Segmented Ceramic Inductor Structure for Stable Wide-Frequency Inductance
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Solution Overview
Problem
Existing inductor technologies face challenges in achieving high inductance per unit area while minimizing frequency dependence and maintaining stable electrical characteristics, particularly in high-density semiconductor applications where organic materials limit magnetic permeability and conductivity variations.
Innovation Solution
The inductor design incorporates a conductor portion made of sintered metal and a magnetic substance portion made of ceramics, with multiple magnetic substance segments of different materials arranged to optimize permeability peaks at various frequencies, reducing frequency dependence and enhancing inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic particles are dispersed in resin to form magnetic substance portion, then ease of manufacture is improved, but magnetic permeability is limited and inductance sufficiency deteriorates
Solution Approach 1:
The patent changes the material state of the magnetic substance portion from dispersed particles in resin to a sintered body with controlled porosity. By controlling the porosity ratio (void volume to total volume) to be 0.05 or more and less than 0.5, the patent achieves both high magnetic permeability and mechanical integrity, resolving the contradiction between ease of manufacture and inductance sufficiency
Solution Approach 2:
The patent uses a composite structure combining sintered magnetic substance with conductor portion. The sintered magnetic substance contains voids that can be filled with conductor material, creating a composite structure that enhances both magnetic permeability and electrical conductivity, thereby improving inductance while maintaining manufacturability
2Productivity
If inductor size is reduced for high-density integration, then productivity is improved, but inductance sufficiency deteriorates
Solution Approach 1:
The patent utilizes the vertical dimension by forming the conductor portion within the porous structure of the sintered magnetic substance. This three-dimensional arrangement allows the conductor to extend through the magnetic substance in the thickness direction, increasing the effective inductance path length without increasing the planar footprint, thus enabling high-density integration while maintaining sufficient inductance
Solution Approach 2:
The patent employs porous sintered magnetic substance with controlled porosity (0.05 ≤ porosity ratio < 0.5). The porous structure provides space for conductor integration while maintaining high magnetic permeability. This allows compact inductor design with sufficient inductance for high-density integration
3Ease of manufacture
If conductor portion and magnetic substance portion are formed separately and then assembled, then ease of manufacture is improved, but electrical characteristic stability deteriorates due to conductivity variations
Solution Approach 1:
The patent merges the formation of the conductor portion and magnetic substance portion into a single sintering process. The green bodies of both materials are stacked and sintered simultaneously, creating strong interfacial bonding and eliminating variability from separate assembly operations. This integrated process ensures stable electrical characteristics while maintaining manufacturing ease
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 design effectively suppresses frequency dependence of inductance while maintaining sufficient inductance and stability of electrical characteristics, allowing for high-density inductor integration in semiconductor elements.
Implementation Method 1
a conductor portion made of a sintered material containing sintered metal
Implementation Method 2
a magnetic substance portion made of ceramics and including a plurality of magnetic substance segments
Implementation Method 3
an inductor including: a conductor portion made of a sintered material containing sintered metal; and a magnetic substance portion made of ceramics
Data Source
AI summary
An inductor includes a conductor portion and a magnetic substance portion. The conductor portion is made of a sintered material containing sintered metal. The magnetic substance portion is made of ceramics, and includes a plurality of magnetic substance segments disposed at different positions in one direction. Each of the magnetic substance segments is penetrated by the conductor portion and inorganically bonded to the conductor portion. The plurality of magnetic substance segments include at least one first magnetic substance segment and at least one second magnetic substance segment. The at least one first magnetic substance segment is made of a first magnetic material with a permeability having a peak at a first frequency. The at least one second magnetic substance segment is made of a second magnetic material with a permeability having a peak at a second frequency different from the first frequency.