Power inductor

• US 10,541,075 B2
• Filed: 06/01/2015
• Issued: 01/21/2020
• Est. Priority Date: 08/07/2014
• Status: Active Grant

• Current Assignee: Moda-InnoChips Co., Ltd.
• Original Assignee: Moda-InnoChips Co., Ltd.
• Inventors: Park, In Kil, Noh, Tae Hyung, Kim, Gyeong Tae, Cho, Seung Hun, Jung, Jun Ho, Nam, Ki Joung, Lee, Jung Gyu
• Primary Examiner(s): Hinson, Ronald
• Application Number:
  US15/502,501
• Publication Number:
  US 20170236632A1
• Time in Patent Office: 1,695 Days
• Field of Search: 336200
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/323 Insulation between winding turns, between winding layers
• CPC Class Codes: H01F 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 41/122 Insulating between turns or between winding layers

Abstract

The present disclosure provides a power inductor, which includes a body, at least one substrate provided inside the body, at least one coil pattern provided on at least one surface of the substrate, and an insulation layer formed between the coil pattern and the body, wherein the insulation layer is formed of parylene.

Claims

1. A power inductor, comprising:

a body comprising a metal powder;

at least one substrate provided inside the body;

at least one coil pattern provided on at least one surface of the substrate; and

an insulation layer formed on the coil pattern for insulation of the coil pattern and the body, wherein the insulation layer is formed of parylene;

wherein the insulation layer is filled between the coil patterns and formed on an upper portion of the coil patterns and a side surface of the coil patterns with a uniform thickness, wherein the insulation layer has a thickness of 3 μ

m to 100 μ

m; and

wherein the metal powder has a surface coated with a first insulator formed of metal oxide, and a second insulator formed of parylene, wherein the second insulator is coated in a thickness of approximately 1 um to approximately 10 um.

2. The power inductor of claim 1, wherein the metal powder comprises a metal alloy powder containing iron.

3. The power inductor of claim 1, wherein the metal powder has a surface further coated with ferrite material.

4. The power inductor of claim 1, wherein the substrate is formed of a copper clad lamination, or formed such that a copper foil is attached to both surfaces of a metal plate containing iron.

5. The power inductor of claim 1, further comprising an external electrode formed outside the body and connected to the coil pattern.

6. The power inductor of claim 1, wherein the body further comprises a polymer, and a heat conducting filler.

7. The power inductor of claim 6, wherein the heat conducting filler comprises one or more selected from the group consisting of MgO, AlN, and a carbon based material.

8. The power inductor of claim 7, wherein the heat conducting filler is included in an amount of approximately 0.5 wt % to approximately 3 wt % with respect to 100 wt % of the metal powder, and has a size of approximately 0.5 um to approximately 100 um.

9. The power inductor of claim 1, wherein the substrate is provided in at least duplicate or more, and the coil pattern is formed on each of at least two or more substrates.

10. The power inductor of claim 9, further comprising a connection electrode provided outside the body and configured to connect at least two or more coil patterns.

11. The power inductor of claim 10, further comprising at least two or more external electrodes connected to the at least two or more coil patterns, respectively, and formed outside the body.

12. The power inductor of claim 11, wherein the at least two or more external electrodes are formed on a same side surface of the body to be spaced apart from each other, or formed on side surfaces of the body that are different from each other.

13. The power inductor of claim 1, further comprising a magnetic layer provided in at least one region of the body, and having a magnetic permeability greater than that of the body.

14. The power inductor of claim 13, wherein the magnetic layer is formed to comprise a heat conducting filler.