Planar inductor and method of manufacturing it

• US 7,791,165 B2
• Filed: 05/09/2005
• Issued: 09/07/2010
• Est. Priority Date: 05/13/2004
• Status: Expired due to Fees

• Current Assignee: Seiko Epson Corporation (Seiko Group)
• Original Assignee: Seiko Epson Corporation (Seiko Group)
• Inventors: Tanaka, Kazuaki
• Primary Examiner(s): PRENTY, MARK V
• Application Number:
  US11/579,747
• Publication Number:
  US 20080157272A1
• Time in Patent Office: 1,947 Days
• Field of Search: 257/531, 257/E21.022, 336/200, 438/381
• US Class Current: 257/531
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 2017/0046 with a conductive path having a bridge
• CPC Class Codes: H01F 2017/0053 with means to reduce eddy currents
• CPC Class Codes: H01F 27/32 Insulating of coils, windings, or parts thereof
• CPC Class Codes: H01F 27/34 Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00

Abstract

A planar inductor comprises a metal element (11-14) on a substrate (300, 310), said metal element being provided with at least one groove (20) extending along and into said element from at least one surface (2) of said element. Said groove or grooves (20) extend into the element in a direction substantially perpendicular to the surface of the substrate (300, 310), giving rise to a higher Q value and a lower serial resistance are also achieved. The inductor may comprise grooved (11, 13, 14) and non-grooved (12) layers.

The invention also relates to a method of manufacturing the inductor.

Claims

1. A planar inductor, comprising a metal element on a substrate, said metal element being provided with at least one groove extending along and into said element from at least one surface of said element, wherein said at least one groove extends into the element in a direction substantially perpendicular to the surface of the substrate,

wherein the metal element comprises at least three superposed metal layers each extending in a direction parallel to the substrate, wherein at least one of said layers is not provided with said at least one groove, and wherein said at least one groove extends from a surface of said inductor and all through at least two of said layers until reaching the at least one layer not being provided with said at least one groove.

2. A planar inductor according to claim 1, the inductor having a spiral shape, said at least one groove also having a spiral shape corresponding to the spiral shape of the inductor.

3. A planar inductor according to claim 1, wherein said at least one groove comprises a plurality of grooves.

4. A planar inductor according to claim 3, wherein said grooves are substantially parallel with each other.

5. A planar inductor according to claim 1, said metal element having a substantially rectangular cross section.

6. A planar inductor according to claim 1, wherein the at least one groove extends into the metal element to an extent corresponding to, at least, 50% of the height of the metal element in the direction perpendicular to the surface of the substrate.

7. A planar inductor according to claim 6, wherein the at least one groove extends into the metal element to an extent corresponding to, at least, 75% of the height of the metal element in the direction perpendicular to the surface of the substrate.

8. A planar inductor, comprising a metal element on a substrate, said metal element being provided with at least one groove extending along and into said element from at least one surface of said element, wherein said at least one groove extends into the element in a direction substantially perpendicular to the surface of the substrate,

wherein the metal element comprises at least three superposed metal layers each extending in a direction parallel to the substrate, wherein at least one of said layers is not provided with said at least one groove, and wherein the at least one layer not provided with said at least one groove is sandwiched between layers provided with said at least one groove.

9. A planar inductor according to claim 8, wherein, in at least a first layer of said layers provided with said at least one groove, said at least one groove extends all through said first layer, from a first surface of said first layer to a second surface of said first layer, reaching the at least one layer not provided with said at least one groove.

10. A planar inductor according to claim 8, the inductor having a spiral shape, said at least one groove also having a spiral shape corresponding to the spiral shape of the inductor.

11. A planar inductor according to claim 8, wherein said at least one groove comprises a plurality of grooves.

12. A planar inductor according to claim 11, wherein said grooves are substantially parallel with each other.

13. A planar inductor according to claim 8, said metal element having a substantially rectangular cross section.

14. A planar inductor according to claim 8, wherein the at least one groove extends into the metal element to an extent corresponding to, at least, 50% of the height of the metal element in the direction perpendicular to the surface of the substrate.

15. A planar inductor according to claim 14, wherein the at least one groove extends into the metal element to an extent corresponding to, at least, 75% of the height of the metal element in the direction perpendicular to the surface of the substrate.

16. A planar inductor, comprising a metal element on a substrate, said metal element being provided with at least one groove extending along and into said element from at least one surface of said element, wherein said at least one groove extends into the element in a direction substantially perpendicular to the surface of the substrate,

wherein the metal element comprises at least two superposed metal layers each extending in a direction parallel to the substrate, wherein at least one of said layers is provided with said at least one groove, wherein at least one of said layers is not provided with said at least one groove, and wherein the at least one groove extends into the metal element to an extent corresponding to, at least, 75% of the height of the metal element in the direction perpendicular to the surface of the substrate.

17. A planar inductor according to claim 16, wherein, said at least one groove extends all through said at least one layer provided with said at least one groove, from a first surface of said layer to a second surface of said layer, reaching said at least one layer not provided with said at least one groove.

18. A planar inductor according to claim 16, wherein the metal element comprises at least three metal layers, said at least one groove extends from a surface of said inductor and all through at least two of said layers until reaching the at least one layer not provided with said at least one groove.

19. A planar inductor according to claim 16, wherein the metal element comprises at least three metal layers, the at least one layer not provided with said at least one groove sandwiched between layers being provided with said at least one groove.

20. A planar inductor according to claim 16, the inductor having a spiral shape, said at least one groove also having a spiral shape corresponding to the spiral shape of the inductor.

21. A planar inductor according to claim 16, wherein said at least one groove comprises a plurality of grooves.

22. A planar inductor according to claim 21, wherein said grooves are substantially parallel with each other.

23. A planar inductor according to claim 16, said metal element having a substantially rectangular cross section.

24. A method of manufacturing a planar inductor, comprising the steps of:

applying a metal element onto a substrate; and

providing said metal element with grooves;

wherein

the grooves are made to extend into the metal element in a direction substantially perpendicular to the surface of the substrate,

wherein the step of applying a metal element onto a substrate comprises the step of applying at least one metal layer onto the substrate; and

wherein the step of providing the metal element with grooves comprises the steps of;

applying a non-metal material on said at least one metal layer;

creating grooves in said non-metal material, said grooves being separated by partitions of said non-metal material; and

filling said grooves with metal, thus creating a grooved metal layer.