Micromagnetic Core Plating Structure to Prevent Edge Horns

The patent divides the electroplating process into multiple sequential steps with different plating solutions and parameters. The first plating step uses a initial solution to build base thickness, followed by additional plating steps that progressively add magnetic material. This segmentation prevents the formation of pattern edge horns that occur in single-step thick plating, while still achieving the required thickness for high power conversion efficiency and magnetic performance.

The patent integrates multiple functional layers (seed layer, magnetic layers, insulating layers, conductive layers) in a nested configuration where each layer serves multiple purposes. The seed layer provides both adhesion and initial current distribution, while subsequent magnetic layers are deposited in a nested sequence that builds up the magnetic core structure. This nesting approach enables compact device dimensions while managing manufacturing complexity through a systematic layer-by-layer process.

The patent achieves high magnetic saturation flux density by systematically changing parameters across multiple layers including material composition (Fe-Co-B-P alloy ratios), layer thicknesses, and electroplating conditions (current density, temperature, pH). Each layer is optimized with specific parameter ranges that collectively deliver superior magnetic properties. The method manages manufacturing complexity by establishing controlled parameter windows that ensure repeatability and consistent magnetic performance across production batches.