Inductor-Embedded Substrate Manufacturing via Magnetic Paste Segmentation
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Solution Overview
Problem
Existing methods for manufacturing inductor-embedded substrates are limited by the use of iron oxide filler due to its inferior magnetic properties and susceptibility to chemical etching solutions, which can degrade the magnetic material resin.
Innovation Solution
A method involving filling a through-hole with a magnetic paste, laminating a metal-foil-attached resin sheet, and curing to form an insulating layer without iron oxide filler, allowing the use of magnetic powders like pure iron or iron alloys for enhanced magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If iron oxide filler is used as magnetic powder, then resistance to chemical etching solution is improved, but magnetic properties such as relative permeability deteriorate
Solution Approach 1:
The patent divides the structure into separate functional layers: a magnetic layer containing iron powder for magnetic properties, and a protective resin layer for chemical resistance. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The resin layer acts as an intermediary between the magnetic layer and the chemical etching environment. It protects the iron powder from direct chemical exposure while allowing the magnetic properties to function effectively.
2Stability of the object's composition
If iron filler is used as magnetic powder, then magnetic properties are improved, but susceptibility to chemical etching solution increases causing degradation
Solution Approach 1:
The patent separates the magnetic material (iron powder) from the chemical environment by creating distinct layers. The magnetic layer contains the iron powder for superior magnetic properties, while the resin layer provides chemical protection.
Solution Approach 2:
The resin layer serves as a protective intermediary that shields the iron powder from chemical etching solutions, preventing degradation while maintaining excellent magnetic properties.
3Reliability
If magnetic powder content in resin composition is increased to increase inductance, then inductance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent separates the magnetic material into a dedicated magnetic layer rather than mixing it throughout the entire resin composition. This allows high magnetic powder content in the magnetic layer for high inductance, while the overall manufacturing process remains manageable through layer-by-layer construction.
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 method enables the production of inductor-embedded substrates with superior magnetic properties and high inductance without the limitations of iron oxide filler, preventing degradation from etching solutions.
Implementation Method 1
a resin composition containing magnetic powder is filled into a first through-hole
Implementation Method 2
curing the resin composition layer to form an insulation layer
Data Source
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AI summary
A method of manufacturing an inductor embedded substrate, the method comprising the following process (A) to process (C) in this order: (A) filling a resin composition containing magnetic powder into a first through-hole that is formed in a substrate having first and second main surfaces to run between the first and the second main surfaces to form a magnetic layer; (B) laminating a metal foil-attached resin sheet containing metal foil and a resin composition layer onto the substrate such that the resin composition layer is bonded to the substrate, and curing the resin composition layer to form an insulation layer; and (C) forming a second through-hole that runs through the metal foil, the insulation layer, and the magnetic layer.