Self-Insulating Metal Vias for High-Inductance Magnetic Microcoils
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Solution Overview
Problem
Miniaturized inductors have low inductances, making them unsuitable for lower frequency applications, and previous attempts at increasing inductance, such as those by Gu et al., require complex manufacturing processes that are not amenable to mass production.
Innovation Solution
A magnetic micro-device with a near-zero conductivity magnetic nanocomposite film layer and self-insulating vias, which allows for greater inductance and can be scaled for cost-effective mass production, comprising a bottom wire layer, magnetic nanocomposite film layer, and top wire layer forming a continuous coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If miniaturized inductors are used to reduce size and weight, then the device size and weight are reduced, but the inductance becomes very low (in the nH range)
Solution Approach 1:
The patent employs a composite structure consisting of magnetic nanocomposite film layers with near-zero conductivity embedded within the inductor device. These magnetic nanocomposite materials provide both magnetic permeability enhancement and electrical insulation, allowing the miniaturized inductor to achieve higher inductance values while maintaining reduced size and weight. The composite nature of the material system enables simultaneous optimization of magnetic and electrical properties that cannot be achieved with conventional homogeneous materials.
2Quantity of substance
If Gu et al.'s direct write method with high magnetic permeability cores is used to increase inductance, then inductances greater than 1 uH are achieved, but the manufacturing process becomes complex and not amenable to mass production
Solution Approach 1:
The patent merges multiple functions into a single integrated structure. The magnetic nanocomposite film layers simultaneously provide magnetic permeability enhancement, electrical insulation between windings, and structural support. This consolidation eliminates the need for separate core insertion steps and manual assembly operations required by Gu et al.'s method, enabling the inductor to be fabricated as a single integrated component suitable for mass production through automated winding and curing processes.
Solution Approach 2:
The magnetic nanocomposite film layers exhibit self-insulating properties due to their near-zero conductivity, eliminating the need for additional insulation materials or complex insulation processes. The material inherently provides both magnetic functionality and electrical isolation, allowing the device to self-regulate its electrical properties without external intervention or additional manufacturing steps.
3Quantity of substance
If conventional inductors are used for lower frequency applications, then adequate inductance (μH to mH range) is achieved, but the device size and weight increase
Solution Approach 1:
The patent fundamentally changes the magnetic permeability parameter by incorporating magnetic nanocomposite materials with high magnetic permeability into the inductor structure. This parameter change allows the device to achieve much higher inductance values in a compact form factor, enabling μH to mH range inductances in miniaturized devices suitable for lower frequency applications without the size and weight penalties of conventional inductors.
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 magnetic micro-device achieves higher inductance than air-core devices and can be efficiently produced in large quantities, addressing the limitations of miniaturized inductors for various frequency applications.
Implementation Method 1
the magnetic nanocomposite film layer comprises one or more of Fe, Co, Ni, FeN, CoFe, CoNiFe, oxide-coated ferromagnetic nanoparticles, or nitride-coated ferromagnetic nanoparticles
Implementation Method 2
Due to the near-zero conductivity of the magnetic nanocomposite film layer, the vias are self-insulating
Implementation Method 3
the bottom wire layer, the plurality of vias, and the top wire layer in combination form at least one continuous coil
Data Source
AI summary
A magnetic micro-device and process to manufacture the same is disclosed. The magnetic micro-device has a near-zero conductivity magnetic nanocomposite film layer with a plurality of apertures through which a corresponding plurality of electrical conductors (vias) pass. Due to the near-zero conductivity of the magnetic nanocomposite film layer, the vias are self-insulating. The presence of the magnetic nanocomposite film layer results in greater inductance than that possible with an air core (or core-less) magnetic micro-device. Potential magnetic micro-devices include toroid micro-inductors, solenoid micro-inductors, toroid micro-transformers, and solenoid micro-transformers. Additional potential magnetic micro-devices include generators, motors, electromagnetic switches, and voice coils (for speakers or microphones). The process used to manufacture the magnetic micro-device can be scaled to cost-effectively produce large numbers of the magnetic micro-device.