Patent ID: 8539666
Filing Date: 2013-09-24
Classification: H01F,H05K,Y10T

Abstract:
1. A method of making an electrical inductor comprising: forming a first subunit comprising a sacrificial substrate, and an electrically conductive layer defining the electrical inductor and comprising a first metal on the sacrificial substrate; forming a second subunit comprising a dielectric layer and an electrically conductive layer on the dielectric layer, the electrically conductive layer defining electrical inductor terminals and comprising the first metal; coating a second metal onto the first metal of at least one of the first and second subunits; selecting the first metal to have a melting point temperature greater than that of the second metal, and selecting the second metal to have a melting point temperature below a lamination temperature of the dielectric layer; aligning the first and second subunits together; heating and pressing the aligned first and second subunits to form an intermetallic compound of the first and second metals by bonding adjacent metal portions of the first and second metals together; and removing the sacrificial substrate.