Encapsulated Magnetic Core Inductor for Efficient Power Delivery
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Solution Overview
Problem
Legacy inductors with air cores in substrate assemblies fail to meet the increasing power delivery efficiency requirements in advanced server architectures.
Innovation Solution
A substrate assembly with an encapsulated magnetic feature, where a magnetic core is integrated within the base substrate, allowing a portion of the coil to extend through the magnetic feature, enhancing the inductor's efficiency by using ferromagnetic materials and dielectric regions for improved magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If air core inductors are used in substrate assemblies, then the device structure remains simple, but the power delivery efficiency is insufficient
Solution Approach 1:
The magnetic feature is encapsulated within the base substrate, with the coil extending through the magnetic feature. This nested configuration integrates the magnetic core inside the substrate structure, creating a compact inductor that improves power delivery efficiency while maintaining a space-efficient design suitable for advanced server architectures
Solution Approach 2:
The inductor combines ferromagnetic materials for the magnetic feature with dielectric regions and conductive coil materials. This composite material approach enhances the magnetic permeability and overall efficiency of the inductor, resolving the contradiction between energy efficiency and structural simplicity by integrating multiple functional materials into a unified structure
2Loss of energy
If magnetic features are encapsulated within the base substrate, then the inductor efficiency is improved, but the manufacturing process complexity increases
Solution Approach 1:
The magnetic feature is formed within the base substrate before the coil is constructed. This preliminary action allows the magnetic core to be pre-positioned and encapsulated, simplifying subsequent coil formation processes and enabling more efficient manufacturing despite the enhanced inductor efficiency achieved through the magnetic feature
Solution Approach 2:
The magnetic feature, dielectric regions, and coil structures are merged into a single integrated inductor assembly. This consolidation reduces the number of separate manufacturing steps and assembly operations, thereby improving ease of manufacture while maintaining the high efficiency benefits of the encapsulated magnetic feature
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 provides greater efficiency for power delivery inductors, surpassing the limitations of air core inductors by utilizing a magnetic core that enhances the inductor's performance in substrate assemblies.
Implementation Method 1
A substrate assembly with an encapsulated magnetic feature, where a magnetic core is integrated within the base substrate, allowing a portion of the coil to extend through the magnetic feature, enhancing the inductor's efficiency by using ferromagnetic materials and dielectric regions for improved magnetic permeability
Data Source
AI summary
Apparatuses, systems and methods associated with a substrate assembly with an encapsulated magnetic feature for an inductor are disclosed herein. In embodiments, a substrate assembly may include a base substrate, a magnetic feature encapsulated within the base substrate, and a coil, wherein a portion of the coil extends through the magnetic feature. Other embodiments may be described and/or claimed.