System and method for gapping an embedded magnetic device

Abstract

Disclosed is an apparatus and method for a magnetic component. The method of an example embodiment includes: forming a feature on a substrate, the feature being a depression defining an inside surface; disposing a first conductive pattern on the substrate and the inside surface of the feature; disposing a permeability material on the inside surface of the feature and the first conductive pattern; disposing a substrate material on the substrate and the feature; disposing a second conductive pattern on the substrate material, the second conductive pattern substantially matching the first conductive pattern to wrap the permeability material between the first conductive pattern and the second conductive pattern producing a winding type structure electrically coupling the first conductive pattern and the second conductive pattern in electrical connection to define at least one electrical circuit to facilitate a magnetic field in the permeability material; and gapping the permeability material to remove at least a portion of the permeability material to produce a gap in the at least a portion of the permeability material.

What is claimed is: 
     
         1 . An embedded magnetic device comprising:
 a feature formed on a substrate, the feature being a depression defining an inside surface, the feature having a first conductive pattern disposed on the substrate and the inside surface of the feature;   permeability material disposed on the inside surface of the feature and the first conductive pattern;   substrate material disposed on the substrate and the feature;   a second conductive pattern disposed on the substrate material, the second conductive pattern substantially matching the first conductive pattern to wrap the permeability material between the first conductive pattern and the second conductive pattern producing a winding type structure electrically coupling the first conductive pattern and the second conductive pattern in electrical connection to define at least one electrical circuit to facilitate a magnetic field in the permeability material; and   a gap in at least a portion of the permeability material.   
     
     
         2 . The embedded magnetic device of  claim 1 , wherein the at least one electrical circuit defines at least two interleaved electrical paths to produce a single inductor type functionality. 
     
     
         3 . The embedded magnetic device of  claim 1 , wherein the at least one electrical circuit defines at least two interleaved electrical paths to produce a transformer type functionality. 
     
     
         4 . The embedded magnetic device of  claim 1 , further including a power converter embedded into the substrate. 
     
     
         5 . The embedded magnetic device of  claim 1  wherein the permeability material is a ferromagnetic core disposed into the substrate and encapsulated and the gap is applied after encapsulation and prior to disposing subsequent substrate layers and conductive patterns. 
     
     
         6 . The embedded magnetic device of  claim 1  wherein the gap is applied after the first and second substrate layers and conductive patterns are applied. 
     
     
         7 . The embedded magnetic device of  claim 1  wherein the inductance of the embedded magnetic device is trimmed or tuned while the inductance is monitored in real-time. 
     
     
         8 . The embedded magnetic device of  claim 1  wherein the gap is cut from both a top surface and a bottom surface of the substrate. 
     
     
         9 . The embedded magnetic device of  claim 1  being configured as a gapped embedded inductor integrated with a power converter on a printed circuit board (PCB). 
     
     
         10 . The embedded magnetic device of  claim 1  being configured as a gapped embedded inductor of a power converter module having substrate material disposed upon first and second conductive layers and a third and fourth conductive pattern disposed on the substrate material where conductive circuitry is disposed to receive additional passive and active devices. 
     
     
         11 . The embedded magnetic device of  claim 1  being configured as a gapped embedded transformer of a power converter module having substrate material disposed upon first and second conductive layers and a third and fourth conductive pattern disposed on the substrate material where conductive circuitry is disposed to receive additional passive and active devices, the third and fourth conductive pattern serving as a printed circuit board (PCB) upon which other passive and active devices are disposed. 
     
     
         12 . The embedded magnetic device of  claim 1  where the gap is a laser cut having a width based on laser power, laser beam width, position of laser focus, feed rate, pulse rate, and pulse duty cycle. 
     
     
         13 . The embedded magnetic device of  claim 1  where the permeability material is a ferromagnetic core having a multi-hole core structure and either an oval or square shape. 
     
     
         14 . An embedded magnetic device comprising:
 a feature formed on a substrate, the feature being a depression defining an inside surface, the feature having a first conductive pattern disposed on the substrate and the inside surface of the feature;   permeability material disposed on the inside surface of the feature and the first conductive pattern;   substrate material disposed on the substrate and the feature;   a second conductive pattern disposed on the substrate material, the second conductive pattern substantially matching the first conductive pattern to wrap the permeability material between the first conductive pattern and the second conductive pattern producing a winding type structure electrically coupling the first conductive pattern and the second conductive pattern in electrical connection to define at least one electrical circuit to facilitate a magnetic field in the permeability material;   a gap in at least a portion of the permeability material;   the substrate material disposed upon the second conductive pattern; and   a third and fourth conductive pattern disposed on the substrate material, the third and fourth conductive pattern wrapping the permeability material producing a winding type structure electrically coupling the third and fourth conductive patterns in electrical connection to define at least one electrical circuit to facilitate a magnetic field in the permeability material.   
     
     
         15 . The embedded magnetic device of  claim 14  being configured as a gapped embedded inductor and a printed circuit board (PCB). 
     
     
         16 . The embedded magnetic device of  claim 14  being configured as gapped embedded transformer and a printed circuit board (PCB). 
     
     
         17 . The embedded magnetic device of  claim 14 , wherein the gap is cleaned with forced air, forced water, or ultrasonic cleaning to eliminate debris. 
     
     
         18 . The embedded magnetic device of  claim 14 , wherein the gap is filled with epoxy, solder mask, polyimide, pre-preg, or gap filling material. 
     
     
         19 . The embedded magnetic device of  claim 14 , wherein the gap is filled with epoxy, solder mask, polyimide, pre-preg, or gap filling material when the substrate material is disposed on the substrate. 
     
     
         20 . The embedded magnetic device of  claim 14  where the permeability material is a ferromagnetic core having a multi-hole core structure and either an oval or square shape. 
     
     
         21 . The embedded magnetic device of  claim 14  including a marking on a top or bottom surface to provide a target and facilitate laser set-up, step, and repeat cutting.