Embedded Inductor with Ferromagnetic Coating
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Solution Overview
Problem
Current inductive components, such as discrete metal coil inductors and spiral metal track inductors in microelectronics, face challenges with unsatisfactory performance, bulkiness, and inability to integrate at the substrate level of integrated circuits, leading to inadequate inductive values and high losses.
Innovation Solution
The integration of a metal winding partially embedded in a ferromagnetic material, optionally combined with a non-magnetic material, within a coating, which enhances electromagnetic performance, reduces parasite resistance, and allows for compact, high-inductive components with improved quality factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If discrete metal coil inductors are used, then inductive values can be achieved, but the components become bulky and cannot be integrated at the substrate level
Solution Approach 1:
The metal winding is embedded within a ferromagnetic coating, nesting one component inside another to achieve high inductance in a compact volume. The ferromagnetic material surrounds and penetrates the metal winding, creating a nested structure that maximizes inductive performance while minimizing overall component size.
Solution Approach 2:
The invention combines metal winding with ferromagnetic coating material to create a composite inductive component. This composite structure integrates two different materials with complementary properties: the conductive metal winding and the high-permeability ferromagnetic coating, achieving superior inductive performance in a compact form factor.
2Reliability
If spiral metal tracks are used in substrate layers, then integration is improved, but electromagnetic performance deteriorates due to non-magnetic dielectric materials and low winding numbers
Solution Approach 1:
The invention applies composite materials by combining metal winding with ferromagnetic coating. This composite structure enhances electromagnetic performance through the high magnetic permeability of the ferromagnetic material, which compensates for the limitations of using simple spiral tracks in non-magnetic dielectric substrates.
Solution Approach 2:
The invention changes the magnetic parameter of the surrounding medium by introducing ferromagnetic coating material. This parameter change (from non-magnetic dielectric to ferromagnetic) dramatically improves electromagnetic performance, quality factor, and reduces losses without requiring increased winding complexity.
3Loss of energy
If metal windings are embedded in ferromagnetic material, then parasite resistance and magnetic flux losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The ferromagnetic coating is applied to the support before the metal winding is formed. This preliminary action allows the coating to be in place to guide and contain the metal deposition process, ensuring proper embedding while simplifying the overall manufacturing sequence.
Solution Approach 2:
The ferromagnetic coating acts as an intermediary material between the support and the metal winding. It provides a magnetic pathway that reduces flux losses and serves as a matrix for embedding the winding, while also facilitating the manufacturing process by enabling subsequent removal of the support.
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
This approach enables the creation of compact, high-inductive components with improved electromagnetic performance, reduced losses, and cost-effective manufacturing, suitable for various microelectronic applications, including transformers and radiofrequency uses.
Implementation Method 1
at least one metal winding at least partially embedded in a coating including at least one ferromagnetic material
Implementation Method 2
at least one metal winding at least partially embedded in a coating including at least one ferromagnetic material
Data Source
AI summary
An integrated circuit device includes at least one inductive component with at least one integrated metal winding that is at least partially embedded in a coating. The coating includes at least one ferromagnetic material. The coating optionally includes a non-magnetic material, for example a dielectric.