Devices, systems and methods including magnetic structures and micromechanical structure

A magnetic device may include a magnetic structure, a device structure, and an associated circuit. The magnetic structure may include a patterned layer of material having a predetermined magnetic property. The patterned layer may be configured to, e.g., provide a magnetic field, sense a magnetic field, channel or concentrate magnetic flux, shield a component from a magnetic field, or provide magnetically actuated motion, etc. The device structure may be another structure of the device that is physically connected to or arranged relative to the magnetic structure to, e.g., structurally support, enable operation of, or otherwise incorporate the magnetic structure into the magnetic device, etc. The associated circuit may be electrically connected to the magnetic structure to receive, provide, condition or process of signals of the magnetic device.

BACKGROUND INFORMATION

Many applications utilize magnetic structures to perform sensing, actuation, and communication, etc. in devices such as integrated circuits, sensors, and micromechanical devices, etc. Such devices may include magnetic structures in place of or in addition to other elements, such as electronic structures.

However, problems arise when integrating magnetic structures into various devices. Manufacturing materials having specific magnetic properties, such as producing a magnetic field or having electrical properties that vary as a function of a magnetic field, typically involves specific requirements, such as related to temperature or contaminants during the manufacturing process. These requirements often conflict with, or unduly restrain, the manufacturing of other materials, such as semiconductors, dielectric and metals, in the same device.

Devices including magnetic structures also typically require specific operational conditions, such as related to the path of a magnetic field, which sometimes conflict with or unduly constrain operational conditions, such as related to other electric, magnetic or electro-magnetic fields, of other elements included in the same device.

Therefore, a need exists for magnetic devices, systems and corresponding methods that integrate magnetic structures in an improved manner.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Embodiments of a magnetic device may incorporate a magnetic structure in an improved manner to provide one or more of improved device area utilization, manufacturability, reliability, performance or cost. The magnetic device may include the magnetic structure, another device structure, and an associated circuit.

The magnetic structure may interact magnetically with the environment of the magnetic device. The magnetic structure may include a layer of material that has a selected magnetic property such as producing a magnetic field or being responsive to a magnetic field. The layer may be patterned to provide one or more separate layer portions having selected shapes, and may be combined with other layers, to provide the selected magnetic properties. The magnetic structure may provide functionalities such as magnetic sensing, magnetic flux channeling, magnetic flux concentrating, magnetic shielding, magnetically actuated motion, etc.

The device structure may be another structure of the device that is physically connected to or arranged relative to the magnetic structure in a predetermined manner to, for example, structurally support, enable the operation of, or more advantageously integrate into the magnetic device the magnetic structure. The device structure may include, for example, a substrate, a layer on the substrate, a recess or aperture in the substrate, or a cap on the substrate, etc. The device structure also may optionally interact with the magnetic structure and/or environment of the magnetic device. For example, the device structure may include a conductive coil to generate a magnetic field. The device structure also may include package and module elements.

The associated circuit may be electrically connected to one or both of the magnetic structure and other device structure to provide functions such as, for example, receiving, providing, conditioning or processing of signals of the magnetic device. The circuit may include one or more of an amplification circuit, an analog-to-digital converter, a digital-to-analog converter, a driver circuit, a processor, a controller, etc. The circuit may be integrated with the magnetic structure on the same substrate or provided on another substrate. The circuit also may be provided as separate components in a device such as a packaged device or module.

FIG.1depicts an embodiment of a magnetic device20that incorporates a magnetic structure24in an improved manner to provide one or more of improved device area utilization, manufacturability, reliability, performance or cost. The magnetic device20may include the magnetic structure24, another device structure28, and an associated circuit32. The magnetic structure24may interact magnetically25with the environment of the magnetic device20. The device structure28may be another structure of the device20that is physically connected to or arranged relative to the magnetic structure24in a predetermined manner. The device structure28also may optionally interact29with the environment of the magnetic device20. The associated circuit32may be electrically connected27,31to one or both of the magnetic structure24and other device structure28to provide one or more functions such as providing, receiving, conditioning or processing of signals. The circuit32also may be electrically connected33external to the magnetic device to receiving or provide data to or from the magnetic device.

The magnetic structure may include a layer of material with a selected magnetic property, such as producing a magnetic field or producing a response to a magnetic field.

For example, the material may produce a temporary or permanent magnetic field. Materials that produce a temporary magnetic field may be referred to as soft magnetic materials, and materials that produce a permanent magnetic field may be referred to as hard magnetic materials. Soft magnetic materials may include, e.g., ferromagnetic material, ferrimagnetic material, etc. Ferromagnetic materials may include, e.g., iron, nickel, cobalt, gadolinium, etc. Ferrimagnetic materials may include, e.g., ferrites of manganese, copper, nickel, iron, etc. Hard magnetic materials may include Alnico, SmCo, NdFeB, etc.

The material may have a selected permeability to magnetic fields, such as a permeability above a predetermined threshold. Magnetic materials that have a selected permeability to magnetic fields, such as a permeability above a predetermined threshold, may include soft magnetic materials, etc.

The material may produce a response to a magnetic field by having an electrical property that varies as a function of the magnetic field experienced by the material. Such a material may include a magnetoresistive material having an electrical resistance that varies as a function of the magnetic field. Magnetoresistive materials may include, e.g., anisotropic magnetoresistive material, colossal magnetoresistive material, etc. Anisotropic magnetoresistive materials may include, e.g., nickel iron, etc. Colossal magnetoresistive materials may include, e.g., manganese perovskite oxides, etc. One or more layers of magnetoresistive material also may be arranged with one or more layers of other material to form a composite magnetoresistive structure. Such a composite magnetoresistive structure may include, e.g., a giant magnetoresistance structure, a tunnel magnetoresistance structure, etc.

The magnetic structure of any of the embodiments of the magnetic device discussed herein may include a material having any of the magnetic properties discussed herein, such as any of producing a magnetic field or producing a response to a magnetic field as discussed herein, among other properties. In some embodiments, the magnetic device may provide selected functionality by specifically utilizing materials having certain selected magnetic properties.

The layer of material may be patterned to impart a perimeter, boundary or shape to the layer to provide specific magnetic properties of the magnetic structure. The specific magnetic properties may include the ability to produce or respond to magnetic fields along specific spatial directions or orientations.

FIGS.2(a)-2(k)depict top views of layers patterned to provide selected perimeters, boundaries or shapes.FIGS.2(a)-2(c)depict embodiments of patterned layers having a cross-shaped, circular, and square or rectangular shapes40,44,48, respectively.FIGS.2(d)-2(e)depict embodiments of patterned layers having a plurality of separate rectangular, square or linear portions52,56arranged in a pattern or array, such as with subsets of the portions arranged facing each, as inFIG.2(d), or in an array with a characteristic spacing between them, as inFIG.2(e).FIGS.2(f)-2(g)depict embodiments of patterned layers having a plurality of separate portions forming concentric rings60, as inFIG.2(f), or strips64outlining rectangular or square shapes with aligned centers, as inFIG.2(g).FIGS.2(g)-2(h)depict embodiment of patterned layers having a plurality of separate arcuate segments68arranged to outline a ring, as inFIG.2(g), or a plurality of L- or T-shaped segments72arranged to outline a square or rectangle, as inFIG.2(h).FIG.2(j)depicts an embodiment of a patterned layer having a plurality of linear portions76connected together to form a single integral segment following a back and forth path.FIG.2(k)depicts an embodiment of a patterned layer having a spiral shape80.

Additional embodiments of the patterned layer may include other arrangements of one or more layer portions. The patterned layer of material may include arrangements of a plurality of any of the exemplary shapes depicted inFIGS.2(a)-2(k)or other shapes. For example, the patterned layer may include a plurality of shapes arranged in one or two dimensional arrays with characteristic periodic spacing between instances of the shapes in the one or two dimensions. Additional embodiments may include only a single ring or strip of the shapes inFIGS.2(f)-2(g); one or more arcuate, T-shaped or L-shaped sections shown inFIGS.2(h)-2(i)in different arrangements; or a plurality of linear or other segments similar to those inFIGS.2(e) and2(j)connected to follow a different path.

The patterned layer of material also may have a selected height characteristic perpendicular to a plane in which the perimeter, boundary or shape of the layer is defined. The selected height characteristic may provide specific magnetic properties of the magnetic structure, such as the ability to produce or respond to magnetic fields along specific spatial directions or orientations.

FIGS.3(a)-3(c)depict cross-sectional side views of embodiments of patterned layers having selected height characteristics perpendicular to a plane in which the perimeter, boundary or shape of the layer is defined. The depicted cross-sections may represent a slice of the patterned layer taken along an axis parallel to the plane in which the perimeter, boundary or shape of the layer is defined, such as along the axes A-A or B-B depicted inFIGS.2(c) and2(e), or along other axes in other directions in the planes of the shapes ofFIGS.2(a)-2(k).FIG.3(a)depicts an embodiment of the patterned layer having a substantially constant height81in the direction perpendicular to the plane defining the shape of the layer along an axis82parallel to the plane defining the shape. A substantially constant height may provide substantially constant magnetic properties of the patterned layer along the axis.

FIGS.3(b)-3(c)depict embodiments of the patterned layer having a height in the direction perpendicular to the plane defining the shape of the layer that vary along axes parallel to the plane defining the shape. InFIG.3(b), the patterned layer may have a height varying from substantially zero to a predetermined height83, and inFIG.3(c), the patterned layer may have a height varying from a first predetermined height86to a second predetermined height87different than the first predetermined height. The height of the patterned layer also may vary according to a selected function of the distance along the axes85,89. InFIGS.3(b)-3(c), the height may vary as a linear function of the distance along the axes85,89. In other embodiments, the height may vary according to other functions of the distance along the axis85,89, such as non-linear functions, stepped functions, etc. A varying height may provide correspondingly varying magnetic properties of the patterned layer along the axis. For example, embodiments of a varying height may be used to produce or respond to magnetic fields along the axis to provide position detection or current sensing of an object along the axis.

The patterned layer of material may be formed in an integral manner with one or more other layers to form a composite layer.FIGS.4(a)-4(b)depict perspective and cross-sectional side views, respectively, of an embodiment of a patterned layer of material formed in an integral manner with another layer of material. The patterned layer of material may include a plurality of separate portions84embedded in the other material88so that the other material88occupies spaces between the separate portions84of the magnetic layer. The patterned layer of material may optionally include a first set of surfaces92exposed at a first surface or boundary of the composite layer, and a second set of surfaces96covered by the other material88within the composite layer. The other layer of material88may be a material having a selected magnetic property or another type of material.

The composite layer may provide specific magnetic, electric or structural properties. In embodiments in which the second material88is also a material having a selected magnetic property, the second material88may alter, such as increase, decrease, or otherwise set, the magnetic properties of the patterned layer of material84to provide specific magnetic properties of the composite layer. In embodiments in which the second material88is another type of material, the second material88also may alter the magnetic properties of the patterned layer of material84to provide specific magnetic properties of the composite layer, or may alternatively provide structural or electrical properties to the composite layer.

The embedded portions of the patterned layer also may have a selected cross-sectional area. InFIGS.4(a)-4(b), the embedded portions may have a rounded or semi-circular cross-sectional area. In other embodiments, the embedded portions may have other cross-sectional areas, such as one or more of square, rectangular, or trapezoidal cross-sectional areas, etc.

The cross-sectional area of the embedded portion also may have a selected constancy along axes. InFIGS.4(a)-4(b), the embedded portions may have a substantially constant cross-sectional area along a longitudinal axis94to which the portions are aligned.FIG.4(c)depicts a cross-sectional top view of another embodiment of a composite layer in which the embedded portions may have a cross-sectional area having a width95that changes along a longitudinal axis97in a predetermined manner, such as in a linear manner.FIG.4(d)depicts a cross-sectional side view of another embodiment of a composite layer in which the embedded portions may have a cross-sectional area having a height99that changes along a longitudinal axis101in a predetermined manner, such as in a linear manner.

The layer of material having the selected magnetic property may include a surface with a selected topography. The selected topography may provide specific magnetic, electric or structural properties to the layer.FIG.5(a)depicts a cross-sectional view of a layer of material102having a top surface100with a plurality of projections104and recesses108. The plurality of projections104may be formed in an array having a characteristic periodic spacing between them, as may be the plurality of recesses108. The projections104and recesses108may be interleaved with each other. The layer of material with the selected topography also may be formed in an integral manner with one or more additional layers to form a composite layer, as discussed above.FIGS.5(b)-5(d)depict cross-sectional views of a patterned layer of material having a selected topography formed in an integral manner with another layer of material. InFIG.5(b), the projections104of the patterned layer102may include portions116exposed above a top surface120of the second layer of material118. InFIG.5(c), the projections104of the patterned layer102and the top surface128of the second layer of material124may be located at substantially the same level. InFIG.5(d), the second layer of material132may completely enclose the projections104of the patterned layer.

The layer of material having the selected magnetic property may include a plurality of separate portions having magnetic polarities aligned according to a selected configuration to provide specific magnetic properties.FIGS.6(a)-6(d)depict top views of embodiments of patterned layers including a plurality of separate portions with aligned magnetic polarities.FIG.6(a)depicts an embodiment of a patterned layer including a plurality of separate portions136arranged in a two dimensional array, each of the separate portions136having magnetic pole axis aligned in a same direction.FIGS.6(b)-6(c)depict embodiments of a patterned layer including a first plurality of separate portions140,148arranged in an array, each having magnetic pole axis aligned in a same first direction, and a second plurality of separate portions144,152also arranged in an array, each having magnetic pole axis aligned in a same second direction, the first and second directions being perpendicular to each other.FIG.6(d)depicts an embodiment of a patterned layer including first and second pluralities of separate portions156,160having magnetic pole axes respectively aligned in first and second perpendicular directions, and third and fourth separate portions164,168having magnetic pole axes respectively aligned in third and fourth perpendicular directions.

The magnetic structure of any of the embodiments of the magnetic device discussed herein may include a patterned layer having any of the properties of patterned layers discussed herein, such as any of the properties of patterned layers discussed in regard to any ofFIGS.2-6and their various subfigures (i.e., (a), (b), etc.), among other properties.

The magnetic structure may be incorporated into the magnetic device in part through its physical connection or arrangement relative to another structure of the magnetic device in a predetermined manner to one or more of structurally support, enable the operation of, or otherwise integrate into the magnetic device the magnetic structure.

The magnetic structure may be connected to or arranged relative to a structure of a substrate.FIG.7depicts an embodiment of the magnetic device161as a substrate-based magnetic device having a magnetic structure connected or arranged relative to a structure of a substrate. The magnetic device161may include one or more substrates167, a magnetic structure163, and an associated circuit169.

The substrate may include one or more substrate structures165, such as one or more of a surface, a recess, a side, etc. The magnetic structure may be physically connected or arranged relative to the one or more substrate structures in a predetermined manner.

The magnetic device also may optionally include one or more other structures171, such as a coil, cap, micromechanical structure, antenna, etc. The magnetic structure may be physically connected to or arranged relative to the other structure in a predetermined manner.

The circuit may be electrically connected to one or both of the magnetic structure and the other device structure to provide, receive, condition or process etc. signals of the magnetic structure or other device structure. The circuit also may provide or receive electrical signals external to the magnetic device, such as one or more of receiving data for controlling a component of the magnetic device, such as to provide a magnetic field to set or change a magnetic field in the magnetic structure, or to transmit data from a component of the magnetic device, such as to transmit data based on an electrical signal produced by the magnetic structure.

The substrate may include a semiconductor. For example, the substrate may be a semiconductor substrate such as utilized to manufacture integrated circuits. In some such embodiments, the magnetic device may be part of an integrated circuit. The substrate alternatively or in addition may include other types of materials, such as one or more of an insulator, glass, ceramic, etc. For example, the substrate may include an insulator such as utilized to manufacture silicon-on-insulator circuits, a glass such as utilized to manufacture displays and other devices, or a ceramic such as utilized to manufacture hybrid circuits.

The magnetic device may include a single substrate on or about which the magnetic structure and the circuit are formed. For example, in one embodiment, the magnetic device may be a single integrated circuit including both the magnetic structure and the associated circuit. Alternatively, the magnetic device may include more than one substrate. For example, the magnetic device may include a first substrate167aon or about which the magnetic structure is formed and a second substrate167bon or about which the circuit is formed.

Any of the embodiments of the magnetic device discussed herein may include one or more substrates according to any of the embodiments of the substrate discussed herein.

The magnetic structure may include a patterned layer of material having a selected magnetic property formed on a substrate in a predetermined manner in relation to other circuits that may be formed on the substrate. In embodiments, the patterned layer may be formed on one or more areas of the substrate without active circuits.FIGS.8(a)-8(b)depict embodiments of a magnetic device at a first stage of a method of fabricating the magnetic device, after a substrate172,174is provided that includes one or more areas176,178without active circuits and one or more areas180,182with or for which active circuits are planned. Active circuits may include powered integrated circuit devices such as transistors. The one or more areas176,178without active circuits may have the same shape as or encompass shapes of the patterned layer of material. The substrate172,174may be processed to produce the one or more areas176,178without active circuits, such as by removing layers on top of the substrate or otherwise conditioning the area to more effectively receive the patterned layer of material.FIGS.8(c)-8(d)depict embodiments of the magnetic device at a second stage of the method of fabrication, in which the patterned layer of material186,188has been formed on the substrates inFIGS.8(a)-8(b)in the one or more areas without active circuits. The layer186,188may assume various shapes as discussed above. The layer186,188may be formed in the areas without active circuits at a separate time as the active circuits, in a separate processing apparatus, or both, to prevent or reduce cross-contamination of the magnetic material with materials of the active circuits.

In other embodiments, the patterned layer may be formed in a same area on the substrate as active circuits. For example, the patterned layer may be formed as a layer above or below a one or more layers containing active circuits formed on the substrate.

The patterned layer also may be formed on a back side of a substrate. The back side of the substrate may exclude include active circuits. The patterned layer may be formed on the back side of a substrate wafer simultaneously for a plurality of integrated circuits or other substrate devices.FIG.9(a)depicts an embodiment of a bottom view of a semiconductor wafer192from which a plurality of integrated circuits or other substrate devices may ultimately be separated after processing.FIG.9(b)depicts an embodiment of a bottom view of the wafer ofFIG.9(a)at a stage of fabrication after a layer of material196having a selected magnetic property has been formed across substantially the entire back surface of the wafer.FIG.9(c)depicts an embodiment of a bottom view of the wafer ofFIGS.9(a)-9(b)at a further stage of fabrication, after the layer has been patterned to form patterned layer shapes200on the back side of the wafer for each of a plurality of integrated circuits or other substrate devices into which the wafer may be separated.

The magnetic structure may be formed as a separate structure that may be attached to a substrate.FIG.10(a)depicts an embodiment of a patterned layer204formed as a separate structure. The separate structure may be formed by one or more of punching, casting, plating, rolling, or depositing, etc. the magnetic layer into the separate structure. The layer also may be formed on a corresponding substrate as a separate structure.FIG.10(b)depicts an embodiment of a patterned layer208formed on a corresponding substrate212as a separate structure. The substrate212may have the same or a corresponding boundary or shape as the layer208. The substrate212also may provide structural support for the layer208, as well as facilitate fabrication of the layer208.

The magnetic device may include the separate magnetic structure attached to a substrate.FIG.11depicts an embodiment of the magnetic device that may include the separate magnetic structure attached to a substrate216.

The magnetic structure also may be physically connected to or arranged relative to other device structures. In embodiments, the other device structure may be a conductive coil. The magnetic structure may be located relative to the conductive coil in a predetermined manner to provide one or more of magnetic, electrical or structural interaction between the magnetic structure and conductive coil. For example, the conductive coil may be operated to provide a magnetic field to set or change a magnetic field in the magnetic structure. The conductive coil also may operate as a transmitter to communicate data based on an electrical signal produced by the magnetic structure, such as to transmit data representing a magnetic field or current sensed by the magnetic structure.

FIG.12depicts a top view of embodiments of the magnetic structure220and conductive coil224. The magnetic structure220may be located in a predetermined manner with respect to a portion228of the conductive coil224. For example, the magnetic structure220may be located above or below a section228of the conductive coil224. The section228of the conductive coil224may include a plurality of conductive segments232232with current flowing in substantially a same direction. The conductive coil224may include a layer of conductive material, such as metal, formed into a pattern, such as spiral or other coiling pattern, to produce sections having a plurality of conductive segments with current flowing in substantially a same direction.

The magnetic device may include the magnetic structure and conductive coil incorporated onto a same side of a substrate such as semiconductor or other substrate.FIG.13depicts an embodiment of the magnetic device that may include the magnetic structure220and conductive coil224formed on a first side of a substrate236.

The magnetic structure and conductive coil also may be incorporated onto different areas or sides of a substrate.FIGS.14(a)-14(c)depict another embodiment of the magnetic device incorporating the magnetic structure240and conductive coil244onto opposite sides of a substrate248.FIG.14(a)depicts a top view of the magnetic device, showing the conductive coil244formed as a layer on a first side of a substrate248.FIG.14(c)depicts a bottom view of the magnetic device, showing the magnetic structure240formed as a patterned layer on a second side of the substrate248.FIG.14(b)depicts a side cross-sectional view of the magnetic device, showing the conductive coil244as the layer on the first side of a substrate248and the magnetic layer240on the second side of the substrate248. The substrate248may optionally also include areas including active circuitry252, such as on either the first or second side of the substrate. InFIG.14(c), an area including active circuitry252may be included on the second side of the substrate248in a separate area from that including the magnetic layer240.

The conductive coil may optionally be formed as plurality of layers.FIG.14(d)depicts a side cross-sectional view of another embodiment of the magnetic device similar to that ofFIGS.14(a)-14(c), but showing the conductive coil256formed as a plurality of layers extending from the first side of a substrate260to the second side of the substrate260.

Embodiments in which the magnetic structure is located above or below a section of the conductive coil, such as those of, e.g.,FIGS.12,13and14(a)-14(d), may be useful for operation to provide a magnetic field to set or change a magnetic field in the magnetic structure. Embodiments in which the magnetic structure may be located in a different area or different side of the substrate from the conductive coil, such as those of, e.g.,FIGS.14(a)-14(d), and34(discussed below), may be useful for operation of the conductive coil as a transmitter to communicate data based on an electrical signal produced by the magnetic structure. Alternatively, the magnetic device may include a structure and/or circuit other than a conductive coil to operate as a transmitter to communicate data based on an electrical signal produced by the magnetic structure, such as one or more of an antenna, a transmitter circuit, etc.

The magnetic device may incorporate the magnetic structure in the predetermined manner so that it is physically aligned with an aperture in a device structure such as a substrate structure or other device structure.FIG.15depicts an embodiment of a magnetic device having a patterned layer264formed on a substrate268. Each of the patterned layer264and substrate268may include an aperture272,274extending from a top surface of the layer264or substrate268to a bottom surface of the layer264or substrate268. Furthermore, the patterned layer264may be positioned relative to the substrate268so that the aperture272in the patterned layer264aligns with the aperture274in the substrate268. The alignment of the apertures272,274may create a path of travel for another component or device through the apertures272,274from one side of the magnetic device to the other.

The alignment of the apertures in the magnetic structure and another device structure may be achieved as a result of a fabrication process for the magnetic device.FIGS.16(a)-16(c)depict embodiments of the magnetic device at various stages of a method of fabricating the magnetic device.FIG.16(a)depicts a cross-sectional side view of an embodiment of the magnetic device at a first stage of the method, after the substrate268is provided.FIG.16(b)depicts a cross-sectional side view of the magnetic device at a second stage of the method, after the patterned layer264is formed on the substrate268. The patterned layer264may be formed in different ways, such as by one or more of depositing, plating, or growing, etc. the patterned layer.FIG.16(c)depicts a cross-sectional side view of an embodiment of the magnetic device at a third stage of the method, after the aperture272,274is formed through the patterned layer264and the substrate268. The aperture272,274may be formed in both the patterned layer264and substrate268by the same process, such as by one or more of etching, drilling, or otherwise removing material to form the aperture. Forming the aperture272,274through both the patterned layer264and the substrate268using the same process may provide both an efficient method of forming the aperture272,274and an accurate alignment of the apertures272,274in the patterned layer264and the substrate268.

The magnetic device also may include one or more magnetic structures arranged relative to each other to provide selected magnetic and other functionalities. In embodiments, the magnetic device may include one or more magnetic structures arranged to provide a magnetic flux concentrator to selectively channel or concentrate magnetic flux. Such a magnetic structure may include one or more patterned layers having a plurality of separate portions with different distributions of material having selected magnetic properties to selectively channel or concentrate magnetic flux. For example, the magnetic structure may include one or more patterned layers to channel or concentrate magnetic flux from a first flux concentration at a first flux surface to a second flux concentration different than the first flux concentration at a second flux surface, the second flux surface having a different distribution or area than the first flux surface.

FIG.17(a)depicts a top view of an embodiment of a magnetic device configured to provide a magnetic flux concentrator, andFIG.17(b)depicts a cross-sectional side view of the embodiment of the magnetic device taken along the axis inFIG.17(a). The magnetic device may include a magnetic flux concentrator278, a magnetic sensor282, and a substrate286. The magnetic flux concentrator278may include a plurality of patterned layers having one or more of different distributions of material having selected magnetic properties along a selected dimension, or different flux surface areas. A first patterned layer290may include an outer concentric ring and a second patterned layer294may include an inner concentric ring. The outer concentric ring may be formed on the substrate286to a first height, and the inner concentric ring may be formed on the substrate286to a second height less than the first height. As a result, the outer concentric ring may have a different material distribution in the vertical direction and different flux surface areas than the inner concentric ring. The material of the patterned layers of the magnetic flux concentrator may be a material having a relatively high permeability to magnetic fields, such as permeability above a predetermined threshold.

The magnetic sensor282also may include a magnetic structure including a patterned layer of material298. The patterned layer of material298of the magnetic sensor282may formed on the substrate286at locations between the first and second patterned layers290,294. The magnetic sensor282also may include electrical interconnections and other components as discussed below. The material of the magnetic sensor may be a magnetoresistive material.

In operation, the magnetic flux concentrator278ofFIGS.17(a)-17(b)may channel and/or concentrate the magnetic flux of a magnetic field in the environment of the magnetic device in a predetermined manner so that the magnetic flux passes through the magnetic sensor282in a selected direction and at a selected concentration.FIG.17(b)shows an exemplary path of magnetic flux302in the space about and through the magnetic device. Above and below the magnetic device, the magnetic flux may be oriented in substantially the vertical direction. As the magnetic flux passes through the magnetic flux concentrator278, it may deviate along the depicted path as a result of the relative arrangement of the patterned layers290,294, which may provide a preferential path for magnetic flux as a function of their magnetic properties. This may result in the magnetic flux bending to take a substantially or at least more horizontal path as it passes through the magnetic sensor282. Channeling and/or concentrating of the magnetic flux along a selected direction may provide a number of advantages, including one or more of enabling the magnetic sensor282to be configured to have an operational sensitivity to magnetic fields along the horizontal direction instead of the vertical direction, which may be advantageous for fabrication of the sensor282, and enabling configurations of a magnetic device that may sense both vertical and horizontal magnetic fields using similar sensor arrangements.

Embodiments of the magnetic device to provide a magnetic flux concentrator may include magnetic structures having patterned layers including other shapes. A magnetic device similar to that ofFIGS.17(a)-17(b)may include a magnetic flux concentrator and a magnetic sensor each having a respective patterned layer including any of the shapes depicted inFIGS.2(a)-2(k). For example, the magnetic flux concentrator may include a partnered layer having first and second aligned rectangles such as depicted inFIG.2(g), segmented concentric rings or aligned squares similar to as depicted inFIGS.2(h) and2(i), etc.

Embodiments of the magnetic device to provide a magnetic flux concentrator also may include magnetic structures having patterned layers including varying heights. A magnetic device similar to that ofFIGS.17(a)-17(b)may include one or more of a magnetic flux concentrator or a magnetic sensor having a height in the vertical direction inFIGS.17(a)-17(b)that varies along the horizontal direction inFIGS.17(a)-17(b), such as depicted inFIGS.3(b)-3(c). For example, the magnetic flux concentrator may include a patterned layer having an outer portion having a height that varies between a first height at a first location, such as at the outermost location of the outer portion, and a second height less than the first height at a second location, such as at the innermost location of the outer portion. Similarly, the magnetic sensor also may include a patterned layer having a height that varies between a first height at a first location and a second height different than the first height at a second location.

The magnetic device may provide still other embodiments of a magnetic flux concentrator to selectively channel or concentrate magnetic flux along different paths.FIGS.18(a)-18(b)depict top and side cross-sectional views of an embodiment of a magnetic device including magnetic structures providing another magnetic flux concentrator306. The magnetic device may include a first magnetic structure and a second magnetic structure formed on a substrate310or a layer on a substrate. The first magnetic structure may include a first patterned layer of material314including one or more separate segments providing a magnetic flux concentrator306to concentrate or channel magnetic flux for the second magnetic structure. The second magnetic structure may provide a magnetic sensor318. The material of the magnetic flux concentrator may be a material having a relatively high permeability to magnetic fields, such as a permeability above a predetermined threshold, and material of the magnetic sensor may be a magnetoresistive material.

The first patterned layer314may provide magnetic flux channeling or concentration by providing a decreasing surface area for the magnetic flux travel. For example, the first patterned layer may include a segment322providing a channeling or concentrating of magnetic flux from a first flux concentration at a flux entry area326to a second flux concentration larger than the first flux concentration at a flux exit area332smaller than the flux entry area. The first patterned layer also may include a segment336providing a channeling or concentrating of magnetic flux from a third flux concentration at a flux entry area340to a fourth flux concentration smaller than the third flux concentration at a flux exit area344larger than the flux entry area.

In other embodiments, the magnetic device may provide yet further configurations of magnetic flux concentrators. For example, the magnetic device may include a magnetic structure similar to those discussed above in regard toFIGS.17(a)-17(b)or18(a)-18(b), but arranged to channel or concentrate magnetic flux as it travels in various different selected directions, such as in one or more of between different concentrations in a single direction, such as a vertical direction, a horizontal direction, or another direction; or as it changes direction from first direction to a second direction, such as a change in direction from a horizontal to vertical direction, from a vertical to a horizontal direction, or from any first predetermined direction to any second different predetermined direction.

In the above and other embodiments, the magnetic device may include a magnetic structure arranged to operate as a magnetic sensor. The magnetic sensor may include a plurality of resistors electrically interconnected between one or more predetermined voltages and one or more output terminals, such as in a bridge formation. At least one of the resistors may be a magnetoresistor formed from a patterned layer of magnetoresistive material. The magnetoresistor may be a variable resistor having an electrical resistance that varies as a function of a magnetic field to which the sensor is exposed. The electrical configuration of the sensor may utilize the variable resistor to provide an output voltage at the output terminals as a function of the magnetic field.

FIG.19is a schematic diagram depicting an electrical representation of an embodiment of a magnetic sensor. The magnetic sensor may include two pairs of resistors R1, R2, R3, R4arranged in a bridge configuration between a supply voltage VS and ground, with first and second output terminals taken at the middle of two legs of the bridge. One or more of the resistors, such as one resistor R2from an upper half of one of the legs of the bridge, and another resistor R3from a lower half of the other of the legs, may be magnetoresistors. In operation, the bridge may become unbalanced and provide a corresponding output voltage VO between the output terminals as a result of the variation in resistance value of the variable resistors R2, R3as a function of the magnetic field experienced by the sensor.

Embodiments of a magnetic structure arranged to operate as a magnetic sensor may include one or more standard resistors formed from an electrically resistive material, such as polysilicon layer or a diffusion region formed in a substrate, and one or more magnetoresistors formed from a patterned layer of magnetoresistive material.

Alternatively, embodiments of a magnetic structure arranged to operate as a magnetic sensor may include one or more standard resistors formed from a patterned layer of magnetoresistive material and a patterned layer of magnetic shielding material, and one or more magnetoresistors formed from the patterned layer of magnetoresistive material.

FIGS.20(a)-20(f)depict embodiments of magnetic structures configured to provide a magnetic sensor such as depicted inFIG.19.FIG.20(a)depicts a cross-sectional side view of a magnetic structure that may be used to implement a magnetic sensor. The magnetic structure may include a first patterned layer of material348formed on a first surface of a layer formed on a substrate, and a second patterned layer of material352formed on a second surface of second layer formed on a substrate. The first and second surfaces may be displayed vertically from each other.

The first patterned layer348may be used to implement resistors of the magnetic sensor.FIG.20(c)depicts a cross-sectional top view of an embodiment of the magnetic sensor ofFIG.20(a), showing greater detail of an embodiment of the first patterned layer348. The first patterned layer348may include a plurality of separate segments350, each of the separate segments350implementing a different resistor of the magnetic sensor. The first patterned magnetic layer348may include a first material such as a magnetoresistive material.

The second patterned layer352may operate as a magnetic shield to eliminate, reduce or otherwise alter the magnetic field in the environment in the vicinity of selected portions of the first patterned layer348.FIG.20(b)depicts a cross-sectional top view of an embodiment of the magnetic sensor ofFIG.20(a), showing greater detail of an embodiment of the second patterned layer352. The second patterned layer352also may include a plurality of segments354. Each of the segments354may align vertically with a corresponding one of a subset of the segments350of the first patterned layer348. Each segment354may channel or focusing the magnetic flux to shield the corresponding segment of the first patterned layer348from the magnetic field. The second patterned magnetic layer352may include a second material having a relatively high permeability to magnetic fields, such as a permeability above a predetermined threshold, e.g., a soft magnetic material. The segments of the second patterned layer may occupy a larger surface area, from the perspective of a top or bottom view, than the corresponding segments of the first patterned layer, in order to provide more effective shielding of those segments of the first patterned layer.

The magnetic structure may thus be used to provide both regular and magnetoresistors from the same patterned layer of material. A first subset of segments of the first patterned layer348aligned with segments of the second patterned layer352, despite including material such as magnetoresistive material, may provide a corresponding resistor in the magnetic sensor with no or a reduced sensitivity to the magnetic field about the sensor, such as the first and fourth resistors R1, R4inFIG.19, due to the presence of the magnetic shielding provided by the second patterned layer. A second subset of segments of the first patterned layer348not aligned with segments of the second patterned layer352may provide magnetoresistors in the magnetic sensor with a sensitivity to the magnetic field, such as the second and third resistors R2, R3inFIG.19, due to including material such as magnetoresistive material without the presence of the magnetic shielding provided by the second patterned layer. Providing both regular and magnetoresistors from the same patterned layer of material may simplifying the fabrication of the magnetic device by eliminating the need for a second resistive material and corresponding additional fabrication steps.

The different layers of patterned material may be provided in different stacking orders.FIG.20(d)depicts a cross-sectional side view of another embodiment of a magnetic sensor having the first patterned layer of material348formed on a surface of a layer formed on a substrate above a second patterned layer of material352formed on a surface of another layer formed on a substrate.

The first and second patterned layers also may include different shape and geometrical configurations, such as any of the shape configurations depicted inFIGS.2(a)-2(k), and various alignments of the first and second patterned layers relative to each other.FIGS.20(e)-20(f)depict top views of another embodiment of first and second patterned layers355,357of a magnetic sensor similar to that of the embodiments ofFIG.20(a)-20(d), but in which the first and second patterned layers may have different shape and geometrical configurations. InFIG.20(f), the first patterned layer355may have a shape similar to that ofFIG.2(d), in which a first subset of rectangular portions are arranged in a first array in a first orientation and a second subset of rectangular portions are arranged in a second array in a second orientation rotated 90° relative to the first orientation. InFIG.20(e), the second patterned layer357may have a single shape overlying an entire subset of the rectangular portions.

The magnetic sensor may include other elements, such as conductors, which are show in schematic form inFIG.20(c), as well as conductive striping to enhance or select direction of sensitivity. Embodiments of magnetic sensor also may include different electrical configurations.

The magnetic device may include a first patterned layer and a second patterned layer arranged relative to each other similar to as shown inFIG.20(a)but to produce other selected magnetic functionality. The first patterned layer may include a material having a selected magnetic property such as, e.g, a magnetoresistive material or a material producing a temporary or permanent magnetic field. The second patterned layer may include magnetically shielding material, such as a material having a permeability to magnetic fields above a predetermined threshold. Each of the first and second patterned layers may have any of the patterned layer properties discussed herein, such as any of the patterned layer shapes discussed in regard toFIGS.2(a)-2(k). Additionally, one or both of the first or second patterned layers may have the inverse of such shapes, i.e., may occupy only an area outside of these shapes. Different combinations of the first and second patterned layers may produce different selected magnetic functionality. For example, in embodiments similar to that shown inFIG.20(a), the first patterned layer may include specific patterned layer shapes and the second patterned layer may include a subset of substantially the same shapes or such a subset scaled to a predetermined degree larger or smaller. Such embodiments may be useful to provide magnetic and other functionality using the same first patterned layer. In other embodiments, the first patterned layer may include specific patterned layer shapes and the second patterned layer may include inverse shapes. Such embodiments may be useful to allow magnetic fields to reach the first patterned layer but not other components such as circuitry that may be adjacent, in between, or have some other spatial relationship to the first patterned layer.

The magnetic device also may include a plurality of magnetic structures stacked on top of each other on a substrate.FIG.21depicts a side view of an embodiment of a magnetic device including a plurality of stacked magnetic structures. The magnetic device may include a first magnetic structure358stacked on top of a second magnetic structure362. The stacked first and second magnetic structures358,362may be stacked on top of another device structure such as a substrate366. The stacked magnetic structures358,362may be separated by one or more insulating or shielding layers370,374. Each of the stacked magnetic structures358,362may include a layer of material378,382having selected magnetic properties formed on a substrate386,390.

The magnetic device also may include a magnetic structure formed in or at least partially in a recess in a substrate or a recess in one or more layers on a substrate.FIGS.22(a)-22(b)depict embodiments of a magnetic device at a first stage of fabrication, after a substrate394,398is provided that includes one or more recesses402,406formed in the substrate394,398or in one or more layers on the substrate394,398. The one or more recesses402,406may be shaped to have the same shape as or encompass shapes of a magnetic layer. The substrate394,398may be processed to produce the one or more recesses402,406, such as by removing material from the substrate394,398or layer on the substrate by one or more of etching, sputtering, etc.FIGS.22(c)-22(d)depict embodiments of the magnetic device at a second stage of fabrication, after a patterned layer410,414of material having a selected magnetic property has been formed in the one or more recesses shown inFIGS.22(a)-22(b). The shapes of the patterned layers410,414may be the same as the shapes of the recesses. Alternatively, a recess may contain a layer having a different shape or a layer having a plurality of shapes.

The magnetic structure also may conformally coat or at least partially conformally coat one or more recess.FIG.23(a)depicts an embodiment of a magnetic device at a first stage of fabrication, in which a plurality of recesses415are formed in a substrate or in one or more layers on the substrate. The plurality of recesses may be separated from each other by non-recessed surfaces417, such as according to a periodic separation distance.FIG.23(b)depicts an embodiment of the magnetic device at a second stage of fabrication, in which a patterned layer419has been formed to conformally coat an area including the recesses and separating surfaces. The patterned layer alternatively may coat only a partial portion of the area including the recesses and separating surfaces.FIG.23(c)depicts another embodiment of the magnetic device at a second stage of fabrication, in which a patterned layer421has been formed to conformally coat a partial portion of the area including the recesses and separating surfaces. This partial coating may be formed directly by forming the coating only in the partial area, or alternatively by forming a coating such as depicted inFIG.23(b)and subsequently removing a portion of the coating. The patterned layer also may coat only a portion of the recesses.FIG.23(d)depicts another embodiment of the magnetic device at a second stage of fabrication, in which a patterned layer423has been formed to conformally coat a partial portion of the recesses, such as a bottom surface of the recesses. This partial conformal coating again may be formed directly by forming the coating only in the partial areas, or alternatively by forming a coating such as depicted inFIG.23(b)and subsequently removing a portion of the coating.

The magnetic device may include conductive wiring arranged about the patterned layer formed in a recess. The conductive wiring may provide a conductive coil or other conductive interconnection about the magnetic layer. The conductive wiring may include one or more of a conductive layer or a through silicon (or other substrate) via (TSV). The conductive layer may include one or more of a horizontal conductive layer or a vertical conductive layer.

FIGS.24(a)-24(c)depict embodiments of a magnetic device at a first stage of fabrication, having a substrate418,422,426in which one or more recesses430,434,438are formed and one or more TSVs442,446,450are formed about the recesses430,434,438.FIGS.24(d)-24(f)depict embodiments of the magnetic device ofFIGS.24(a)-24(c)at a second stage of fabrication, in which a patterned layer454,458,462has been formed in the one or more recesses430,434,438.FIGS.24(g)-24(i)depict embodiments of the magnetic device ofFIGS.24(a)-24(f)at a third stage of fabrication, in which one or more conductive layers466,470,474have been formed between the TSVs442,446,450over the material454,458,462in the one or more recesses430,434,438. Another conductive layer may be formed at a lower layer or on the back side of the substrate to complete interconnection of the conductive wiring, such as to form conductive coils about the material454,458,462.

Conductive wiring about the patterned layer of material may form a conductive coil having a variety of configurations and for a variety of purposes. A conductive coil about the material may be used to generate or reinforce a magnetic field in the material. A conductive coil about the patterned layer also may be used to set, such as to initialize or change the direction of, a magnetization of the material, such as a magnetization of an anisotropic magnetoresistive material used to implement a magnetoresistor. The conductive coil may include one or more windings about one or more separate segments of the patterned layer at one or more locations of the segments. For example, inFIG.24(g), the conductive coil may include a plurality of windings478about a single separate segment of the patterned layer. InFIG.24(h), the conductive coil may include a plurality of windings482,484about each of a plurality of separate segments of the patterned layer. InFIG.24(i), the conductive coil may include a first plurality of windings488about a first location of a single continuous segment of the patterned layer, and a second plurality of windings492about a second location482of the single continuous segment of the patterned layer. The first and second pluralities of windings488,492optionally may be used to provide magnetic fields to the first and second locations of the segment in different directions. The first and second locations of the single segment of the patterned layer optionally may be used to produce, conduct, channel or concentrate magnetic flux in different directions.

One or more patterned layer of material having a selected magnetic property may be formed at a plurality of levels in and about a recess.FIGS.25(a)-25(b)depict top and cross-sectional side views of an embodiment of a magnetic device at a first stage of fabrication, in which a recess496having a plurality of levels500is formed in a substrate504. Each of the plurality of levels500of the recess496may include a surface. Each surface may be parallel to a primary plane of the substrate504. Each surface also may be offset from other level surfaces by an inter-level distance.FIGS.25(c)-25(d)depict top and cross-sectional side views of the magnetic device ofFIGS.25(a)-25(b)at a second stage of fabrication, in which a plurality of patterned layers of material are formed at a plurality of levels in and about the recess496. The patterned layers may include one or more patterned layers508formed inside the recess on a surface of one of the levels500inside the recess496. Although the exemplary embodiment ofFIGS.25(c)-25(d)depict a single patterned layer at a single level500inside the recess496, other embodiments may include a plurality of patterned layers, each at a different level500inside the recess496. The patterned layers also may include a patterned layer512formed on a surface bordering or about the boundary of the recess496. The patterned layers508,512may have the same shape as the recess496or level of the recess496on or about which they are formed. The patterned layers508,512may be offset from each other according to the inter-level distances between levels on which they are formed.

Embodiments of the magnetic device may provide functionality based on the presence of the patterned layers at different levels. For example, a plurality of layers provided on different levels offset from each other by inter-level distances may be used to provide magnetic sensing as a function of an axis along which the levels are offset. For example, the magnetic device inFIG.25(d)may provide magnetic sensing as a function of a central axis516of the recess496. This may be useful to sense properties of an object that may enter the recess496, such as the position of the object with respect to the central axis516or the presence or level of a current associated with an object with respect to the central axis516.

Different types of magnetic structures may be formed in and about a recess.FIGS.26(a)-26(b)depict top and cross-sectional side views of an embodiment of a magnetic device at a first stage of fabrication, in which a recess520having a plurality of levels524is formed in a substrate528.FIG.26(c)depicts a side cross-sectional view of the magnetic device ofFIGS.26(a)-26(b)at a second stage of fabrication, in which a patterned layer of material532having a selected magnetic property is formed at a level524in the recess520.FIG.26(d)depicts a side cross-sectional view of the magnetic device ofFIGS.26(a)-26(c)at a third stage of fabrication, in which a magnetic structure536is placed at another level524in the recess520. The magnetic structure536may include a patterned layer540formed on a substrate544. InFIG.26(d), the patterned layer532formed on the level524of the recess520may be formed at the same vertical height as the patterned layer540formed on the substrate544placed in the recess520. However, in other embodiments, the patterned layer532on the level524in the recess520may be at a different vertical height than that of patterned the layer540on the substrate544in the recess520.

The magnetic structure may include different shapes or portions of shapes of patterned layers formed at different levels.FIG.27(a)depicts a top view of an embodiment of a magnetic device including patterned layers548,552having a plurality of separate arcuate segments arranged to outline a ring.FIG.27(b)depicts a cross-sectional side view of the magnetic device ofFIG.27(a)taken along a first axis passing through a first subset of the segments556. The first subset of segments556may be formed as a first patterned layer548on a first surface of a substrate or layer on the substrate.FIG.27(c)depicts a cross-sectional side view of the magnetic device ofFIG.27(a)taken along a second axis passing through a second subset of the segments560. The second subset of segments560may be formed as a second patterned layer552at a second level in a recess in the substrate or on a layer of the substrate. Forming different shapes or portions of shapes of patterned layers on different levels may provide specific functionality of the magnetic devices, such as specific magnetic sensing properties, resulting from the distribution of geometric shapes to different levels.

Magnetic structures also may be arranged about a recess to provide a magnetic flux concentrator.FIG.28(a)depicts a cross-sectional side view of an embodiment of the magnetic flux concentrator device ofFIG.17(a), in which at least one of the patterned layers of the magnetic flux concentrator may be formed on a surface of a level inside a recess564. Another of the patterned layers of the magnetic flux concentrator may be formed on a surface about the recess564. InFIG.28(a), the magnetic sensor also may be formed on a surface about the recess564. However, in other embodiments, the magnetic sensor also may be formed on a surface of a level inside the recess564.FIG.28(b)depicts a cross-sectional side view of another embodiment of the magnetic device ofFIG.17(a), similar to the embodiment ofFIG.28(a), but in which the magnetic sensor may be formed on a surface of a level inside the recess564. Other embodiments may include further variations of distributions of components of the magnetic flux concentrator and magnetic sensor to different levels in and about a recess.

Other magnetic devices discussed herein also may be configured in and about one or more recesses. For example, one or more of the patterned layers of the magnetic concentrator device ofFIGS.18(a)-18(b)also may be formed in one or more recesses Similarly, one or more of the patterned layers of the magnetic sensor device embodiments ofFIGS.20(a)-20(f)may be formed in one or more recess.

The magnetic structure may be located on a back side of a substrate or in a recess on a back side of a substrate.FIG.29depicts a cross-sectional side view of a magnetic device including one or more magnetic structures568, each located in a corresponding recess572in a back side of a substrate576. Each of the magnetic structures568may include a patterned layer580formed on a substrate584. The magnetic device also may include one or more TSVs588electrically connecting the magnetic structures to a front side of the substrate, which may include integrated circuitry592.

The magnetic structure also may include a patterned layer of material having a selected magnetic property formed on an angled surface. The angled surface may be a surface of a walls of a recess. Forming the patterned layer on an angled surface may provide selected functionality as a function of the angle of the surface, such as enabling one or more of vertical or three-dimensional sensitivity for a magnetic sensor formed from such layers.

FIG.30(a)depicts a cross-sectional side view of an embodiment of a magnetic device including a patterned layer596formed on an angled surface600of a wall of a recess604in a substrate608. The surface600may be configured to have a predetermined angle relative to a primary plane of the substrate608or a surface of a layer on the substrate608.FIG.30(b)depicts a top view of an embodiment of the magnetic device depicted inFIG.29(a). The layer596may be patterned to form, e.g., a magnetic sensor. The recess604may have the same shape as or encompass the patterned layer596. As with other embodiments discussed herein, the patterned layer596may have any of the patterned layer properties discussed herein, such as any of the patterned layer shapes discussed herein regard toFIGS.2(a)-2(k).

The magnetic structure also may include patterned layers formed on a plurality of different angled surfaces.FIG.31(a)depicts a cross-sectional side view of an embodiment of a magnetic device including a plurality of patterned layers612,616, each formed on a different angled surface620,624of a wall of a recess628in a substrate632. Each of the surfaces620,624may be configured to have a corresponding predetermined angle relative to a primary plane of the substrate632or a surface of a layer on the substrate632. The predetermined angle for each wall optionally may be different than that of the other walls.FIG.31(b)depicts a top view of an embodiment of the magnetic device depicted inFIG.31(a). The layers612,616may be patterned to form, e.g, a magnetic sensor. The recess628may be shaped to have the same shape as or encompass the patterned magnetic layers612,616.

A plurality of patterned layers may be formed on a plurality of different angled surfaces of a plurality of different recesses.FIG.32depicts a top view of another embodiment of a magnetic device including a plurality of patterned layers636,640,644,648, each formed on a different angled surface652,656,660,664forming a wall of a different recess. Each of the patterned layers636,640,644,648may include a plurality of separate segments oriented in a different directions.

The magnetic structure also may be formed on a cap mounted on a substrate.FIGS.33(a)-33(b)depict perspective and cross-sectional side views of an embodiment of a magnetic device having a magnetic structure formed on a cap668mounted on a substrate672. The magnetic structure may include a patterned layer of material676having a selected magnetic property formed on a surface or in a recess of the top portion of the cap668. The cap668may be mounted on the substrate672over a substrate structure680to partially or completely enclose a volume about the substrate structure680from the environment outside the cap668. The cap668may include the top portion located over the substrate structure680and sidewalls extending from the top portion to the substrate672. The cap668may optionally be a capping substrate formed from another substrate. The substrate structure680may be located under the cap668. The substrate structure680may include one or more of integrated circuitry, a micromechanical structure, a sensor structure, or another magnetic structure, etc.

The magnetic device also may include conductive wiring to electrically interconnect the magnetic structure on the cap with the circuit structure under the cap.FIG.33(c)depicts a cross-sectional side view of an embodiment of the magnetic device similar to the embodiment ofFIGS.33(a)-33(b), but which includes one or more TSVs684extending through the cap from the top surface of the cap to the substrate under the cap. The TSVs684, optionally along with one or more conductive layers, may electrically interconnect the magnetic structure with the substrate structure under the cap.FIG.33(d)depicts a cross-sectional side view of another embodiment of the magnetic device similar to the embodiment ofFIGS.33(a)-33(b), but which may include one or more wire bonds688extending from the top surface of the cap to the substrate to electrically interconnect the magnetic structure on the cap to the substrate structure under the cap.

Magnetic structures also may be formed at a plurality of different levels on and about a cap.FIGS.34(a)-34(b)depict perspective and cross-sectional side views of an embodiment of a magnetic device having magnetic structures formed at a plurality of different levels on and about a cap692mounted on a substrate696. A first magnetic structure may include a first patterned layer700formed at a first level on the cap692as discussed above in regard toFIGS.33(a)-(d). A second magnetic structure may include a second patterned layer704formed at a second level on or in a recess in the substrate696about the cap692. The first level may be offset from the second level by a predetermined distance. The first and second magnetic layers700,704may have a common shape, such as concentric rings or aligned square or rectangular shapes. The second layer704may partially or wholly surround the cap692.

As with other embodiments discussed herein, a patterned layer formed on a cap may have a selected magnetic property to provide a selected magnetic functionality. In embodiments, the patterned layer may include a magnetoresistive material arranged to form a magnetic sensor. In other embodiments, the patterned layer may include a material producing a temporary or permanent magnetic field. In yet other embodiments, the patterned layer may include a magnetically shielding material, such as a material having a permeability to magnetic fields above a predetermined threshold.

Other structures may be formed on the cap in addition to the magnetic structure.FIG.35depicts an embodiment of a magnetic device including a magnetic structure708and a conductive coil712formed on a cap716mounted on a substrate720. The conductive coil712may be formed in separate area from the magnetic structure708, as inFIG.35, or may be formed under or above the magnetic structure. A conductive coil formed in a separate area may provide, e.g., a radio-frequency identification structure. A conductive coil formed below or above the magnetic structure may be used to provide a magnetic field to set or modify the magnetic properties of the magnetic structure.

The magnetic device also may provide a magnetic flux concentrator on or in the cap.FIG.36(a)depicts an embodiment of a magnetic device including a first magnetic structure forming a magnetic flux concentrator and one or more second magnetic structures forming one or more magnetic sensors in and about a cap mounted on a substrate. The magnetic flux concentrator may include patterned layer of a material717deposited in a sidewall of the cap. The patterned layer may extend substantially to the top and bottom of the sidewall, or to within a predetermined distance of the top and bottom. The patterned layer of the magnetic flux concentrator may be formed along a substantially vertical plane. The one or more magnetic sensors may include a patterned layer of material715,719formed on the cap and/or on the substrate. The patterned layers may be formed within a predetermined distance of the ends of the patterned layer of the magnetic flux concentrator. The patterned layers of the magnetic sensors may be formed along a substantially horizontal plane. The patterned layer of the magnetic flux concentrator may include a material having a relatively high permeability to magnetic fields, such as a permeability above a predetermined threshold, and the patterned layers of the magnetic sensors may include a magnetoresistive material.

In operation, the magnetic flux concentrator may channel or concentrate magnetic flux as it travels in a vertical direction721in an area above and below the patterned layer into the patterned layer. This channeling or concentrating may produce localized translation of the magnetic flux from a vertical direction or similar directions to a horizontal direction or similar directions723near the ends of the magnetic flux concentrator where the magnetic sensors are located. Channeling and/or concentrating of the magnetic flux may enable the magnetic sensor to sense a vertical magnetic field using an operational sensitivity to magnetic fields along the horizontal direction instead of the vertical direction.

FIG.36(b)depicts another embodiment of a magnetic device similar to the embodiment ofFIG.36(a), but in which a magnetic flux concentrator may include patterned layer of a material725deposited on a surface of the sidewall of the cap.

Additionally, the magnetic structure may be formed on the cap according to any of the embodiments of the magnetic structure formed on a substrate discussed herein, such as in regard toFIGS.7to44and their various subfigures (i.e., (a), (b), etc.), among other embodiments, with the cap being the substrate and having corresponding substrate structures.

The magnetic structure also may include a patterned layer formed on or as part of a micromechanical structure. The micromechanical structure may include one or more of a variety of different structures, including one or more of a beam, a plate, a comb, a diaphragm, or a gear, etc. The patterned layer may form part or all of a mechanically active portion of the micromechanical structure.

FIG.37(a)depicts an embodiment of a magnetic device including a magnetic structure having a patterned layer forming a micromechanical beam724suspended from a substrate728. The beam724may be a cantilever including an anchor portion732connecting the beam724to the substrate728and a suspended portion736suspended over another portion of the substrate728. The suspended portion736of the beam724may be flexible, and may be configured to bend toward and away from the substrate in response to stimuli. The patterned layer may include a material that produces a permanent or temporary magnetic field. The patterned layer may form substantially the entire beam724, including both the anchor portion732and the suspended portion736, as shown inFIG.37(a). However, the patterned layer of the magnetic structure alternatively may form only a part of the micromechanical device.FIG.37(b)depicts another embodiment of a magnetic device similar to the embodiment depicted inFIG.37(b), but in which a patterned layer may form only a part of the micromechanical device, such as a patterned layer740on a suspended portion of a beam, which may be formed form another material, such as an oxide, polysilicon or other material.

The magnetic device also optionally may include another magnetic structure including a patterned layer744formed under the micromechanical structure on, in, or in a recess of the substrate728. The patterned layer may include a material that produces a permanent or temporary magnetic field. The second magnetic structure may interact magnetically with the magnetic structure of the micromechanical structure724. Other embodiments may omit the second magnetic structure744formed under the micromechanical structure724.

The magnetic device may further include a cap748mounted on the substrate728about the micromechanical structure724. The cap748may partially or wholly enclose the micromechanical structure724to protect the micromechanical structure724from the environment about the magnetic device.

The magnetic device also may include conductive wiring to electrically interconnect the micromechanical structure to other device components. The conductive wiring may include a conductive layer752electrically interconnecting the magnetic structure to other locations on the same side of the substrate728as the micromechanical structure724, as shown inFIG.37(a). The conductive wiring also may include one or conductive layers and TSVs interconnecting the micromechanical device to locations on the opposite side of the substrate.FIG.37(c)depicts another embodiment of a magnetic device similar to the embodiment depicted inFIG.37(a), but in which the magnetic device may include one or conductive layers756and TSVs760interconnecting the micromechanical device to locations on the opposite side of the substrate.

In operation, the micromechanical beam structure depicted inFIGS.37(a)-37(c)may provide a variety of functionality, such as operating as a switch, a sensor, etc. For example, the micromechanical beam structure may operate as a magnetic switch such as a reed relay to make an electrical interconnection between a conductive contact764at a free end of the beam724and a second conductive contact768on the substrate728under the free end of the beam724in response to external stimuli such as a magnetic field. The micromechanical beam structure also may be used to detect external magnetic fields as a function of the deflection of the beam structure in response to such fields. The micromechanical beam structure further may be used to produce selectively changing magnetic fields by moving the beam structure in response to a stimuli such as a magnetic field or acceleration. A selectively changing magnetic field may be used in various applications such as, e.g., implementing an isolated data link.

The magnetic device may include a plurality of micromechanical structures formed in part or in whole from magnetic structures.FIGS.38(a)-38(b)depicts top views of embodiments of a magnetic device including a plurality of micromechanical beams771,772formed from patterned layers similar to as shown inFIGS.37(a)-37(b). InFIG.38(a), the plurality of beams771may be arranged adjacent to each other, in a same spatial orientation, in a one dimensional array. InFIG.38(b), the plurality of beams772may be arranged with spatial orientations at angles relative to each other, such as at angles of 90° or 180°. The plurality of micromechanical structures may be arranged relative to each other to implement various devices, such as, e.g., an interconnected array of magnetic switches. For example, the embodiment ofFIG.38(a)may be used to detect or otherwise provide functionality as a function of a variation of a magnetic field along the array of beams. The embodiment ofFIG.38(b)may be used to detect or otherwise provide functionality as a function of a directionality of a magnetic field relative to the array of beams as a whole.

A micromechanical beam structure formed from a magnetic structure also may be configured to bend laterally instead of or in addition to toward and away from the substrate. The micromechanical beam may be configured to bend in a particular direction by dimensioning the beam below a predetermined thickness in that direction to allow flexing of the beam.FIGS.39(a)-39(b)depict top and side views of embodiments of a magnetic device including a micromechanical beam773formed from a patterned layer similar to as shown inFIGS.37(a)-37(b), but in which the beam may be configured to bend laterally from side to side, in a direction parallel to a primary plane of the substrate, instead of or in addition to bending toward and away from the substrate. The magnetic device also may include one or more elements positioned laterally on one or more sides of the beams. The lateral elements may be or include one or more of a movement limiting structure, an electrical contact, or a secondary magnetic structure.

The magnetic device may include a plurality of micromechanical beams formed from magnetic structures and configured to move laterally.FIG.40depicts a top view of an embodiment of a magnetic device including a plurality of micromechanical beams777formed from a patterned layer similar to as shown inFIGS.39(a)-39(b). The plurality of beams may be arranged in spatial orientations at angles relative to each other, such as at angles of 90° or 180°. In other embodiments, the plurality of beams may be arranged adjacent to each other, in a same spatial orientation, in a one dimensional array, such as similar to as shown inFIG.38(a). As discussed above, a plurality of micromechanical structures may be arranged relative to each other to implement various devices. For example, the embodiment ofFIG.40also may be used to detect or otherwise provide functionality as a function of a directionality of a magnetic field relative to the array of beams as a whole.

The micromechanical beam formed from the magnetic structure may take forms other than the cantilever beams depicted inFIGS.37-40.FIG.41(a)-41(b)depict side views of additional embodiments of micromechanical beam structures that may be formed from a magnetic structure. InFIG.41(a), the beam structure776may include first and second anchor portions780,784, at opposite ends of the structure776, connecting the structure776to a substrate786, and a suspended portion788suspended over the substrate786. InFIG.41(b), the beam structure792may include a central anchor portion796connecting the structure792to a substrate800, and first and second suspended portions804,808suspended over the substrate800. In each case, the suspended portion of the beam may be flexible and bend in response to magnetic stimuli.

AlthoughFIGS.38-41depict beam structures formed wholly from patterned layers, in other embodiments, these micromechanical beam structures may be formed either in whole or in part from a patterned layer, such as show by comparison inFIGS.37(a)-37(b). Additionally, although for clarity of illustrationFIGS.38-41essentially depict only the plurality of micromechanical structures, the magnetic device also may include other components to enable and/or augment the function of these structures, such as one or more of a cap, electrical connections, second magnetic structure, etc., similar to as shown inFIGS.37(a)-37(c).

The magnetic structure also may be formed on or as part of other types of micromechanical structures. For example, the magnetic structure may be formed on or as part of a micromechanical diaphragm.FIGS.42(a)-42(c)depict cross-sectional side views of a magnetic device including a magnetic structure formed on a micromechanical diaphragm formed on a substrate803. The diaphragm may include one or more anchor portions805connected to the substrate, and a suspended portion807suspended over an area of the substrate. The suspended portion may be flexible, and may be configured to bend toward and away from the substrate in response to stimuli. The suspended portion may include one or more recesses809in which a patterned layer811,815,817may be formed. The patterned layer may partially fill the recesses, such as inFIG.42(a), wholly fill the recess, such as inFIG.42(b), or overflow the recess, such as inFIG.42(c). The patterned layer may include a material that produces a permanent or temporary magnetic field.

A cap such as shown inFIGS.33-37also may be configured as a micromechanical diaphragm such as shown inFIGS.42(a)-42(c).

The magnetic structure also may be formed on or as part of other types of micromechanical structures. For example, the magnetic structure may be formed on or as part of a micromechanical scanner.FIGS.43(a)-43(b)depict top and bottom views of a magnetic device including a magnetic structure formed on a micromechanical scanner. The micromechanical scanner may include the rotatable platform819, an inner actuating ring821, and an outer actuating ring823. The micromechanical scanner may be formed from a substrate or layers on a substrate.

The rotatable platform may include a top surface on which a layer of material having a selected reflectance may be formed, a bottom surface on which a patterned layer of material825having a selected magnetic property and a set of electrical contacts829connected to the patterned layer may be formed, and a set of electrostatic actuator components827such as drive combs. The rotatable platform may be connected to the inner actuating ring by one or more torsional springs831. The inner actuating ring may include first and second sets electrostatic actuator components832,833such as drive combs. The inner actuating ring may be connected to the outer actuator ring by one or more torsional springs835. The outer actuator ring may include a set of electrostatic actuator components837such as drive combs, and a set of electrical contacts839. The electrical contacts of the rotatable platform may be electrically connected to the electrical contacts of the outer actuator ring by a set of bond wires841. Although shown as having essentially square outlines inFIGS.43(a)-43(b), the rotatable platform, inner actuating ring, and outer actuating ring alternatively may be formed to have other outlines, such as rectangular, circular, or elliptical outlines, etc.

The patterned layer may include a magnetoresistive material arranged to form a magnetic sensor. For clarity of illustration, the patterned layer is shown as a single square region inFIG.43(b), but may instead include any of patterned layer shape configurations discussed herein, such as one or more patterned layer shapes electrically interconnected and arranged to form a magnetic sensor.

In operation, the rotatable platform may rotate about a first axis843in response to the application of electric signals to the electrostatic actuator components of the platform and inner actuator ring. Similarly, the rotatable platform may be rotated about a second axis845in response to the application of electric signals to the electrostatic actuator components of the inner actuator ring and the outer actuator ring.FIGS.44(a)-44(c)depict cross sectional front views of the magnetic device, taken along an axis offset from the torsional springs. InFIG.44(a), the rotatable platform may be in a quiescent state, with no rotation about either axis. InFIG.44(b), the rotatable platform may be rotated about the first axis. InFIG.44(c), the rotatable platform may be rotated about the second axis. The reflective layer may scan a light source such as a laser directed onto the rotatable platform in a corresponding two dimensional pattern. The magnetic sensor may provide an output signal representing the orientation of the rotatable platform by sensing the magnetic field in the environment of the magnetic device, which may have a known orientation relative to the magnetic device as a whole. For clarity of illustration, the bond wires841are omitted fromFIGS.44(a)-44(c), however they may be configured to have sufficient size and flexibility to accommodate the rotation of the platform about both axes while still maintaining an electrical connection between the electrical contacts829on the rotatable platform and the electrical contacts839on the outer ring.

Any of the embodiments of the magnetic device discussed herein may include a magnetic structure having a patterned layer having any of physical connections or arrangements relative to the substrate discussed herein, such as any of the connections or arrangements discussed in regard to any ofFIGS.7to44and their various subfigures (i.e., (a), (b), etc.), among other connections and arrangements.

The magnetic device may include a magnetic structure connected to or arranged relative to a structure of a package.FIG.45depicts an embodiment of the magnetic device801as a packaged magnetic device having the magnetic structure connected or arranged relative to a structure of a package. The magnetic device may include package803, a magnetic structure805, one or more substrates807, and an associated circuit809.

The package may include one or more package structures811, such as one or more of an aperture, an enclosure, etc. The magnetic structure may be physically connected or arranged relative to the one or more package structures in a predetermined manner.

The magnetic structure, substrate, substrate structure815, and circuit of the packaged magnetic device may include any of the embodiments of these components and their interconnections and arrangements discussed above in regard to any other embodiments of the magnetic device, such as discussed above in regard toFIGS.7to44and their various subfigures (i.e., (a), (b), etc.), among other embodiments.

FIG.46depicts an embodiment of a packaged magnetic device. The packaged magnetic device may include the magnetic structure, a package, and the corresponding circuit. The magnetic structure may include a patterned layer856formed on a substrate860. The associated circuit may include an integrated circuit864formed on one or more additional substrates. The magnetic structure and its substrate may be attached to the integrated circuit to form a substrate stack.

The package may include an enclosure868to selectively expose a portion of the magnetic structure while enclosing other portions of the device. The enclosure may include an aperture857to expose a portion of the magnetic structure, such as a surface of the patterned layer or a coated surface of the patterned layer, to an environment external to the package, and an enclosing portion859enclosing another portion of one or more of the magnetic structure or the circuit to provide a barrier to the external environment. Exposing the magnetic structure to the external environment may enhance the magnetic performance of the magnetic structure by providing selective access to or from the magnetic structure by a magnetic field. Enclosing the other portion of the magnetic structure or integrated circuit may enhance the electrical performance of the other portion of the magnetic structure or integrated circuit by selectively preventing access to or from the magnetic structure by a magnetic, electric or electromagnetic field, or provide other types of protection from the external environment. The package also may include a conductive lead frame and wire bonds to provide electrical connections between terminals of the package and one or more of the magnetic structure or the integrated circuit.

In other embodiments, a packaged magnetic device may include the magnetic structure and circuit formed together on a single substrate, such as on the same or different sides of such a substrate, that is packaged similarly to as shown inFIG.42.

FIG.47(a)depicts a cross-sectional view of another embodiment of a packaged magnetic device, incorporating a magnetic structure formed on or as part of a micromechanical scanner such as shown inFIGS.43and44. The packaged magnetic device may include an enclosure965, a substrate967containing a micromechanical scanner969such as shown inFIGS.43and44, a package substrate971, a lens973and one or more electrical interconnections975. For clarity of illustration, the micromechanical scanner969is shown as a single schematic entity, however it may include all of the components shown inFIGS.43-44. The enclosure may include an aperture977to position the lens and admit light to the scanner, and a portion978to receive and position the scanner relative to the aperture and lens. The electrical connections, which may include bond wires, may electrically connect the scanner to the package substrate. As discussed above in regard toFIGS.43and44, a patterned layer of magnetoresistive material979forming a magnetic sensor may be formed on the scanner.

The packaged magnetic device may also include a second patterned layer. The second patterned layer may include a material providing a predetermined permanent or temporary magnetic field.FIGS.47(b) and47(c)depict cross-sectional views of embodiments of a packaged magnetic device similar to as shown inFIG.47(a), but including a second patterned layer. InFIG.47(b), the second patterned layer981may be formed on a portion of the package enclosure or the package substrate. In operation, the second patterned layer may provide a predetermined magnetic field about the scanner, and the magnetic sensor formed form the first patterned layer may provide an output representing the rotational position of the scanner based on the magnetic field sensed by the sensor. InFIG.47(c), the nature of the patterned layers may be reversed, with a first patterned layer983formed on the scanner including a material providing the predetermined magnetic field, and a second patterned layer985formed on the package enclosure or package substrate including a magnetoresistive material forming a magnetic sensor. Such an embodiment may operate according to similar principles as for the embodiment ofFIG.47(b), but with the generating and sensing of magnetic fields performed at interchanged locations.

The magnetic device may include a magnetic structure connected to or arranged relative to a structure of a module incorporating a plurality of substrates.FIG.48depicts an embodiment of a magnetic device817as a module-based magnetic device. The magnetic device may include a plurality of substrates819, a magnetic structure821, and an associated circuit823. The magnetic device also may optionally also include one or more other structures825, such as a coil, cap, micromechanical structure, antenna, etc.

The magnetic structure may be physically connected or arranged relative to one or more structure827of one or more of the module substrates. For example, the magnetic structure may be physically connected or arranged relative to structures of one or more of the module substrate according to any of the embodiments of the magnetic structure and substrates and their interconnections and arrangements discussed above in regard to substrate-based magnetic device, such as discussed above in regard toFIGS.7to44and their various subfigures (i.e., (a), (b), etc.), among other embodiments. In embodiments, the magnetic structure may be formed on one of the substrates according to any of these embodiments, while the plurality of substrates may include a further plurality of substrates connected to an arranged relative to the magnetic structure and first substrate as discussed below.

The magnetic structure, substrate, circuit and other structures of the module magnetic device may include any of the embodiments of these components and their interconnections and arrangements discussed above in regard to other magnetic device embodiments.

FIG.49(a)depicts a perspective view of an embodiment of a module812that may include one or more magnetic structures (or magnetic structures on substrates)816and a substrate structure having a plurality of substrates820.FIG.49(b)depicts a cross-sectional side view of the module shown inFIG.49(a). The substrate structure may include a plurality of substrates820layered on top of each other. In embodiments, the substrate structure may be a laminated substrate structure including a plurality of laminated layers.

The one or more magnetic structures may be attached to a substrate of the substrate structure. The magnetic structure816may be attached to a substrate of the substrate structure so that the magnetic structure fully embedded within the substrate structure, as shown inFIG.49(b). Alternatively, the magnetic structure may be attached to a substrate of the substrate structure so that the magnetic structure is exposed at an external surface of the module.FIG.49(c)-49(d)depict cross-sectional side views of embodiments of the magnetic module similar to that shown inFIG.49(a)-49(b), but in which the magnetic structure may be attached to a substrate of the substrate structure so that the magnetic structure, such as a surface of a patterned layer or a coated surface of a patterned layer, is exposed at an external surface of the module. InFIG.49(c), a plurality of magnetic structures824may be attached to a substrate of the substrate structure so that the magnetic structures, such as surfaces of patterned layers or coated surfaces of patterned layers, are exposed at an external surface on a same side of the module. InFIG.49(d), a plurality of magnetic structures828may be attached to substrates of the substrate structure so that the magnetic structures, such as surfaces of patterned layers or coated surfaces of the patterned layers, are exposed at external surfaces on different, such as opposing, sides of the module.

The module also may include one or more components attached to the substrates of the substrate structure in addition to the magnetic structure. The components may be electrically connected to the magnetic structure by one or more of conductive traces or vias laid along or through the substrates.

The magnetic structure may be physically aligned with apertures in a plurality of substrates.FIG.50(a)depicts an exploded view of an embodiment of a magnetic device including a patterned layer832of a magnetic structure with an aperture aligned to apertures in a plurality of substrates836,840of a substrate structure. The substrate structure may include the plurality of substrates stacked on top of each other, such as, for example, in a module. The patterned layer may be located between two substrates so that an aperture in the patterned layer aligns with apertures in each of the substrates. As discussed above in regard toFIGS.15-16, the alignment of the apertures may create a path of travel for another component or device from one side of the magnetic device to another side of the magnetic device.FIG.50(b)depicts a side view of an embodiment of the magnetic device shown inFIG.50(a). The patterned layer may optionally be positioned within a recess formed in one or more of the substrates to allow for a tighter packing of the substrates into a stacked substrate structure.

The magnetic structure also may be physically aligned with one or more apertures in a module.FIG.51(a)-51(b)depict perspective and cross-sectional side views of an embodiment of a magnetic module844that may include one or more magnetic structures aligned with an aperture845in a substrate structure having a plurality of substrates848. The aperture may extend from one side to another side of the module through a plurality of substrates848. The magnetic structures852may be connected to one or more of the substrates at the sides of the aperture so that the magnetic structures are exposed to the aperture.FIG.51(c)is a cross-sectional side view depicting another embodiment of a magnetic module similar to the embodiment depicted inFIG.51(b), but in which an aperture may extend from one side of the module through a plurality of substrates and end in the interior of the module, and a magnetic structure853may be connected to one or more of the substrates at the bottom of the aperture so that the magnetic structure is exposed to the aperture.FIG.51(d)is a perspective view depicting another embodiment of a magnetic module similar to the embodiment depicted inFIGS.51(a)-51(b), but in which an additional aperture855may extend from a third side of the module through a plurality of the substrates to a fourth side of the module, the additional aperture intersecting the first aperture.

The magnetic structure also may be provided in association with a micro-fluidic structure.FIG.52(a)is a cross-sectional side view depicting an embodiment of a portion of the magnetic device including a micro-fluidic channel857and a magnetic structure859. The channel may include an inlet861to accept a flow of fluid into a first channel portion863, a channel structure865to separate the channel into a plurality of second channel portions867, and a plurality of outlets to provide fluid outflow from the second channel portions. The magnetic structure may include one or more patterned layers formed about a portion of the channel, such as a patterned layer formed connected or adjacent to a wall at least partially forming the channel. For example, as depicted inFIG.52(a), the magnetic structure may include a first patterned layer formed connected to or adjacent to a first wall at least partially forming the channel, such as a layer869formed on top of a top wall of the channel, and a second patterned layer formed connected to or adjacent to a second wall at least partially forming the channel, such as a layer871formed below a bottom wall at least partially forming the channel.

The patterned layer may include a material producing a magnetic field. In embodiments, the patterned layer may include a material producing a permanent magnetic field. InFIG.52(a), the patterned layer may include a hard magnetic material producing a permanent magnetic field. In other embodiments, the patterned layer may include a material producing a temporary magnetic field. In such embodiments, the magnetic device also may include a coil connected to or arranged relative to the patterned layer in a predetermined manner to set and/or change a magnetic field in the material.FIG.52(b)is a cross-sectional side view depicting another embodiment of a portion of the magnetic device including a micro-fluidic channel and a magnetic structure such as shown inFIG.52(a)and conductive coils873,875. The magnetic structure may include a patterned layer including a soft magnetic material producing a temporary magnetic field. The conductive coils may be driven by the associated circuit of the magnetic device to produce a magnetic field to set and/or supplement the magnetic field produced by the material, such as to provide one or more of a static magnetic field having a single field orientation, or a changing magnetic field having changing field orientations.

In operation, a fluid flowing into the channel at the inlet may include a plurality of different types of particles having different responses to magnetic fields, and the magnetic structure may be used to provide a magnetic field to separate the different types of particles into respective different ones of the second channel portions. For example, as depicted inFIGS.52(a)-52(b), fluid flowing into the channel inlet may include a first type of particles877that may move in a first direction toward a first of the second channel portions in response to a selected applied magnetic field, and a second type of particles879that may move in a second direction toward a first of the second channel portions in response to a selected applied magnetic field. The different types of particles may exhibit different responses to the magnetic field as a result of their own magnetic properties. In other embodiments, the fluid or particles added to the fluid may exhibit a response to the magnetic field, producing a characteristic of the fluid flow, such as a density gradient, that may separate the different types of particles according to their density.

The magnetic device may incorporate micro-fluidic and magnetic structures such as shown inFIGS.52(a)-52(b)in a variety of configurations.FIG.52(c)depicts an embodiment of a magnetic device including the micro-fluidic and magnetic structures such as shown inFIG.52(a)-52(b)as one or more layers in a multi-layer structure. The layers881of the multilayer structure may take a variety of forms. In embodiments, the layers of the multilayer structure may be layers formed on a substrate. In other embodiments, the layers of the multilayer structure may include substrates of a multi-substrate structure such as a magnetic module.

The magnetic device may include a magnetic structure connected to or arranged relative to a structure of a system.FIG.53depicts an embodiment of the magnetic device883as or as part of a system having the magnetic structure connected or arranged relative to a structure of the system. The magnetic device may include a magnetic structure885, a system structure887, and an associated circuit889. The system structure may include any of the structures connected to or arranged relative to the magnetic structure discussed in regard to any other embodiment of the magnetic device herein. The magnetic structure, system structure, and circuit may include any of the embodiments of these components and their interconnections and arrangements of any embodiments of the magnetic device discussed herein.

The magnetic device also may include a magnetic structure including a plurality of aligned patterned layers.FIG.54(a)depicts an exploded view of an embodiment of magnetic structure including a plurality of patterned layers872arranged in a stack. Each of the patterned layers may include an aperture aligned with apertures of the other magnetic structures in the stack. Each of the patterned layers also may optionally include a boundary or shape aligned to that of the other magnetic structures in the stack. The patterned layers may each be separately formed patterned layers such as discussed above in regard toFIGS.10(a)-10(b).FIG.54(b)depicts a non-exploded perspective view of the magnetic structure depicted inFIG.54(a).

The magnetic structure also may include a plurality of aligned patterned layers arranged in combination with other layers.FIG.55(a)depicts an exploded view of an embodiment of magnetic structure including a plurality of patterned layers876arranged in combination with other layers880in a stack. Each of the patterned layers and the other layers may include an aperture aligned with apertures of the other layers in the stack. Each of the patterned layers also may optionally include a boundary or shape aligned to that of the other magnetic structures in the stack. The patterned layers may each be separately formed patterned layers, such as with or without a corresponding substrate, as discussed above. The other layers may include a non-magnetic material such as a substrate on which the patterned layers may be formed or a separate spacer.FIG.55(b)depicts a non-exploded perspective view of the magnetic structure depicted inFIG.55(a).

As discussed above, the magnetic device may include circuitry that may be electrically connected to one or more of the magnetic structure and other device structures to provide functions such as providing, receiving, conditioning, and processing of signals of the magnetic structure and other device structures.

The magnetic device may incorporate the circuit on a same substrate as the magnetic structure. For example, the magnetic device may incorporate the circuit and the magnetic structure on a same side of a substrate, each in a separate area or in the same area. Alternatively, the magnetic device may incorporate the circuit on a different side of a substrate from the magnetic structure. The magnetic device also may incorporate the circuit on a different substrate than that including the magnetic structure.

The magnetic device may include a circuit to perform one or more of receiving and manipulating an electrical signal from the magnetic structure of the magnetic device, generating and providing an electrical signal to the magnetic structure, generating and providing an electrical signal to a conductive coil, or generating and providing an electrical signal to a transmitter, among other functions.

For example, the magnetic device may include a circuit to receive and manipulate electrical signals from the magnetic structure.FIG.56depicts an embodiment of the magnetic structure and a circuit that may be used to receive and manipulate electrical signals from the magnetic structure. The circuit may include an amplification circuit900, an analog-to-digital converter (ADC)904, and a processor or controller908. The amplification circuit900may be electrically coupled to the magnetic structure to receive an output of the magnetic structure and perform one or more of buffering or amplifying the signal received from the magnetic structure. The amplification circuit900may include one or more operational amplifiers to perform the buffering or amplifying. The ADC904may be electrically coupled to the amplification circuit to receive an output of the amplification circuit900and convert the received signal from an analog to a digital representation. The ADC904may include one or more of a flash ADC, pipeline ADC, sigma-delta ADC, successive approximation ADC, etc. The processor or controller908may be electrically coupled to the ADC904to receive an output of the ADC904and perform one or more of processing the received digitized signal to extract information from the digitized signal or generate a control signal as a function of the digitized signal.

The magnetic device also may include a circuit to generate and provide an electrical signal to the magnetic structure.FIG.57depicts an embodiment of the magnetic structure and a circuit that may be used to generate and provide an electrical signal to the magnetic structure. The circuit may include a processor or controller916, a digital-to-analog converter (DAC)920, and a driver circuit924. The processor or controller916may generate a control signal representing an electrical signal to be provided to the magnetic structure. The processor or controller916may generate the control signal by as a function of a digitized signal representing a signal output by the magnetic structure or another signal. The DAC920may be electrically coupled to the processor or controller to receive the control signal output by the processor or controller916and convert the control signal from a digital to an analog representation. The DAC920may include one or more of a R-2R ladder DAC, an oversampling DAC, a hybrid DAC, etc. The driver circuit924may be electrically coupled to the DAC920to receive the analog signal output from the DAC920and provide a corresponding drive signal to the magnetic structure. The driver circuit924may perform one or more of buffering or amplifying the signal from the DAC920. The driver circuit924may include one or more transistors to perform the buffering or amplifying.

The magnetic device also may include a circuit to generate and provide an electrical signal to a conductive coil. The conductive coil may be used to generate a magnetic field to set or alter properties of, or to be otherwise used in association with, the magnetic structure.FIG.58depicts an embodiment of a circuit that may be used to generate and provide an electrical signal to the conductive coil. The circuit may include a processor or controller932, a digital-to-analog converter (DAC)936, and a driver circuit940. The processor or controller932may generate a control signal representing an electrical signal to be provided to the conductive coil. The processor or controller932may generate the control signal by as a function of a digitized signal representing a signal output by the magnetic structure or another signal. The DAC936may be electrically coupled to the processor or controller to receive the control signal output by the processor or controller932and convert the control signal from a digital to an analog representation. The DAC936may include one or more of a R-2R ladder DAC, an oversampling DAC, a hybrid DAC, etc. The driver circuit940may be electrically coupled to the DAC936to receive the analog signal output by the DAC936and provide a corresponding drive signal to the conductive coil. The driver circuit940may perform one or more of buffering or amplifying the signal from the DAC936. The driver circuit940may include one or more transistors to perform the buffering or amplifying.

The magnetic device also may include a circuit to generate and provide an electrical signal based on a signal from the magnetic structure, such as representing a magnetic field or current sensed by the magnetic structure, for transmission.FIG.59depicts an embodiment of a magnetic sensor and a circuit that may be used to generate and provide an electrical signal to a transmitting element. The circuit may include an amplification circuit945, and ADC947, a transmitter949and a transmitting element951such as a conductive coil, antenna, etc. The amplification circuit and ADC may be configured and operate as discussed above in regard to the circuit ofFIG.49. The transmitter circuit may be electrically coupled to the ADC to receive the digital signal output by the ADC and provide a corresponding transmission drive signal to the transmitting element.

In embodiments where the magnetic structure forms a magnetic sensor, such as, e.g., an anisotropic magnetoresistive sensor or other magnetoresistive sensor, several embodiments of the amplification and driver circuits may be provided.FIG.60depicts an embodiment of a magnetic sensor960and an amplification circuit964to provide an output representing a sensed magnetic field. The amplification circuit may include a single operational amplifier, and the magnetic sensor may include a single magnetoresistor968.FIG.61depicts an embodiment of a magnetic sensor968and an amplification circuit and linearizing circuit972to provide a linearized output representing a sensed magnetic field. The amplification and linearizing circuit may including a single operational amplifier, and the magnetic sensor may include a single magnetoresistor.FIG.62depicts another embodiment of a magnetic sensor976, an amplification circuit980, and a linearizing circuit984to provide a linearized output representing a sensed magnetic field. The amplification and linearizing circuits may each include an operational amplifier, and the magnetic sensor may include a single magnetoresistor.FIG.63depicts an embodiment of a magnetic sensor988and an amplification circuit and linearizing circuit992to provide an output representing a sensed magnetic field. The amplification and linearizing circuit may include a single operational amplifier, and the magnetic sensor may include a pair of magnetoresistors.FIG.64depicts an embodiment of a magnetic sensor996, an amplification circuit1000, and linearizing circuit1004to provide a linearized output representing a sensed magnetic field. The amplification and linearizing circuits may each include an operational amplifier, and the magnetic sensor may include a pair of magnetoresistors. In other embodiments, the amplification circuit to provide an output representing a sensed magnetic field may include one or more operational transconductance amplifiers.

The magnetic sensor also may be driven to bias, drive, or modulate signals of the sensor.FIG.65depicts an embodiment of a magnetic sensor1008and a driver circuit1012that may be used to bias, drive or modulate signals of the magnetic sensor. The magnetic sensor and driver circuit ofFIG.65also may be used with embodiments of an amplification circuit, such as any of the embodiments of the amplification and/or linearizing circuits inFIGS.60-64.

Embodiments of the circuit of the magnetic device may include any subset or combination of components of any of the circuits discussed herein. For example, the circuit may include one or more components of any of the circuits discussed herein. The circuit also may include one or more components of one or more of the circuits discussed herein arranged in any order, such as an order different from that shown in the exemplary figures. The circuit also may include components in addition to the components or any subset of components of the circuits discussed herein.

Signals of and between the circuits and subcircuits discussed above may be either single-ended or differential signals.

The patterned layers discussed herein may be formed as a thin films, such as layers produced by integrated circuit substrate processing. Alternatively, the patterned layers discussed herein may be relatively thick films, such as layers produced by screen printing or other thick film processes.

Any feature of any of the embodiments of the magnetic device described herein can optionally be used in any other embodiment of the magnetic device. For example, embodiments of the magnetic device may include any combination of any embodiment of the magnetic structure discussed herein with any embodiment of the other device structure discussed herein and any embodiment of the circuit discussed herein. Also, embodiments of the magnetic device can optionally include any subset of the components or features of the magnetic device discussed herein. For example, embodiments of the magnetic device may optionally include any combination of any embodiment of the magnetic structure discussed herein with any embodiment of the other device structure discussed herein, while omitting the circuit.