Embedded magnetic component device

An embedded magnetic component device comprising:

• a base substrate including opposing first and second sides, and a cavity therein, the cavity including a cavity floor, side walls connected by the cavity floor;
• a magnetic core housed in the cavity;
• an insulating layer located on the base substrate to cover the cavity and the magnetic core and to define an insulated substrate;
• one or more electrical windings passing through the insulated substrate and disposed around the magnetic core;
• a layer of adhesive located on the cavity floor, securing the magnetic core in the cavity;
• and
• two or more channels located in the insulating substrate and connecting the cavity to two or more portions of an exterior of the insulated substrate, each of the two or more channels including a channel floor connecting to the cavity floor;
• wherein
• the layer of adhesive extends into the channel floor of at least one of the channels and an edge of the adhesive layer in the at least one channel extends to the exterior of the insulated substrate.

A method of manufacturing a plurality of embedded magnetic component devices each including a magnetic core embedded in a cavity formed in an insulating substrate and one or more electrical windings formed around the core, the method comprising:

• a) preparing a mother base substrate including a row of cavities for respective magnetic cores, each of the cavities including a cavity floor and side walls connected by the cavity floor, and channels formed between the neighboring cavities in the mother base substrate so as to connect the cavities, each of the channels including a channel floor connected to the cavity floor;
• b) installing magnetic cores into the respective cavities so that the magnetic cores are secured in the cavities by the adhesive;
• c) applying an insulating layer to the mother base substrate to cover the magnetic cores and the cavities so as to obtain an insulated mother substrate, the insulating layer including holes for receiving adhesive, the holes communicating with the channels between the magnetic cores;
• d) dispensing adhesive into the channels through the holes so that the adhesive contacts the magnetic core and secures the magnetic core to the cavity floor throughout the row of cavities;
• and
• e) after completion of the individual devices, separating the components to form individual devices.