Coil component

• US 9,142,343 B2
• Filed: 07/03/2013
• Issued: 09/22/2015
• Est. Priority Date: 07/04/2012
• Status: Active Grant

• Current Assignee: TDK Corporation
• Original Assignee: TDK Corporation
• Inventors: Ohkubo, Hitoshi, Ito, Tomokazu, Itoh, Hideto, Maeda, Yoshihiro, Ohta, Manabu, Kaname, Yuuya, Kawahara, Takahiro
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): HOSSAIN, KAZI S
• Application Number:
  US13/935,442
• Publication Number:
  US 20140009254A1
• Time in Patent Office: 811 Days
• Field of Search: 336/200, 336/223, 336/232, 336/230
• US Class Current: 1/1
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 2017/0073 with a special conductive pattern, e.g. flat spiral
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/022 Encapsulation
• 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

Abstract

A coil component 1 includes a substrate 2, a planar spiral conductor 10a formed on a top surface 2t of the substrate 2, a lead conductor 11a connected to an outer peripheral end of the planar spiral conductor 10a, a dummy lead conductor 15a formed on the top surface of the substrate 2 and between an outermost turn of the planar spiral conductor 10a and an end 2X₂ of the substrate 2 and free from an electrical connection with another conductor within the same plane, external electrodes 26a and 26b arranged in parallel with the top surface of the substrate 2, and a bump electrode 25a formed on a surface of the lead conductor 11a and connects the lead conductor 11a with the external electrode 26a. The external terminals 26a and 26b have a larger area than the bump electrodes 15a and 15b for securing a bonding strength.

Claims

1. A coil component comprising:

a substrate;

a planar spiral conductor that is formed on a surface of the substrate by electrolytic plating;

a lead conductor that is formed on the surface of the substrate and connected to an outer peripheral end of the planar spiral conductor;

a dummy lead conductor that is formed on the surface of the substrate and between an outermost turn of the planar spiral conductor and an end of the substrate, and free from an electrical connection with another conductor at least within the same plane;

an insulating resin layer that is formed on the surface of the substrate to cover the planar spiral conductor, the lead conductor, and the dummy lead conductor;

a metal magnetic powder-containing resin layer that covers the insulating resin layer;

an external electrode that is formed on the metal powder-containing resin layer; and

a bump electrode that penetrates the insulating resin layer and the metal magnetic power-containing resin layer and is connected between the lead conductor and the external electrode, wherein

the external electrode has an area greater than that of the bump electrode,

the metal magnetic powder-containing resin layer has a main surface that is substantially parallel to the surface of the substrate and a side surface that is substantially perpendicular to the main surface, and

the external electrode is selectively formed on the main surface of the metal magnetic powder-containing resin layer so that the side surface of the metal magnetic powder-containing resin layer is free from the external electrode.

2. The coil component as claimed in claim 1, wherein

the planar spiral conductor has a circular spiral shape, and

a side surface of the dummy lead conductor opposed to the planar spiral conductor is curved along the outermost turn of the planar spiral conductor.

3. The coil component as claimed in claim 1 further comprising a first through-hole magnetic body and second through-hole magnetic bodies, the first and second through-hole magnetic bodies being made of the same material as that of the metal magnetic powder-containing resin layer, wherein

the first through-hole magnetic body penetrates the substrate in a center portion surrounded by the planar spiral conductor, and

the second through-hole magnetic bodies penetrate the substrate outside the planar spiral conductor.

4. The coil component as claimed in claim 3, wherein

the substrate has a rectangular shape,

the planar spiral conductor has an elliptical spiral shape, and

the second through-hole magnetic bodies are formed corresponding to each of four corners of the substrate.

5. The coil component as claimed in claim 4, wherein

the substrate includes first and second sides that are parallel to each other, and third and fourth sides that are orthogonal to the first and second sides and parallel to each other,

the lead conductor is extended along the first side,

the dummy lead conductor is extended along the second side, and

the second through-hole magnetic bodies are arranged on the third or fourth sides.

6. The coil component as claimed in claim 5, wherein the bump electrode is extended along the first side.

7. A coil component comprising:

a substrate having top and bottom surfaces;

a first planar spiral conductor that is formed on the top surface of the substrate by electrolytic plating;

a second planar spiral conductor that is formed on the bottom surface of the substrate by electrolytic plating;

a first through-hole conductor that penetrates the substrate to connect an inner peripheral end of the first planar spiral conductor with an inner peripheral end of the second planar spiral conductor;

a first dummy lead conductor that is formed on the top surface of the substrate and between an outermost turn of the first planar spiral conductor and an end of the substrate, and free from an electrical connection with another conductor at least within the same plane;

a second dummy lead conductor that is formed on the bottom surface of the substrate and between an outermost turn of the second planar spiral conductor and an end of the substrate, and free from an electrical connection with another conductor at least within the same plane;

a first lead conductor that is formed on the top surface of the substrate and vertically overlapped with the second dummy lead conductor, and is connected to an outer peripheral end of the first planar spiral conductor;

a second lead conductor that is formed on the bottom surface of the substrate and vertically overlapped with the first dummy lead conductor, and is connected to an outer peripheral end of the second planar spiral conductor;

a second through-hole conductor that penetrates the substrate to connect the first dummy lead conductor with the second lead conductor;

first and second external electrodes that are formed in parallel with the top surface of the substrate;

a first bump electrode that is formed on a surface of the first lead conductor by electrolytic plating and connects the first lead conductor with the first external electrode; and

a second bump electrode that is formed on a surface of the first dummy lead conductor by electrolytic plating and connects the first dummy lead conductor with the second external electrode, wherein

the first external electrode has an area greater than that of the first bump electrode, and

the second external electrode has an area greater than that of the second bump electrode.

8. The coil component as claimed in claim 7, wherein

the first and second planar spiral conductors have a circular spiral shape,

a side surface of the first dummy lead conductor opposed to the first planar spiral conductor is curved along the outermost turn of the first planar spiral conductor, and

a side surface of the second dummy lead conductor opposed to the second planar spiral conductor is curved along the outermost turn of the second planar spiral conductor.

9. The coil component as claimed in claim 7 further comprising:

a first metal magnetic powder-containing resin layer that is arranged on a top surface side of the substrate; and

a second metal magnetic powder-containing resin layer that is arranged on a bottom surface side of the substrate, wherein

each of the first and second external electrodes is formed not on a side surface but selectively on a main surface of the first metal magnetic powder-containing resin layer, and

the first and second bump electrodes penetrate the first metal magnetic powder-containing resin layer and are connected to the first and second electrode external electrodes, respectively.

10. The coil component as claimed in claim 9 further comprising first and second through-hole magnetic bodies that are made of the same material as that of the first and second metal magnetic powder-containing resin layers, and penetrate the substrate to connect the first metal magnetic powder-containing resin layer with the second metal magnetic powder-containing resin layer, wherein

the first through-hole magnetic body penetrates the substrate in a center portion surrounded by the first and second planar spiral conductors, and

the second through-hole magnetic bodies penetrate the substrate outside the first and second planar spiral conductors.

11. The coil component as claimed in claim 10 wherein

the substrate has a rectangular shape,

the first and second planar spiral conductors have an elliptical spiral shape, and

the second through-hole magnetic bodies are formed corresponding to each of four corners of the substrate.

12. A coil component comprising:

a substrate having top and bottom surfaces opposite to each other;

a first spiral conductor formed on the top surface of the substrate;

a second spiral conductor formed on the bottom surface of the substrate;

a first conductor formed on the top surface of the substrate and connected to an outer peripheral end of the first spiral conductor;

a second conductor formed on the top surface of the substrate;

a third conductor formed on the bottom surface of the substrate and connected to an outer peripheral end of the second spiral conductor;

a first through-hole conductor connected between an inner peripheral end of the first spiral conductor and an inner peripheral end of the second spiral conductor;

a second through-hole conductor connected between the second conductor and the third conductor;

a first insulating layer formed on the top and bottom surfaces of the substrate to cover the first and second spiral conductors and the first to third conductors;

a second insulating layer formed on the top and bottom surfaces of the substrate with an intervention of the first insulating layer;

first and second external electrodes formed on the second insulating layer;

a first bump electrode connected between the first conductor and the first external electrode; and

a second bump electrode connected between the second conductor and the second external electrode.

13. The coil component as claimed in claim 12, further comprising:

a fourth conductor formed on the bottom surface of the substrate; and

a third through-hole conductor connected between the first conductor and the fourth conductor.

14. The coil component as claimed in claim 13, wherein each of the first and second conductors is curved along an outermost turn of the first spiral conductor, and each of the third and fourth conductors is curved along an outermost turn of the second spiral conductor.

15. The coil component as claimed in claim 12, wherein the second insulating layer includes a metal magnetic powder.

16. The coil component as claimed in claim 12, wherein the second insulating layer has a main surface that is substantially parallel to the top and bottom surfaces of the substrate and a side surface that is substantially perpendicular to the main surface, and

wherein the first and second external electrodes are selectively formed on the main surface of the second insulating layer so that the side surface of the second insulating layer is free from the first and second external electrodes.

17. The coil component as claimed in claim 12, wherein the first spiral conductor has one of a clockwise rotation and a counterclockwise rotation from the outer peripheral end to the inner peripheral end viewed from the top surface of the substrate, and the second spiral conductor has the other of the clockwise rotation and the counterclockwise rotation from the outer peripheral end to the inner peripheral end viewed from the top surface of the substrate.

18. The coil component as claimed in claim 12, wherein the substrate includes a glass cloth.