Magnetic-Layer Inductor Via Structure for Stable Plating
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Solution Overview
Problem
The formation of vias in inductors with magnetic layers results in a large amount of molten solid magnetic particles, hindering the stable formation of plated layers, which affects the electrical connection to external devices.
Innovation Solution
The inductor design includes a via with an inner peripheral surface having an endless shape and a small amount of molten solid, ensuring a stable conductive member formation by maintaining the molten solid at 10% or less, and featuring a tapered surface that increases the cross-sectional area towards the principal surface, along with a process stabilization layer to enhance stability and connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a via is formed by laser irradiation to the magnetic layer, then the via can be created to enable electrical connection, but a large amount of molten solid magnetic particles remain on the inner peripheral surface of the via, hindering stable plated layer formation
Solution Approach 1:
The patent changes the physical-chemical parameters of the magnetic layer by adding binder resin and controlling the ratio of magnetic particles to binder resin (0.95:0.05 to 70:30 by volume). This parameter adjustment reduces molten solid generation during laser via formation while maintaining the layer's magnetic properties and structural integrity, enabling both via formation and stable plated layer deposition.
Solution Approach 2:
The patent creates a composite magnetic layer combining magnetic particles with binder resin. This composite structure allows the layer to maintain its magnetic functionality while the binder resin reduces excessive molten solid generation during laser processing. The composite material enables controlled via formation with minimal molten solid residue, solving the contradiction between via formation capability and plated layer formation stability.
2Quantity of substance
If the magnetic layer contains only magnetic particles, then the magnetic properties are maximized, but laser irradiation causes excessive molten solid that hinders conductive member formation
Solution Approach 1:
The patent adjusts the compositional parameters of the magnetic layer by introducing binder resin and controlling the volume ratio of magnetic particles to binder resin within 0.95:0.05 to 70:30. This parameter optimization maintains sufficient magnetic particle content for required magnetic properties while the binder resin suppresses excessive molten solid generation during laser processing, ensuring reliable conductive member formation.
Solution Approach 2:
The binder resin acts as an intermediary substance between magnetic particles during laser irradiation. It mediates the thermal response of the magnetic layer, absorbing and distributing heat to prevent excessive localized melting of magnetic particles. This intermediary function allows the layer to maintain magnetic properties while reducing molten solid that would otherwise hinder conductive member formation.
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 inductor achieves stable conductive member formation and reliable electrical connections to external devices, with improved processing stability and reduced risk of conductive wire deterioration.
Implementation Method 1
The slit is formed with a laser
Implementation Method 2
the irradiation of the laser to the magnetic layer causes a large amount of molten solid of the magnetic particles to remain on the inner peripheral surface of the via
Data Source
AI summary
An inductor includes a wire and a magnetic layer which has a via, having an inner peripheral surface. On a cross-section across the via, a first point and a second point are located at one side and the other side in a direction in which the first principal surface extends and are kept 50 μm away from a first edge on one side of the inner peripheral surface in the thickness direction, and a third point and a fourth point are located at one side and the other side in the extending direction and are kept 50 μm away from a second edge on the other side of the inner peripheral surface in the thickness direction. An area of a quadrangle having all four points as vertices and an area of the molten solid inside the quadrangle are obtained, along with a percent (S1/S0×100) of the area.