Method of making a multilayer monolithic magnetic component
First Claim
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1. A method for constructing a solid composite magnetic component comprising the steps of:
- preparing a magnetic material in a ceramic material format having a first sintering rate and a first sintering temperature;
preparing an insulating non-magnetic material in a ceramic material format, with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature;
preparing apertures in the insulating non-magnetic material for accepting the magnetic material;
depositing conductors within the insulating non-magnetic material which are connected to form at least a winding to provide electromagnetic excitation of the magnetic material;
forming a composite structure of the magnetic material and the insulating non-magnetic material by adding the magnetic material to the apertures to form a structure with well defined magnetic and insulating non-magnetic regions; and
co-firing the structure to form a solid composite structure.
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Abstract
Magnetic components are fabricated as monolithic structures using multilayer co-fired ceramic tape techniques. Fabrication of these magnetic components involves constructing multiple layers of a magnetic material and an insulating non-magnetic material to form a monolithic structure with well defined magnetic and insulating non-magnetic regions. Windings are formed using screen printed conductors connected through the multilayer structure by conducting vias.
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Citations
33 Claims
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1. A method for constructing a solid composite magnetic component comprising the steps of:
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preparing a magnetic material in a ceramic material format having a first sintering rate and a first sintering temperature; preparing an insulating non-magnetic material in a ceramic material format, with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature; preparing apertures in the insulating non-magnetic material for accepting the magnetic material; depositing conductors within the insulating non-magnetic material which are connected to form at least a winding to provide electromagnetic excitation of the magnetic material; forming a composite structure of the magnetic material and the insulating non-magnetic material by adding the magnetic material to the apertures to form a structure with well defined magnetic and insulating non-magnetic regions; and co-firing the structure to form a solid composite structure. - View Dependent Claims (2, 3, 4)
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5. A method for constructing a solid composite magnetic component comprising the steps of:
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preparing a magnetic material in a ceramic material format having a first sintering rate and a first sintering temperature; preparing an insulating non-magnetic material in a ceramic tape format with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature; including apertures in the insulating non-magnetic material for accepting the magnetic material; forming a structure by successive layering of the insulating non-magnetic material and adding the magnetic material to the apertures to form a first structure with well defined magnetic and insulating non-magnetic regions; depositing conducting paths on selected layers of the insulating nonmagnetic material and joining the conducting paths to form windings encircling selected portions of the apertures containing the magnetic material; applying pressure to laminate the first structure; and co-firing the first structure to form a solid composite structure. - View Dependent Claims (6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A process for producing a solid composite magnetic component comprising at least two different materials each comprised of a ferrite matrix;
- wherein the ferrite materials are of the form M1+x Fe2-y O4-z
comprising the steps of; preparing a magnetic material by; providing a first ferrite powder of a substantially MnZn ferrite composition suitable to provide a relatively high permeability in a resulting first ferrite matrix, preparing an insulating non-magnetic material by; providing a second ferrite powder of a substantially Ni ferrite composition suitable to provide a high resistivity and a low permeability in a resulting second ferrite matrix, adding a Cu oxide to the second ferrite powder in an amount ranging from 1% mol to 10% mol of the total amount of the second ferrite powder so that the second ferrite powder has a sintering rate and sintering temperature substantially identical to that of the first ferrite powder, admixing the second ferrite powder with an organic binding material and forming the resulting mixture into a ceramic tape, defining different tape layers with specified layers having certain defined apertures; forming a layered structure with the different tape layers in which the apertures form a geometric structure suitable for a magnetic core and in which the apertures are filled with a material comprising the first ferrite powder, laminating the layered structure by applying a pressure thereto, firing the laminated structure; sintering the resulting structure at a temperature exceeding 800°
centigrade to produce a sintered product having two ferrite matrix materials in a single composite structure;cooling the single composite structure to form the solid composite magnetic component. - View Dependent Claims (24, 25, 26)
- wherein the ferrite materials are of the form M1+x Fe2-y O4-z
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27. A method for constructing a solid composite magnetic component with multilayer ceramic tape layers;
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comprising the steps of; providing a first ferrite powder of MnZn ferrite composition having a specific sintering rate and temperature; providing a second ferrite powder of a Ni ferrite composition and further doped with copper oxide particles in an amount equaling 1-10% of the overall molar composition to introduce a liquid phase into the second ferrite material to lower its sintering temperature and modify its sintering rate so that they equal the specific sintering rate and temperature; preparing a magnetic material comprising a binder and the first ferrite powder of a MnZn ferrite composition; preparing an insulating non-magnetic material in the form of a ceramic tape comprising a binder and the second ferrite power of a Ni ferrite composition; forming apertures in the insulating non-magnetic material for accepting the magnetic material; placing pluralities of the insulating non-magnetic materials formed of ceramic tape adjacent each other at least in part in layers and inserting the magnetic material in the apertures to assemble a multilayer structure having well defined regions of high permeability and well defined regions of low permeability adjacent the regions of high permeability; and applying pressure to laminate the multilayer structure; co-firing the laminated structure to a temperature within a range of 800 to 1400 degrees Centigrade to join the layers into a solid composite structure. - View Dependent Claims (28, 29, 30)
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31. A method for constructing a solid composite structure including at least a magnetic component comprising the steps of:
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preparing a magnetic ceramic material having a first sintering rate and a first sintering temperature; preparing an insulating non-magnetic material in a ceramic tape format, with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature; forming a structure by successive layering of the insulating non-magnetic material and combining it with the magnetic material to form a first structure with well defined magnetic and non-magnetic regions; printing conductors on a portion of the structure so as to magnetically engage the magnetic material; applying pressure to laminate the structure; and co-firing the first structure to form a solid composite structure. - View Dependent Claims (32, 33)
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Specification