ELECTROMAGNETIC COMPONENT AND FABRICATION METHOD THEREOF

• US 20150155091A1
• Filed: 02/13/2015
• Published: 06/04/2015
• Est. Priority Date: 04/24/2012
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: CHANG, WEI-CHIEN, WU, CHIA-CHI, CHIANG, LANG-YI, WU, TSUNG-CHAN, YEH, JIH-HSU
• Granted Patent: US 10,332,669 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core

Abstract

An electromagnetic component includes a coil portion with a multi-layer stack structure, a molded body encapsulating the coil portion, and two electrodes respectively coupled to two terminals of the coil portion. The coil portion is fabricated using plating, laminating and/or pressing manufacturing techniques.

Claims

1. An electromagnetic component, comprising:

a conductive structure, wherein the conductive structure comprises a coil formed in a plurality of conductive layers separated by at least one insulating layer, wherein a hollow space is formed inside the coil and extended from a top surface to a bottom surface of the conductive structure; and

a magnetic molding body encapsulating the conductive structure and extending into the hollow space, wherein a first portion of the magnetic molding body disposed inside the hollow space is in contact with a portion of the coil on the plurality of conductive layers.

2. The electromagnetic component according to claim 1, wherein the conductive structure comprises a substrate under the plurality of conductive layers and the at least one insulating layer, wherein the hollow space penetrates the substrate.

3. The electromagnetic component according to claim 1, wherein a blind via is disposed in the first insulating layer over a second trace on the second conductive layer, wherein a first conductive trace of the first conductive layer is formed over and being extended into the blind via to electrically connect the first conductive trace to the second conductive trace on the second conductive layer

4. The electromagnetic component according to claim 1, wherein the first portion of the magnetic molding body inside the hollow space is in contact with a portion of the coil disposed in each of the plurality of conductive layers.

5. The electromagnetic component according to claim 1, wherein the conductive structure comprises a first conductive layer on the top surface and a second conductive layer on the bottom surface thereof, wherein the magnetic molding body is in contact with the first conductive layer and the second conductive layer.

6. The electromagnetic component according to claim 1, wherein the magnetic molding body encapsulating the conductive structure and extending into the hollow space is integrally formed.

7. The electromagnetic component according to claim 1, wherein two adjacent conductive layers are connected by at least one blind via.

8. The electromagnetic component according to claim 1, wherein a first portion of the coil disposed on a first conductive layer has two ending points to form a first slit therebetween, wherein said two ending points are electrically connected to adjacent conductive layers through via(s).

9. The electromagnetic component according to claim 1, wherein a first portion of the coil disposed on a first conductive layer has two ending points to form a first slit therebetween, wherein said two ending points are electrically connected to adjacent conductive layers through blind via(s).

10. The electromagnetic component according to claim 1, wherein one conductive layer of the conductive structure comprises a first conductive trace having a first width, a second conductive trace containing an ending point of the coil and having a second width less than the first width and a third conductive trace, wherein the width of the third conductive trace is shrunk gradually from the inner side of the coil only so as to connect the first conductive trace to the second conductive trace of the coil.

11. The electromagnetic component according to claim 1, wherein the coil comprises a first conductive trace having a first width, a second conductive trace containing a first ending point of the coil and having a second width less than the first width and a third conductive trace, wherein the width of the third conductive trace is shrunk gradually so as to connect the first conductive trace to the second conductive trace of the coil, wherein the extended length of the first conductive trace is greater than that of the second conductive trace.

12. The electromagnetic component according to claim 1, wherein the coil comprises a first conductive trace having a first width, a second conductive trace containing a first ending point of the coil and having a second width less than the first width and a third conductive trace, a third conductive trace containing a second ending point of the coil and having a third width less than the first width, and a fourth conductive trace, wherein the width of the fourth conductive trace is shrunk gradually so as to connect the first conductive trace to the second and the third conductive trace of the coil, wherein the extended length of the first conductive trace is greater than that of any one of the second conductive trace and the third conductive trace.

13. The electromagnetic component according to claim 1, wherein two electrodes are respectively coupled to two ending portion of the coil, wherein the two electrodes are exposed through the magnetic body.

14. The electromagnetic component according to claim 13, wherein the coil comprises a conductive trace on a conductive layer, wherein the conductive trace has a tapered sidewall.

15. An electromagnetic component, comprising:

a substrate;

a conductive structure on the substrate, wherein the conductive structure comprises a coil formed in a plurality of conductive layers separated by at least one insulating layer, wherein a hollow space is formed inside the coil and extended from a top surface of the conductive structure to a bottom surface of the substrate; and

a molding body encapsulating the conductive structure and extending into the hollow space.

16. The electromagnetic component according to claim 15, wherein a first portion of the magnetic body disposed in the hollow space is in contact with the coil.

17. The electromagnetic component according to claim 16, wherein a second portion of the magnetic body is in contact with the coil at the top surface of the conductive structure.

18. The electromagnetic component according to claim 15, wherein the magnetic molding body encapsulating the conductive structure and extending into the hollow space is integrally formed.

19. An electromagnetic component, comprising:

a conductive structure, wherein the conductive structure comprises a coil formed in a plurality of conductive layers separated by at least one insulating layer, wherein a first insulating layer is disposed on a first conductive layer and a second conductive layer is disposed on the first insulating layer, wherein a blind via is disposed in the first insulating layer over a first trace on the first conductive layer, wherein a second conductive trace of the second conductive layer is formed over and being extended into the blind via to electrically connect the second conductive trace to the first conductive trace on the first conductive layer.

20. The electromagnetic component according to claim 19, wherein a hollow space is formed in the inner side of the coil, wherein a magnetic body encapsulates the conductive structure and extends into the hollow space.