Electronic transformer/inductor devices and methods for making same

Abstract

The present invention relates to a method of forming inductive elements, such as inductors, chokes and transformers used as an integral part of the manufacture of PCBs or FLEXs, preferably from ferromagnetic materials. In a preferred embodiment, holes (56, 58) are formed through the ferromagnetic substrate (50) and plated with a conductive material. The placement of these holes and subsequent design will form the inductive element in the plane of the medium in which the device is formed; the substrate (50) for the magnetic core (90). By employing this approach, the inductive element can be minimized to a physical size compatible with the demands of modern surface mount technology (SMT) for integrated circuits (ICs). This process also allows these components to be fabricated using mass production techniques, thereby avoiding the need to manipulate individual devices during the fabrication process. In another preferred embodiment, a series of thin, concentric high permeability rings (315) are etched on the substrate (330) to provide high permeability transformers and inductors with minimal eddy current effects.

Description

field of invention [0001] The present invention relates to inductive components and methods of manufacturing these components. Background of the invention [0002] Inductive components are usually manufactured with a ferromagnetic core and a coil of insulated wire. Ferromagnetic cores are usually toroidal cores, rod cores, or assemblies consisting of a ferromagnetic portion in the shape of the lower part of the E and a ferromagnetic cap connecting the three legs of the E, as shown in Figure 1. [0003] Toroidal and rod cores are wound manually or automatically with insulated copper wire to form a large number of multi-turn coils for a transformer or a single coil for an inductor. The assembly is then typically encapsulated to protect the copper wires. Circuit contacts are formed by the soldered ends of the wires as required by the application. This solution has high labor costs due to handling the individual components. There is also considerable variability in electroni...

AI Technical Summary

Problems solved by technology

[0005] The power transformer constructed as shown also has the disadvantage that the heat generated by the resistive losses in the coils is not easily dissipated because the E-core and cap separate these coils from the heat sink

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