CN-122025376-A - Coil assembly

Abstract

The present disclosure provides a coil assembly including a body including first and second surfaces opposite to each other in a first direction, third and fourth surfaces opposite to each other in a second direction, and fifth and sixth surfaces opposite to each other in a third direction, a recess formed on at least one of the first, second, third and fourth surfaces, the body including a magnetic material, a coil including a winding portion disposed within the body and a lead disposed at least partially in the recess, and first and second lead frames disposed on the body, spaced apart from each other in the first direction and connected to the lead. The ratio a/b is equal to or greater than 0.042 and equal to or less than 0.502, where a is the average length of the recess in the third direction and b is the average lengths of the first and second lead frames in the third direction.

Inventors

• JIN YIXIE
• LI DONGJIAN
• CAO ZHENGXI
• Hong Shangxian
• AN TONGHUI
• LIANG ZHENHE

Assignees

• 三星电机株式会社

Dates

Publication Date

20260512

Application Date

20250915

Priority Date

20241111

Claims (20)

1. 1. A coil assembly, comprising: A body including a magnetic material, the body including first and second surfaces opposing each other in a first direction, third and fourth surfaces opposing each other in a second direction, and fifth and sixth surfaces opposing each other in a third direction, wherein at least one recess is formed on at least one of the first, second, third, and fourth surfaces; A coil comprising a winding disposed within the body and at least one lead disposed at least partially in the at least one recess; A first lead frame and a second lead frame disposed on the main body, spaced apart from each other in the first direction, and connected to the at least one lead, Wherein the ratio a/b is equal to or greater than 0.042 and equal to or less than 0.502, wherein a is the average length of the at least one recess in the third direction and b is the average length of the first and second lead frames in the third direction.
2. 2. The coil assembly of claim 1, wherein a is 0.21mm or more and 2.51mm or less.
3. 3. The coil assembly of claim 1, wherein b is 1.8mm or more and 5.0mm or less.
4. 4. The coil assembly of claim 1, wherein the at least one recess comprises a first recess and a second recess formed on the third surface of the body and spaced apart from each other in the first direction.
5. 5. The coil assembly of claim 4, wherein the first recess extends to the first surface of the body and the second recess extends to the second surface of the body.
6. 6. The coil assembly of claim 1, wherein the at least one recess comprises a first recess formed on the first surface of the body and a second recess formed on the second surface of the body.
7. 7. The coil assembly of claim 1, wherein the first and second lead frames each include an inner surface facing the third surface of the body, and the at least one lead is in contact with the inner surface of the first lead frame and the inner surface of the second lead frame.
8. 8. The coil assembly of claim 7, wherein the inner surface of the first lead frame is coplanar with the third surface of the body and the inner surface of the second lead frame is coplanar with the third surface of the body.
9. 9. The coil assembly of claim 1, wherein the first and second lead frames cover the at least one lead and are not disposed in the at least one recess.
10. 10. The coil assembly of claim 1, wherein the first lead frame includes a side surface portion disposed on the first surface of the body and a lower surface portion disposed on the third surface of the body, and the second lead frame includes a side surface portion disposed on the second surface of the body and a lower surface portion disposed on the third surface of the body.
11. 11. The coil assembly of claim 10, wherein: The at least one recess includes a first recess formed on the first surface of the body and a second recess formed on the second surface of the body, A third recess is also formed in the first surface of the body, A fourth recess is also formed in the second surface of the body, At least a part of the side surface portion of the first lead frame is disposed in the third recess, and At least a portion of the side surface portion of the second lead frame is disposed in the fourth recess.
12. 12. The coil assembly of claim 11, wherein the first recess is formed in a center of the third recess and recessed from the third recess into the main body, the second recess is formed in a center of the fourth recess and recessed from the fourth recess into the main body, and at least a portion of the at least one lead is disposed in the first recess and the second recess.
13. 13. A coil assembly, comprising: a body having at least one recess formed on one surface thereof, the body comprising a magnetic material; a coil including a winding portion disposed within the body and a lead disposed at least partially in the at least one recess, and At least one lead frame disposed on the one surface of the body, the at least one lead frame including an inner surface in contact with the lead and an outer surface opposite the inner surface, Wherein the inner surface of the at least one leadframe is coplanar with the one surface of the body.
14. 14. The coil assembly of claim 13, wherein the at least one lead frame covers the leads and is not disposed in the at least one recess.
15. 15. The coil assembly of claim 13 wherein, The body includes first and second surfaces opposite to each other in a first direction, third and fourth surfaces opposite to each other in a second direction, the at least one lead frame includes first and second lead frames spaced apart from each other in the first direction, and the at least one recess is formed on the third surface of the body.
16. 16. The coil assembly of claim 15, wherein: The at least one recess includes a first recess and a second recess spaced apart from each other in the first direction on the third surface of the body, The first recess extends from the third surface to the first surface of the body, and The second recess extends from the third surface to the second surface of the body.
17. 17. A coil assembly, comprising: A main body including a magnetic material, the main body including first and second surfaces opposing each other in a first direction, third and fourth surfaces opposing each other in a second direction, and fifth and sixth surfaces opposing each other in a third direction, wherein the first and third surfaces have first recesses formed thereon, and the second and third surfaces have second recesses formed thereon; A coil including a winding portion provided in the main body, and a first lead and a second lead extending in the first direction from both ends of the winding portion, bending, and extending along the first recess and the second recess, respectively; A first lead frame and a second lead frame disposed on the main body to be spaced apart from each other in the first direction, the first lead frame being in surface contact with an outer surface of the first lead disposed in the first recess, the second lead frame being in surface contact with an outer surface of the second lead disposed in the second recess, Wherein at least a portion of the first lead frame is disposed outside the first surface, the first surface being an outermost surface of the body, and at least a portion of the second lead frame is disposed outside the second surface, the second surface being another outermost surface of the body.
18. 18. The coil assembly of claim 17, wherein the first lead frame includes an anchor embedded in the body and covering the first lead, and The second lead frame includes an anchor embedded in the body and covering the second lead.
19. 19. The coil assembly of claim 18, wherein a portion of the first lead is disposed in an interior slot of the anchor of the first lead frame, and A portion of the second lead is disposed in an interior groove of the anchor of the second lead frame.
20. 20. The coil assembly of claim 17, wherein each of the first and second lead frames includes an anchor embedded in the body, the anchor including at least one protrusion having an L-shape.

Description

Coil assembly The present application claims the benefit of priority from korean patent application No. 10-2024-0159160 filed on 11 months 2024 at 11, the disclosure of which is incorporated herein by reference in its entirety. Technical Field The present disclosure relates to a coil assembly. Background An inductor (a coil assembly) is a representative passive electronic component used in an electronic device with a resistor and a capacitor. Recently, the market for high current power inductors for applications such as Artificial Intelligence (AI), electrical fields, and robotics has increased, and in particular, as the current and voltage used in electronic devices have increased, the importance of the efficiency of the inductor devices has become significant. The medium and large power inductors include a magnetic body, a coil, and a lead frame. The lead frame forms an L-shaped electrode by a bending process, and a recess is generally formed on a surface of the magnetic body on which the lead frame is disposed, so that the lead frame is caught in the surface of the magnetic body without steps. Disclosure of Invention An aspect of the present disclosure is to provide a coil assembly in which vibration resistance is enhanced and bonding between a lead frame and a coil is improved. Another aspect of the present disclosure is to provide a coil assembly capable of easily securing a bonding strength with a substrate when mounted on the substrate. According to one aspect of the present disclosure, a coil assembly includes a body including first and second surfaces opposite to each other in a first direction, third and fourth surfaces opposite to each other in a second direction, and fifth and sixth surfaces opposite to each other in a third direction, wherein at least one recess is formed on at least one of the first, second, third, and fourth surfaces, and the body includes a magnetic material, a coil including a winding portion disposed within the body and at least one lead disposed at least partially in the at least one recess, and first and second lead frames disposed on the body, spaced apart from each other in the first direction, and connected to the at least one lead. The ratio a/b is equal to or greater than 0.042 and equal to or less than 0.502, wherein a is an average length of the at least one recess in the third direction and b is an average length of the first and second lead frames in the third direction. According to another aspect of the present disclosure, a coil assembly includes a body having at least one recess formed on one surface of the body and including a magnetic material, a coil including a winding disposed within the body and a lead disposed at least partially in the at least one recess, and at least one lead frame disposed on the one surface of the body and including an inner surface in contact with the lead and an outer surface opposite the inner surface. The inner surface of the at least one leadframe is coplanar with the one surface of the body. According to still another aspect of the present disclosure, a coil assembly includes a body including a magnetic material, the body including first and second surfaces opposite to each other in a first direction, third and fourth surfaces opposite to each other in a second direction, and fifth and sixth surfaces opposite to each other in a third direction, wherein the first and third surfaces have first recesses formed thereon and the second and third surfaces have second recesses formed thereon, a coil including a winding portion provided in the body, and first and second leads extending in the first direction from both ends of the winding portion, respectively, bent and extending along the first and second recesses, respectively, and first and second lead frames provided on the body, spaced apart from each other in the first direction, the first and second lead frames being in contact with an outer surface of the first lead provided in the first recess, the second lead frames being in contact with an outer surface of the second lead provided in the second recess. At least a portion of the first lead frame is disposed outside the first surface, the first surface being an outermost surface of the body, and at least a portion of the second lead frame is disposed outside the second surface, the second surface being another outermost surface of the body. Drawings The above and other aspects, features and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings in which: Fig. 1 is a perspective view illustrating a coil assembly according to a first embodiment of the present disclosure; Fig. 2 is a diagram illustrating a lead frame and leads of fig. 1; fig. 3 is a perspective view showing the body of fig. 1 before bending the lead frame; fig. 4 is a diagram illustrating the coil assembly of fig. 1 viewed in the Z-direction; FIG. 5 is a cro