Embedded toroidal transformers in ceramic substrates
First Claim
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1. A transformer embedded in an LTCC substrate, comprising:
- a ceramic substrate comprised of a plurality of ceramic tape layers;
at least a first one of said ceramic tape layers layered between a plurality of second ceramic tape layers, said first ceramic tape layer having a larger permeability value as compared to said second ceramic tape layers;
andat least one conductive coil disposed within said plurality of ceramic tape layers, said conductive coil in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a region which defines a ceramic toroidal core, wherein said ceramic toroidal core is intersected by said first ceramic tape layer.
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Abstract
Method for forming a transformer (118) in a ceramic substrate. The method can include the steps of forming at least one conductive coil (119a, 119b) comprising a plurality of turns about an unfired ceramic toroidal core region (120a, 120b) defined within an unfired ceramic substrate (100). The method can also include the step of co-firing the unfired ceramic toroidal core region (120a, 120b), the unfired ceramic substrate (100), and the conductive coil (119a, 119b) to form an integral ceramic substrate structure with the conductive coil at least partially embedded therein.
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Citations
23 Claims
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1. A transformer embedded in an LTCC substrate, comprising:
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a ceramic substrate comprised of a plurality of ceramic tape layers; at least a first one of said ceramic tape layers layered between a plurality of second ceramic tape layers, said first ceramic tape layer having a larger permeability value as compared to said second ceramic tape layers; and at least one conductive coil disposed within said plurality of ceramic tape layers, said conductive coil in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a region which defines a ceramic toroidal core, wherein said ceramic toroidal core is intersected by said first ceramic tape layer. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A transformer embedded in an LTCC substrate, comprising:
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a ceramic substrate comprised of a plurality of ceramic tape layers; at least a first one of said ceramic tape layers layered between a plurality of second ceramic tape layers, said first ceramic tape layer having a larger permeability value as compared to said second ceramic tape layers; at least one conductive coil formed in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a region which defines a ceramic toroidal core, wherein said ceramic toroidal core is intersected by said first ceramic tape layer ; and at least one conductive metal ground plane layer disposed within said ceramic substrate, wherein said conductive metal ground plane layer is interposed between said conductive coil and at least one surface mount component disposed on an outer surface of said ceramic substrate.
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8. A method for forming a transformer in a ceramic substrate, comprising the steps of:
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forming an unfired ceramic substrate comprised of a plurality of ceramic tape layers; positioning at least a first one of said ceramic tape layers at a location layered between a plurality of second ceramic tape layers; selecting a permeability of said first ceramic tape layer to be a larger value as compared to said second ceramic tape layers; forming at least one conductive coil formed in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a toroidal core region; co-firing said plurality of tape layers comprising said unfired ceramic substrate, and said conductive coil to form an integral ceramic substrate structure with said conductive coil at least partially embedded therein; and disposing a conductive ground plane layer between said conductive coil and at least one surface mount component disposed on an outer surface of said ceramic substrate.
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9. A method for forming a transformer in a ceramic substrate, comprising the steps of:
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forming an unfired ceramic substrate comprised of a plurality of ceramic tape layers; positioning at least a first one of said ceramic tape layers at a location layered between a plurality of second ceramic tape layers; selecting a permeability of said first ceramic tape layer to be a larger value as compared to said second ceramic tape layers; forming a plurality of vias and traces in said unfired ceramic substrate to define at least one conductive coil formed in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a toroidal core region; co-firing said plurality of tape layers comprising said unfired ceramic substrate and said conductive coil to form an integral ceramic substrate structure with said conductive coil at least partially embedded therein; and disposing a conductive ground plane layer between said conductive coil and at least one surface mount component disposed on an outer surface of said ceramic substrate.
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10. A method for forming a transformer in a ceramic substrate, comprising the steps of:
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forming an unfired ceramic substrate comprised of a plurality of ceramic tape layers; positioning at least a first one of said ceramic tape layers at a location layered between a plurality of second ceramic tape layers; selecting a permeability of said first ceramic tape layer to be a larger value as compared to said second ceramic tape layers; forming at least one conductive coil formed in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a toroidal core region; positioning said conductive coil so that it is intersected by said first ceramic tape layer; and co-firing said plurality of tape layers comprising said unfired ceramic substrate, and said conductive coil to form an integral ceramic substrate structure with said conductive coil at least partially embedded therein. - View Dependent Claims (11, 12, 13, 14, 15)
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16. A method for forming a transformer in a ceramic substrate, comprising the steps of:
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forming an unfired ceramic substrate comprised of a plurality of ceramic tape layers; positioning at least a first one of said ceramic tape layers at a location layered between a plurality of second ceramic tape layers; selecting a permeability of said first ceramic tape layer to be a larger value as compared to said second ceramic tape layers; forming a plurality of vias and traces in said unfired ceramic substrate to define at least one conductive coil formed in the shape of a toroid having a central axis oriented transverse to said tape layers, and comprising a plurality of turns about a toroidal core region; positioning said conductive coil so that it is intersected by said first ceramic tape layer; and co-firing said plurality of tape layers comprising said unfired ceramic substrate and said conductive coil to form an integral ceramic substrate structure with said conductive coil at least partially embedded therein. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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Specification