Patent ID: 6189203
Filing Date: 2001-02-20
Classification: H05K,Y02P,Y10T

Abstract:
A method of manufacturing a surface mountable power supply, comprising:providing a substrate having opposing upper and lower conductive layers, a portion of conductive traces on said upper and lower conductive layers forming windings of a planar magnetic device;mounting a first lead of a lower electrical component on a first pad on said lower conductive layer, said lower electrical component subject to forces capable of detaching said lower electrical component from said substrate when said power supply passes through a reflow soldering process;coupling an inter-substrate conductive mount to said lower conductive layer, said conductive mount composed of a material having a melting point above a solder reflow temperature, adapted to mount said power supply to an adjacent substrate and provide a conductive path therebetween and including first and second compliant solder joints at interfaces of said substrate and said adjacent substrate, respectively;reflow soldering said lower electrical component and said conductive mount to said lower conductive layer with solder;placing a second lead of an upper electrical component on a second pad on said upper conductive layer;further reflow soldering said upper electrical component to said upper conductive layer, said lower electrical component of a sufficiently low weight such that a surface tension of a liquid state of said solder is sufficient to maintain said lower electrical component in contact with said lower conductive layer; andforming a planar magnetic device by arranging a core through apertures of said substrate proximate said windings.