Integrated Magnetic Core and Winding Lamina for IC Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a challenge in developing small, affordable isolation transformers suitable for integration with integrated circuits, as existing wire wound transformers are large and expensive, and shrinking their size while maintaining high isolation and reliability is difficult.
Innovation Solution
A microelectronic device is designed with a first magnetic core segment and a second magnetic core segment, featuring a winding lamina between them, where the first magnetic core segment includes a winding support portion and an extension portion both made of ferromagnetic material, with a filler material between the winding lamina and the core segment to enhance reliability, and external leads with electrical connections to the winding loops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire wound transformers are used, then isolation and reliability are maintained, but size and cost increase
Solution Approach 1:
The magnetic core is divided into multiple segments (first magnetic core segment, second magnetic core segment, third magnetic core segment) that can be separately manufactured and then assembled. This segmentation enables smaller individual components to be combined into a complete transformer structure, achieving high isolation and reliability through proper magnetic coupling while maintaining a compact overall size suitable for integration with integrated circuits.
Solution Approach 2:
The winding lamina is positioned between magnetic core segments in a nested arrangement where the winding structure is integrated within the magnetic core assembly. This nesting approach allows the transformer components to be tightly packed together, maximizing space utilization and achieving compact dimensions while maintaining the necessary magnetic pathways for high isolation performance.
2Volume of moving object
If wire wound transformers are shrunk, then size is reduced, but isolation and reliability deteriorate
Solution Approach 1:
The transformer employs composite construction combining multiple magnetic core segments with different geometries (winding support portion, extension portion, and interconnecting portions) and winding lamina structures. This composite approach allows each component to be optimized for its specific function while working together to maintain high isolation and reliability in a compact package, avoiding the degradation that would result from simply shrinking a traditional wire wound transformer.
3Ease of manufacture
If traditional wire winding method is used, then electrical connections are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The traditional mechanical wire winding process is replaced with a laminated construction approach where conductive windings are formed as planar structures on the winding support portion. This substitution eliminates complex winding operations, reduces manufacturing steps, and enables more straightforward integration with semiconductor fabrication processes, thereby reducing both manufacturing complexity and cost while improving productivity and suitability for IC integration.
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 configuration allows for a compact, reliable, and cost-effective magnetic component with improved reliability by eliminating voids and providing a low magnetic reluctance path, suitable for integration with integrated circuits.
Implementation Method 1
providing a low magnetic reluctance path
Implementation Method 2
The first magnetic core segment includes a winding support portion that includes ferromagnetic material
Implementation Method 3
The winding lamina is attached to the winding support portion by an adhesive material
Data Source
AI summary
A microelectronic device includes a magnetic component having a first magnetic core segment and a second magnetic core segment, with a winding lamina between them. The first magnetic core segment includes a winding support portion with ferromagnetic material. The winding lamina is attached to the winding support portion. The first magnetic core segment also includes an extension portion with ferromagnetic material extending from the winding support portion. The winding lamina has winding loops of electrically conductive material that surround ferromagnetic material. A filler material is formed between the winding lamina and the first magnetic core segment, contacting both the winding lamina and the first magnetic core segment. The second magnetic core segment is attached to the extension portion of the first magnetic core segment. The second magnetic core segment includes ferromagnetic material. The winding loops are electrically coupled to external leads through electrical connections.