Method for making an electrical inductor and related inductor devices

A method of making an electrical inductor comprising:

• forming a first subunit comprising a sacrificial substrate, and an electrically conductive layer defining the electrical inductor and comprising a first metal on the sacrificial substrate;
• forming a second subunit comprising a liquid crystal polymer (LCP) dielectric layer and an electrically conductive layer on the LCP dielectric layer, the electrically conductive layer defining electrical inductor terminals and comprising the first metal;
• selecting the first metal to have a melting point temperature greater than that of a second metal, and selecting the second metal to have a melting point temperature below a lamination temperature of the LCP dielectric layer;
• coating the second metal onto the first metal of at least one of the first and second subunits;
• aligning the first and second subunits together;
• heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals by bonding adjacent metal portions of the first and second metals together;
• and
• removing the sacrificial substrate.

A method of making an electrical inductor comprising:

• forming a first subunit comprising a sacrificial substrate, and an electrically conductive layer defining the electrical inductor and comprising a first metal on the sacrificial substrate;
• forming a second subunit comprising a liquid crystal polymer (LCP) dielectric layer and an electrically conductive layer on the LCP dielectric layer, the electrically conductive layer defining electrical inductor terminals and comprising the first metal;
• coating a second metal onto the first metal of at least one of the first and second subunits;
• aligning the first and second subunits together;
• heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals bonding adjacent metal portions together;
• and
• removing the sacrificial substrate.

A method of making an electrical inductor comprising:

• forming a first subunit comprising a sacrificial substrate, an electrically conductive layer defining the electrical inductor and comprising a first metal on the sacrificial substrate, and a release layer between the sacrificial substrate and the electrically conductive layer;
• forming a second subunit comprising a dielectric layer and an electrically conductive layer on the dielectric layer, the electrically conductive layer defining electrical inductor terminals and comprising the first metal;
• coating a second metal onto the first metal of at least one of the first and second subunits;
• aligning the first and second subunits together;
• heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals bonding adjacent metal portions together;
• and
• removing the sacrificial substrate.

A method of making an electrical inductor comprising:

• forming a first subunit comprising a sacrificial substrate, and an electrically conductive layer defining the electrical inductor and comprising a first metal on the sacrificial substrate;
• forming a second subunit comprising a dielectric layer, an electrically conductive layer on the dielectric layer, and a circuit on the dielectric layer and coupled to the electrically conductive layer, the electrically conductive layer defining electrical inductor terminals and comprising the first metal;
• coating a second metal onto the first metal of at least one of the first and second subunits;
• aligning the first and second subunits together;
• heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals bonding adjacent metal portions together;
• and
• removing the sacrificial substrate.