Embedded toroidal inductor

• US 7,158,005 B2
• Filed: 02/10/2005
• Issued: 01/02/2007
• Est. Priority Date: 02/10/2005
• Status: Active Grant

• Current Assignee: Harris Corporation (L3Harris Technologies, Inc.)
• Original Assignee: Harris Corporation (L3Harris Technologies, Inc.)
• Inventors: Provo, Terry, Pleskach, Michael D., Payan, Bayardo A., Thomson, Andrew J.
• Primary Examiner(s): MAI, ANH T
• Application Number:
  US11/055,154
• Publication Number:
  US 20060176139A1
• Time in Patent Office: 691 Days
• Field of Search: 336/200, 336/223, 336/232, 336/229, 296/021
• US Class Current: 336/229
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 2027/2814 with only part of the coil or of the winding in the printed circuit board, e.g. the remaining coil or winding sections can be made of wires or sheets
• CPC Class Codes: H01F 41/046 structurally combined with ferromagnetic material
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A toroidal inductor, including a substrate (100), a toroidal core region (434) defined within the substrate, and a toroidal coil including a first plurality of turns formed about the toroidal core region and a second plurality of turns formed about the toroidal core region. The second plurality of turns can define a cross sectional area (440) greater than a cross sectional area (442) defined by the first plurality of turns. The substrate and the toroidal coil can be formed in a co-firing process to form an integral substrate structure with the toroidal coil at least partially embedded therein. The first and second plurality of turns can be disposed in alternating succession. The toroidal core region can be formed of a substrate material having a permeability greater than at least one other portion of the substrate.

Claims

1. A method for forming an inductor, comprising:

forming in a substrate a first plurality of conductive vias radially spaced a first distance from a central axis so as to define a first inner circumference;

forming in said substrate a second plurality of conductive vias radially spaced a second distance from said central axis so as to define a second inner circumference, said second distance greater than said first distance;

forming in said substrate a third plurality of conductive vias radially spaced a third distance from said central axis so as to define an outer circumference, said third distance greater than said second distance;

forming a first plurality of conductive traces disposed in a first plane defined orthogonal to said central axis, said first plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said first and third plurality of conductive vias;

forming a second plurality of conductive traces disposed in said first plane, said second plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said second and third plurality of conductive vias;

forming a third plurality of conductive traces disposed in a second plane spaced from said first plane and defined orthogonal to said central axis to define an electrical connection between circumferentially offset ones of said first and third plurality of conductive vias;

forming a fourth plurality of conductive traces disposed in said second plane to define an electrical connection between circumferentially offset ones of said second and third plurality of conductive visa to define a three dimensional toroidal coil.

2. The method according to claim 1, further comprising co-firing said substrate and said toroidal coil to form an integral substrate structure with said toroidal coil at least partially embedded therein.

3. The method according to claim 1, further comprising forming at least a toroid shaped core region of said substrate, defined within said toroidal coil, of a material having at least one electrical characteristic different from at least one other portion of said substrate.

4. The method according to claim 3, further comprising selecting said electrical characteristic to be a permeabilty.

5. The method according to claim 3, further comprising selecting said material to be a low-temperature co-fired ceramic (LTCC) material.

6. The method according to claim 3, further comprising co-firing said substrate and said material to form an integral substrate structure.

7. The method according to claim 1, further comprising forming said substrate by stacking a plurality of substrate layers, and selecting at least one of said substrate layers to have a relative permeability greater than one.

8. The method, according to claim 7, further comprising positioning said at least one substrate layer having a relative permeability greater than one to be at least partially contained within a toroid shaped core region of said substrate, defined within said toroidal coil.

9. The method according to claim 1, further comprising:

forming in said substrate a fourth plurality of conductive vies radially spaced a fourth distance from said central axis so as to define a third inner circumference, said fourth distance less than said first distance;

forming a fifth plurality of conductive traces disposed in said first plane, said fifth plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said fourth and third plurality of conductive vias;

forming a sixth plurality of conductive traces disposed in said second plane to define an electrical connection between circumferentially offset ones of said fourth and third plurality of conductive vias.

10. An inductor, comprising:

a first plurality of conductive vias formed in a substrate and radially spaced a first distance from a central axis so as to define a first inner circumference;

a second plurality of conductive vias formed in said substrate and radially spaced a second distance from said central axis so as to define a second inner circumference, said second distance greater than said first distance;

a third plurality of conductive vias formed in said substrate and radially spaced a third distance from said central axis so as to define an outer circumference, said third distance greater than said second distance;

a first plurality of conductive traces disposed in a first plane defined orthogonal to said central axis, said first plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said first and third plurality of conductive vias;

a second plurality of conductive traces disposed in said first plane, said second plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said second and third plurality of conductive vias;

a third plurality of conductive traces disposed in a second plane spaced from said first plane and defined orthogonal to said central axis to define an electrical connection between circumferentially offset ones of said first and third plurality of conductive vias;

a fourth plurality of conductive traces disposed in said second plane to define an electrical connection between circumferentially offset ones of said second and third plurality of conductive vias to define a three dimensional toroidal coil.

11. The inductor according to claim 10, wherein said substrate, said conductive vias and said conductive traces comprise an integral substrate structure with said toroidal coil at feast partially embedded therein.

12. The inductor according to claim 10, wherein at least a toroid shaped core region of said substrate, defined within said toroidal coil, comprises a material having at least one electrical characteristic different from at least one other portion of said substrate.

13. The inductor according to claim 12, wherein said electrical characteristic is permeability.

14. The inductor according to claim 12, wherein said substrate material is a low-temperature co-fired ceramic (LTCC) material.

15. The inductor according to claim 12, wherein said material is integral with said substrate.

16. The inductor according to claim 10, wherein said substrate comprises a stack of substrate layers, and at least one of said substrate layers has a relative permeability greater than one.

17. The inductor according to claim 16, wherein at least one substrate layer having a relative permeability greater than one is at least partially contained within a toroid shaped core region of said substrate which is defined within said toroidal coil.

18. The inductor according to claim 10, further comprising:

a fourth plurality of conductive vias radially spaced a fourth distance from said central axis so as to define a third inner circumference, said fourth distance less than said first distance;

a fifth plurality of conductive traces disposed in said first plane, said fifth plurality of conductive traces forming an electrical connection between substantially radially adjacent ones of said fourth and third plurality of conductive vias;

a sixth plurality of conductive traces disposed in said second plane to define an electrical connection between circumferentially offset ones of said fourth and third plurality of conductive visa.

19. A printed circuit board, comprising:

a substrate;

a toroidal core region defined within said substrate; and

a single continuous toroidal coil comprising a first plurality of turns formed about said toroidal core region and a second plurality of turns formed about said toroidal core region, said second plurality of turns defining a cross sectional area greater than a cross sectional area defined by said first plurality of turns.

20. The printed circuit board according to claim 19, wherein said substrate and said single continuous toroidal coil comprise an integral substrate structure with said single continuous toroidal coil at least partially embedded therein.

21. The printed circuit board according to claim 19, wherein said first and second plurality of turns are disposed in alternating succession.

22. The printed circuit board according to claim 19, wherein said first and second plurality of turns are contained within said substrate at all points.

23. The printed circuit board according to claim 19, wherein said toroidal core region comprises a substrate material that has a permeability greater than a second substrate material comprising at least one other portion of said substrate.

24. The printed circuit board according to claim 19, wherein said single continuous toroidal coil further comprises a third plurality of turns formed about said toroidal core region, said third plurality of turns defining a cross sectional area greater than a cross sectional area defined by said second plurality of turns.

25. A method for forming an inductor in a substrate, comprising:

forming a single continuous toroidal coil comprising a first plurality of turns about a toroidal core region defined in said substrate and a second plurality of turns about said toroidal core region, said second plurality of turns defining a cross sectional area greater than a cross sectional area defined by said first plurality of turns.

26. The method according to claim 25, further comprising co-firing said substrate and said single continuous toroidal coil to form an integral substrate structure with said single continuous toroidal coil at least partially embedded therein.

27. The method according to claim 25, further comprising disposing said first and second plurality of turns in alternating succession.

28. The method according to claim 25, further comprising forming said toroidal corn region with a substrate material to have a permeability greater than at least one other portion of said substrate.

29. The method according to claim 25, further comprising forming said single continuous toroidal coil with a third plurality of turns about said toroidal core region, said third plurality of turns defining a cross sectional area greater than said cross sectional area defined by said second plurality of turns.

30. A toroidal inductor, comprising:

a substrate;

a toroidal core region defined within said substrate; and

a single continuous toroidal coil comprising a first plurality of turns formed about said toroidal core region and a second plurality of turns formed about said toroidal core region, said second plurality of turns defining a cross sectional area greater than a cross sectional area defined by said first plurality of turns.

31. The toroidal inductor according to claim 30, wherein said substrate and said single continuous toroidal coil comprise an integral substrate structure with said single continuous toroidal coil at least partially embedded therein.

32. The toroidal inductor according to claim 30, wherein said first and second plurality of turns are disposed in alternating succession.

33. The toroidal inductor according to claim 30, further wherein said toroidal core region comprises a substrate material having a permeability greater than at least one other portion of said substrate.

34. The toroidal inductor according to claim 30, further comprising a third plurality of turns formed about said toroidal core region, said third plurality of turns defining a cross sectional area greater than said cross sectional area defined by said second plurality of turns.