Methods of fabrication of coaxial vias and magnetic devices

A method for manufacturing of an inductor comprising the steps of:

• providing a first substrate of magnetic material having at least one through-hole with a conductive coating;
• providing a second conductive substrate having a surface from which an elongated electrical conductor projects therefrom;
• disposing said first substrate in relation to said second substrate so that said at least one electrical conductor is disposed in said through-hole;
• disposing in said through-hole a dielectric material;
• and
• said second substrate is disposed with respect to said second surface leaving a space therebetween and further including injecting in said space dielectric material.

A method of fabricating a magnetic device comprising the steps of:

• providing a first substrate of magnetic material having at least one through-hole;
• providing a second substrate having a surface from which an elongated electrical conductor projects therefrom;
• disposing said first substrate in relation to said second substrate so that said at least one electrical conductor is disposed in said through-hole;
• disposing in said through-hole a dielectric material;
• and
• said at least one elongated conductor comprises a central elongated conductor having an exterior surface, a dielectric layer disposed on said exterior surface and an electrically conductive layer disposed on said dielectric layer to form winding of the magnetic device.

A method comprising the steps of:

• providing a first substrate of magnetic material having a first side and a second side having a plurality of through-holes extending from said first side to said second side, said through-holes each having a sidewall;
• disposing on said sidewalls an electrically conductive material;
• disposing on said first side a first pattern of electrically conductive material;
• said electrically conductive material on said sidewalls electrically interconnecting said first pattern of electrically conductive material and said second pattern of electrically conductive material to form a first coil of electrical conductors for a magnetic device;
• providing a second substrate of a plate of electrically conductive material;
• disposing on a surface of said second substrate a plurality of elongated electrical conductors;
• providing a plurality of elongated electrical conductors, each having a first end and a second end;
• disposing said first ends in electrical contact with said surface so that said first ends project away from said surface;
• disposing said first substrate in relation to said second substrate so that some of said plurality of elongated electrical conductors are disposed in same of said plurality of through-holes so that there is a first space between said elongated conductors and said sidewalls and so that there is a second space between said surface and said first pattern of electrically conductive material;
• disposing in said first space and said second space a dielectric material;
• disposing a dielectric material over said second pattern of electrically conductive material;
• disposing on said dielectric material disposed over said second pattern of electrically conductive material a third pattern of electrically conductive material parts of which are electrically connected to said plurality of elongated electrical conductors;
• patterning said plate to form a fourth pattern of electrically conductive material so that said third pattern and said fourth pattern are electrically interconnected by said plurality of elongated electrical conductors to form a second coil of electrical conductors of the magnetic device.

A method of fabricating a magnetic device comprising the steps of:

• providing a first substrate of magnetic material having a plurality of through-holes extending therethrough;
• providing a second substrate comprising:
• a first side and a second side, a first a pattern of electrical conductors on said first side, a second pattern of electrical conductors on said second side, a plurality of through-holes extending from said first side to said second side exposing parts of said second pattern of electrical conductors;
• providing a third substrate comprising:
• a third side and a fourth side, a third pattern of electrical conductors on said third side, a fourth pattern of electrical conductors on said fourth side, a plurality of through-holes extending from said third side to said fourth side exposing parts of said fourth pattern of electrical conductors;
• providing a plurality of elongated electrical conductors;
• disposing said first substrate between said second substrate and said third substrate with two of said plurality of elongated conductors in said through-holes in said first substrate to provide electrical connection between said first pattern and said second pattern said third pattern and said fourth pattern of electrically conductive material through said plurality of elongated electrical conductors.