Systems and methods of fabricating coils for coreless transformers and inductors

A method of fabricating a coreless printed circuit board (PCB)-based transformer (cPCBT) comprising at least one primary winding element and one secondary winding element, said cPCBT having a windings' turn ratio of the primary winding element to the secondary winding element operable to achieve a step-up/down-operation, the method comprising:

• providing an ink jet printing system having:
• a first print head adapted to dispense a dielectric ink;
• a second print head adapted to dispense a conductive ink;
• a conveyor, operably coupled to the first and second print heads, configured to convey a substrate to each print heads;
• and
• a computer aided manufacturing (“CAM”) module, in communication with each of the first, and second print heads, the CAM further comprising a central processing module (CPM) including at least one processor, in communication with a non-transitory computer readable storage device operable to store instructions that, when executed by the at least one processor cause the CAM to control the ink-jet printing system, by carrying out steps that comprise:
• receiving a 3D visualization file representing the cPCBT;
• and
• generating a file library having a plurality of ordered files, each ordered file representing a substantially 2D layer for printing the cPCBT having thereon:
• at least one of:
• a conductive pattern;
• and a dielectric pattern, and a metafile representing at least the printing order;
• providing the dielectric inkjet ink composition, and the conductive inkjet ink composition;
• using the CAM module, obtaining a first ordered layer file for printing;
• using the first print head, forming the pattern corresponding to the dielectric inkjet ink of the first ordered layer file on the substrate;
• using actinic radiation, curing the dielectric pattern;
• using the second print head, forming the conductive pattern in the first ordered file for printing of cPCBT;
• using heat, sintering the pattern corresponding to the conductive inkjet ink in the first ordered layer file, wherein the steps of curing and sintering are carried out separately;
• using the CAM module, obtaining from the library an ordered layer file representative of a subsequent layer for printing the cPCBT;
• using the first print head, forming the pattern corresponding to the dielectric ink in the subsequent ordered layer file;
• using actinic radiation, curing the dielectric pattern in the subsequent ordered layer file;
• using the second print head, forming the conductive pattern in the subsequent ordered layer file for printing of cPCBT;
• using heat, sintering the conductive pattern in the subsequent ordered layer file;
• and
• repeating the steps of, obtaining from the library an ordered layer file representative of a subsequent layer for printing the cPCBT—to the step of sintering the conductive pattern in the subsequent ordered layer file, wherein a final conductive layer is printed, thereby forming the cPCBT, with a windings' turn ratio of a primary winding element to a secondary winding element that is operable to achieve a step-up/down-operation, and wherein each of the primary winding element and the secondary winding element of the windings is comprised of a plurality of sub-element arcs of predetermined radians concatenated to a subsequent sub-element arc with at least one of:
• a blind via, and a buried via each formed in the steps of printing the first, the subsequent, or the final conductive pattern.