Low profile layered coil and cores for magnetic components

• US 20080061917A1
• Filed: 09/12/2006
• Published: 03/13/2008
• Est. Priority Date: 09/12/2006
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bogert, Robert James, Manoukian, Daniel Minas
• Granted Patent: US 7,791,445 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core
• CPC Class Codes: Y10T 29/49078 Laminated
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base

Abstract

A low profile magnetic component with planar coil portion, polymer-based supporting structure and methods of fabrication.

Claims

1. A magnetic component comprising:

a first coil layer defining a generally planar coil winding; and

first and second dielectric layers sandwiching the coil layer, wherein one of the first second layers comprises a core opening defining a receptacle for the introduction of a magnetic core material.

2. The component of claim 1, wherein the first coil layer comprises a double sided coil.

3. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a polymer-based film.

4. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a polyimide film.

5. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a liquid crystal polymer.

6. The component of claim 1, wherein both of the first and second dielectric layers comprise a core opening extending therethrough.

7. The component of claim 1, wherein the coil layer comprises an electroformed coil winding formed independently of the first and second dielectric layers.

8. The component of claim 1, wherein the first coil layer comprises a first base layer and a first planar coil portion extending on a surface of the first base layer, the component further comprising a second coil layer comprising a second base layer and a second planar coil portion extending on a surface of the second base layer, wherein the first coil layer and the second coil layer are stacked and the first coil portion and the second coil portion are connected in series.

9. The component of claim 1, further comprising surface mount terminations.

10. The component of claim 1, wherein the first dielectric layer, the second dielectric layer and the coil layer are laminated together.

11. The component of claim 1, wherein the core opening is substantially circular.

12. The component of claim 1, wherein the component is an inductor.

13. A low profile magnetic component comprising:

first and second dielectric layers, one of the first and second dielectric layers comprising a polymer based material;

a coil layer sandwiched between the first and second dielectric layers, the coil layer defining a generally planar coil portion;

wherein at least one of the first second layers comprises a core opening defining a receptacle for the introduction of a magnetic core material; and

a magnetic material situated in the core opening and encasing the coil portion.

14. The component of claim 13, wherein the first coil layer comprises a double sided coil.

15. The component of claim 13, wherein at least one of the first and second dielectric layers comprises a polyimide film.

16. The component of claim 13, wherein the coil layer comprises an electroformed coil winding formed independently of the first and second dielectric layers.

17. The component of claim 13, further comprising surface mount terminations.

18. The component of claim 13, wherein the at least one coil layer comprises multiple coil layers, each of the coil layers defining a generally planar coil portion, and each of the coil layers being connected in series.

19. The component of claim 18, wherein each of the layers includes a plurality of termination openings, each of the coil portions on the coil layers being interconnected by selected ones of the termination openings.

20. A low profile magnetic component comprising:

at least one coil layer, each coil layer including a dielectric base layer and a generally planar coil winding extending thereon;

a first outer dielectric layer and a second outer dielectric layer extending on opposing sides of the stacked coil layers, at least one of the first and second outer dielectric layers comprising a polyimide material; and

at least one of the first second layers comprises a core opening exposing the planar coil winding; and

a magnetic permeable material filling the core opening and covering the planar coil winding.

21. The component of claim 20, wherein the at least one coil layer comprises a plurality of stacked coil layers, each of the coil layers including a dielectric base layer and a generally planar coil winding extending thereon.

22. The component of claim 21, wherein the coil windings of adjacent coil layers are connected in series.

23. The component of claim 20, wherein the coil winding is formed independently of the first and second outer dielectric layers.

24. The component of claim 20, wherein the planar coil winding comprises a double sided coil.

25. The component of claim 20, further comprising surface mount terminations.

26. The component of claim 20, wherein the magnetic permeable material is flush mounted with the first and second outer dielectric layers.

37. The component of claim 24, wherein the magnetic permeable material is flush with a surface of the means for insulating.

27. A method of fabricating a conductive component comprising:

providing at least one outer dielectric layer, the outer dielectric layer having a core opening formed therethrough;

providing a coil layer including a substantially planar coil portion formed on at least one dielectric base layer;

stacking the outer dielectric layer and the coil layer; and

applying a magnetic core material over the coil portion via the core opening.

28. The method of claim 27, further comprising laminating the outer dielectric layer to the coil layer.

29. The method of claim 27, further comprising singulating the stacked layers into discrete components.

30. The method of claim 27, wherein providing a coil layer comprises providing a plurality of coil layers stacked upon one another, each of the coil layers including a termination opening, the method further comprising filling the termination opening to interconnect the coil layers in series.

31. The method of claim 27 further comprising forming surface mount terminations on the outer dielectric layer.

32. The method of claim 27 wherein providing a coil layer comprises providing a double sided coil extending on a dielectric base layer.

33. The method of claim 27 wherein providing a coil layer comprises electroforming a coil portion having a number of turns on a major surface of the dielectric base layer.

34. A magnetic component comprising:

means for establishing a number of coil turns, the coil turns extending in a plane;

planar means for insulating the means for establishing, the means for insulating sandwiching the means for establishing a number of coil turns; and

means for receiving a magnetic permeable material, located in the means for insulating and exposing the coil turns; and

a magnetic permeable material situated in the means for receiving.

35. The component of claim 34, wherein the means for establishing comprises a plurality of separately fabricated coil portions, the component further comprising means for connecting the coil portions in series.

36. The component of claim 34, further comprising means for terminating the means for establishing to a circuit board.