Planar magnetic component and method for manufacturing the same

Planar magnetic element and method of manufacturing same

PLANAR MAGNETIC COMPONENT AND METHOD FOR MANUFACTURING THE SAME

This invention relates to a planar magnetic component structure, and more particularly to an embedded magnetic component structure for use in a transformer.

Conventionally, in a transformer having an embedded magnetic component used in a communication connector, the magnetic component used is, for example, an iron powder core, and the iron powder core is generally made of a magnetic material such as ferroferric oxide. In view of the fragile nature of the iron powder core, it has been proposed to surround the embedded magnetic element with a resilient filler, such as an elastic epoxy material as described in U.S. Patent No. 8,203,418 B2, to buffer the magnetic element. The stress caused by thermal expansion and contraction during the operation of the component and the possibility of cracking of the magnetic component.

However, the inventors of the present invention found that the elastic epoxy resin material cannot avoid the cracking phenomenon of the iron powder core during the pressing process. In view of this, it is necessary to propose a new transformer structure with embedded magnetic components to improve the protection of the iron powder core and thereby improve the manufacturing yield of the transformer.

The invention provides a planar magnetic component and a method for forming the same to improve the fabrication yield of the transformer.

In order to achieve the above advantages or other advantages, an embodiment of the present invention provides a planar magnetic component comprising a substrate and a magnetic structure embedded in the substrate. The magnetic structure includes iron a layer of magnetic material and at least one first hard protective layer. The first hard protective layer is disposed on one side of the ferromagnetic material layer.

In an embodiment of the invention, the magnetic structure further comprises a second hard protective layer on the opposite side of the ferromagnetic material layer.

In an embodiment of the invention, the first hard protective layer and the second hard protective layer are made of a reactive resin having an epoxy group, and the ferromagnetic material layer is an iron powder core.

In one embodiment of the invention, the glass transition temperature (Tg) of the reactive resin is greater than 200 °C.

In one embodiment of the invention, the coefficient of thermal expansion (CTE) of the reactive resin is greater than or equal to the coefficient of thermal expansion of the substrate.

In an embodiment of the invention, the first conductor layer and the second conductor layer are further included, wherein the first conductor layer is disposed on a side of the substrate away from the magnetic structure, and the second conductor layer is disposed on the substrate adjacent to the magnetic structure. One side, and the first hard protective layer is between the ferromagnetic material layer and the second conductor layer.

In an embodiment of the invention, the adhesive layer is further disposed between the first hard protective layer and the second conductive layer, and the adhesive layer is also located between the substrate and the second conductive layer.

In an embodiment of the invention, the first conductor layer and/or the second conductor layer are made of copper, and the adhesive layer is made of polypropylene (PP).

In an embodiment of the invention, the method further includes a plurality of through holes and at least one wire, each through hole penetrating through the second conductor layer, the adhesive layer, the magnetic structure, the substrate and the first conductor layer, and the wire traverses the through hole and is wound around Around the magnetic structure, the substrate is a printed circuit board (PCB).

The present invention further provides a method of forming a planar magnetic component, comprising: providing a substrate having a first surface; forming a recess in the substrate, the recess penetrating a portion of the first surface; and forming a magnetic structure in the recess. The method for forming the above magnetic structure includes: Forming a layer of ferromagnetic material; and forming at least one first hard protective layer on one side of the layer of ferromagnetic material.

In an embodiment of the present invention, the substrate further includes a zero-conductor layer formed on the first surface, and before the forming the recess in the substrate, the method further includes removing the zero by an etching process. Conductor layer.

In an embodiment of the invention, the method of forming the magnetic structure further comprises forming a second hard protective layer on an opposite side of the ferromagnetic material layer.

In an embodiment of the invention, the substrate has been formed with a first conductor layer on a second surface of the opposite first surface of the substrate.

In an embodiment of the invention, the method further comprises forming an adhesive layer on the first surface of the substrate and a side of the first hard protective layer away from the ferromagnetic material layer, and the first hard protective layer is located on the adhesive layer and the ferromagnetic material layer between.

In an embodiment of the invention, the method further comprises forming a second conductor layer on a side of the adhesive layer away from the first hard protective layer and the first surface.

In an embodiment of the invention, the method further includes forming a plurality of through holes, each through hole penetrating through the second conductor layer, the adhesive layer, the magnetic structure, the substrate and the first conductor layer, so that at least one wire passes through the through hole and is wound Around the magnetic structure.

In summary, the present invention utilizes a separate protective layer on the upper and lower sides of the ferromagnetic material layer in the planar magnetic element to protect the ferromagnetic material layer from cracking during subsequent pressing, thereby improving The yield of a transformer made using a planar magnetic component.

The above and other objects, features and advantages of the present invention will become more <RTIgt;

<p>100 planar magnetic components</p><p>110Substrate</p><p>111 zeroth conductor layer</p><p>112First conductor layer</p><p>120 Magnetic structure</p><p>122 Ferromagnetic material layer</p><p>124First hard protective layer</p><p>126Second hard protective layer</p><p>130Adhesive layer</p><p>140Second conductor layer</p><p>S1 first surface</p><p>S2 second surface</p><p>H1 groove</p><p>V1, V2 through hole</p><p>1220solid cylinder</p><p>1221ring body</p>

1A to FIG. 1G are flowcharts showing a method of forming a planar magnetic component according to an embodiment of the present invention; schematic diagram.

1H and 1I are schematic views showing the shape of a ferromagnetic material layer of the present invention.

1A to 1G are schematic flow charts showing a method of forming a planar magnetic component according to an embodiment of the present invention. Referring first to FIGS. 1A-1B, the method for forming a planar magnetic component of the present invention includes the steps of: providing a substrate 110 having a first surface S1 formed with a zeroth conductor layer 111, and a second surface S2 of the substrate 110 A first conductor layer 112 is formed, and the first surface S1 and the second surface S2 are opposite surfaces of the substrate 110 (shown in FIG. 1A); the zeroth conductor layer 111 located on the first surface S1 is removed by an etching process ( Shown in Figure 1B). The substrate is, for example, a printed circuit board (PCB). The material of the first zero conductor layer 111 and the first conductor layer 112 is, for example, copper.

Referring to FIG. 1C and FIG. 1D, after removing the zero-conductor layer 111, a recess H1 is formed in the substrate 110, wherein the recess H1 penetrates a portion of the first surface S1 (shown in FIG. 1C); The magnetic structure 120 is formed in H1 such that the magnetic structure 120 is thus embedded in the substrate 110 (shown in FIG. 1D).

The magnetic structure 120 includes a ferromagnetic material layer 122 and at least one first hard protective layer 124, wherein the first hard protective layer 124 is located on one side of the ferromagnetic material layer 122. The ferromagnetic material layer 122 is, for example, an iron powder core, and the magnetic structure further includes, for example, a second hard protective layer 126 on the opposite side of the ferromagnetic material layer 122. The first hard protective layer 124 and the second hard protective layer 126 are disposed on opposite sides (for example, upper and lower sides) of the ferromagnetic material layer 122 to protect the ferromagnetic material layer 122 from cracking during the pressing process. . Therefore, the material of the first hard protective layer 124 and the second hard protective layer 126 is, for example, a reactive resin which is completely hardened and has an epoxy group, and a glass transition temperature of the reactive resin having an epoxy group (Glass transition temperature, referred to as Tg) is, for example, greater than 200 ° C, and the coefficient of thermal expansion (CTE) of the reactive resin having an epoxy group is, for example, greater than or equal to the substrate 110. Thermal expansion coefficient.

Therefore, the method for forming the magnetic structure 120 is, for example, first filling a bottom portion of the recess H1 with a reactive resin having an epoxy group to form the second hard protective layer 126, and then disposing the ferromagnetic material layer 122 for the second hard protection. Above the layer 126, another layer of a reactive resin having an epoxy group is further filled over the ferromagnetic material layer 122 to form the first hard protective layer 124, and the fabrication of the magnetic structure 120 is completed.

After the magnetic structure 120 is completed, referring to FIG. 1E, the adhesive layer 130 is formed on the first surface S1 of the substrate 110 and one side of the first hard protective layer 124 away from the ferromagnetic material layer 122, wherein the first hard protective layer 124 Located between the adhesive layer 130 and the ferromagnetic material layer 122. The material of the adhesive layer 130 is, for example, polypropylene (PP).

Referring to FIG. 1F, after the adhesive layer 130 is formed, the second conductive layer 140 is formed on the side of the adhesive layer 130 away from the first hard protective layer 124 and the first surface S1. The material of the second conductor layer 140 is, for example, copper.

Referring to FIG. 1G, after completing the second conductor layer 140, a plurality of via holes are formed. The through holes V1 and V2 are illustrated in FIG. 1G, but the number of through holes in the present invention is not limited thereto. Each of the through holes V1, V2 penetrates through the second conductor layer 140, the adhesive layer 130, the magnetic structure 120, the substrate 110 and the first conductor layer 112, so that at least one wire can pass through the through holes V1, V2 and be wound around the magnetic structure Around 120, the winding structure of the planar magnetic element 100 of the present invention is completed. In addition, referring to FIG. 1H and FIG. 1I, the ferromagnetic material layer 122 is, for example, a solid cylinder 1220 or a ring body 1221, and the shape of the groove H1 is also adjusted according to the shape of the ferromagnetic material layer 122. However, the shape of the ferromagnetic material layer 122 of the present invention is not limited thereto. It is worth mentioning that if the ferromagnetic material layer 122 is a solid cylinder, the sidewalls of the via holes V1, V2 further include an insulating layer (not shown), and the magnetic structure 120 and the crossing pass through the insulating layer. The wires of the holes V1, V2 can be isolated from each other.

In addition, the planar magnetic component 100 of the present invention can be applied to a set-top box, an RF router, an RF mobile device, in addition to a wide-band planar transformer in a communication connector. The production of components for non-Ethernet applications such as the Internet and consumer electronics.

In summary, the present invention utilizes a separate protective layer on the upper and lower sides of the ferromagnetic material layer in the planar magnetic element to protect the ferromagnetic material layer from cracking during subsequent pressing, thereby improving The yield of a transformer made using a planar magnetic component.

While the present invention has been described in its preferred embodiments, the present invention is not intended to limit the invention, and the present invention may be modified and modified without departing from the spirit and scope of the invention. The scope of protection is subject to the definition of the scope of the patent application.