Method for manufacturing a planar electronic device having a magnetic component

• US 9,070,509 B2
• Filed: 02/16/2011
• Issued: 06/30/2015
• Est. Priority Date: 01/11/2007
• Status: Active Grant

• Current Assignee: TE Connectivity Solutions GmbH (TE Connectivity Limited)
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Limited)
• Inventors: Dalmia, Sidharth, Viray, Spencer, Harrison, Lee, Kerlin, Jess, Nguyen, Khanh, Kubes, Steven R.
• Primary Examiner(s): Tugbang, A. Dexter
• Application Number:
  US13/028,949
• Publication Number:
  US 20110272094A1
• Time in Patent Office: 1,595 Days
• Field of Search: 296/021, 296/04, 296/06, 296/07, 296/09, 528/408, 525/108, 336/200, 336/208, 336/221, 264/272.13, 264/272.19
• US Class Current: 1/1
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: C08G 59/621 Phenols
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 41/0253 for manufacturing permanent magnets
• 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 41/046 structurally combined with ferromagnetic material
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49069 Data storage inductor or core
• 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

Abstract

A method for manufacturing a planar electronic device includes applying a non-conductive fluid polymer to a lower side of a planar substrate. The substrate includes a hole extending through the substrate. The method also includes curing the fluid polymer to form a solid centering layer on the lower side of the substrate, with the centering layer extending across the hole along the lower side of the substrate. The method further includes loading a ferrite material body into the hole of the substrate through the upper side of the substrate, embedding the ferrite material body in an encapsulating material in the hole, and forming one or more conductive loops around the ferrite material body. The ferrite material body is held within the substrate between the lower side and the upper side of the substrate by the encapsulating material.

Claims

1. A method for manufacturing a planar electronic device, the method comprising:

applying a non-conductive fluid polymer to a lower side of a planar substrate, the substrate including a hole extending through the substrate between the lower side and an opposite upper side of the substrate;

curing the fluid polymer to form a solid centering layer on the lower side of the substrate, the centering layer extending across the hole along the lower side of the substrate;

loading a ferrite material body into the hole of the substrate through the upper side of the substrate such that the ferrite material body contacts the centering layer, the centering layer preventing the ferrite material body from moving beyond the lower side of the substrate;

embedding the ferrite material body in an encapsulating material that is deposited into the hole and around the ferrite material body; and

forming one or more conductive loops around the ferrite material body, wherein the ferrite material body is held within the substrate between the lower side and the upper side of the substrate by the encapsulating material.

2. The method of claim 1, wherein planes defined by the upper side and the lower side of the substrate are boundaries of an envelope for receiving the ferrite material body and the ferrite material body is disposed within the envelope.

3. The method of claim 2, wherein the ferrite material body does not intersect the plane defined by the lower side of the substrate.

4. The method of claim 2, wherein the ferrite material body does not intersect the plane defined by the upper side of the substrate.

5. The method of claim 1, further comprising applying the fluid polymer to the upper side of the substrate and across the hole along the upper side of the substrate, the fluid polymer on the upper side curing to form an upper centering layer.

6. The method of claim 1, wherein applying the fluid polymer to the lower side of the substrate includes applying the fluid polymer to a supporting surface of a transfer board that is separate from the substrate, transferring the fluid polymer on the supporting surface to the lower side of the substrate, and removing the substrate and the solid centering layer from the supporting surface.

7. The method of claim 1, wherein applying the fluid polymer to the lower side of the substrate includes providing a fiber sheet within the fluid polymer and curing the fluid polymer includes curing the fiber sheet within the fluid polymer to form a fiber-reinforced layer as the centering layer.

8. The method of claim 1, further comprising forming the hole in the substrate such that the hole has different diameter dimensions in different locations within the substrate between the upper side of the substrate and the lower side of the substrate, the different diameter dimensions formed by an angled inner surface of the substrate that tapers the different diameter dimensions.

9. A method for manufacturing a planar electronic device, the method comprising:

applying a non-conductive fluid polymer to a lower side of a planar substrate, the substrate including a hole extending through the substrate between the lower side and an opposite upper side of the substrate;

curing the fluid polymer to form a solid centering layer on the lower side of the substrate, the centering layer extending across the hole along the lower side of the substrate;

loading a ferrite material body into the hole of the substrate through the upper side of the substrate, the centering layer preventing the ferrite material body from moving beyond the lower side of the substrate;

embedding the ferrite material body in an encapsulating material that is deposited into the hole and around the ferrite material body; and

forming one or more conductive loops around the ferrite material body, wherein the ferrite material body is held within the substrate between the lower side and the upper side of the substrate by the encapsulating material,

wherein applying the fluid polymer to the lower side of the substrate includes applying the fluid polymer to a supporting surface of a transfer board that is separate from the substrate, transferring the fluid polymer on the supporting surface to the lower side of the substrate, and removing the substrate and the solid centering layer from the supporting surface.

10. The method of claim 9, wherein planes defined by the upper side and the lower side of the substrate are boundaries of an envelope for receiving the ferrite material body and the ferrite material body is disposed within the envelope.

11. The method of claim 10, wherein the ferrite material body does not intersect one or more of the plane defined by the lower side of the substrate or the plane defined by the upper side of the substrate.

12. The method of claim 9, further comprising applying the fluid polymer to the upper side of the substrate and across the hole along the upper side of the substrate, the fluid polymer on the upper side curing to form an upper centering layer.

13. The method of claim 9, wherein applying the fluid polymer to the lower side of the substrate includes providing a fiber sheet within the fluid polymer and curing the fluid polymer includes curing the fiber sheet within the fluid polymer to form a fiber-reinforced layer as the centering layer.

14. The method of claim 9, further comprising forming the hole in the substrate such that the hole has different diameter dimensions in different locations within the substrate between the upper side of the substrate and the lower side of the substrate, the different diameter dimensions formed by an angled inner surface of the substrate that tapers the different diameter dimensions.

15. A method for manufacturing a planar electronic device, the method comprising:

forming a hole in a planar substrate such that the hole has different diameter dimensions in different locations within the substrate between an upper side of the substrate and an opposite lower side of the substrate, the different diameter dimensions formed by an angled inner surface of the substrate that tapers the different diameter dimensions;

applying a non-conductive fluid polymer to the lower side of the substrate, the substrate including the hole extending through the substrate between the lower side and the upper side of the substrate;

curing the fluid polymer to form a solid centering layer on the lower side of the substrate, the centering layer extending across the hole along the lower side of the substrate;

loading a ferrite material body into the hole of the substrate through the upper side of the substrate, the centering layer preventing the ferrite material body from moving beyond the lower side of the substrate;

embedding the ferrite material body in an encapsulating material that is deposited into the hole and around the ferrite material body; and

forming one or more conductive loops around the ferrite material body, wherein the ferrite material body is held within the substrate between the lower side and the upper side of the substrate by the encapsulating material.

16. The method of claim 15, wherein planes defined by the upper side and the lower side of the substrate are boundaries of an envelope for receiving the ferrite material body and the ferrite material body is disposed within the envelope, wherein the ferrite material body does not intersect one or more of the plane defined by the lower side of the substrate or the plane defined by the upper side of the substrate.

17. The method of claim 15, further comprising applying the fluid polymer to the upper side of the substrate and across the hole along the upper side of the substrate, the fluid polymer on the upper side curing to form an upper centering layer.

18. The method of claim 15, wherein applying the fluid polymer to the lower side of the substrate includes applying the fluid polymer to a supporting surface of a transfer board that is separate from the substrate, transferring the fluid polymer on the supporting surface to the lower side of the substrate, and removing the substrate and the solid centering layer from the supporting surface.

19. The method of claim 15, wherein applying the fluid polymer to the lower side of the substrate includes providing a fiber sheet within the fluid polymer and curing the fluid polymer includes curing the fiber sheet within the fluid polymer to form a fiber-reinforced layer as the centering layer.