Low profile layered coil and cores for magnetic components

• US 7,791,445 B2
• Filed: 09/12/2006
• Issued: 09/07/2010
• Est. Priority Date: 09/12/2006
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Manoukian, Daniel Minas, Bogert, Robert James
• Primary Examiner(s): Enad; Elvin G
• Assistant Examiner(s): HINSON, RONALD
• Application Number:
  US11/519,349
• Publication Number:
  US 20080061917A1
• Time in Patent Office: 1,456 Days
• Field of Search: 336/200, 296/021
• US Class Current: 336/200
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 5/003 Printed circuit coils
• 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
• CPC Class Codes: Y10T 29/49078 Laminated
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base

Abstract

A low profile magnetic component with planar coil portion, polymer-based supporting structure and methods of fabrication.

Claims

1. A magnetic component comprising:

a first coil layer defining a generally planar coil winding and an open center;

first and second dielectric layers sandwiching the coil layer, wherein each of the first and second dielectric layers comprises a core opening defining a receptacle proximate the open center; and

a magnetic core material applied in the receptacle of each of the first and second dielectric layers and the open center, wherein the coil winding proximate each receptacle is embedded in the magnetic core material.

2. The component of claim 1, wherein the first coil layer comprises a double sided coil.

3. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a polymer-based film.

4. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a polyimide film.

5. The component of claim 1, wherein at least one of the first and second dielectric layers comprises a liquid crystal polymer.

6. The component of claim 1, wherein both of the first and second dielectric layers comprise a core opening extending therethrough.

7. The component of claim 1, wherein the coil layer comprises an electroformed coil winding formed independently of the first and second dielectric layers.

8. The component of claim 1, wherein the first coil layer comprises a first base layer and a first planar coil portion extending on a surface of the first base layer, the component further comprising a second coil layer comprising a second base layer and a second planar coil portion extending on a surface of the second base layer, wherein the first coil layer and the second coil layer are stacked and the first coil portion and the second coil portion are connected in series.

9. The component of claim 1, further comprising surface mount terminations.

10. The component of claim 1, wherein the first dielectric layer, the second dielectric layer and the coil layer are laminated together.

11. The component of claim 1, wherein the core opening is substantially circular.

12. The component of claim 1, wherein the component is an inductor.

13. A low profile magnetic component comprising:

first and second dielectric layers, one of the first and second dielectric layers comprising a polymer based material;

a coil layer sandwiched between the first and second dielectric layers, the coil layer defining a generally planar coil portion and a center opening therein;

wherein at least one of the first and second dielectric layers comprises a core opening defining a receptacle for the introduction of a magnetic core material; and

a magnetic material applied in the core opening and the center opening and embedding the coil portion.

14. The component of claim 13, wherein the first coil layer comprises a double sided coil.

15. The component of claim 13, wherein at least one of the first and second dielectric layers comprises a polyimide film.

16. The component of claim 13, wherein the coil layer comprises an electroformed coil winding formed independently of the first and second dielectric layers.

17. The component of claim 13, further comprising surface mount terminations.

18. The component of claim 13, wherein the at least one coil layer comprises multiple coil layers, each of the coil layers defining a generally planar coil portion, and each of the coil layers being connected in series.

19. The component of claim 18, wherein each of the layers includes a plurality of termination openings, each of the coil portions on the coil layers being interconnected by selected ones of the termination openings.

20. A low profile magnetic component comprising:

at least one coil layer, each coil layer including a dielectric base layer, a generally planar coil winding extending thereon, and an open center area;

a first outer dielectric layer and a second outer dielectric layer extending on opposing sides of the stacked coil layers, at least one of the first and second outer dielectric layers comprising a polyimide material and at least one of the first second layers comprising a core opening exposing the planar coil winding and the open center area; and

a magnetic permeable material filling the core opening and the open center area and covering the planar coil winding.

21. The component of claim 20, wherein the at least one coil layer comprises a plurality of stacked coil layers, each of the coil layers including a dielectric base layer and a generally planar coil winding extending thereon.

22. The component of claim 21, wherein the coil windings of adjacent coil layers are connected in series.

23. The component of claim 20, wherein the coil winding is formed independently of the first and second outer dielectric layers.

24. The component of claim 20, wherein the planar coil winding comprises a double sided coil.

25. The component of claim 20, further comprising surface mount terminations.

26. The component of claim 20, wherein the magnetic permeable material is substantially coplanar with the first and second outer dielectric layers.

27. A method of fabricating a conductive component comprising:

providing at least one outer dielectric layer, the outer dielectric layer having a core opening formed therethrough;

providing a coil layer including a substantially planar coil winding portion formed on at least one dielectric base layer, and an open center area in the coil winding portion;

stacking the outer dielectric layer and the coil layer such that the coil winding portion and the open center area is exposed through the core opening; and

applying a magnetic core material over the exposed coil portion via the core opening, wherein the magnetic core material fills the open center area and embeds the coil winding portion.

28. The method of claim 27, further comprising laminating the outer dielectric layer to the coil layer.

29. The method of claim 27, further comprising singulating the stacked layers into discrete components.

30. The method of claim 27, wherein providing a coil layer comprises providing a plurality of coil layers stacked upon one another, each of the coil layers including a termination opening, the method further comprising filling the termination opening to interconnect the coil layers in series.

31. The method of claim 27 further comprising forming surface mount terminations on the outer dielectric layer.

32. The method of claim 27 wherein providing a coil layer comprises providing a double sided coil extending on a dielectric base layer.

33. The method of claim 27 wherein providing a coil layer comprises electroforming a coil portion having a number of turns on a major surface of the dielectric base layer.

34. A magnetic component comprising:

means for establishing a number of coil turns, the coil turns extending in a plane about an open center area;

planar means for insulating the means for establishing, the means for insulating sandwiching the means for establishing a number of coil turns; and

means for receiving a magnetic permeable material, located in the means for insulating and exposing the coil turns; and

a magnetic permeable material filling the means for receiving and the open center area and embedding the means for establishing.

35. The component of claim 34, wherein the means for establishing comprises a plurality of separately fabricated coil portions, the component further comprising means for connecting the coil portions in series.

36. The component of claim 34, further comprising means for terminating the means for establishing to a circuit board.

37. The component of claim 34, wherein the magnetic permeable material is substantially coplanar with a surface of the means for insulating.

38. A magnetic component comprising:

at least a first dielectric sheet layer and a second dielectric sheet layer, each of the first and second dielectric sheet layers comprising a non-ceramic material;

a coil defining a coil winding having opposing sides side defined by a rounded inner periphery and a rounded outer periphery, and an open center being substantially coextensive with the inner periphery, the coil being fabricated independently of the first and second dielectric sheet layers;

wherein the first and second dielectric sheet layers extend on the respective opposing sides of the coil and are pressed around the coil; and

a magnetic core material extending through the first and second dielectric sheet layers and filling the open center;

wherein the magnetic core material further extends radially away from the open center on at least one of the opposing sides and defines a circular core piece extending to the rounded outer periphery; and

wherein the magnetic core material is fabricated from a different material than at least one of the first dielectric sheet layer and the second dielectric sheet layer.

39. The magnetic component of claim 38, wherein each of the first and second sheet dielectric sheet layers comprises a dielectric film laminated to coil.

40. The magnetic component of claim 38, wherein at least one of the first and second sheet layers includes a core opening exposing one of the opposing sides of the coil winding, and the magnetic core material filling the core opening and the open center area of the coil.

41. The magnetic component of claim 38, wherein the coil comprises an electroformed coil layer.

42. The magnetic component of claim 38, wherein at least one of the first and second dielectric sheet layers comprises a polymer based dielectric sheet layer.