Air Core Inductor Structural Integrity via Sacrificial Core
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Solution Overview
Problem
Current methods for producing air core inductors are impractical due to their flimsy nature, requiring costly modifications to IC manufacturing processes and lacking structural integrity, making them unsuitable for mass production.
Innovation Solution
A conducting coil with an air core is manufactured using existing IC processes, where lower and upper conducting bands are supported by a sacrificial core material and coated with a curable substance or passivation layer to provide structural integrity after the core is removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air core conducting coils are produced using existing techniques, then the inductors can have high-Q values, but the coils lack structural integrity and are flimsy during fabrication
Solution Approach 1:
A sacrificial core material is introduced as an intermediary supporting structure during fabrication. This temporary core provides mechanical support to the conducting bands during manufacturing processes, and is later removed to leave the desired air core configuration. This mediator enables production of air core inductors with proper structural integrity during fabrication.
Solution Approach 2:
The conducting bands are formed and positioned around the sacrificial core material before the core is removed. This preliminary formation of the conducting structure while supported by the core ensures proper geometric configuration and structural integrity prior to final air core completion.
2Reliability
If shaped conducting bands are used to form air core inductors, then high-Q values can be achieved, but costly modifications to IC manufacturing processes are required
Solution Approach 1:
The invention uses standard planar conducting band formation techniques already present in IC manufacturing processes. The same photolithography and deposition tools used for creating interconnect patterns are employed to form the inductor conducting bands, eliminating the need for specialized shaped band equipment or process modifications.
Solution Approach 2:
The sacrificial core material serves as a temporary placeholder that enables standard planar processing techniques to create what would otherwise require complex three-dimensional shaped bands. The core allows conventional two-dimensional fabrication methods to produce functional air core inductors.
3Reliability
If the sacrificial core material is removed to create an air core, then the desired electrical properties are achieved, but the conducting coil becomes flimsy and lacks structural support
Solution Approach 1:
A coating material is applied to the conducting bands before or during the sacrificial core removal process. This coating provides ongoing structural support to the conducting bands after the sacrificial core is removed, preventing the coil from becoming flimsy while maintaining the air core configuration for optimal electrical performance.
Solution Approach 2:
The conducting bands are combined with a coating material to form a composite structure. The coating material (such as passivation layer or curable substance) provides mechanical strength and structural support, while the conducting bands maintain their electrical function in the air core configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for the production of robust air core inductors with high-Q values and reduced parasitic capacitance, enabling mass production without altering existing IC manufacturing processes, ensuring structural integrity and reliability.
Implementation Method 1
coated with a curable substance or passivation layer to provide structural integrity after the core is removed
Data Source
AI summary
Solid state components having an air core and methods of producing such components are presented. An air core component preferably has lower conducting bands, upper conducting, and conducting posts that collectively form a conducting coil. A coating material placed at least over the upper bands of the coil provides structural support for the coil. The coil can be built around or in a sacrificial core material that can be removed leaving an air core behind.