Patent ID: 11894176
Assignee: MURATA MANUFACTURING CO., LTD.
Field: Electrical machinery, apparatus, energy (Electrical engineering)
Classification: CPC H | IPC H

Claim 0:
1. A method of manufacturing an embedded magnetic component device, comprising:
a) preparing an insulating substrate formed of a resin material and including a cavity therein;
b) installing a magnetic core made of ferrite in the cavity with an air gap between the cavity and the magnetic core, the magnetic core including a first section and a second section;
c) forming isolated primary and secondary electrical windings that pass through the insulating substrate and that are disposed around the first and second sections of the magnetic core, the secondary winding being spaced away from the primary electrical winding so as to be isolated from the primary electrical winding, the primary electrical winding being located on first and second sides of the insulating substrate, and the secondary electrical winding being located on the first and the second sides of the insulating substrate;
d) forming a first isolation barrier of a resin material which is not a solder resist on the first side of the insulating substrate, covering at least the portion of the first side of the insulating substrate between the primary electrical winding and the secondary electrical winding where the primary electrical winding and the secondary electrical winding are closest, to form a solid bonded joint with the first side of the insulating substrate; and
e) forming a second isolation barrier of a resin material which is not a solder resist on the second side of the insulating substrate, covering at least the portion of the second side of the insulating substrate between the primary electrical winding and the secondary electrical winding where the primary electrical winding and the secondary electrical winding are closest, to form a solid bonded joint with the second side of the insulating substrate; wherein:
step c) includes:
forming upper conductive traces on the first side of the insulating substrate;
forming lower conductive traces on the second side of the insulating substrate;
forming through holes though the insulating substrate; and
plating the through holes to form conductive vias to connect the upper conductive traces and the lower conductive traces and to form a coil conductor around the magnetic core;

the first isolation barrier covers the upper conductive traces;
the second isolation barrier covers the lower conductive traces;
the insulating substrate includes a base insulating substrate and a cover layer formed on the base insulating substrate;
the cover layer covers the cavity in which the magnetic core is housed and provides the first side of the insulating substrate; and
the insulating substrate, the first isolation barrier, and the second isolation barrier are made of only the same materials.