Coil component

A coil component includes a body; and a coil disposed within the body, wherein the coil includes: a first coil conductor including a first conductor pattern with a planar coil shape and a first lead terminal extended to at least one surface of the body; a second coil conductor including a second conductor pattern with a planar coil shape and a second lead terminal extended to at least one surface of the body; and a connection conductor connecting the first and second coil conductors to each other and including a third lead terminal extended to at least one surface of the body.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to Korean Patent Application No. 10-2015-0174825, filed on Dec. 9, 2015 with the Korean Intellectual Property Office, the entirety of which is incorporated herein by reference.

BACKGROUND

The present disclosure relates to a coil component.

Recently, in accordance with increasing usage of portable electronic devices, research has been undertaken to extend the lifespans of batteries as long as possible. Several technologies for improving system efficiency and improving battery performance have been actively developed for smartphones and the like. For example, current consumption in batteries has been reduced in accordance with improvements in the performance of semiconductor elements (an application processor (AP), a memory, and the like). The following two technologies have been used in order to improve battery efficiency.

In a first technology, a multiphase converter technology, power inductors used in an output of a converter are connected to each other in parallel to reduce loss at high current and to enable miniaturization of the power inductors. In a second technology, a pulse frequency modulation (PFM) technology, an operating frequency of a converter is slowed or omitted at a low current to reduce loss. The second technology is used in a standby mode of the portable electronic device to reduce loss.

However, the two technologies described above have limitations, in that a circuit must be configured in a relatively complex manner to improve efficiency over an entire band from the low current to the high current.

SUMMARY

An aspect of the present disclosure provides a coil component having improved efficiency over an entire band from a low current to a high current.

According to an aspect of the present disclosure, a coil component may be configured by connecting a plurality of coils having different levels of DC resistance (DCR) and similar levels of inductance (L) to each other in series.

According to an aspect of the present disclosure, a coil component comprises: a body; and a coil disposed within the body. The coil includes: a first coil conductor including a first conductor pattern with a planar coil shape and a first lead terminal extended to at least one surface of the body; a second coil conductor including a second conductor pattern with a planar coil shape and a second lead terminal extended to at least one surface of the body; and a connection conductor connecting the first and second coil conductors to each other and including a third lead terminal extended to at least one surface of the body.

According to another aspect of the present disclosure, a coil component comprises: a body having a first surface and a second surface opposing each other in a first direction, a third surface and a fourth surface opposing each other in a second direction, and a fifth surface and a sixth surface opposing each other in a third direction; a coil disposed within the body and including a first coil conductor having a first conductor pattern with a planar coil shape and having a first lead terminal led out to the first surface of the body, a second coil conductor having a second conductor pattern with a planar coil shape and having a second lead terminal led out to the second surface of the body, and a connection conductor disposed between the first and second coil conductors to connect the first and second coil conductors to each other and having a third lead terminal led out to the third surface of the body; and an electrode disposed on the body and including a first electrode conductor entirety covering the first surface of the body and portions of the third to sixth surfaces of the body, a second electrode conductor entirety covering the second surface of the body and portions of the third to sixth surfaces of the body, and a third electrode conductor covering portions of the third, fourth, fifth and sixth surfaces of the body.

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, for example, due to manufacturing techniques and/or tolerances, modifications of the shape shown may be estimated. Thus, embodiments of the present disclosure should not be construed as being limited to the particular shapes of regions shown herein, for example, to include a change in shape results in manufacturing. The following embodiments may also be constituted by one or a combination thereof.

The contents of the present disclosure described below may have a variety of configurations and propose only a required configuration herein, but are not limited thereto.

Electronic Device

FIG. 1is a view schematically illustrating various examples 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 an electronic device. For example, an application processor, a direct current (DC) to DC converter, a communications processor, a wireless local area network Bluetooth (WLAN BT)/wireless fidelity frequency modulation global positioning system near field communications (Wi-Fi FM GPS NFC), a power management integrated circuit (PMIC), a battery, an SMBC, a liquid crystal display active matrix organic light emitting diode (LCD AMOLED), an audio codec, a universal serial bus (USB) 2.0/3.0 port, a high definition multimedia interface (HDMI) port, a CAM, and the like, may be used. Here, various kinds of coil components may be appropriately used between these electronic components depending on their purposes in order to remove noise, or the like. For example, a power inductor1, high frequency (HF) inductors2, a general bead3, a bead4for a high frequency (GHz), common mode filters5, and the like, may be used. A coil component according to the present disclosure may be these coil components for various purposes.

In detail, the power inductor1may be used to store electricity in magnetic field form to maintain an output voltage, thereby stabilizing power. In addition, the high frequency inductor2may be used to match impedances to secure a required frequency or to cut out noise and an alternating current (AC) component. In addition, the general bead3may be used to remove noise from power and signal lines or remove a high frequency ripple. In addition, the bead4for a high frequency (GHz) may be used to remove high frequency noise of a signal line and a power line related to an audio. In addition, the common mode filter5may be used to pass a current therethrough in a differential mode and remove only common mode noise.

FIG. 2is a view schematically illustrating various examples of a coil component used in a smartphone.

Referring toFIG. 2, a plurality of components (some of which are not denoted by reference numerals) may be mounted on a mother board1001of the smartphone. In this case, coil components used to maintain an output voltage to stabilize power, for example, power inductors1001to1011having various sizes and forms may be used in the vicinity of a buck power management integrated circuit (PMIC)1015. Here, the power inductors1001,1003to1005, and1007to1011may be single power inductors, and the power inductors1002and1006may be multiphase power inductors.

An electronic device in which the coil component according to the present disclosure is used may typically be a smartphone as described above, but is not limited thereto. The electronic device may also be, for example, a personal digital assistant, a digital video camera, a digital still camera, a network system, a computer, a monitor, a television, a video game, or a smart watch. The electronic device may also be various other electronic devices well-known in those skilled in the art, in addition to the devices described above.

Coil Component

Hereinafter, a coil component according to the present disclosure, particularly, a power inductor, will be described for convenience of explanation. However, the coil component according to the present disclosure may also be applied as the coil components for various purposes as described above.

FIG. 3is a schematic perspective view illustrating a coil component according to an exemplary embodiment in the present disclosure.

Referring toFIG. 3, a coil component100according to the exemplary embodiment may include a body10, a coil20disposed within the body10, and an electrode30disposed on the body10.

The body10may form an exterior of the coil component100, and may have a first surface S1and a second surface S2opposing each other in a first direction, a third surface S3and a fourth surface S4opposing each other in a second direction, and a fifth surface S5and a sixth surface S6opposing each other in a third direction. The body10may have a hexahedral shape. However, a shape of the body10is not limited thereto.

The body10may contain a magnetic material having magnetic properties. For example, the body10may be formed by mixing ferrite or metal magnetic particles with a resin. The ferrite may be a material such as an Mn—Zn based ferrite, an Ni—Zn based ferrite, an Ni—Zn—Cu based ferrite, an Mn—Mg based ferrite, a Ba based ferrite, an Li based ferrite, or the like. The metal magnetic particle may contain one or more selected from the group consisting of iron (Fe), silicon (Si), chromium (Cr), aluminum (Al), and nickel (Ni). For example, the metal magnetic particle may be a Fe—Si—B—Cr based amorphous metal, but is not necessarily limited thereto. The metal magnetic particle may have a diameter of about 0.1 to 30 μm. The body10may have a form in which the ferrite or metal magnetic particles are dispersed in a thermosetting resin such as an epoxy resin, a polyimide resin, or the like.

The magnetic material of the body10may be a magnetic material-resin composite in which metal magnetic powder particles and a resin mixture are mixed with each other. The metal magnetic powder particles may contain iron (Fe), chromium (Cr), or silicon (Si) as a main component. For example, the metal magnetic powder particles may contain iron (Fe)-nickel (Ni), iron (Fe), iron (Fe)-chromium (Cr)-silicon (Si), or the like, are not limited thereto. The resin mixture may contain epoxy, polyimide, liquid crystal polymer (LCP), or the like, but is not limited thereto. The metal magnetic powder particles may be metal magnetic powder particles having at least two average particle sizes. In this case, metal magnetic powder particles having different sizes may be fully filled in the magnetic material-resin composite, such that a packing factor of the magnetic material-resin composite may be increased.

The coil20may perform various functions in the electronic device through a property appearing in a coil of the coil component100. For example, the coil component100may be a power inductor. In this case, the coil may serve to store electricity in magnetic field form to maintain an output voltage, thereby stabilizing power. A through-hole (not denoted by a reference numeral) may be formed in a central portion of the coil20, and may be filled with the magnetic material configuring the body10. A detailed description for the coil20will be provided below.

The electrode30may serve to electrically connect the coil component100to the electronic device when the coil component100is mounted on the electronic device. The electrode30may include first to third electrode conductors31to33disposed on the body10to be spaced apart from each other. The first electrode conductor31may cover the first surface S1of the body10, and may be extended to portions of the third surface S3, the fourth surface S4, the fifth surface S5, and the sixth surface S6. The first electrode conductor31may be connected to a lead terminal of the coil20led out to the first surface S1of the body10. The second electrode conductor32may cover the second surface S2of the body10, and may be extended to portions of the third surface S3, the fourth surface S4, the fifth surface S5, and the sixth surface S6. The second electrode conductor32may be connected to a lead terminal of the coil20led out to the second surface S2of the body10. The third electrode conductor33may enclose portions of the third surface S3, the fourth surface S4, the fifth surface S5, and the sixth surface S6of the body10. The third electrode conductor33may be connected to a lead terminal of the coil20led out to the third surface S3of the body10.

The electrode30may include a conductive resin layer and a conductor layer formed on the conductive resin layer. The conductive resin layer may be formed by printing paste, and may contain one or more conductive metals selected from the group consisting of copper (Cu), nickel (Ni), and silver (Ag), and a thermosetting resin. The conductor layer may contain 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 in the conductor layer by plating.

The electrode30may include a pre-plating layer (not illustrated) in order to improve electrical reliability between the coil20and the electrode30, if necessary. The pre-plating layer (not illustrated) may be formed by plating a conductive material, for example, copper (Cu). The electrode30may be formed by applying at least one of nickel (Ni) and tin (Sn) to the pre-plating layer (not illustrated) or may be formed by applying at least one of silver (Ag) and copper (Cu) to the pre-plating layer (not illustrated) and then applying at least one of nickel (Ni) and tin (Sn). Therefore, a contact area of the electrode30may be increased, and silver (Ag), copper (Cu), and the like, for forming the electrode30, do not need to be separately applied.

FIG. 4is a schematic enlarged cross-sectional view of a coil of the coil component ofFIG. 3viewed in direction A.

FIG. 5is a schematic enlarged cross-sectional view of a coil of the coil component ofFIG. 3viewed in direction B.

FIG. 6is a schematic enlarged cross-sectional view of a coil of the coil component ofFIG. 3viewed in direction C.

Referring toFIGS. 4 through 6, the coil20may include a first coil conductor21having a first conductor pattern with a planar coil shape and having a first lead terminal P1led out to the first surface S1of the body10, a second coil conductor22having a second conductor pattern with a planar coil shape and having a second lead terminal P2led out to the second surface S2of the body10, and a connection conductor23disposed between the first and second coil conductors21and22to connect the first and second coil conductors21and22to each other and having a third lead terminal P3led out to the third surface S3of the body10.

The first coil conductor21may have the first conductor pattern with the planar coil shape. The first conductor pattern may be a plating pattern formed by a general plating method, but is not limited thereto. Since the first conductor pattern may have at least two turns, the first conductor pattern may be thin and implement a high inductance. The first conductor pattern may include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

The first coil conductor21may have the first lead terminal P1. The first lead terminal P1may also be a plating pattern formed by a general plating method, but is not limited thereto. The first lead terminal P1may be led out to the first surface S1of the body10to thereby be connected to the first electrode conductor31. However, the first lead terminal P1is not necessarily limited thereto, but may also be led out to another surface of the body10to thereby be connected to the first electrode conductor31. The first lead terminal P1may also include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

The second coil conductor22may have the second conductor pattern with the planar coil shape. The second conductor pattern may be a plating pattern formed by a general plating method, but is not limited thereto. Since the second conductor pattern may have at least two turns, the second conductor pattern may be thin and implement a high inductance. The second conductor pattern may include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

The second coil conductor22may have the second lead terminal P2. The second lead terminal P2may also be a plating pattern formed by a general plating method, but is not limited thereto. The second lead terminal P2may be led out to the second surface S2of the body10to thereby be connected to the second electrode conductor32. However, the second lead terminal P2is not necessarily limited thereto, but may also be led out to another surface of the body10to thereby be connected to the second electrode conductor32. The second lead terminal P2may also include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

The connection conductor23may electrically connect the first coil conductor21and the second coil conductor22to each other. As a result, the first coil conductor21and the second coil conductor22may be connected to each other in series to form a coil20rotated in the same direction. The connection conductor23may be a plating pattern formed by a general plating method, but is not limited thereto. An insulating material such as a support member (not illustrated), or the like, may be present between the first coil conductor21and the second coil conductor22. In this case, the connection conductor23may penetrate through the insulating material. The connection conductor23may include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

The connection conductor23may have the third lead terminal P3. The third lead terminal P3may also be a plating pattern formed by a general plating method, but is not limited thereto. The third lead terminal P3may be led out to the third surface S3of the body10to thereby be connected to the third electrode conductor33. However, the third lead terminal P3is not necessarily limited thereto, but may also be led out to another surface of the body10to thereby be connected to the third electrode conductor33. The third lead terminal P3may also include a seed layer and a plating layer. The seed layer may include a plurality of layers. For example, the seed layer may include an adhesion layer containing one or more of titanium (Ti), titanium-tungsten (Ti—W), molybdenum (Mo), chromium (Cr), nickel (Ni), and nickel-chromium (Ni—Cr), and a base plating layer disposed on the adhesion layer and containing the same material as that of the plating layer, for example, copper (Cu), but is not limited thereto. The plating layer may contain a conductive material, for example, copper (Cu), aluminum (Al), silver (Ag), tin (Sn), gold (Au), nickel (Ni), lead (Pd), or alloys thereof, and may generally contain copper (Cu), but is not limited thereto.

FIG. 7is a view schematically illustrating an equivalent circuit of the coil component ofFIG. 3.

FIG. 8is a view schematically illustrating an equivalent circuit in a case in which the coil component ofFIG. 3is used in an electronic device.

Referring toFIGS. 7 and 8, the first coil conductor21and the second coil conductor22may have a first inductance L1and a second inductance L2, respectively. The first coil conductor21and the second coil conductor22may have a first DC resistance DCR1and a second DC resistance DCR2, respectively. The first coil conductor21and the second coil conductor22may be connected to each other in series by the connection conductor23to configure one coil20. The coil20including the first coil conductor21and the second coil conductor22connected to each other in series may be connected to the outside of the first lead terminal P1, the second lead terminal P2, and the third lead terminal P3.

The first inductance L1and the second inductance L2may have substantially the same value. For example, a difference between the first inductance L1and the second inductance L2may be 0.1 μH or less. The first DC resistance DCR1and the second DC resistance DCR2may have different values. For example, a difference between the first DC resistance DCR1and the second DC resistance DCR2may be 40 mΩ or more. A difference between levels of DC resistance may be implemented by, for example, designing a cross-sectional area of the first conductor pattern of the first coil conductor21to be very small and designing a cross-sectional area of the second conductor pattern of the second coil conductor22to be very wide. Here, the cross-sectional area refers to a value obtained by multiplying a line width of the conductor pattern by a height of the conductor pattern. The first and second levels of inductance may become similar to each other by a method of allowing the turn of the first conductor pattern of the first coil conductor21to be more than that of the second conductor pattern of the second coil conductor22.

In this case, both of an inductance and a DC resistance in a low current (Path1) section may be larger than those in a high current (Path2) section. That is, in the low current (Path1) section, an inductance L may be increased to significantly reduce AC loss, and in the high current (Path2) section, a DC resistance (RDC) may be reduced to significantly reduce DC loss. That is, efficiency of the power inductor may be significantly improved depending on a condition of a current by making paths of the low current (Path1, L1+L2, DCR1+DCR2) section and the high current (Path2, L2, DCR2) section different from each other.

FIG. 9is a view schematically illustrating an efficiency improvement effect in the case in which the coil component ofFIG. 3is used in an electronic device.

Referring toFIG. 9, it may be appreciated that efficiency in a low current band as well as efficiency in a high current band are improved in a power inductor according to the Inventive Example, that is, a power inductor according to the present disclosure in which a first coil conductor (L1=0.47 μH, DCR=5 mΩ) and a second coil conductor (L=0.47 μH, DCR=50 mΩ) having similar inductance (L) values and different DC resistance (RDC) values are connected to each other in series as compared to in a power inductor according to the Comparative Example, that is, a general power inductor having only one coil conductor (L=0.47 μH, DCR=5 mΩ). In addition, since the power inductor according to the present disclosure is formed of one coil, a mounting area and a surface mounted technology (SMT) process cost of the power inductor may be reduced at the time of mounting the power inductor on the electronic device as compared to in a case in which a plurality of coils are connected to each other in series.

FIG. 10is a view schematically illustrating an equivalent circuit of a coil component according to another example.

Referring toFIG. 10, a coil component according to another example may be a coil component in which first to fourth coil conductors having first to fourth levels of inductance L1to L4, respectively, are connected to each other in series. In this case, the coil component may be connected to the outside through first to fifth lead terminals P1to P5. That is, the coil component according to the present disclosure is not necessarily limited to a case in which two coil conductors are connected to each other in series, but may be extended to a case in which two or more coil conductors are connected to each other in series. This generally means that a coil of the coil component may be an array of N coil conductors. In this case, the coil may have N+1 lead terminals. Here, N indicates an integer of 2 or more.

Meanwhile, in the present disclosure, a phrase ‘electrically connected’ includes both of a case in which one component is physically connected to another component and a case in which one component is not physically connected to another component. In addition, terms ‘first’, ‘second’, and the like, are used to distinguish one component from another component, and do not limit a sequence, importance, and the like, of the corresponding components. In some cases, a first component may be termed a second component and a second component may also be similarly termed a first component, without departing from the scope of the present disclosure.

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

In addition, 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 interpreted otherwise in a context.

As set forth above, according to an exemplary embodiment in the present disclosure, efficiency of a coil component over an entire band from a low current to a high current may be improved.