Miniature circuitry and inductive components and methods for manufacturing same

Abstract

Miniature circuitry and inductor components in which multiple levels of printed circuitry are formed on each side of a support panel, typically a printed circuit board or rigid flex. Magnetic members are embedded in one or more cavities in said support panel. Electrical connection between the plural levels of circuitry and multiple windings around the magnetic members are provided by plural plated through hole conductors. Small through hole openings accommodate a plurality of the plated through hole conductors since each is insulated from the others by a very thin layer of vacuum deposited organic layer such as parylene having a high dielectric strength. Adhesion of this plated copper to the organic layer is provided by first applying an adhesive promotor to the surface of the organic layer followed by the vacuum deposition of the organic layer.

1 . A miniature magnetic device having a base member,
 a cavity formed in said base,   a magnetic member located in said cavity, said member providing a magnetic core of said magnetic device,   a plurality of openings in said base,   a plurality of plated through hole conductors formed in said through hole openings, each of said conductors being respectively electrically insulated from another plated through hole conductor in the same hole by a thin vacuum deposited polymer film,   said plated through hole conductors providing windings of said magnetic device,   wherein said magnetic member has a substantially E-shaped configuration.   
   
   
       2 . A miniature magnetic device having a base member,
 a cavity formed in said base,   a magnetic member located in said cavity, said member providing a magnetic core of said magnetic device,   a plurality of openings in said base,   a plurality of plated through hole conductors formed in said through hole openings, each of said conductors being respectively electrically insulated from another plated through hole conductor in the same hole by a thin vacuum deposited polymer film,   said plated through hole conductors providing windings of said magnetic device,   wherein said magnetic member has substantially the shape of an oblong toroid.   
   
   
       3 . A miniature magnetic device having a base member,
 a cavity formed in said base,   a magnetic member located in said cavity, said member providing a magnetic core of said magnetic device,   a plurality of openings in said base,   a plurality of plated through hole conductors formed in said through hole openings, each of said conductors being respectively electrically insulated from another plated through hole conductor in the same hole by a thin vacuum deposited polymer film,   said plated through hole conductors providing windings of said magnetic device,   wherein said magnetic member has an asymmetric configuration.