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US 12,658,351 B2Granted
Stacked magnetic cores having small footprints
AssigneeThe Florida International University Board of Trustees
InventorsCarlos Riera Cercado, Markondeyaraj Pulugurtha, Juan Camilo Gomez, Veeru Jaiswal
Life of this patent
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Abstract
Stacked magnetic cores that can achieve high density with a small footprint are provided. A stacked magnetic core can include a plurality of magnetic films with an adhesive film between each magnetic film and the adjacent magnetic film(s). That is, the magnetic films and adhesive films can be disposed in an alternating fashion. Each adhesive film can be a dielectric/insulating film such that each magnetic film is electrically insulated from every other magnetic film.
Claims16
An electrical component, comprising:
- a stacked magnetic core comprising a plurality of magnetic films and a plurality of adhesive films stacked in an alternating fashion such that each magnetic film is electrically isolated from each other magnetic film;
- a coil wrapped around the plurality of magnetic films;
- and
- a magnetic paste disposed around the coil to form a closed magnetic loop with a tuned reluctance in a range of from 5 micrometers (μm) to 100 μm,
- each magnetic film comprising a monolithic cobalt-nickel-iron (CoNiFe) alloy having a cobalt content of 40-65 atomic percent, a saturation magnetization greater than 2.0 Tesla (D), and a metastable nanostructure with oxides less than 5 nanometers (nm)
- each magnetic film being formed by electroplating under application of a uniform unidirectional magnetic field,
- each adhesive film comprising a spin-coated polymer,
- the plurality of magnetic films comprising a first magnetic film, a second magnetic film, and a third magnetic film,
- the plurality of adhesive films comprising a first adhesive film disposed on an upper surface of the first magnetic film and a second adhesive film disposed on an upper surface of the second magnetic film,
- the second magnetic film being disposed on the first adhesive film,
- the third magnetic film being disposed on the second adhesive film,
- the first adhesive film adhering the first magnetic film to the second magnetic film,
- the second adhesive film adhering the second magnetic film to the third magnetic film,
- a footprint of the stacked magnetic core, measured in a first plane having the upper surface of the first magnetic film, being 1 square millimeters (mm2) or less,
- the stacked magnetic core having an inductance density of at least 8 nanohenries per square millimeter (nH/mm2),
- the stacked magnetic core having a coercivity of no more than 1 Oersted (Oe),
- a thickness of each adhesive film of the plurality of adhesive films, measured in a first direction perpendicular to the first plane, being in a range of from 0.1 micrometers (μm) to 1 μm,
- a thickness of each magnetic film of the plurality of magnetic films, measured in the first direction, being in a range of from 0.5 μm to 2 μm, and
- the electrical component being an inductor or a transformer.
16 more elements
An electrical component, comprising:
- a first stacked magnetic core comprising a first magnetic film, a first adhesive film disposed on an upper surface of the first magnetic film, and a second magnetic film disposed on the first adhesive film;
- a first coil wrapped around the first magnetic film and the second magnetic film;
- and
- a magnetic paste disposed around the first coil to form a closed magnetic loop with a tuned reluctance in a range of from 5 μm to 100 μm,
- each of the first magnetic film and the second magnetic film comprising a monolithic CoNiFe alloy having a cobalt content of 40-65 atomic percent, a saturation magnetization greater than 2.0 T. and a metastable nanostructure with oxides less than 5 nm,
- each magnetic film being formed by electroplating under application of a uniform unidirectional magnetic field,
- the first adhesive film comprising a spin-coating polymer,
- the first adhesive film adhering the first magnetic film to the second magnetic film,
- the first magnetic film being electrically insulated from the second magnetic film by the first adhesive film,
- a footprint of the stacked magnetic core, measured in a first plane having the upper surface of the first magnetic film, being 15 square millimeters (mm2) or less, and
- the electrical component being an inductor or a transformer.
8 more elements
An electrical component, comprising:
- a stacked magnetic core comprising a first magnetic film, a first adhesive film disposed on an upper surface of the first magnetic film, and a second magnetic film disposed on the first adhesive film;
- a magnetic paste disposed around the coil to form a closed magnetic loop with a tuned reluctance in a range of from 5 μm to 100 μm;
- and
- a coil wrapped around the stacked magnetic core,
- the first adhesive film adhering the first magnetic film to the second magnetic film, the first magnetic film being electrically insulated from the second magnetic film by the first adhesive film,
- each of the first magnetic film and the second magnetic film comprising a monolithic CoNiFe alloy having a cobalt content of 40-65 atomic percent, a saturation magnetization greater than 2.0 T. and a metastable nanostructure with oxides less than 5 nm,
- each magnetic film being formed by electroplating under application of a uniform unidirectional magnetic field,
- the first adhesive film comprising a spin-coating polymer
- the stacked magnetic core being disposed in a closed loop, the closed loop having a discontinuity in the closed loop forming an air gap, the closed loop being shaped as a toroid or a rectangular frame, and
- the magnetic paste being disposed inside the airgap.
7 more elements
Dependencies are inferred from the claim text.