Inductor Made of Component Carrier Material Comprising Electrically Conductive Plate Structures
20210050141 ยท 2021-02-18
Inventors
Cpc classification
H01F17/0033
ELECTRICITY
H05K1/185
ELECTRICITY
International classification
Abstract
An inductor component includes a plurality of stacked layer structures made of component carrier material with electrically conductive plate structures, and a plurality of electrically conductive interconnect structures connecting the electrically conductive plate structures to thereby form an inductance with multiple windings.
Claims
1. An inductor component, comprising: a plurality of stacked layer structures made of component carrier material and electrically conductive plate structures; and a plurality of electrically conductive interconnect structures connecting the electrically conductive plate structures to thereby form an inductance with multiple windings.
2. The inductor component according to claim 1, further comprising at least one of the following features: wherein the plurality of electrically conductive interconnect structures comprise at least one of the group consisting of vertical interconnect structures, inclined interconnect structures, and horizontal interconnect structures; wherein the inductance is formed as a coil structure with multiple windings aligned along a common central axis and defined by the interconnect structures and the connected electrically conductive plate structures.
3. The inductor component according to claim 1, further comprising: wherein an electrically conductive material filling factor of the inductor component, defined as a ratio between a partial volume of electrically conductive material of the inductor component and a total volume of the inductor component, is at least 50%, in particular is at least 80%, more particularly is at least 90%.
4. The inductor component according to claim 1, wherein the electrically conductive plate structures have a thickness of at least 200 m, in particular at least 400 m.
5. The inductor component according to claim 1, wherein the interconnect structures comprise at least one of the group consisting of metal filled vias, and metallic inlays.
6. The inductor component according to claim 1, wherein a space between the electrically conductive plate structures and the interconnect structures is filled at least partially by electrically insulating material.
7. The inductor component according to claim 1, further comprising: a magnetic structure, in particular a magnetically soft structure, more particularly a ferrite structure, in a space delimited by the electrically conductive plate structures and the interconnect structures.
8. The inductor component according to claim 7, wherein the magnetic structure is configured as a planar layer.
9. The inductor component according to claim 7, wherein the magnetic structure is configured as one of the group consisting of a magnetic inlay and printed magnetic paste.
10. The inductor component according to claim 1, wherein at least one of the electrically conductive plate structures comprises a plurality of separate strips, in particular a plurality of coplanar separate strips.
11. The inductor component according to claim 10, comprising at least one of the following features: wherein coplanar separate strips of two opposing electrically conductive plate structures are positioned in parallel planes; wherein separate strips of two opposing electrically conductive plate structures are pivoted relative to one another; wherein a width of the strips is larger than a gap between adjacent strips of a respective one of the electrically conductive plate structures.
12. The inductor component according to claim 1, wherein the component carrier material comprises or consists of copper and resin, in particular resin with reinforcing fibers.
13. The inductor component according to claim 1, wherein a thickness of each of the electrically conductive plate structures is larger than a thickness of electrically insulating material between the electrically conductive plate structures, wherein in particular a thickness ratio between a thickness of a respective one of the electrically conductive plate structures and a thickness of the electrically insulating material is at least 2, in particular is at least 4, more particularly is at least 7.
14. The inductor component according to claim 1, further comprising: an electrically conductive contact structure at an exterior surface of the inductor component electrically contacting at least one of the interconnect structures, wherein in particular the electrically conductive contact structure is configured as one of the group consisting of at least one metal inlay and a patterned galvanic metal layer.
15. A component carrier, comprising: a stack having at least one electrically conductive layer structure and/or at least one electrically insulating layer structure; and an inductor component embedded in or surface mounted on the stack, the inductor component having a plurality of stacked layer structures made of component carrier material and electrically conductive plate structures; and a plurality of electrically conductive interconnect structures connecting the electrically conductive plate structures to thereby form an inductance with multiple windings.
16. The component carrier according to claim 15, wherein the component carrier is configured as one of the group consisting of a printed circuit board and a substrate.
17. The component carrier according to claim 15, wherein a stacking direction of the stack is parallel to a stacking direction of the stacked layer structures.
18. The component carrier according to claim 15, wherein a stacking direction of the stack is different from, in particular is perpendicular and/or slanted to, a stacking direction of the stacked layer structures.
19. A method of manufacturing an inductor component, comprising: stacking a plurality of layer structures made of component carrier material and comprising electrically conductive plate structures; and connecting the electrically conductive plate structures by a plurality of electrically conductive interconnect structures to thereby form an inductance with multiple windings.
20. The method according to claim 19, further comprising one of the following features: wherein at least one of the electrically conductive plate structures is formed by providing a plate with integrally connected strips, interconnecting the plate with the other layer structures, and subsequently removing part of the material of the plate to thereby separate the strips from one another; wherein at least one of the electrically conductive plate structures is formed by forming an interconnected body of a plurality of alternating electrically conductive plates and electrically insulating layers, separating the body into a plurality of bars, and separating the bars into a plurality of multi-layer structures.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0055]
[0056]
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0057] Embodiments of the present invention are now described and illustrated in the accompanying drawings. The invention is not restricted to the described or illustrated example embodiments.
[0058] The illustrations in the drawings are schematically presented. In different drawings, similar or identical elements are provided with the same reference signs.
[0059] Before, referring to the drawings, exemplary embodiments will be de-scribed in further detail, some basic considerations will be summarized based on which exemplary embodiments of the invention have been developed.
[0060] According to an exemplary embodiment of the invention, an embedded inductor architecture making use of component carrier technology is provided.
[0061] In order to obtain inductors or coil-like structures with a high Q-factor, it has turned out to be necessary to have an as high metallic (in particular copper) content as possible. In other words, a high metal filling factor of a PCB-based inductor component is desired. As a result of such a high metal filling factor, the ohmic resistance may be reduced and electric losses may be suppressed. Exemplary embodiments of the invention allow to increase the copper filling factor due to the implementation of thick (in particular non-foldable) electrically conductive plate structures rather than thin copper foils patterned by etching technology.
[0062] According to an exemplary embodiment of the invention, such electrically conductive plate structures may be provided as pre-formed copper elements which, as a result of their manufacturing process, can be provided with a very high copper content and with a pronounced thickness. Such electrically conductive plate structures may be positioned relatively close to one another by lamination technology.
[0063] With the mentioned manufacturing architecture, the electrically conductive structures in the plane of carrying electric current may be placed very close to one another. This increases the copper filling factor of the inductor component. For example, a copper filling factor of at least 90%, in particular of at least 95% may be achieved. This increases the coil quality Q of the inductor component. Upon formation of interconnect structures for connecting the mentioned electrically conductive plate structures in a vertical or z-direction (and/or extending horizontally and/or slanted with regard to both the horizontal and the vertical direction), also the copper filling factor in vertical direction can be rendered very high, in particular at least 90%, more particularly at least 95%.
[0064] Conventional thin copper foils of small thickness patterned by etching require a very small thickness in order to be patternable by etching. Due to this limitation, the copper filling factor of such conventional inductor structures is quite small, rendering electric losses high and the Q-factor low. Exemplary embodiments of the invention overcome such limitations by making a paradigm shift in terms of PCB technology, i.e. implementing (for instance punched or laminated) electrically conductive plate structures with high copper filling factor, low ohmic properties and high Q-factor. A further advantage of exemplary embodiments of the invention is that, when copper inlays are implemented as interconnect structures, no significant topology occurs, resulting in flat and compact inductor components, which are consequently highly appropriate in terms of being embedded itself in a component carrier. The described manufacturing technology of exemplary embodiments of the invention is compatible with very different inductor shapes, such as ring coils, longitudinal coils, double longitudinal coils, etc.
[0065] Conductive plate structures arranged in different layers may be accomplished by copper filled bores. For example, these structures may for instance be vertically arranged copper filled bores or through connections for coupling various sections of two or more electrically conductive plate structures arranged in different layers. The impact on the manufactured coil is then low, since the distance over the core is usually larger than the bores through the thin intermediate layer(s). It is however also possible to interconnect electrically conductive layer structures by copper inlays, which additionally increases the metal filling factor.
[0066] The manufactured coil can be equipped with a soft magnetic or magnetizable structure such as a ferrite core. Such a core may be embodied as another inlay, may be embedded, or may even be printed by a magnetic paste. Such a soft magnetic material may be made of ferrite, or any other permanent magnetic material, etc. It is however alternatively also possible to configure the inductor component as air coil, i.e. without ferrite core. Copper layers or plate structures may be provided with a thickness of for example 400 m or more. In contrast to this, one or more electrically insulating layers (for instance made of prepreg material) between the electrically conductive plate structures may have a smaller thickness than the electrically conductive plate structures, for instance may have a thickness of 50 m or less. Thereby, the copper filling factor may be rendered very high.
[0067] In a highly preferred exemplary embodiment, slitted copper sheets may be implemented for forming the electrically conductive plate structures (see
[0068] In another preferred embodiment (see
[0069] Inductor components manufactured according to exemplary embodiments of the invention may be used in addition to one or more embedded and/or surface mounted (for instance active and/or passive electronic) components in a component carrier. Inductor components according to exemplary embodiments of the invention furthermore allow the manufacture of transformers, voltage converters and other electronic members, in particular for high voltage applications. This allows to obtain an even higher degree of integration.
[0070]
[0071] The component carrier 120, which is here embodied as a printed circuit board (PCB) with embedded inductor component 100, comprises a stack of a plurality of electrically conductive layer structures 122 and a plurality of electrically insulating layer structures 124. In the shown embodiment, the electrically insulating layer structures 124 are layers comprising resin and reinforcing fibers therein. More precisely, the exterior electrically insulating layer structures 124 may be made of prepreg or FR4, i.e. may be made based on an epoxy resin filled with reinforcing for glass fibers. The vertically most central one of these layers is cut so as to define a through hole, recess or cavity 199 in which the inductor component 100 is embedded. The vertically most central one of the electrically insulating layer structures 124 is a core 151 of fully cured material, which may for instance be made of FR4 material. The other electrically insulating layer structures 124 are substantially continuous layers through which vertical interconnect structures (forming part of the electrically conductive layer structures 122) are formed for electrically contacting the inductor component 100. In the shown embodiment, the electrically conductive layer structures 122 comprise patterned copper foils, continuous copper foils and vertical interconnect structures embodied as copper filled vias.
[0072] As can be taken from
[0073] In the shown embodiment, the inductor component 100 comprises itself a further laminated stack, i.e. a plurality of stacked layer structures 102 made of component carrier material. Such component carrier material may be material used for printed circuit boards (PCBs) or IC substrates such as copper, epoxy resin and glass fibers.
[0074] In particular, the inductor component 100 shown in
[0075] Beyond this,
[0076] As can be taken from
[0077] A recess in the core 151, which defines the cavity 199, is filled with the inductor component 100 as described. The plurality of electrically conductive layer structures 122 and electrically insulating layer structures 124 may be laminated on both opposing main surfaces of the core 151 with embedded inductor component 100. The lamination procedure for manufacturing such a component carrier 120 with embedded inductor component 100 may use initially at least partially uncured dielectric material such as B-stage resin which may cross-link upon lamination. The embedded architecture according to
[0078] For manufacturing the component carrier 120 shown in
[0079] According to
[0080]
[0081] Referring to
[0082] Referring to
[0083] Referring to
[0084] Referring to
[0085]
[0086]
[0087]
[0088] Referring to
[0089]
[0090] Still referring to
[0091] Different multi-layer structures 140 may differ from one another concerning shape and/or size. More specifically, different multi-layer structures 140 may be shaped and dimensioned so that abutting multi-layer structures 140 seamlessly fit to one another to thereby form an inductor component together. For instance, the multi-layer structures 140 may comprise one or more cubes, one or more cuboids, one or more parallelepipeds, and/or one or more three-dimensional bodies having six planar faces at least two opposing of which being not parallel to one another. Other shapes of the multi-layer structures 140 are possible as well as long as they can be assembled to form an inductor component.
[0092] It should also be appreciated that the non-cuboid multi-layer structures 140 shown on the right-hand side of
[0093] It should be noted that the term comprising does not exclude other elements or steps and the article a or an does not exclude a plurality. Also, elements described in association with different embodiments may be combined.
[0094] Implementation of embodiments of the invention is not limited to the preferred embodiments shown in the figures and described above. Instead, a multiplicity of variants is possible which variants use the solutions shown and the principle according to embodiments the invention even in the case of fundamentally different embodiments.