terminal electrode420disposed on the sixth surface106of the body100, and the second connection electrode410disposed on the third surface103of the body100and connecting the second terminal electrode420to the second lead-out portion232. In the exemplary embodiment, the lower insulating layer640may be disposed on the sixth surface106of the body100, and thus, the first and second terminal electrode320and420may be disposed on the lower insulating layer640.

The first and second terminal electrode320and420may be formed by selectively removing the metal film formed on the sixth surface106of the body100. When the first and second terminal electrode320and420are formed of a plurality of layers, the first and second terminal electrode320and420may include layers formed by selectively removing the metal film. For example, when the above described RCC is used, the first and second terminal electrode320and420may be formed by selectively removing a copper film of the RCC. With regard to the copper film, a surface roughness of one surface being in contact with the insulting film may be lower than a surface roughness of the other surface opposing one surface. Thus, when the first and second terminal electrode320and420are formed using the RCC, as the surface roughness of the lower surfaces of the first and second terminal electrode320and420, mounting surfaces of the coil component1000, is relatively low, the first and second terminal electrode320and420may be formed to be planar.

The first and second connection electrodes310,410may be formed by a vapor deposition process such as a sputtering process, or may be formed by a paste printing process, or the like.

The external electrodes300and400may be formed of a conductive material such as copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pb), chromium (Cr), titanium (Ti), or alloys thereof, but an example of the material is not limited thereto. The external electrodes300and400may be formed of a single layer or multiple layers. For example, the first and second terminal electrode320and420of the first and second external electrodes300and400may be formed in order on the lower insulating layer640, and may be formed of three layers including copper (Cu), nickel (Ni), and tin (Sn), but an exemplary embodiment thereof is not limited thereto.

The third external electrode500may include a third terminal electrode520disposed on the sixth surface106of the body100, and a third connection electrode510disposed on the third surface103of the body100and the first external insulating layer610and connecting the third terminal electrode520to the first shielding layer710. The third external electrode500may be spaced apart from the first and second external electrodes300and400and may not be electrically connected to the first and second external electrodes300and400.

The third terminal electrode520and the third connection electrode510may be formed by the process of forming the first and second terminal electrode320and420and the first and second connection electrodes310and410and may be formed of the materials forming the first and second terminal electrode320and420and the first and second connection electrodes310and410.

When the coil component1000is mounted on a printed circuit board, the third terminal electrode520may be electrically connected to a ground of the printed circuit board, and the like. Thus, the third external electrode500may transfer electrical energy accumulated on the first shielding layer710to the printed circuit board.

A cover insulating layer630may cover the first shielding layer710, the first to third connection electrodes310,410, and510, the fifth surface105of the body100, and the plurality of walls101,102,103, and104of the body. In other words, a third shielding layer730, which will be described later, may be disposed on the first to fifth surfaces101,102,103,104, and105of the body100, and the cover insulating layer640may be disposed between the first to fifth surfaces101,102,103,104, and105and the third shielding layer730to not be electrically connected to the body100and the external electrodes300,400, and500.

The cover insulating layer630may include a thermoplastic resin such as a polystyrene resin, a vinyl acetate resin, a polyester resin, a polyethylene resin, a polypropylene resin, a polyamide resin, a rubber resin, an acrylic resin, and the like, or a thermosetting resin such as a phenolic resin, an epoxy resin, a urethane resin, a melamine resin, an alkyd resin, and the like.

The cover insulating layer630may have a thickness of 10 nm to 100 μm. When a thickness of the cover insulating layer630is lower than 10 nm, properties of a coil component such as a Q factor may reduce, and when a thickness of the cover insulating layer630is greater than 100 μm, an overall length, width, and thickness of the coil component may increase such that it may be difficult to reduce a size of the coil component. In one embodiment, the cover insulating layer630is 50 nm, 100 nm, 500 nm, 1 μm, or 50 μm. In one embodiment, the thickness of the external insulating layer610is 50 nm, 100 nm, 500 nm, 1 μm, or 50 μm.

The cover insulating layer630may be formed by layering an insulating film on each of the first to fifth surfaces101,102,103,104, and105of the body100. Alternatively, the cover insulating layer630may be formed by depositing an insulating material on the first to fifth surfaces101,102,103,104, and105of the body100by a vapor deposition process such as chemical vapor deposition.

The third shielding layer730may be disposed on the cover insulating layer630, and may be disposed on each of the first to fifth surfaces101,102,103,104, and105of the body100. The third shielding layer730may be disposed on surfaces of the body100except for the sixth surface106of the body, and may reduce a magnetic flux leakage of the coil component1000. Portions of the third shielding layer730respectively disposed on the first to fourth surfaces101,102,103, and104of the body100may be configured such that ends of the portions of the third shielding layer730may not extend to each edge region between the sixth surface and the first to fourth surfaces101,102,103, and104of the body.

The third shielding layer730may include at least one of a conductive material or a magnetic material. For example, the conductive material may be a metal or an alloy including one or more materials selected from a group consisting of copper (Cu), aluminum (Al), iron (Fe), silicon (Si), boron (B), chromium (Cr), niobium (Nb), nickel (Ni) or alloys thereof, or may be Fe—Si or Fe—Ni. Also, the third shielding layer730may include one or more materials selected from a group consisting of a ferrite, a permalloy, and an amorphous ribbon. The third shielding layer730may have a double-layer structure having a layer including the conductive material and a layer including a magnetic material, or may have a single-layer structure including the conductive material and/or a magnetic material.

The third shielding layer730may include two or more microstructures isolated from each other. For example, the third shielding layer730may be formed of amorphous ribbon sheets divided into a plurality of pieces and isolated from one another.

The third shielding layer730may be formed through a vapor deposition process such as a sputtering process, but an exemplary embodiment thereof is not limited thereto.

A cover layer800may be formed on the first to fifth surfaces101,102,103,104, and105and may cover the third shielding layer730. The cover layer800may cover ends of portions of the third shielding layer730disposed on the first to fourth surfaces101,102,103, and104of the body100. In other words, the cover layer800may cover the third shielding layer730along with the cover insulating layer630.

The cover layer800may be formed through a vapor deposition process, or the like, but an exemplary embodiment thereof is not limited thereto. The cover layer800may include a thermoplastic resin such as a polystyrene resin, a vinyl acetate resin, a polyester resin, a polyethylene resin, a polypropylene resin, a polyamide resin, a rubber resin, an acrylic resin, and the like, a thermosetting resin such as a phenolic resin, an epoxy resin, a urethane resin, a melamine resin, an alkyd resin, and the like, a photosensitive resin, a parylene, and silicon oxide (SiOx) or silicon nitride (SiNx).

Although not illustrated, the coil component1000according to the exemplary embodiment may further include an insulating film formed along surfaces of the first and second coil patterns211and212, the first and second lead-out portions231and232, and the internal insulating layer IL. The insulating film may protect the first and second coil patterns211and212and the first and second lead-out portions231and232, may insulate the first and second coil patterns211and212and the lead-out portions231and232from the body100, and may include a well-known insulating material. The insulating material included in the insulating film is not limited to any particular material. The insulating film may be formed by a vapor deposition process, or the like, but an exemplary embodiment thereof is not limited thereto. The insulating film may also be formed by layering an insulating film on both surfaces of the internal insulating layer IL.

The cover insulating layer630and the cover layer800may be directly disposed in the coil component in the exemplary embodiment, and thus, the cover insulating layer630and the cover layer800may be distinct from a molding material for molding a coil component and a printed circuit substrate in a process of mounting the coil component on the printed circuit board. For example, the cover insulating layer630and the cover layer800may not be in contact with a printed circuit substrate, differently from a molding material. Also, the cover insulating layer630and the cover layer800may not be supported by or fixed to a printed circuit substrate, differently from a molding material. Further, differently from a molding material surrounding a connection member such as a solder ball which connects a coil component with a printed circuit substrate, the cover insulating layer630and the cover layer800may not surround a connection member. As the cover insulating layer630and the cover layer800are not molding materials formed by heating an epoxy molding component, and the like, flowing the epoxy molding component onto a printed circuit board and performing a curing process, it may not be necessary to consider a void occurring during a process of forming a molding material or warpage of a printed circuit board caused by a difference in coefficients of thermal expansion between a molding material and a printed circuit board.

Also, the first to third shielding layers710and730may be directly disposed in the coil component in the exemplary embodiment, and thus, the first to third shielding layers710and730may be distinct from a shielding can, and the like, which is coupled to a printed circuit board to shield EMI after mounting the coil component on a printed circuit board. For example, the first to third shielding layers710and730may not require a fixing member for fixing the first to third shielding layers710and730to a printed circuit board, and may not be directly in contact with a printed circuit board, differently from a general shielding can. In one embodiment, the coil component of the present invention may have more than three shielding layers.

Accordingly, in the coil component1000according to the exemplary embodiment, as the first to third shielding layers710and730are directly formed in the coil component1000, a magnetic flux leakage occurring in a coil component may be shielded in an efficient manner. In other words, as electronic devices are reduced in size and have higher performances, the number of electronic components included in an electronic device and a distance between adjacent electronic components have been reduced recently. In the exemplary embodiment, each coil component is shielded such that a magnetic flux leakage occurring in coil components may be shielded effectively, thereby reducing sizes of electronic components and implementing high performance. Further, in the coil component1000, the amount of an effective magnetic material may be increased in a shield region as compared to a configuration in which a shielding can is used, thereby improving properties of the coil component.

Also, in the coil component1000according to the exemplary embodiment, a size of the coil component may be significantly reduced while implementing an electrode structure in a lower portion. In other words, a general coil component may have a width smaller than a length, whereas, in the exemplary embodiment, the coil component may be configured such that the first and second lead-out portions231and232, both ends of the coil portion200, may not respectively be exposed to both front and rear surfaces101and102of the body100opposing each other in a length direction, but may be exposed to both surfaces103and104of the body100opposing each other in a width direction. Accordingly, even when external electrodes are formed, a length of the coil component may not increase. Also, the first and second lead-out portions231and232, both ends of the coil portion200, may be exposed to one surface103between the both surfaces103and104of the body100, and external electrodes may not be necessarily formed on the other surface104of the body100, thereby significantly reducing an increase in width.

Second Embodiment

FIG.7is a diagram illustrating a coil component according to another exemplary embodiment.FIG.8is a diagram illustrating a coil component in which some of elements illustrated inFIG.7are omitted.FIG.9is a diagram illustrating a third surface of a body illustrated inFIG.8.FIG.10is a cross-sectional diagram taken along line IV-IV′ inFIG.7.FIG.11is a cross-sectional diagram taken along line in V-V′. With regard toFIG.8,FIG.8illustrates an exemplary embodiment of a coil component in which the cover insulating layer630, the third shielding layer730, and the cover layer800are omitted.

Referring toFIGS.1to11, a coil component2000according to an exemplary embodiment may further include a second external insulating layer620and a second shielding layer720, as compared to the coil component1000described in the aforementioned exemplary embodiment. Thus, in the exemplary embodiment, a second external insulating layer620and a second shielding layer720, which are not described in the aforementioned exemplary embodiment, will be described. With regard to the other elements in the exemplary embodiment, the descriptions of the elements described in the aforementioned exemplary embodiment may be similarly applied.

The second shielding layer720may be disposed on the first shielding layer710. For example, in the exemplary embodiment, the first shielding layer710may include a conductive material, and the second shielding layer720may include a magnetic material. The first shielding layer710may be formed of a metal film such as a copper film, and the second shielding layer720may be formed of a shield film including a ferrite, and the like.

The second external insulating layer620may be disposed between the first shielding layer710and the second shielding layer720. Accordingly, in the exemplary embodiment, on the fifth surface105of the body100, a first external insulating layer610, a first shielding layer710, a second external insulating layer620, and a second shielding layer720may be disposed in order.

A third connection electrode510of a third external electrode500in the exemplary embodiment may be disposed on the third surface103of the body100, the first external insulating layer610, the first shielding layer710, the second external insulating layer620and the second shielding layer720. Thus, the first and second shielding layer710and720may be electrically connected to the third terminal electrode520.

In the exemplary embodiment, both of a reflective shielding effect by the first shielding layer710and an absorption shielding effect by the second shielding layer720may be implemented. In other words, in a lower frequency band of 1 MHz or lower, a magnetic flux leakage may be absorbed and shielded using the second shielding layer720, and in a high frequency band higher than 1 MHz, a magnetic flux leakage may be reflected and shielded using the first shielding layer710. Thus, the coil component2000according to the exemplary embodiment may shield a magnetic flux leakage in a relatively broad frequency band.

Meanwhile, in the exemplary embodiment, differently from the above described example, the first shielding layer710may include a magnetic material, and the second shielding layer720may include a conductive material.

According to the aforementioned exemplary embodiments, a size of a coil component may be reduced.

Also, according to the aforementioned exemplary embodiments, an electrode structure on a lower surface may be easily formed on a lower surface of a coil component.

Further, according to the aforementioned exemplary embodiment, a shielding structure may be easily formed.