US 2016/0111196 A1Published application

Embedded magnetic component device

AssigneeMurata Manufacturing Co., Ltd.

InventorLee FRANCIS

Life of this patent

Estimating the term…

Loading patent…

Abstract

A magnetic core is situated in a cavity routed into an insulating substrate. The cavity and magnetic core are coved with a first insulating layer. Through holes are then formed through the first insulating layer and the insulating substrate, and plated to form conductive vias. Metallic traces are added to the exterior surfaces of the first insulating layer and the insulating substrate to form upper and lower winding layers. The metallic traces and conductive vias define the respective primary and secondary side windings for an embedded transformer. At least a second set of the outer conductive vias, are spaced farther from the cavity than a first set, and have greater via hole diameter than the vias in the first set. This reduces the resistance of the windings for a given substrate size and improves the performance of the device.

Claims19

Dependent claims

An embedded magnetic component device, comprising:

an insulating substrate including a first side and a second side opposite the first side, and including a cavity therein, the cavity including an inner and an outer periphery;
a magnetic core included in the cavity;
and
an electrical winding that extends through the insulating substrate and around the magnetic core;
wherein
the electrical winding includes:
upper conductive traces located on the first side of the insulating substrate;
lower conductive traces located on the second side of the insulating substrate;
inner conductive connectors extending through the insulating substrate adjacent to the inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces;
and
outer conductive connectors extending through the insulating substrate adjacent to the outer periphery of the magnetic core, the outer conductive connectors respectively define electrical connections between respective first upper conductive traces and respective first lower conductive traces;
wherein
the outer conductive connectors include a first set of outer conductive connectors and a second set of outer conductive connectors;
the first set of outer conductive connectors are located along the outer periphery of the cavity and are spaced from the outer periphery of the cavity by a first distance;
the second set of the outer conductive connectors are located adjacently without the first set of outer conductive connectors in between and at a greater distance from the outer periphery of the cavity than the first set of outer conductive connectors;
each of the first and second set of outer conductive connectors is electrically connected to one of the inner conductive connectors through one of the upper conductive traces or one of the lower conductive traces;
two outer conductive connectors of the second set of outer conductive connectors are located directly adjacent to respective ones of the first set of outer conductive connectors;
in a thickness direction of the insulating substrate, either:
the upper conductive traces connected to the first set of outer conductive connectors do not overlap with the upper conductive traces connected to the second set of outer conductive connectors;
or
the lower conductive traces connected to the first set of outer conductive connectors do not overlap with the lower conductive traces connected to the second set of outer conductive connectors;
and
adjacent inner conductive connectors connected to the second set of the outer conductive connectors are located at different distances from the cavity.

20 more elements

A method of manufacturing an embedded magnetic component device, comprising:

a) preparing an insulating substrate including a first side and a second side opposite the first side, and including a toroidal cavity therein, the toroidal cavity including an inner and an outer periphery;
b) installing a magnetic core in the toroidal cavity;
c) forming an electrical winding that extends through the insulating substrate and around the magnetic core, the electrical winding including:
upper conductive traces located on the first side of the insulating substrate;
lower conductive traces located on the second side of the insulating substrate;
inner conductive connectors extending through the insulating substrate adjacent to the inner periphery of the magnetic core, the inner conductive connectors respectively defining electrical connections between respective upper conductive traces and respective lower conductive traces;
and
outer conductive connectors extending through the insulating substrate adjacent to the outer periphery of the magnetic core, the outer conductive connectors respectively defining electrical connections between respective first upper conductive traces and respective first lower conductive traces;
and
d) in step c) forming the outer conductive connectors to include a first set of outer conductive connectors and a second set of outer conductive connectors;
wherein
the first set of outer conductive connectors are located along the outer periphery of the toroidal cavity and are spaced from the outer periphery of the toroidal cavity by a first distance;
and
the second set of the outer conductive connectors are located adjacently without the first set of outer conductive connectors in between and at a greater distance from the outer periphery of the toroidal cavity than the first set of outer conductive connectors;
each one of the first and second set of outer conductive connectors is electrically connected to one of the inner conductive connectors through one of the upper conductive traces or one of the lower conductive traces
two outer conductive connectors of the second set of outer conductive connectors are located directly adjacent to respective ones of the first set of outer conductive connectors;
in a thickness direction of the insulating substrate, either:
the upper conductive traces connected to the first set of outer conductive connectors do not overlap with the upper conductive traces connected to the second set of outer conductive connectors;
or
the lower conductive traces connected to the first set of outer conductive connectors do not overlap with the lower conductive traces connected to the second set of outer conductive connectors;
and
adjacent inner conductive connectors connected to the second set of the outer conductive connectors are located at different distances from the cavity.

19 more elements

Dependencies are inferred from the claim text.