Rolled-Up Electromagnetic Component for On-Chip Power Density
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Solution Overview
Problem
Current technologies face challenges in maximizing power density and minimizing size and cost of inductors for magnetic induction applications, particularly in achieving high power handling with small footprints, due to conflicting design requirements.
Innovation Solution
The development of rolled-up electromagnetic components using a multilayer sheet in a rolled configuration with a soft magnetic material integrated into the core, employing self-rolled-up membrane (S-RuM) technology and geometric transformation of 2D sheets into 3D microtubes, which enhances magnetic field distribution and energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional planar inductor designs are used, then manufacturing simplicity is maintained, but power density and magnetic field strength are limited
Solution Approach 1:
The patent transforms the traditional planar 2D inductor structure into a 3D rolled-up cylindrical configuration. This dimensional change allows the conductive traces to form multiple turns around a core, significantly increasing the magnetic field generation capability and power density while maintaining compatibility with standard planar fabrication processes. The rolled-up structure enables vertical stacking of magnetic fields, achieving high power density without proportionally increasing footprint area.
Solution Approach 2:
The patent embeds a soft magnetic core material within the rolled-up conductive structure, creating a nested configuration where the magnetic core is surrounded by multiple turns of conductive traces. This nested arrangement maximizes the utilization of magnetic flux by confining it within the high-permeability core, thereby enhancing power density and magnetic field strength without requiring proportional increases in conductor material or device area.
2Area of stationary object
If inductor size is reduced for small footprint applications, then area is minimized, but power handling ability deteriorates
Solution Approach 1:
By transitioning from a planar to a rolled-up 3D structure, the patent achieves multiple turns of conductive traces within a compact footprint. The vertical stacking of turns in the rolled configuration allows the inductor to handle higher power levels without increasing the planar footprint area, as the additional turns are arranged in the vertical dimension rather than spreading out horizontally.
Solution Approach 2:
The patent employs a composite structure combining conductive traces with a soft magnetic core material. This composite configuration enhances the power handling ability within a small footprint by utilizing the high magnetic permeability of the core material to concentrate and enhance magnetic flux, thereby increasing inductance and power handling capability without proportionally increasing the device area.
3Quantity of substance
If more turns are added to increase inductance, then inductance density improves, but device area increases
Solution Approach 1:
The rolled-up structure enables multiple turns to be stacked vertically around the magnetic core, achieving high inductance density without requiring large planar areas. The cylindrical geometry allows turns to be arranged in the vertical dimension, concentrating the magnetic flux path through the core and achieving high inductance values within a compact footprint.
Solution Approach 2:
By nesting multiple turns of conductive traces around a magnetic core, the patent achieves high inductance density within a compact volume. The nested configuration ensures that magnetic flux generated by each turn is efficiently coupled through the high-permeability core, maximizing inductance per unit area and per unit volume.
4Power
If soft magnetic material is integrated into the core, then magnetic field strength increases, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates the soft magnetic core material during the fabrication process itself, depositing or forming the magnetic core layer on the substrate before rolling up the structure. This preliminary integration of the magnetic core eliminates the need for separate post-fabrication assembly steps, maintaining manufacturing simplicity while achieving enhanced magnetic field strength through the high-permeability core material.
Solution Approach 2:
The patent merges the magnetic core integration with the roll-up fabrication process, combining what would traditionally be separate steps into a unified manufacturing flow. The magnetic core is deposited and patterned on the same substrate as the conductive traces, then both are rolled up together in a single process, thereby achieving high magnetic field strength without significantly increasing manufacturing complexity.
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 results in high-density, large current-handling 3D coil structures capable of achieving milliTesla- to Tesla-level magnetic induction, offering improved inductance density and immunity to parasitic substrate effects, with potential applications in on-chip energy storage and RF/millimeter-wave inductors.
Implementation Method 1
Electrically controlled generation of strong magnetic induction (e.g., up to Tesla level) at room temperature
Implementation Method 2
a soft magnetic material disposed within the core
Data Source
AI summary
A rolled-up electromagnetic component for on-chip applications comprises: a multilayer sheet in a rolled configuration comprising at least one turn about a longitudinal axis; a core defined by a first turn of the rolled configuration; and a soft magnetic material disposed within the core, where the multilayer sheet comprises a conductive pattern layer on a strain-relieved layer. A method of making a rolled-up electromagnetic component for on-chip applications includes forming a rolled-up device comprising: a multilayer sheet in a rolled configuration having at least one turn about a longitudinal axis, where the multilayer sheet comprises a conductive pattern layer on a strain-relieved layer; and a core defined by a first turn of the rolled configuration. The method further includes introducing a soft magnetic material into the core.