Method for manufacture of multi-layer-multi-turn high efficiency inductors with cavity

• US 8,692,642 B2
• Filed: 03/12/2013
• Issued: 04/08/2014
• Est. Priority Date: 03/09/2009
• Status: Active Grant

• Current Assignee: Nucurrent, Inc.
• Original Assignee: Nucurrent, Inc.
• Inventors: Singh, Vinit, Babcock, Jacob, Frysz, Christine A.
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/797,478
• Publication Number:
  US 20130205582A1
• Time in Patent Office: 392 Days
• Field of Search: 336/200, 336206-208, 336/232, 296/021
• US Class Current: 336/200
• CPC Class Codes: A61N 1/0553 Paddle shaped electrodes, e.g. for laminotomy
• CPC Class Codes: A61N 1/3605 Implantable neurostimulators for stimulating central or peripheral nerve system
• CPC Class Codes: A61N 1/37229 Shape or location of the implanted or external antenna
• CPC Class Codes: A61N 1/3756 Casings with electrodes thereon, e.g. leadless stimulators
• CPC Class Codes: A61N 1/3787 from an external energy source
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01F 17/00 Fixed inductances of the signal type coils in general H01F5/00; inductors without a potential-jump or surface barrier specially adapted for integrated circuits, details thereof and multistep manufacturing processes therefor H01L28/10
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 29/02 with tappings on coil or winding; with provision for rearrangement or interconnection of windings
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/00 Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H01F 7/06 Electromagnets; Actuators including electromagnets electric coils H01F5/00; devices for holding workpieces using electric force B23Q3/15; load-engaging elements for lifting articles electromagnetically B66C1/06; electromagnetic couplings F16D27/00; magnetic brakes F16D63/002; electromagnetically operated valves F16K11/24, F16K31/00; analysing materials by magnetic means G01N27/72, G01N27/80; electromagnets for winding mechanical clocks G04C1/02; electromagnetic relays H01H51/00; windings for salient poles of dynamo-electric machines H02K3/18; electromagnets for telegraphic communication H04L; for arc lamps H05B31/28
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 7/00 : Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
• CPC Class Codes: H01R 43/00 : Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors of trolley lines B60M1/28
• CPC Class Codes: H02J 2310/23 : The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 50/005 : Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/12 : of the resonant type
• CPC Class Codes: H02P 13/00 : Arrangements for controlling transformers, reactors or choke coils, for the purpose of obtaining a desired output
• CPC Class Codes: H03H 7/01 : Frequency selective two-port networks
• CPC Class Codes: H04B 5/24 : Inductive coupling
• CPC Class Codes: H04B 5/45 : Transponders
• CPC Class Codes: H04B 5/72 : for local intradevice communication
• CPC Class Codes: H04B 5/77 : for interrogation
• CPC Class Codes: H04B 5/79 : for data transfer in combination with power transfer
• CPC Class Codes: H05B 6/06 : Control, e.g. of temperature, of power
• CPC Class Codes: H05B 6/1245 : with special coil arrangements
• CPC Class Codes: H05B 6/36 : Coil arrangements
• CPC Class Codes: H05B 6/362 : with flat coil conductors
• CPC Class Codes: H05K 1/165 : incorporating printed inductors
• CPC Class Codes: H05K 2201/0352 : Differences between the conductors of different layers of a multilayer
• CPC Class Codes: Y02B 40/00 : Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y10T 29/49005 : Acoustic transducer
• CPC Class Codes: Y10T 29/4902 : Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/4908 : Acoustic transducer
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49155 : Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49195 : with end-to-end orienting

Abstract

A multi-layer, multi-turn structure for an inductor having a plurality of conductor layers separated by layers of insulator is described. The inductor further comprises a connector electrically connected between the conductor layers. The structure of the inductor may comprise a cavity therewithin. The structure of the inductor constructed such that electrical resistance is reduced therewithin, thus increasing the efficiency of the inductor. The inductor is particularly useful at operating within the radio frequency range and greater.

Claims

1. A method of manufacturing an inductor structure, the method comprising the following steps:

a) providing a first conductor and a second conductor, the first conductor and the second conductor being electrically conductive;

b) positioning an insulator between the first conductor and the second conductor, thereby forming an inductor structure;

c) forming an inductor cavity having an inductor cavity width, an inductor cavity length, and an inductor cavity depth residing within the inductor structure;

d) connecting electrically the first conductor and the second conductor with at least, one connector, wherein propagation of an electrical current within at least the first conductor causes a magnetic flux to be generated within the inductor when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current occurs.

2. The method of claim 1 including generating an electromotive force when at least one of the frequency, the magnitude, or the waveform shape is changed.

3. The method of claim 2 including providing a magnitude of the magnetic flux proportional to the amount of change of at least one of the frequency, the magnitude, or the waveform shape of the electrical current.

4. The method of claim 1 including reducing an electrical resistance of at least the first conductor or the second conductor when a cross-sectional area of a conducting skin depth within at least the first conductor or the second conductor is increased.

5. The method of claim 1 including providing a thickness of the first conductor about equal to a thickness of a skin depth of the first conductor at a given operating frequency.

6. The method of claim 1 including providing a thickness of the first conductor ranging from about 1.25 times to about 4 times a thickness of a skin depth of the first conductor at a given operating frequency.

7. The method of claim 1 including providing a thickness of the second conductor ranging from about 1.25 times to about 4 times a thickness of a skin depth of the second conductor at a given operating frequency.

8. The method of claim 1 including providing a first conductor thickness about the same as a second conductor thickness.

9. The method of claim 1 including providing a first conductor thickness different from a second conductor thickness.

10. The method of claim 1 including providing a thickness of a first skin depth of the first conductor layer about the same as a thickness of a second skin depth of the second conductor.

11. The method of claim 1 including providing a thickness of a first skin depth of the first conductor different than a thickness of a second skin depth of the second conductor.

12. The method of claim 1 including providing a thickness of the insulating less than about 5 cm.

13. The method of claim 1 including providing an inductor quality factor greater than about 5.

14. The method of claim 13 including defining the inductor quality factor by the equation

15. The method of claim 1 including forming at least one of the first and second conductors from a thermally conductive material.

16. The method of claim 1 including providing the connector comprising at least one of a via, a solder, a tab, a wire, a pin, a rivet, a filled mesh structure, a conductive polymer, a conductive composite, a conductive adhesive, a liquid metal, or a foamed metal.

17. The method of claim 1 including electrically connecting the first conductor and the second conductor in parallel or series with at least the one connector.

18. The method of claim 1 including forming the inductor structure in which the first and second conductors are positioned in about a parallel orientation, a perpendicular orientation, or at an angular relationship with respect to each other.

19. The method of claim 1 including providing a third conductor and a fourth conductor electrically connected in parallel or series, wherein the first and second conductors are connected electrically in parallel or series and are further electrically connectable in series or parallel with the third and fourth conductors.

20. The method of claim 1 including electrically connecting the inductor to an electrical circuit operating at about 3 kHz or greater.

21. The method of claim 20 including selecting the electrical circuit from the group consisting of a mixer circuit, an impedance matching circuit, an upconverting mixer circuit, a downconverting mixer circuit, a modulator, a demodulator, a synthesizing circuit, a PLL synthesizing circuit, an amplifying circuit, an electrical driver circuit, an electrical detecting circuit, an RF log detector, an RF RMS detector, an electrical transceiver, a power controller, and combinations thereof.

22. The method of claim 1 including electrically connecting the inductor within an induction heating circuit.

23. The method of claim 1 including electrically connecting a control circuit with the inductor or other component comprising the electrical circuit.

24. The method of claim 1 including providing at least the first and second conductors with at least a partial revolution.

25. The method of claim 1 including providing the first conductor or the second conductor having a material selected from the group consisting of copper, titanium, platinum, platinum and iridium alloys, tantalum, niobium, zirconium, hafnium, nitinol, cobalt-chromium-nickel alloys, stainless steel, gold, a gold alloy, palladium, carbon, silver, a noble metal, a conductive polymer, a conductive adhesive, a conductive composite, a liquid metal, a foamed metal, a conductive tape, a conductive ribbon, a conductive foil, a conductive leaf, a wire, a deposited metal, a biocompatible material, and combinations thereof.

26. The method of claim 1 including forming at least one insulator from an electrically insulative material.

27. The method of claim 1 including providing the insulator having an electrically insulative material selected from the group consisting of air, polystyrene, silicon dioxide, a biocompatible ceramic, a conductive dielectric material, a non-conductive dielectric material, a piezoelectric material, a pyroelectric material, a ferrite material, and combinations thereof.

28. The method of claim 1 including providing the insulator layer comprising a first material having a first dielectric constant and a second material having a second dielectric constant, the second material residing within the inductor cavity, the first and second dielectric constants being not equal.

29. The method of claim 28 including providing the second material selected from the group consisting of a polymeric material, a piezoelectric material, a pyroelectric material, and combinations thereof.

30. The method of claim 1 including providing the inductor cavity width ranging from about 80 percent to about 99 percent of an inductor width.

31. The method of claim 1 including providing the inductor cavity length ranging from about 80 percent to about 99 percent of an inductor length.

32. The method of claim 1 including providing the inductor cavity depth about equal to an inductor depth, such that the cavity extends through at least a top inductor surface or a bottom inductor surface.

33. The method of claim 1 including providing the inductor cavity depth less than an inductor depth, such that the inductor cavity resides between a top inductor surface and a bottom inductor surface.

34. A method of manufacturing an inductor structure, the method comprising the following steps:

a) providing a first inductor subassembly comprising the following steps;

i) providing a first conductive conductor and a second conductive conductor spaced apart from the first conductor, the first conductor and the second conductor being electrically conductive;

ii) positioning a first insulator in a space between the first conductor and the second conductors thereby forming a first inductor structure;

iii) forming a first inductor cavity having a first inductor cavity width, a first inductor cavity length, and a first inductor cavity depth within the first structure;

iv) connecting the first conductor layer and the second conductor layer electrically in parallel or series with a first connector;

c) providing a second inductor subassembly comprising the following steps;

i) providing a third conductor and a fourth conductor spaced apart from the third conductor, the third conductor and the fourth conductor being electrically conductive;

ii) positioning a second insulator in a space between the third conductor and the fourth conductors, thereby forming a second inductor structure;

iii) connecting the third conductor and the fourth conductor electrically in parallel or series with a second connector;

connecting the first inductor subassembly electrically in series or parallel to the second inductor subassembly such that when an electrical current is propagated within at least the first conductor, a magnetic flux is generated within the inductor when a change in at least one of a frequency, a magnitude, or a waveform shape of the propagated electrical current occurs.

35. The method of claim 34 including orienting the first conductor subassembly and the second inductor subassembly such that the first and second inductor subassemblies are positioned about parallel, about perpendicular, or at an angular relationship with respect to each other.

36. The method of claim 34 including forming a second inductor cavity having a second inductor cavity width, a second inductor cavity length, and a second inductor cavity depth within the second inductor subassembly structure.