Planar Magnetic Core on Multilayer Substrate
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Solution Overview
Problem
Current methods for producing magnetic devices with small dimensions are not practical for high-volume, low-cost manufacturing, as they require complex and costly processes such as milling precise apertures in printed wiring boards and involve discrete magnetic components that are larger than needed for compact applications.
Innovation Solution
A multilayer substrate with planar windings and a molded ferromagnetic structure is used, where a polymer solution containing a ferromagnetic component, such as nanocrystalline nickel zinc ferrite, is deposited to form a magnetic core, eliminating the need for discrete magnetic components and allowing for compact, low-profile designs without additional interconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If discrete magnetic devices with traditional structures are used, then sufficient magnetic flux density is achieved, but the device size becomes too large for compact applications
Solution Approach 1:
The patent transitions from traditional three-dimensional discrete magnetic devices to a planar two-dimensional structure integrated on a printed wiring board. The magnetic core and windings are arranged in flat layers, enabling compact integration while maintaining magnetic performance through optimized planar geometry and multiple metallic layers.
Solution Approach 2:
The invention merges the magnetic core, windings, and support structure into a single integrated planar device. The ferromagnetic material is deposited directly on the printed wiring board to form the core, with metallic layers forming windings that are electrically connected through vias, eliminating the need for separate discrete components and reducing overall device volume.
2Manufacturing precision
If complex aperture milling is performed to insert and secure magnetic cores to PWB, then precise core positioning is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical aperture milling process with a deposition-based approach. The ferromagnetic material is deposited directly onto the printed wiring board in the desired core shape and position, eliminating the need for mechanical milling operations. This can be achieved through techniques such as screen printing, spray deposition, or sputtering, which are more cost-effective for high-volume manufacturing.
Solution Approach 2:
The magnetic core structure is formed as part of the board fabrication process itself, rather than as a separate post-processing step. The ferromagnetic material is deposited during the board manufacturing sequence, integrating core formation with the lamination and metallization processes, thereby eliminating subsequent assembly operations.
3Volume of moving object
If planar windings are formed directly in buried metallic layers of PWB, then compact device size is achieved, but complex and costly manufacturing operations are required
Solution Approach 1:
The metallic layers in the printed wiring board serve multiple functions: they provide both the magnetic core structure and the winding conductors. The same lamination and metallization processes that create the board structure also form the functional magnetic components, eliminating the need for separate winding operations and reducing manufacturing complexity.
4Volume of moving object
If discrete magnetic devices in IC packages are used, then power conversion functionality is achieved, but the device size is larger than needed for low power compact applications
Solution Approach 1:
The patent optimizes the magnetic device structure for specific local applications by tailoring the core geometry, winding configuration, and material composition to match the requirements of low-power compact applications. The planar structure allows for customized designs that can be precisely matched to the power and space constraints of specific electronic devices.
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 approach enables the production of compact magnetic devices with enhanced inductance and power density, suitable for high-volume production, while reducing manufacturing costs and size constraints, meeting the needs of compact electronic products.
Implementation Method 1
a polymer solution containing a ferromagnetic component, such as nanocrystalline nickel zinc ferrite, is deposited to form a magnetic core
Data Source
AI summary
An embodiment of the invention relates to an apparatus including a magnetic device and a related method. A multilayer substrate is constructed with a winding formed in a metallic layer, an electrically insulating layer above the metallic layer, and a via formed in the electrically insulating layer to couple the winding to a circuit element positioned on the multilayer substrate. A depression is formed in the multilayer substrate, and a polymer solution, preferably an epoxy, containing a ferromagnetic component such as nanocrystaline nickel zinc ferrite is deposited within a mold positioned on a surface of the multilayer substrate above the winding and in the depression. An integrated circuit electrically coupled to the winding may be located on the multilayer substrate. The multilayer substrate may be a semiconductor substrate or a printed wiring board, and the circuit element may be an integrated circuit formed on the multilayer substrate.