High power density printed circuit board (PCB) embedded inductors

A device comprising:

• a plurality of upper conductors disposed along an upper surface of a substrate, wherein the plurality of upper conductors is radially disposed about a central axis, wherein a trace clearance between adjacent upper conductors is less than a width of each upper conductor, wherein the substrate comprises a printed circuit board (PCB);
• a plurality of lower conductors disposed along a lower surface of the substrate, wherein the lower substrate is disposed opposite the upper surface, wherein the plurality of lower conductors is radially disposed about the central axis, wherein a trace clearance between adjacent lower conductors is less than a width of each lower conductor;
• and
• a plurality of through-substrate conductors connecting respective upper conductors to respective lower conductors so as to form a series electrical connection, wherein the series electrical connection comprises a toroid configuration, wherein the toroid configuration comprises a plurality of turns about a reference circle that is defined along a reference plane between the upper surface and the lower surface.

A method for designing a PCB-embedded inductor, the method comprising:

• adjusting an outer diameter of the inductor and a number of turns of the inductor based on predetermined physical constraints and predetermined performance specifications, wherein the inductor comprises:
• a plurality of upper conductors disposed along an upper surface of a substrate, wherein the plurality of upper conductors is radial disposed about a central axis;
• a plurality of lower conductors disposed along a lower surface of the substrate, wherein the lower surface is disposed opposite the upper surface, wherein the plurality of lower conductors is radially disposed about the central axis;
• and
• a plurality of through-substrate conductors connecting respective upper conductors to respective lower conductors so as to form a series electrical connection, wherein the series electrical connection comprises a toroid configuration;
• adjusting one or more attributes of the inductor including (i) a trace clearance, (ii) a thickness of at least one of the upper conductor or the lower conductor, (iii) a diameter of the through-substrate conductors, and (iv) a number of through-substrate conductors, wherein the trace clearance comprises a distance between adjacent conductors;
• determining a plurality of device performance metrics, based on the adjusted attributes of the inductor;
• determining, based on the device performance metrics being above a plurality of device requirements, that the inductor should be fabricated;
• and
• fabricating the inductor according to the adjusted attributes.