Embedded PCB Inductor with Magnetic Layer for High-Frequency Power Efficiency
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Solution Overview
Problem
There is a demand for a printed circuit board with an inductor function that maintains high permeability at high frequencies, as existing solutions face challenges in power efficiency due to increased power supply switching frequencies in PMICs, leading to issues with resistance and size considerations.
Innovation Solution
A novel printed circuit board structure incorporating a magnetic member with a magnetic layer, a core layer, and planar spiral coil patterns, where the magnetic member is embedded within the core layer and covered by build-up layers, allowing for improved inductance performance by minimizing the electrical path and maintaining high permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If power supply switching frequency is increased to improve power efficiency, then power efficiency is improved, but inductance performance deteriorates at high frequencies
Solution Approach 1:
The patent changes the magnetic material parameters by using a magnetic layer with specific permeability characteristics that maintains high inductance performance at high frequencies, enabling the inductor to function effectively with increased switching frequencies while preserving power efficiency
Solution Approach 2:
The patent employs a composite structure combining a magnetic layer with specific magnetic properties and a non-magnetic base layer, creating a composite material system that achieves both high power efficiency and maintained inductance performance at elevated frequencies
2Area of stationary object
If inductor size is reduced to minimize package area, then area is reduced, but inductance performance deteriorates
Solution Approach 1:
The patent utilizes magnetic layers with optimized permeability parameters that enable high inductance values to be achieved within reduced physical dimensions, allowing compact inductor designs without sacrificing inductance performance
Solution Approach 2:
The patent transitions from planar inductor designs to three-dimensional stacked configurations with multiple coil patterns at different levels, utilizing the vertical dimension to increase inductance density and maintain performance while reducing footprint area
3Loss of energy
If electrical path is minimized to reduce resistance, then resistance is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent divides the inductor structure into segmented coil patterns distributed across multiple layers, with each segment contributing to the overall inductance while maintaining short current paths, thereby reducing resistance through optimized current distribution
Solution Approach 2:
The patent implements nested conductive vias that pass through magnetic members to electrically connect coil patterns across different layers, creating compact current paths that minimize resistance while integrating seamlessly into the multilayer structure
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 proposed structure enhances inductance performance while reducing the size and maintaining high permeability at high frequencies, addressing the limitations of existing solutions by embedding the inductor within the circuit board.
Implementation Method 1
a magnetic member including a magnetic layer
Implementation Method 2
a magnetic member including a magnetic layer
Implementation Method 3
a first coil pattern disposed above the magnetic member, and including a planar spiral structure; and a second coil pattern disposed below the magnetic member, and including a planar spiral structure
Data Source
AI summary
A printed circuit board includes a magnetic member including a magnetic layer, a first coil pattern disposed above the magnetic member, and having a planar spiral structure, and a second coil pattern disposed below the magnetic member, and having a planar spiral structure.