Surface-mount inductor structures for forming one or more inductors with substrate traces
10056182 ยท 2018-08-21
Assignee
Inventors
- Gregorio R. Murtagian (Phoenix, AZ, US)
- Robert L. Sankman (Phoenix, AZ, US)
- Brent S. Stone (Chandler, AZ, US)
- Kaladhar Radhakrishnan (Chandler, AZ, US)
- Joshua D. HEPPNER (Chandler, AZ, US)
Cpc classification
H01F17/045
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2924/00012
ELECTRICITY
Y10T29/4902
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01F2027/297
ELECTRICITY
H01F27/027
ELECTRICITY
H01F27/06
ELECTRICITY
International classification
H01F27/29
ELECTRICITY
H01L27/08
ELECTRICITY
H05K7/00
ELECTRICITY
H01F27/06
ELECTRICITY
Abstract
Embodiments of the present disclosure are directed towards an inductor structure having one or more strips of conductive material disposed around a core. The strips may have contacts at a first end and a second end of the strips, and may be disposed around the core with a gap between the contacts. The inductor structure may be mounted on a surface of a substrate, and one or more traces may be formed in the surface of the substrate to electrically couple two or more of the strips of conductive material to one another to form inductive coils. Other embodiments may be described and/or claimed.
Claims
1. An electronic device comprising: a substrate with: a first side; a second side opposite the first side; and a trace that is generally parallel with the first side; a die coupled with the first side by one or more die interconnect structures; an encapsulant coupled with the die and the first side; a first inductor structure coupled with the second side within a die-shadow of the die, wherein the first inductor structure includes a first core that includes a magnetic material and has a first plurality of strips of conductive material disposed therein, and wherein respective first strips of the first plurality of strips include respective contacts at a first end and a second end of the respective first strips, the respective contacts coupled with the substrate such that a contact of a first one of the first plurality of strips is coupled with a contact of a second one of the first plurality of strips via the trace, wherein the respective first strips have a gap between the first end and the second end of the respective first strips, and the first inductor structure has a gap between each of the respective first strips of the first plurality of strips; and a second inductor structure coupled with the second side within the die-shadow of the die, wherein the second inductor structure includes a second core with a second plurality of strips of conductive material disposed therein, wherein respective second strips of the second plurality of strips include respective contacts at a first end and a second end of the respective second strips, the respective contacts coupled with the substrate, wherein the respective second strips have a gap between the first end and the second end of the respective second strips, and the second inductor structure has a gap between each of the respective second strips of the second plurality of strips.
2. An electronic device comprising: a substrate with a first side and a second side opposite the first side; a die coupled with the first side by one or more die interconnect structures; a first inductor structure coupled with the second side, wherein the first inductor structure includes a first core with a first plurality of strips of conductive material disposed therein, wherein respective first strips of the first plurality of strips include respective contacts at a first end and a second end of the respective first strips, the respective contacts coupled with the substrate, wherein the respective first strips have a gap between the first end and the second end of the respective first strips, and the first inductor structure has a gap between each of the respective first strips of the first plurality of strips; and a second inductor structure coupled with the second side, wherein the second inductor structure includes a second core with a second plurality of strips of conductive material disposed therein, wherein respective second strips of the second plurality of strips include respective contacts at a first end and a second end of the respective second strips, the respective contacts coupled with the substrate, wherein the respective second strips have a gap between the first end and the second end of the respective second strips, and the second inductor structure has a gap between each of the respective second strips of the second plurality of strips; wherein the substrate further includes a trace that is generally parallel with the first side of the substrate, the trace to couple a contact of a first one of the first plurality of strips with a contact of a second one of the first plurality of strips.
3. The electronic device of claim 2, further comprising an encapsulant coupled with the die and the first side.
4. The electronic device of claim 2, wherein the core of the first inductor structure includes a magnetic material.
5. The electronic device of claim 4, wherein the magnetic material is iron or ferrite.
6. The electronic device of claim 4, wherein the core of the first inductor structure further includes a non-magnetic material.
7. The electronic device of claim 6, wherein the magnetic material is spread throughout the non-magnetic material.
8. The electronic device of claim 2, wherein the first inductor structure and the second inductor structure are within a die-shadow of the die.
9. The electronic device of claim 8, wherein the die has a lateral area parallel with the first side of the substrate, and the die-shadow is a portion of the die that is perpendicular to the first side of the substrate within the lateral area of the die.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings. To facilitate this description, like reference numerals designate like structural elements. Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.
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DETAILED DESCRIPTION
(22) Embodiments of the present disclosure describe surface-mount inductor structures for forming one or more inductors with substrate traces, and associated techniques and configurations. In the following description, various aspects of the illustrative implementations will be described using terms commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some of the described aspects. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the illustrative implementations. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well-known features are omitted or simplified in order not to obscure the illustrative implementations.
(23) In the following detailed description, reference is made to the accompanying drawings which form a part hereof, wherein like numerals designate like parts throughout, and in which is shown by way of illustration embodiments in which the subject matter of the present disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.
(24) For the purposes of the present disclosure, the phrase A and/or B means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase A, B, and/or C means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).
(25) The description may use perspective-based descriptions such as top/bottom, in/out, over/under, and the like. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of embodiments described herein to any particular orientation.
(26) The description may use the phrases in an embodiment, or in embodiments, which may each refer to one or more of the same or different embodiments. Furthermore, the terms comprising, including, having, and the like, as used with respect to embodiments of the present disclosure, are synonymous.
(27) The term coupled with, along with its derivatives, may be used herein. Coupled may mean one or more of the following. Coupled may mean that two or more elements are in direct physical or electrical contact. However, coupled may also mean that two or more elements indirectly contact each other, but yet still cooperate or interact with each other, and may mean that one or more other elements are coupled or connected between the elements that are said to be coupled with each other. The term directly coupled may mean that two or more elements are in direct contact.
(28) In various embodiments, the phrase a first feature formed, deposited, or otherwise disposed on a second feature, may mean that the first feature is formed, deposited, or disposed over the second feature, and at least a part of the first feature may be in direct contact (e.g., direct physical and/or electrical contact) or indirect contact (e.g., having one or more other features between the first feature and the second feature) with at least a part of the second feature.
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(30) The strips 104a-f include respective contacts 108a-l at ends of the strips 104a-f as best seen in
(31) The inductor structure 100 may be formed of any suitable materials. In some embodiments the core may include an insulating material, such as plastic (e.g., molded plastic). Alternatively, or additionally, the core may include a magnetic material, such as iron and/or ferrite. For example, the core 102 may include a magnetic material surrounded by a non-magnetic material (e.g., plastic), a non-magnetic material with portions of a magnetic material spread throughout the non-magnetic material, and/or the core 102 may be composed entirely of a magnetic material. The magnetic material may improve the magnetic flux and/or efficiency of inductors formed by the inductor structure 100.
(32) The strips 104a-f may include any suitable conductive material or materials, such as copper. In some embodiments, the strips 104a-f may be plated, such as with nickel, tin, palladium, silver and/or gold, to prevent corrosion and/or facilitate soldering. In some embodiments, the inductor structure 100 may further include a housing 106. The housing 106 may be a separate piece or may be integrated with the core 102. For example, in one embodiment, the housing 106 and core 102 may be formed as a single piece by plastic over-molding. Other embodiments of the inductor structure 100 may not include a housing 106.
(33) In various embodiments, the inductor structure 100 may be mounted to a substrate (e.g., substrate 702 shown in
(34) In various embodiments, any set of two or more of the strips 104a-f may be coupled to one another by one or more traces to form an inductor. The inductor structure 100 may be used to form any suitable number and/or arrangement of inductors. For example, the inductor structure 100 may be used to form one inductor that includes up to six strips, two inductors that each include three strips, or one inductor including two strips and one inductor including four strips. It will be apparent that many other arrangements of one or more inductors are possible using inductor structure 100. In some embodiments, a transformer, including a first inductor and a second inductor, may be formed from the inductor structure 100. In some embodiments, the one or more inductors formed by the inductor structure 100 may be included in a voltage regulator to convert a supply voltage (e.g., from a power supply) to an input voltage for a circuit (e.g., on a die).
(35) In some embodiments, the spacing between the strips 104a-f may not be the same between each adjacent strip. For example, the strips 104a-f may be arranged into groups of strips that are spaced together. The grouping and/or spacing may facilitate an intended electrical connection among the strips 104a-f, and/or facilitate a desired inductance. As shown in
(36) The inductor structure 100 may be manufactured in any suitable manner. The inductor structure 100 may be manufactured at a relatively low cost, with low manufacturing complexity. For example, in some embodiments, the strips may be formed from conductive wire (e.g., copper wire). The core may be molded, e.g. from plastic. The strips may be bent and/or wrapped around the core to form the inductor structure 100.
(37) In embodiments, the strips may be formed from a sheet of conductive material. For example,
(38) Referring again to
(39) Additionally, although inductor structure 100 is shown with six strips 104a-f, other embodiments may include any number of one or more strips. For example,
(40) Furthermore, it will be apparent that other arrangements of the strips and/or contacts of the inductor structure are possible without departing from the embodiments described herein.
(41) For example,
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(46) In some embodiments, the substrate 702 is an epoxy-based laminate substrate having a core and/or build-up layers such as, for example, an Ajinomoto Build-up Film (ABF) substrate. The substrate 702 may include other suitable types of substrates in other embodiments including, for example, substrates formed from glass, ceramic, or semiconductor materials.
(47) Although IC assembly 700 is shown in
(48) In some embodiments, one or more inductor structures as described herein may be mounted on a same substrate on which a die is mounted. In some embodiments, the inductor structures may be used to route electrical power from a power source to the die. For example, the inductor structures may be included in a voltage regulator to regulate the power delivered to the die. In some embodiments, the inductor structure may be mounted on a land side of the substrate, opposite the die.
(49) For example,
(50) As discussed herein, the inductor structure 806 may include one or more strips of conductive material having contacts at a first end and a second end of each strip. The strips may be disposed around a core of the inductor structure 806, with a gap between the first end and second end of the individual strips. The strips may be disposed adjacent to one another in an array. The IC package assembly 800 may further include traces 808 on a surface of the second side to electrically couple two or more of the strips of conductive material to one another to form inductive coils. Accordingly, the inductor structure 806 may be used to form one or more inductors in combination with the traces 808.
(51) In some embodiments, the inductor structures 806 may be included in a voltage regulator to route electrical power from a power source (not shown) to the die 804. The voltage regulator may convert a supply voltage provided by the power supply to an input voltage used by the die 804. In some embodiments, the supply voltage may be higher than the input voltage. The voltage regulator may include one or more other components besides inductor structure 806, such as one or more capacitors and/or switches. In some embodiments, the voltage regulator may be a single or multiple phase voltage regulator, such as a Buck voltage regulator.
(52) In some embodiments, one or more inductor structures 806 may be used to form a transformer. The transformer may be used in the voltage regulator. For example, the traces 808 may form a first inductor and a second inductor from one or more of the inductor structures 806. The first inductor may be electrically coupled to the power source and the second inductor may be electrically coupled to the die 804 to transform the supply voltage provided by the power supply to the input voltage used by the die 804.
(53) In some embodiments, the inductor structures 806 may be coupled to the second side S2 within a shadow of the die 804 (shown at 805). In some embodiments, the inductor structures 806 may be mounted to a land-side cavity on the second side S2 of the substrate 802. One or more other devices, such as one or more capacitors, may also be mounted on the second side S2 of the substrate 802.
(54) The die 804 may be attached to the substrate 802 according to a variety of suitable configurations, including a flip-chip configuration, as depicted, or other configurations such as wirebonding and the like. In the flip-chip configuration, an active side of the die 804 is attached to the first side S1 of the substrate 802 using die interconnect structures 810 such as bumps, pillars, or other suitable structures. The active side of the die 804 may have one or more transistor devices formed thereon. The die 804 may represent a discrete chip and may be, include, or be a part of a processor, memory, or application-specific integrated circuit (ASIC) in some embodiments. In some embodiments, an encapsulant 812 such as, for example, molding compound or underfill material may fully or partially encapsulate the die 804.
(55) The die interconnect structures 810 may be configured to route electrical signals between the die 804 and the substrate 802. In some embodiments, the electrical signals may include, for example, input/output (I/O) signals and/or power or ground signals associated with the operation of the die 804.
(56) The substrate 802 may include structures configured to route electrical signals to or from the die 804 and/or inductor structures 806. The structures may include, for example, traces (e.g., traces 808) disposed on one or more surfaces of the substrate 802 and/or internal structures such as, for example, trenches, vias or other interconnect structures (not shown) to route electrical signals through the substrate 802. For example, in some embodiments, the substrate 802 may include structures such as die bond pads (not shown) configured to receive the die interconnect structures 810 and route electrical signals between the die 804 and the substrate 802.
(57) In some embodiments, the substrate 802 is an epoxy-based laminate substrate having a core and/or build-up layers such as, for example, an Ajinomoto Build-up Film (ABF) substrate. The substrate 802 may include other suitable types of substrates in other embodiments including, for example, substrates formed from glass, ceramic, or semiconductor materials.
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(59) At 902, the method 900 includes providing a substrate (e.g., substrate 802 of
(60) In some embodiments, the method 900 may further include forming the substrate. The substrate may be formed using techniques such as, for example, lamination of electrically insulative materials, deposition of electrically conductive materials, patterning of the electrically conductive materials by additive or subtractive processes, creating holes or vias by mechanical means, laser drilling or etch processes, the like, and other techniques.
(61) At 904, the method 900 further includes forming an inductor structure (e.g., inductor structure 100, 200, 300, 400, 500, 600, and/or 806 described herein). The inductor structure may include a core and a plurality of strips of conductive material having contacts at a first end and a second end. The strips may be disposed around the core with a gap between the first end and the second end.
(62) In some embodiments, forming the inductor structure at 904 may include forming the strips from a sheet of conductive material and/or over-molding the core around the strips (e.g., as shown in
(63) At 906, the method 900 further includes forming one or more traces (e.g., traces 808) on the second surface of the substrate to electrically couple two or more strips of the conductive material to one another to form one or more inductors. The traces may be formed by any suitable method, such as etching to form a stencil on the second surface.
(64) At 908, the method 900 further includes mounting the inductor structure on the second surface of the substrate. The inductor structure may be mounted on the second surface with respective contacts of the inductor structure coupled to the one or more traces to form the one or more inductors. For example, the inductor structure may be mounted with the contacts disposed in or on holes in the stencil that are electrically connected by the traces. The contacts may be coupled to the second surface, for example, by soldering.
(65) Various operations are described as multiple discrete operations in turn, in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. Embodiments of the present disclosure may be implemented into a system using any suitable hardware and/or software to configure as desired.
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(67) Depending on its applications, computing device 1000 may include other components that may or may not be physically and electrically coupled to the motherboard 1002. These other components may include, but are not limited to, volatile memory (e.g., DRAM), non-volatile memory (e.g., ROM), flash memory, a graphics processor, a digital signal processor, a crypto processor, a chipset, an antenna, a display, a touchscreen display, a touchscreen controller, a battery, an audio codec, a video codec, a power amplifier, a global positioning system (GPS) device, a compass, a Geiger counter, an accelerometer, a gyroscope, a speaker, a camera, and a mass storage device (such as hard disk drive, compact disk (CD), digital versatile disk (DVD), and so forth).
(68) The communication chip 1006 may enable wireless communications for the transfer of data to and from the computing device 1000. The term wireless and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium. The term does not imply that the associated devices do not contain any wires, although in some embodiments they might not. The communication chip 1006 may implement any of a number of wireless standards or protocols, including but not limited to Institute for Electrical and Electronic Engineers (IEEE) standards including Wi-Fi (IEEE 802.11 family), IEEE 802.16 standards (e.g., IEEE 802.16-2005 Amendment), Long-Term Evolution (LTE) project along with any amendments, updates, and/or revisions (e.g., advanced LTE project, ultra mobile broadband (UMB) project (also referred to as 3GPP2), etc.). IEEE 802.16 compatible BWA networks are generally referred to as WiMAX networks, an acronym that stands for Worldwide Interoperability for Microwave Access, which is a certification mark for products that pass conformity and interoperability tests for the IEEE 802.16 standards. The communication chip 1006 may operate in accordance with a Global System for Mobile Communication (GSM), General Packet Radio Service (GPRS), Universal Mobile Telecommunications System (UMTS), High Speed Packet Access (HSPA), Evolved HSPA (E-HSPA), or LTE network. The communication chip 1006 may operate in accordance with Enhanced Data for GSM Evolution (EDGE), GSM EDGE Radio Access Network (GERAN), Universal Terrestrial Radio Access Network (UTRAN), or Evolved UTRAN (E-UTRAN). The communication chip 1006 may operate in accordance with Code Division Multiple Access (CDMA), Time Division Multiple Access (TDMA), Digital Enhanced Cordless Telecommunications (DECT), Evolution-Data Optimized (EV-DO), derivatives thereof, as well as any other wireless protocols that are designated as 3G, 4G, 5G, and beyond. The communication chip 1006 may operate in accordance with other wireless protocols in other embodiments.
(69) The computing device 1000 may include a plurality of communication chips 1006. For instance, a first communication chip 1006 may be dedicated to shorter range wireless communications such as Wi-Fi and Bluetooth and a second communication chip 1006 may be dedicated to longer range wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE, Ev-DO, and others.
(70) The processor 1004 of the computing device 1000 may include a die (e.g., die 804 of
(71) The communication chip 1006 may also include a die (e.g., die 804 of
(72) In various implementations, the computing device 1000 may be a laptop, a netbook, a notebook, an ultrabook, a smartphone, a tablet, a personal digital assistant (PDA), an ultra mobile PC, a mobile phone, a desktop computer, a server, a printer, a scanner, a monitor, a set-top box, an entertainment control unit, a digital camera, a portable music player, or a digital video recorder. In further implementations, the computing device 1000 may be any other electronic device that processes data.
(73) The above description of illustrated implementations of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific implementations of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
(74) These modifications may be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific implementations disclosed in the specification and the claims. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.