Built-in-circuit substrate magnetizing Ni layer
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Solution Overview
Problem
Built-in-circuit substrates used in communication systems experience intermodulation distortion due to RF signals interacting with the Ni layer, leading to noise and degraded communication characteristics when multiple RF signals with different frequencies are used.
Innovation Solution
A built-in-circuit substrate configuration that includes a substrate body with an electrical circuit, an outer electrode with a Ni layer, and a magnet arranged on the substrate body to magnetize the Ni layer to its saturation region, preventing intermodulation distortion by applying an external magnetic field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Sn layer is made thin to improve solder wetability, then the RF signal flows into the Ni layer causing intermodulation distortion, but making the Sn layer thicker prevents RF signal penetration while maintaining solder wetability
Solution Approach 1:
The patent applies an external magnetic field to magnetize the Ni layer, converting the harmful intermodulation distortion effect into a beneficial saturated state. By saturating the magnetic domains in the Ni layer, the material becomes linear and no longer generates intermodulation distortion when RF signals pass through it, thus converting a harmful nonlinear magnetic effect into a beneficial linear state.
Solution Approach 2:
The patent changes the magnetic state parameter of the Ni layer from unsaturated to saturated by applying an external magnetic field. This parameter change transforms the magnetic characteristics of the Ni layer, eliminating the intermodulation distortion while maintaining the thin Sn layer configuration for good solder wetability.
2Adaptability or versatility
If multiple RF signals with different frequencies are used to improve communication functionality, then intermodulation distortion is generated in the Ni layer degrading communication characteristics, but limiting to single frequency reduces functionality
Solution Approach 1:
The external magnetic field saturates the Ni layer's magnetic domains, converting the harmful intermodulation distortion that occurs with multiple RF signals into a beneficial linear magnetic state. This allows the system to support multiple frequency signals for improved communication functionality while eliminating the distortion that would degrade communication characteristics.
3Object-generated harmful factors
If the Ni layer is removed to eliminate intermodulation distortion, then solder wetability is improved, but the protective function and diffusion barrier are lost
Solution Approach 1:
Instead of removing the Ni layer, the patent magnetizes it to saturation using an external magnetic field. This converts the harmful nonlinear magnetic properties into beneficial linear properties, eliminating intermodulation distortion while preserving the Ni layer's protective function and diffusion barrier properties.
Solution Approach 2:
The patent changes the magnetic state parameter of the Ni layer from unsaturated to saturated, which eliminates intermodulation distortion while maintaining all the functional benefits of the Ni layer including protection and diffusion barrier properties.
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 solution effectively prevents noise caused by intermodulation distortion, improving communication characteristics by ensuring the Ni layer operates within its saturation region, even when multiple RF signals are present, and reduces the profile of the substrate while enhancing the selection flexibility of the magnet's placement.
Implementation Method 1
an external magnetic field that magnetizes the Ni layer of the outer electrode to the saturation region of magnetic flux density on a magnetic hysteresis curve of the Ni layer is applied by the magnet arranged on the substrate body
Implementation Method 2
the Ni layer, which is formed of a magnetic material (ferromagnetic material), has a magnetic flux density-magnetic field strength characteristic (B-H characteristic) that is expressed by a magnetic hysteresis curve
Implementation Method 3
when an RF signal flows to an outer electrode, the RF signal attempts to flow to the Sn layer, which is the outermost layer of the outer electrode, due to the skin effect
Data Source
AI summary
A built-in-circuit substrate includes a substrate body, an electrical circuit including inner electrodes provided inside the substrate body and to which an RF signal is input, outer electrodes which are provided on the substrate body so as to be connected to the electrical circuit and which each include an underlying metal layer and a nickel layer covering at least a portion of the underlying metal layer, and a permanent magnet which is arranged on the substrate body. Thus, noise caused by intermodulation distortion generated in the nickel layers of the outer electrodes is prevented.