Patent Publication Number: US-2021193369-A1

Title: Coil component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2019-233233, filed on 24 Dec. 2019, the entire contents of which are incorporated herein by reference. 
     TECHNICAL FIELD 
     The present disclosure relates to a coil component. 
     BACKGROUND 
     The specification of Unites States Patent Application, Publication No. 2017-196091 (Patent Document 1) discloses a coil component which includes two coils aligned in an element body and a non-magnetic layer disposed between the two coils. This document demonstrates that mutual interference between the magnetic fluxes of the two coils is suppressed by the non-magnetic layer. 
     SUMMARY 
     In the coil component according to the above-described conventional technology, mutual interference of magnetic fluxes cannot be sufficiently suppressed, and further suppression of the mutual interference of the magnetic fluxes is required. 
     According to the present disclosure, a coil component capable of further suppressing mutual interference of magnetic fluxes is provided. 
     A coil component according to one aspect of the present disclosure includes an element body, a first coil provided in the element body and wound around a first magnetic core, a second coil provided in the element body, wound around a second magnetic core extending in a direction along the first magnetic core, and adjacent to the first coil in a direction perpendicular to the first magnetic core, and a non-magnetic part bridged between the first coil and the second coil in a cross section including the magnetic core of the first coil and the magnetic core of the second coil of the element body. 
     In the above-described coil component, the non-magnetic part is bridged between the first coil and the second coil in a cross section including the magnetic core of the first coil and the magnetic core of the second coil of the element body. Therefore, a magnetic flux in a direction along the first magnetic core is hindered by the non-magnetic part between the first coil and the second coil. Therefore, a magnetic flux of the first coil and a magnetic flux of the second coil are difficult to interfere with each other. 
     In the coil component according to another aspect, the first coil and the second coil may be formed in a first layer of the element body. 
     In the coil component according to another aspect, the non-magnetic part may include a first portion positioned in the first layer. 
     The coil component according to another aspect may further include a resin part extending between the first coil and the second coil in the first layer. The resin part may constitute the first portion of the non-magnetic part. 
     In the coil component according to another aspect, the non-magnetic part may include a second portion positioned in a second layer. The second layer overlaps the first layer of the element body. 
     The coil component according to another aspect may further include an insulating substrate provided in the element body, formed of a non-magnetic insulating material, and including a main surface. The first coil and the second coil are formed on the main surface. The insulating substrate may constitute at least a part of the second portion of the non-magnetic part. 
     In the coil component according to another aspect, at least one of the first coil and the second coil may include a first coil pattern provided on one main surface of the insulating substrate and a second coil pattern provided on the other main surface. 
     The coil component according to another aspect may further include a protective film covering the insulating substrate along with the first coil and the second coil integrally. The protective film may constitute at least a part of the second portion of the non-magnetic part. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of a coil component according to an embodiment. 
         FIG. 2  is a view illustrating a main body part of the coil component illustrated in  FIG. 1 . 
         FIG. 3  is a view illustrating an internal structure of the main body part illustrated in  FIG. 2 . 
         FIG. 4  is a view illustrating a first planar coil pattern provided on an upper surface of a substrate. 
         FIG. 5  is a view illustrating a second planar coil pattern provided on a lower surface of the substrate. 
         FIG. 6  is a cross-sectional view along line VI-VI of the main body part illustrated in  FIG. 2 . 
         FIG. 7  is view in which a main part of the cross-sectional view of  FIG. 6  is enlarged. 
         FIG. 8  is a view illustrating a coil component having a different form. 
         FIG. 9  is a view illustrating a coil component having a different form. 
         FIG. 10  is a view illustrating a coil component having a different form. 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In the description, the same elements or elements having the same function will be denoted by the same reference signs and duplicate descriptions thereof will be omitted. 
     A coil component  10  according to an embodiment will be described with reference to  FIGS. 1 to 3 . 
     The coil component  10  is configured to include a main body part  12  (element body) having a rectangular flat plate-like outer shape, and two pairs of external terminal electrodes  14 A,  14 B,  14 C, and  14 D provided on surfaces of the main body part  12 . The main body part  12  includes a rectangular upper surface  12   a  and a rectangular lower surface  12   b  parallel to each other, a pair of side surfaces  12   c  and  12   d  perpendicular to the upper surface  12   a  and the lower surface  12   b , and a pair of end surfaces  12   e  and  12   f  perpendicular to the pair of main surfaces  12   a  and  12   b  and the pair of side surfaces  12   c  and  12   d . The external terminal electrodes  14 A,  14 B,  14 C, and  14 D are formed on the side surfaces  12   c  and  12   d  in pairs. As an example, the main body part  12  is designed with dimensions such that a long side length of the upper surface  12   a  is 3.2 mm, a short side length of the upper surface is 2.0 mm, and a height is 0.5 mm. 
     The main body part  12  is configured to include an insulating substrate  20 , a first coil C 1  and a second coil C 2  provided on the insulating substrate  20 , and a magnetic material  30 . 
     The insulating substrate  20  is a plate-shaped member provided inside the main body part  12  and is formed of a non-magnetic insulating material. As the insulating substrate  20 , a substrate in which a glass cloth is impregnated with an epoxy-based resin and having a plate thickness of 10 μm to 60 μm can be used. Further, a BT resin, polyimide, aramid, or the like can also be used in addition to an epoxy-based resin. As a material of the insulating substrate  20 , a ceramic or glass can also be used. A material of the insulating substrate  20  may be a mass-produced printed circuit board material and may be a resin material particularly used for a BT printed circuit board, an FR4 printed circuit board, or an FR5 printed circuit board. 
     A plurality of through holes including a first through hole  20   c  and a second through hole  20   d  are provided in the insulating substrate  20 . The first through hole  20   c  and the second through hole  20   d  both have an elliptical shape and are aligned in a direction in which the pair of end surfaces  12   e  and  12   f  face each other. 
     As illustrated in  FIGS. 4 and 5 , the first coil C 1  is configured to include planar coil patterns  22  and  24  wound around the first through hole  20   c  of the insulating substrate  20 . The planar coil patterns  22  and  24  of the first coil C 1  are constituted by a first planar coil pattern  22  formed on an upper surface  20   a  of the insulating substrate  20  and a second planar coil pattern  24  formed on a lower surface  20   b  of the insulating substrate  20 . 
     As illustrated in  FIG. 4 , the first planar coil pattern  22  is wound around the first through hole  20   c  a plurality of times (about 4 turns in the present embodiment) in a planar spiral shape. The first planar coil pattern  22  has an outer end portion  22   a  that reaches the side surface  12   c  of the main body part  12  to be exposed. The external terminal electrode  14 A is formed in a region of the side surface  12   c  at which the outer end portion  22   a  of the first planar coil pattern  22  is exposed, and the outer end portion  22   a  of the first planar coil pattern  22  is connected to the external terminal electrode  14 A on the side surface  12   c . Also, the first planar coil pattern  22  has an inner end portion  22   b  positioned in an edge region of the first through hole  20   c . The first planar coil pattern  22  is connected to the second planar coil pattern  24  at the inner end portion  22   b  via a first through conductor V 1  to be described below. 
     As illustrated in  FIG. 5 , the second planar coil pattern  24  has a symmetrical shape with respect to the first planar coil pattern  22  when viewed from the upper surface  20   a  side of the insulating substrate  20 . More specifically, the first planar coil pattern  22  and the second planar coil pattern  24  have a line-symmetrical relationship. Therefore, similarly to the first planar coil pattern  22 , the second planar coil pattern  24  is wound around the first through hole  20   c  a plurality of times (about 4 turns in the present embodiment) in a planar spiral shape. The second planar coil pattern  24  has an outer end portion  24   a  that reaches the side surface  12   d  of the main body part  12  to be exposed. The external terminal electrode  14 B is formed in a region of the side surface  12   d  at which the outer end portion  24   a  of the second planar coil pattern  24  is exposed, and the outer end portion  24   a  of the second planar coil pattern  24  is connected to the external terminal electrode  14 B on the side surface  12   d . Also, the second planar coil pattern  24  has an inner end portion  24   b  at a position overlapping the inner end portion  22   b  of the first planar coil pattern  22 . 
     The first coil C 1  includes the first through conductor V 1  that connects the inner end portion  22   b  of the first planar coil pattern  22  to the inner end portion  24   b  of the second planar coil pattern  24 . The first through conductor V 1  penetrates the insulating substrate  20  in a thickness direction, is in contact with the inner end portion  22   b  of the first planar coil pattern  22  at an upper end thereof, and is in contact with the inner end portion  24   b  of the second planar coil pattern  24  at a lower end thereof. 
     When a voltage is applied between the external terminal electrodes  14 A and  14 B, a current flows through the first planar coil pattern  22  and the second planar coil pattern  24  connected by the first through conductor V 1  in the same circumferential direction (for example, clockwise direction) when viewed from the upper surface  20   a  side of the insulating substrate  20 . Therefore, in the first coil C 1 , the first planar coil pattern  22  and the second planar coil pattern  24  cooperate to function as one coil. 
     As illustrated in  FIGS. 4 and 5 , the second coil C 2  is configured to include planar coil patterns  22  and  24  wound around the second through hole  20   d  of the insulating substrate  20 . The second coil C 2  is aligned with the first coil C 1  in a direction in which the pair of end surfaces  12   e  and  12   f  face each other. As in the planar coil patterns  22  and  24  of the first coil C 1 , the planar coil patterns  22  and  24  of the second coil C 2  are constituted by a first planar coil pattern  22  formed on the upper surface  20   a  of the insulating substrate  20  and a second planar coil pattern  24  formed on the lower surface  20   b  of the insulating substrate  20 . 
     The first planar coil pattern  22  of the second coil C 2  has the same shape as the first planar coil pattern  22  of the first coil C 1 . Regarding the second coil C 2 , the external terminal electrode  14 C is formed in a region of the side surface  12   c  at which an outer end portion  22   a  of the first planar coil pattern  22  is exposed, and the outer end portion  22   a  of the first planar coil pattern  22  is connected to the external terminal electrode  14 C on the side surface  12   c . Also, the external terminal electrode  14 D is formed in a region of the side surface  12   d  at which an outer end portion  24   a  of the second planar coil pattern  24  is exposed, and the outer end portion  24   a  of the second planar coil pattern  24  is connected to the external terminal electrode  14 D on the side surface  12   d . Further, an inner end portion  22   b  of the first planar coil pattern  22  and an inner end portion  24   b  of the second planar coil pattern  24  positioned at positions overlapping each other in an edge region of the second through hole  20   d  are connected via a second through conductor V 2  similarly to the first through conductor V 1 . 
     In the second coil C 2 , similarly to the first coil C 1 , when a voltage is applied between the external terminal electrodes  14 C and  14 D, the first planar coil pattern  22  and the second planar coil pattern  24  cooperate to function as one coil. 
     The first planar coil pattern  22  and the second planar coil pattern  24  can be formed using plating. 
     In the first coil C 1  and the second coil C 2 , a side surface of the first planar coil pattern  22  (that is, a surface perpendicular to the insulating substrate  20 ) is covered with a resin wall  25 , a side surface of the second planar coil pattern  24  is covered with a resin wall  26 , and the resin walls  25  and  26  are formed of an insulating resin material. The resin walls  25  and  26  can be provided on the insulating substrate  20  before the first planar coil pattern  22  and the second planar coil pattern  24  are formed, and in this case, the first planar coil pattern  22  and the second planar coil pattern  24  are plated and grown in a space between walls defined by the resin walls  25  and  26 . That is, formation regions of the first planar coil pattern  22  and the second planar coil pattern  24  are defined by the resin walls  25  and  26  provided on the insulating substrate  20 . The resin walls  25  and  26  can be provided on the insulating substrate  20  after the first planar coil pattern  22  and the second planar coil pattern  24  are formed, and in this case, the resin walls  25  and  26  are provided in the first planar coil pattern  22  and the second planar coil pattern  24  by filling, coating, or the like. As will be described below, a space between the resin walls  25  and  26  between the first coil C 1  and the second coil C 2  is filled with a resist (resin part)  27 . The resist  27  can be formed through the same process as the process of forming the resin walls  25  and  26 . The resist  27  is formed of an insulating resin material and may be the same resin material as that of the resin walls  25  and  26 . 
     The insulating substrate  20 , together with the first coil C 1  and the second coil C 2 , is integrally covered with a protective film  28 . The protective film  28  covers an upper surface of the first planar coil pattern  22  and a lower surface of the second planar coil pattern  24 , and fills a space between the first coil C 1  and the second coil C 2  on the insulating substrate  20 . Specifically, the protective film  28  fills a space between the first planar coil pattern  22  of the first coil C 1  and the first planar coil pattern  22  of the second coil C 2  on the upper surface  20   a  of the insulating substrate  20 , and fills a space between the second planar coil pattern  24  of the first coil C 1  and the second planar coil pattern  24  of the second coil C 2  on the lower surface  20   b  of the insulating substrate  20 . The protective film  28  may be formed of a resin such as, for example, an epoxy resin or a polyimide resin and may be formed, for example, using a photolithography method. 
     The magnetic material  30  integrally covers the insulating substrate  20 , the first coil C 1 , and the second coil C 2 . More specifically, the magnetic material  30  covers the insulating substrate  20 , the first coil C 1 , and the second coil C 2  from a vertical direction (thickness direction of the insulating substrate), and covers outer circumferences of the insulating substrate  20 , the first coil C 1 , and the second coil C 2 . Also, the magnetic material  30  fills insides of the through holes  20   c  and  20   d  of the insulating substrate  20 , and fills inner regions of the first coil C 1  and the second coil C 2 . In the magnetic material  30 , the magnetic material  30  of a portion filling the inside of the through hole  20   c  of the insulating substrate  20  and the inner region of the first coil C 1  constitutes a magnetic core Z 1  of the first coil C 1 , and the magnetic material  30  of a portion filling the inside of the through hole  20   d  of the insulating substrate  20  and the inner region of the second coil C 2  constitutes a magnetic core Z 2  of the second coil C 2 . In the present embodiment, the magnetic core Z 1  of the first coil C 1  and the magnetic core Z 2  of the second coil C 2  have a parallel relationship. 
     The magnetic material  30  is formed of a metal magnetic powder-containing resin. The metal magnetic powder-containing resin is a binder powder in which a metal magnetic powder is bound by a binder resin. The metal magnetic powder of the metal magnetic powder-containing resin constituting the magnetic material  30  may be formed of, for example, an iron-nickel alloy (a Permalloy alloy), carbonyl iron, an amorphous, non-crystalline, or crystalline FeSiCr-based alloy, Sendust, or the like. The binder resin may be, for example, a thermosetting epoxy resin. In the present embodiment, a content of the metal magnetic powder in the binder powder is 80 to 92% by volume percentage and 95 to 99% by mass percentage. From a viewpoint of magnetic characteristics, a content of the metal magnetic powder in the binder powder may also be 85 to 92% by volume percentage and 97 to 99% by mass percentage. A magnetic powder of the metal magnetic powder-containing resin constituting the magnetic material  30  may be a powder having an average particle diameter of one type, or may be a mixed powder having average particle diameters of a plurality of types. In the present embodiment, the magnetic powder of the metal magnetic powder-containing resin constituting the magnetic material  30  is a mixed powder having average particle diameters of three types. When the magnetic powder of the metal magnetic powder-containing resin constituting the magnetic material  30  is a mixed powder, types of the magnetic powder having different average particle sizes may be the same or different. 
     The cross-sectional view of  FIG. 6  illustrates a cross section including both the magnetic core Z 1  of the first coil C 1  and the magnetic core Z 2  of the second coil C 2 . As illustrated in  FIG. 6 , the main body part  12  has a laminated structure including the insulating substrate  20 , the planar coil patterns  22  and  24 , and the protective film  28 . In the present embodiment, the laminated structure of the main body part  12  is constituted by first layers L 11  and L 12  in which the planar coil patterns  22  and  24  are respectively positioned, and second layers L 21  to L 23  which directly overlap the first layers L 11  and L 12  and in which the insulating substrate  20  or the protective film  28  is positioned. 
       FIG. 7  is view in which a main part of the cross-sectional view of  FIG. 6  is enlarged, and more specifically, is a view in which a portion between the first coil C 1  and the second coil C 2  in the main body part  12  is enlarged. As illustrated in  FIG. 7 , a non-magnetic part  40  is provided to be bridged between the first coil C 1  and the second coil C 2 . In the present embodiment, the non-magnetic part  40  is constituted by the resin walls  25  and  26  and the resist  27  positioned in the first layers L 11  and L 12 , a part of the insulating substrate  20  positioned in the second layer L 21 , and a part of the protective film  28  positioned in the second layers L 22  and L 23 . As described above, the resin walls  25  and  26 , the resist  27 , the protective film  28 , and the insulating substrate  20  are all formed of a non-magnetic material. 
     In the present embodiment, the resin walls  25  and  26  and the resist  27  form a resin part extending between the first coil C 1  and the second coil C 2  in the first layers L 11  and L 12 , and the resin part constitutes a first portion  40   a  of the non-magnetic part  40 . Also, in the present embodiment, a portion of the insulating substrate  20  connecting the first coil C 1  and the second coil C 2  constitutes a part of the second portion  40   b  of the non-magnetic part  40  positioned in the second layer L 21  overlapping the first layers L 11  and L 12 . Further, in the present embodiment, a portion of the protective film  28  connecting the first coil C 1  and the second coil C 2  constitutes a part of the second portion  40   b  of the non-magnetic part  40  positioned in the second layer L 22  and L 23  overlapping the first layers L 11  and L 12 . 
     In the coil component  10  described above, the non-magnetic part  40  is stretched between the first coil C 1  and the second coil C 2  in the cross section of the element body illustrated in  FIG. 6 . Therefore, a magnetic flux in a direction along the magnetic core Z 1  of the first coil C 1  and the magnetic core Z 2  of the second coil C 2  is hindered or blocked by the non-magnetic part  40  between the first coil C 1  and the second coil C 2 . Therefore, a magnetic flux of the first coil C 1  and a magnetic flux of the second coil C 2  are difficult to interfere with each other. 
     Further, the non-magnetic material constituting the non-magnetic part  40  can be appropriately replaced with a different non-magnetic material, and a part thereof can also be configured as a space (void). For example, as illustrated in  FIG. 8 , the non-magnetic part  40  may have a configuration in which there is a space S in the portion of the resist  27  described above. 
     Also, the non-magnetic part  40  is not limited to the configuration in which the insulating material is present in all of the first layers L 11  and L 12  and the second layers L 21  to L 23  described above, and may also have a configuration in which the insulating material is present in a part (one layer or a plurality of layers) of the first layers L 11  and L 12  and the second layers L 21  to L 23 . For example, as illustrated in  FIG. 9 , the non-magnetic part  40  may be constituted only by the resin walls  25  and  26  and the resist  27  positioned in the first layers L 11  and L 12  (that is, the first portion  40   a ), and a portion of the insulating substrate  20  connecting the first coil C 1  and the second coil C 2  positioned in the second layer L 21  (that is, the second portion  40   b ), and the non-magnetic part  40  in this case does not include the protective film  28 . Also, as illustrated in  FIG. 10 , the non-magnetic part  40  may be constituted only by a portion of the insulating substrate  20  connecting the first coil C 1  and the second coil C 2  positioned in the second layer L 21  (that is, the second portion  40   b ), and the non-magnetic part  40  in this case does not include the resist  27  and the protective film  28 . The disclosure may also have an aspect in which the magnetic material  30  is interposed between the first coil C 1  and the second coil C 2 . 
     Further, the present disclosure is not limited to the above-described embodiments and may take various aspects. 
     For example, the coil component may have a configuration that does not include the insulating substrate. In this case, the first coil and the second coil may be constituted by a one-layer planar coil pattern. Both the first coil and the second coil need not be configured by a two-layer planar coil pattern (for example, a first planar coil pattern and a second planar coil pattern), and only one of them may be configured by a two-layer planar coil pattern. The two-layer planar coil pattern does not have to be line-symmetrical. Also, the number of turns of the first coil and the number of turns of the second coil can be increased or decreased as appropriate. The magnetic core of the first coil and the magnetic core of the second coil do not necessarily have to have a parallel relationship, and one magnetic core may be slightly inclined with respect to the other magnetic core.