Micromagnetic Device Electroplating for High-Frequency Power Converters
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Solution Overview
Problem
Current methods for manufacturing integrated micromagnetic devices are not suitable for high-volume production due to issues with electrolyte life, uniformity of magnetic and conductive layer deposition, and repeatability of high-performance magnetic characteristics at high switching frequencies, leading to reliability and cost challenges.
Innovation Solution
A power converter design incorporating a micromagnetic device with a layered structure including insulating and conductive winding layers, and magnetic core layers formed using an electroplating process with a specific electrolyte and tooling system, enabling high-volume production and low-cost manufacturing with improved magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional electroplating processes are used to form magnetic core layers, then manufacturing cost is reduced, but electrolyte life is limited and deposition uniformity deteriorates
Solution Approach 1:
The patent modifies the electrolyte composition by adding specific additives and adjusting chemical parameters to extend electrolyte life while maintaining deposition quality. The electrolyte includes novel components that prevent degradation and maintain stability during prolonged electroplating operations, directly addressing the electrolyte life limitation of conventional processes.
2Ease of manufacture
If conventional electroplating processes are used to form magnetic core layers, then manufacturing cost is reduced, but deposition uniformity deteriorates
Solution Approach 1:
The patent optimizes electroplating parameters including current density, temperature, and electrolyte composition to achieve uniform magnetic core layer deposition. The modified electrolyte formulation and controlled plating conditions ensure consistent thickness and composition across the substrate surface, resolving the uniformity issue while maintaining cost-effectiveness.
Solution Approach 2:
The patent implements process monitoring and control mechanisms to maintain consistent deposition quality. By monitoring electrolyte composition and plating parameters in real-time, the system adjusts conditions to preserve deposition uniformity throughout production, preventing the quality deterioration that occurs in conventional uncontrolled processes.
3Device complexity
If conventional electroplating processes are used to form magnetic core layers, then manufacturing simplicity is maintained, but repeatability of magnetic characteristics deteriorates
Solution Approach 1:
The patent establishes tightly controlled electrolyte composition specifications and electroplating parameters that ensure repeatable magnetic core layer properties. The modified electrolyte formula and standardized process conditions produce consistent magnetic characteristics across batches, directly improving repeatability without significantly increasing process complexity.
4Use of energy by moving object
If micromagnetic devices are designed for high switching frequencies exceeding one megahertz, then power converter efficiency is improved, but manufacturing reliability deteriorates
Solution Approach 1:
The patent optimizes magnetic core layer composition and structure specifically for high-frequency operation. The electroplated magnetic layers are formulated with appropriate thickness, composition, and microstructure to minimize losses at switching frequencies exceeding one megahertz, enabling efficient power conversion while maintaining manufacturing reliability through the standardized electroplating process.
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 enables the production of micromagnetic devices with high-performance magnetic characteristics at switching frequencies exceeding one megahertz, ensuring dimensional stability and low internal stresses, thus supporting further processing steps and reducing manufacturing costs.
Implementation Method 1
a micromagnetic device with conductive and magnetic structures such as conductive windings and magnetic cores with micron-scaled dimensions
Implementation Method 2
magnetic core layers formed using an electroplating process with a specific electrolyte and tooling system, enabling high-volume production and low-cost manufacturing with improved magnetic characteristics
Data Source
AI summary
A power converter including a power train, a controller and a driver. In one embodiment, the power train includes a switch that conducts for a duty cycle and provides a regulated output characteristic for the power converter, and a micromagnetic device. The micromagnetic device includes a first conductive winding layer selectively formed above a first seed layer, and first and second magnetic core layers formed thereabove. The micromagnetic device also includes a second seed layer formed above the second magnetic core layer, and a second conductive winding layer formed above the second seed layer and in vias to the first conductive winding layer. The first and second conductive winding layers form a winding for the micromagnetic device. The controller provides a signal to control the duty cycle of the switch, and the driver provides a drive signal to the switch as a function of the signal from the controller.