Magnetic components

• US 7,477,128 B2
• Filed: 09/22/2005
• Issued: 01/13/2009
• Est. Priority Date: 09/22/2005
• Status: Active Grant

• Current Assignee: Radial Electronics, Inc.
• Original Assignee: Radial Electronics, Inc.
• Inventors: Quilici, James E.
• Primary Examiner(s): Mai; Anh T
• Application Number:
  US11/233,824
• Publication Number:
  US 20070063807A1
• Time in Patent Office: 1,209 Days
• Field of Search: 336/200, 336/223, 336/232
• US Class Current: 336/223
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 17/062 Toroidal core with turns of coil around it
• 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 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 41/042 by thin film techniques
• CPC Class Codes: H01F 41/064 Winding non-flat conductive wires, e.g. rods, cables or cords
• CPC Class Codes: H05K 1/0284 Details of three-dimensional rigid printed circuit boards H05K1/119 takes precedence; shaping of the substrate H05K3/0014
• CPC Class Codes: H05K 1/144 Stacked arrangements of planar printed circuit boards
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/0129 Thermoplastic polymer, e.g. auto-adhesive layer; Shaping of thermoplastic polymer
• CPC Class Codes: H05K 2201/0141 Liquid crystal polymer [LCP]
• CPC Class Codes: H05K 2201/086 for inductive purposes, e.g. printed inductor with ferrite core
• CPC Class Codes: H05K 2201/09036 Recesses or grooves in insulating substrate
• CPC Class Codes: H05K 2201/09045 Locally raised area or protrusion of insulating substrate
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2203/0139 Blade or squeegee, e.g. for screen printing or filling of holes
• CPC Class Codes: H05K 2203/0143 Using a roller; Specific shape thereof; Providing locally adhesive portions thereon
• CPC Class Codes: H05K 2203/0292 : Using vibration, e.g. during soldering or screen printing
• CPC Class Codes: H05K 3/0014 : Shaping of the substrate, e.g. by moulding
• CPC Class Codes: H05K 3/20 : by affixing prefabricated conductor pattern H05K1/187, H05K3/046, H05K3/4658, H05K3/4682 takes precedence
• CPC Class Codes: H05K 3/4611 : by laminating two or more circuit boards H05K3/4652 takes precedence
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• 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

Abstract

Disclosed is an apparatus and method for a magnetic component. The magnetic component includes a substrate having a feature and a first conductive pattern disposed on the feature. The magnetic component also includes a permeability material disposed within the feature. A substrate material is disposed on the substrate to facilitate substantial enclosure of the permeability material between the substrate and the substrate material, where the substrate material has a second conductive pattern. The first conductive pattern and the second conductive pattern cooperate to be capable of facilitating magnetic properties of the permeability material.

Claims

1. An apparatus comprising:

a substrate, the substrate having a feature and a first conductive pattern disposed on the feature;

a permeability material disposed within the feature; and

a substrate material disposed on the substrate to facilitate substantial enclosure of the permeability material between the substrate and the substrate material, the substrate material having a second conductive pattern, wherein the first conductive pattern and the second conductive pattern define at least one electrical circuit being adapted for coupling to a current source so as to cooperate to be capable of facilitating a magnetic field about the permeability material.

2. The apparatus of claim 1, wherein the substrate comprises a thermoplastic type material.

3. The apparatus of claim 2, wherein the thermoplastic type material comprises a polyetherimide type material.

4. The apparatus of claim 1, wherein the substrate comprises a resin type material.

5. The apparatus of claim 4, wherein the resin type material comprises a liquid crystal type material.

6. The apparatus of claim 1, wherein the feature comprises a feature having a toroidal type shape.

7. The apparatus of claim 1, wherein the feature comprises a feature formed by utilization of a machining type process.

8. The apparatus of claim 1, wherein the feature comprises a feature formed by utilization of a lithography type process.

9. The apparatus of claim 1, wherein the first conductive pattern comprises a conductive pattern that substantially lines portions of inside surfaces of the feature.

10. The apparatus of claim 1, wherein the first conductive pattern comprises a conductive pattern disposed by utilization of a stamping type approach.

11. The apparatus of claim 1, wherein the first conductive pattern comprises a conductive pattern disposed by utilization of a plating type approach.

12. The apparatus of claim 1, wherein the first conductive pattern comprises a conductive pattern disposed by utilization of a laser structuring type approach.

13. The apparatus of claim 1, wherein the permeability material comprises a ferromagnetic type material.

14. The apparatus of claim 1, wherein the permeability material comprises a separate solid object that substantially matches a shape of the feature.

15. The apparatus of claim 1, wherein the permeability material comprises a liquid type form material.

16. The apparatus of claim 1, wherein the permeability material comprises a powder type material.

17. The apparatus of claim 1, wherein the permeability material comprises a material utilized with a vibration based type approach.

18. The apparatus of claim 1, wherein the substrate material comprises one or more lamination layers.

19. The apparatus of claim 18, wherein the one or more lamination layers comprises one or more circuit layers.

20. The apparatus of claim 1, wherein the substrate material comprises a liquid dielectric type material.

21. The apparatus of claim 20, wherein the liquid dielectric type material comprises a liquid dielectric material disposed by utilization of at least one of a spray type, roller type, and/or a squeegee type approach.

22. The apparatus of claim 1, wherein the substrate material comprises a substrate material having the second conductive pattern disposed as part of a process of disposing the substrate material.

23. The apparatus of claim 1 further comprising the first and second conductive material facilitating a winding type structure around the permeability material.

24. The apparatus of claim 1 further comprising vias between the first conductive pattern and the second conductive pattern.

25. The apparatus of claim 1 further comprising interconnects between the first conductive pattern and the second conductive pattern.

26. The apparatus of claim 1, wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a common mode filter type functionality.

27. The apparatus of claim 1, wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating an inductor type functionality.

28. The apparatus of claim 1, wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a transformer type functionality.

29. The apparatus of claim 1, wherein the feature depends from a first surface, wherein the feature defines a groove of revolution about an axis perpendicular to the first surface, the groove of revolution defining a groove surface surrounding a groove hub including a portion of the first surface, the substrate further including the first conductive pattern disposed on the feature.

30. The apparatus of claim 29, wherein the permeability material comprises a ferromagnetic type material.

31. The apparatus of claim 29, wherein the first conductive pattern comprises a plurality of discontinuous first conductive traces radiating from about the axis, the first conductive pattern extending from the groove hub along the groove surface to external the groove about a periphery of the groove, wherein the second conductive pattern comprises a plurality of discontinuous second conductive traces radiating from adjacent an axis, the second conductive traces extending from the groove hub to the groove periphery in electrical communication with the first conductive traces.

32. The apparatus of claim 31 wherein the first and second conductive patterns define at least one continuous winding beginning at a first interconnect and terminating at a second interconnect.

33. The apparatus of claim 29 further comprising vias between the first conductive pattern and the second conductive pattern coupling the first conductive pattern and the second conductive pattern in electrical communication.

34. The apparatus of claim 29, further comprising interconnects coupling in electrical communication the first conductive pattern and the second conductive pattern.

35. The apparatus of claim 29, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define four interleaved electrical paths capable of facilitating a dual common mode filter type functionality.

36. The apparatus of claim 29, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a single common mode filter type functionality.

37. The apparatus of claim 29, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a single inductor type functionality.

38. The apparatus of claim 29, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a transformer type functionality.

39. The apparatus of claim 29, wherein the substrate material includes a second surface, the substrate material having a second feature depending from the second surface, wherein the second feature defines a second groove of revolution about an axis perpendicular to the second surface, the second groove defining a second groove surface surrounding a second groove hub including a portion of the second surface, the substrate material further including the second conductive pattern disposed on the second feature, the substrate and substrate material in cooperative engagement so as to define a cavity defined by the first groove and the second groove.

40. The apparatus of claim 29, wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a transformer type functionality.

41. An apparatus comprising:

a substrate including a first surface, the substrate having a feature depending from the first surface, wherein the feature defines a groove of revolution about an axis perpendicular to the first surface, the groove defining a groove surface surrounding a groove hub including a portion of the first surface, the substrate further including a first conductive pattern disposed on the feature;

a permeability material disposed within the feature; and

a substrate material disposed on the first surface to facilitate substantial enclosure of the permeability material between the substrate and the substrate material, the substrate material having a second conductive pattern, wherein the first conductive pattern and the second conductive pattern are in electrical communication so as to define at least one electrical circuit adapted for coupling to a current source so as to cooperate to be capable of facilitating a magnetic field about the permeability material.

42. The apparatus of claim 41, wherein the feature defines a toroidal shape.

43. The apparatus of claim 41, wherein the permeability material comprises a ferromagnetic type material.

44. The apparatus of claim 41, wherein the first conductive pattern comprises a plurality of discontinuous first conductive traces radiating from about the axis, the first conductive pattern extending from the groove hub along the groove surface to external the groove about a periphery of the groove, wherein the second conductive pattern comprises a plurality of discontinuous second conductive traces radiating from adjacent an axis, the second conductive traces extending from the groove hub to the groove periphery in electrical communication with the first conductive traces.

45. The apparatus of claim 44 wherein the first and second conductive patterns define at least one continuous winding beginning at a first interconnect and terminating at a second interconnect.

46. The apparatus of claim 41 further comprising vias between the first conductive pattern and the second conductive pattern coupling the first conductive pattern and the second conductive pattern in electrical communication.

47. The apparatus of claim 41 further comprising interconnects coupling in electrical communication the first conductive pattern and the second conductive pattern.

48. The apparatus of claim 41, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define four interleaved electrical paths capable of facilitating a dual common mode filter type functionality, and wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a dual common mode filter type functionality.

49. The apparatus of claim 41, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a single common mode filter type functionality, and wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a single common mode filter type functionality.

50. The apparatus of claim 41, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a single inductor type functionality, and wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a single inductor type functionality.

51. The apparatus of claim 41, wherein the first conductive pattern and second conductive pattern are electrically interconnected so as to define two interleaved electrical paths capable of facilitating a transformer type functionality, and wherein the magnetic properties of the permeability material comprise magnetic properties capable of facilitating a transformer type functionality.

52. The apparatus of claim 41, wherein the substrate material includes a second surface, the substrate material having a second feature depending from the second surface, wherein the second feature defines a second groove of revolution about an axis perpendicular to the second surface, the second groove defining a second groove surface surrounding a second groove hub including a portion of the second surface, the substrate material further including the second conductive pattern disposed on the second feature, the substrate and substrate material in cooperative engagement so as to define a cavity defined by the first groove and the second groove.