Integration of a coil and a discontinuous magnetic core

• US 9,293,245 B2
• Filed: 08/05/2013
• Issued: 03/22/2016
• Est. Priority Date: 08/05/2013
• Status: Expired due to Fees

• Current Assignee: Snaptrack Incorporated (Qualcomm, Inc.)
• Original Assignee: Qualcomm MEMS Technologies Incorporated (Qualcomm, Inc.)
• Inventors: Stephanou, Philip Jason, Kim, Jitae, Shenoy, Ravindra Vaman, Lai, Kwan-yu
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): Hinson, Ronald
• Application Number:
  US13/958,645
• Publication Number:
  US 20150035638A1
• Time in Patent Office: 960 Days
• Field of Search: 336/200, 336/223, 336/232
• US Class Current: 1/1
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 2017/004 with the coil helically wound around an axis without a core
• CPC Class Codes: H01F 2017/0066 with a magnetic layer
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 41/046 structurally combined with ferromagnetic material

Abstract

A particular device includes a coil and a discontinuous magnetic core. The discontinuous magnetic core includes a first elongated portion, a second elongated portion, and at least two curved portions, where the portions are coplanar and physically separated from each other. The discontinuous magnetic core is arranged to form a discontinuous loop. The discontinuous magnetic core is deposited as a first layer above a dielectric substrate. A first portion of the coil extends above a first surface of the magnetic core. A second portion of the coil extends below a second surface of the magnetic core. The second portion of the coil is electrically coupled to the first portion of the coil. The second surface of the magnetic core is opposite the first surface of the magnetic core.

Claims

1. An apparatus comprising:

a dielectric substrate having a first surface and a second surface opposite the first surface;

a first magnetic core comprising;

a first elongated portion;

a second elongated portion physically separate from the first elongated portion; and

at least two curved portions physically separate from the first elongated portion and from the second elongated portion, the at least two curved portions being substantially coplanar with the first elongated portion and the second elongated portion, the at least two curved portions, the first elongated portion, and the second elongated portion forming a discontinuous loop on the first surface of the dielectric substrate; and

a second magnetic core comprising;

a first elongated portion;

a second elongated portion physically separate from the first elongated portion; and

at least two curved portions physically separate from the first elongated portion and from the second elongated portion, the at least two curved portions being substantially coplanar with the first elongated portion and the second elongated portion, the at least two curved portions, the first elongated portion, and the second elongated portion forming a second discontinuous loop on the second surface of the dielectric substrate and

a first coil including wherein a first portion of the first coil that extends above a first surface of the first magnetic core and above a first surface of the second magnetic core and a second portion of the first coil that extends below a second surface of the first magnetic core and below a second surface of the second magnetic core the second portion being coupled with the first portion.

2. The apparatus of claim 1, wherein:

the dielectric substrate includes a glass material,

the first coil includes a conductive via that extends at least partially within the dielectric substrate, and

the conductive via forms a portion of a turn of the first coil.

3. The apparatus of claim 1, wherein the second magnetic core is substantially symmetrical to the first magnetic core.

4. The apparatus of claim 1, wherein the dielectric substrate includes an alkaline earth boro-aluminosilicate glass, a glass-based laminate, sapphire (Al₂O₃), quartz, a ceramic, or a combination thereof.

5. The apparatus of claim 1, wherein at least one of the first magnetic core and the second magnetic core is formed includes Cobalt (Co), Iron (Fe), Tantalum (Ta), Zirconium (Zr), Nickel (Ni), Cobalt Iron (CoFe), Cobalt Tantalum Zirconium (CoTaZr), Nickel Iron (NiFe), or a combination thereof.

6. The apparatus of claim 1, wherein the first magnetic core has a racetrack toroid shape.

7. The apparatus of claim 6, wherein the second magnetic core has a racetrack toroid shape.

8. The apparatus of claim 1, wherein the first coil includes a plurality of conductive elements that coil around the first magnetic core.

9. The apparatus of claim 8, wherein the plurality of conductive elements of the first coil also around the second magnetic core.

10. The apparatus of claim 1, further comprising one or more electrical insulators between at least two of the separate portions of the first magnetic core.

11. The apparatus of claim 10, further comprising one or more electrical insulators between at least two of the separate portions of the second magnetic core.

12. The apparatus of claim 1, wherein the first magnetic core is a uniaxial core.

13. The apparatus of claim 12, wherein the second magnetic core is a uniaxial core.

14. The apparatus of claim 1, further comprising a second coil interspersed with the first coil, wherein a first portion of the second coil extends above the first surface of the first magnetic core and above the first surface of the second magnetic core, wherein a second portion of the second coil extends below the second surface of the first magnetic core and below the second surface of the second magnetic core and wherein the second portion of the second coil is coupled with the first portion of the second coil.

15. The apparatus of claim 14, wherein the first coil and the second coil form a transformer.

16. An electronic device comprising:

the apparatus of claim 1; and

at least one die coupled with the apparatus of claim 1.

17. The electronic device of claim 16 the device being selected from a group consisting of a set top box, a music player, a video player, an entertainment unit, a navigation device, a communications device, a personal digital assistant (PDA), a fixed location data unit, and a computer.

18. An apparatus comprising:

a dielectric substrate having a first surface and a second surface opposite the first surface;

a first magnetically anisotropic magnetic core on the first surface of the dielectric substrate the first magnetic core including a plurality of physically separate segments along an easy axis of the first magnetic core on the first surface of the dielectric substrate;

a second magnetic core on the second surface of the dielectric substrate; and

a first coil including a first portion that extends above a first surface of the first magnetic core and above a first surface of the second magnetic core, and a second portion that extends below a second surface of the first magnetic core and below a second surface of the second magnetic core, the second portion being coupled with the first portion.

19. The apparatus of claim 18, wherein:

the dielectric substrate includes a glass material, the first coil includes a conductive via that extends at least partially within the dielectric substrate, and the conductive via forms a portion of a turn of the coil.

20. The apparatus of claim 18, wherein the second magnetic core is substantially symmetrical to the first magnetic core.

21. The apparatus of claim 18, wherein the dielectric substrate includes an alkaline earth boro-aluminosilicate glass, a glass-based laminate, sapphire (Al₂O₃), quartz, a ceramic, or a combination thereof.

22. The apparatus of claim 18, wherein at least one of the first magnetic core and the second magnetic core includes Cobalt (Co), Iron (Fe), Tantalum (Ta), Zirconium (Zr), Nickel (Ni), Cobalt Iron (CoFe), Cobalt Tantalum Zirconium (CoTaZr), Nickel Iron (NiFe), or a combination thereof.

23. The apparatus of claim 18, wherein the second magnetic core is a magnetically anisotropic magnetic core.

24. The apparatus of claim 18, wherein the second magnetic core includes a plurality of physically separate segments along an easy axis of the second magnetic core on the second surface of the dielectric substrate.

25. An electronic device comprising:

the apparatus of claim 18; and

at least one die coupled with the apparatus of claim 18.

26. The electronic device of claim 25, the device being selected from a group consisting of a set top box, a music player, a video player, an entertainment unit, a navigation device, a communications device, a personal digital assistant (PDA), a fixed location data unit, and a computer.

27. The apparatus of claim 18, wherein the plurality of physically separate segments of the first magnetic core collectively have a racetrack toroid shape.

28. The apparatus of claim 27, wherein the second magnetic core has a racetrack toroid shape.

29. The apparatus of claim 18, wherein the coil includes a plurality of conductive elements that coil around the first magnetic core.

30. The apparatus of claim 29, wherein the plurality of conductive elements of the first coil also coil around the second magnetic core.

31. The apparatus of claim 18, further comprising one or more electrical insulators between at least two of the plurality of physically separate segments of the first magnetic core.

32. The apparatus of claim 31, wherein the second magnetic core includes a plurality of physically separate segments along an easy axis of the second magnetic core on the second surface of the dielectric substrate, and wherein the apparatus further comprises one or more electrical insulators between at least two of the plurality of physically separate segments of the second magnetic core.

33. The apparatus of claim 18, wherein the first magnetic core is a uniaxial core.

34. The apparatus of claim 33, wherein the second magnetic core is a uniaxial core.

35. The apparatus of claim 18, further comprising a second coil interspersed with the first coil, wherein a first portion of the second coil extends above the first surface of the first magnetic core and above the first surface of the second magnetic core, wherein a second portion of the second coil extends below the second surface of the first magnetic core and below the second surface of the second magnetic core, and wherein the second portion of the second coil is coupled with the first portion of the second coil.

36. The apparatus of claim 35, wherein the first coil and the second coil form a transformer.

37. An apparatus comprising:

dielectric supporting means having a first surface and a second surface opposite the first surface;

first means for guiding a magnetic field comprising;

a first elongated portion;

a second elongated portion physically separate from the first elongated portion;

at least two curved portions physically separate from the first elongated portion and from the second elongated portion, the at least two curved portions being substantially coplanar with the first elongated portion and the second elongated portion, the at least two curved portions, the first elongated portion, and the second elongated portion forming a discontinuous loop on the first surface of the dielectric supporting means; and

second means for guiding the magnetic field comprising;

a first elongated portion;

a second elongated portion physically separate from the first elongated portion;

at least two curved portions physically separate from the first elongated portion and from the second elongated portion, the at least two curved portions being substantially coplanar with the first elongated portion and the second elongated portion the at least two curved portions, the first elongated portion, and the second elongated portion forming a second discontinuous loop on the second surface of the dielectric supporting means; and

means for inducing a magnetic field including a first portion that extends above a first surface of the first means for guiding the magnetic field and above a first surface of the second means for guiding the magnetic field, and a second portion that extends below a second surface of the first means for guiding the magnetic field and below a second surface of the second means for guiding the magnetic field, the second portion being coupled with the first portion.

38. An electronic device comprising:

the apparatus of claim 37; and

at least one die coupled with the apparatus of claim 37.

39. The electronic device of claim 38 the device being selected from a group consisting of a set top box, a music player, a video player, an entertainment unit, a navigation device, a communications device, a personal digital assistant (PDA), a fixed location data unit, and a computer.

40. An apparatus comprising:

dielectric supporting means having a first surface and a second surface opposite the first surface;

first magnetically anisotropic means for guiding a magnetic field, the first means for guiding the magnetic field being on the first surface of the dielectric supporting means, the first means for guiding the magnetic field including a plurality of physically separate segments along an easy axis of the first means for guiding the magnetic field, the plurality of physically separate segments being on the first surface of the dielectric supporting means;

second means for guiding the magnetic field, the second means for guiding the magnetic field being on the second surface of the dielectric supporting means; and

means for inducing a magnetic field including a first portion that extends above a first surface of the first means for guiding the magnetic field and above a first surface of the second means for guiding the magnetic field, and

a second portion that extends below a second surface of the first means for guiding the magnetic field and below a second surface of the second means for guiding the magnetic field the second portion being coupled with first portion.

41. An electronic device comprising:

the apparatus of claim 40; and

at least one die coupled with the apparatus of claim 40.

42. The electronic device of claim 41, the device being selected from a group consisting of a set top box, a music player, a video player, an entertainment unit, a navigation device, a communications device, a personal digital assistant (PDA), a fixed location data unit, and a computer.