Abstract:
A method in accordance with an embodiment comprises forming a feature on a substrate, disposing a first conductive pattern on the substrate and the feature, disposing a permeability material within the feature, disposing a substrate material on the substrate and the feature to facilitate substantial enclosure of the permeability material between the substrate and the substrate material, and disposing a second conductive pattern on the substrate material. The first conductive pattern and the second conductive pattern define at least one electrical circuit operable for coupling to a current source so as to cooperate to be capable of facilitating a magnetic field about the permeability material.

Description:
RELATED APPLICATIONS 
     This is a divisional application claiming priority to U.S. Non-provisional patent application Ser. No. 11/233,824, filed on Sep. 22, 2005, U.S. Pat. No. 7,477,128, which is in its entirety incorporated herewith by reference. 
    
    
     BACKGROUND 
     The disclosure generally relates to magnetic components. 
     Wide range of electronic devices may have various magnetic components. Magnetic components may be capable of providing various functions. For example, magnetic components in electronic devices may function as transformers, inductors, filters, and so forth. 
     Commonly, in order to have magnetic properties, magnetic components may comprise of an assembly of one or more wires wound around a material having permeability properties such as ferromagnetic material having a toroidal type shape, a rod type shape, etc. When a current is applied to the one or more wires, the component may produce a magnetic field, which may be utilized to address a wide range of electrical needs associated with electronic devices. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings, in which like references may indicate similar elements and in which: 
         FIG. 1  illustrates a perspective exploded view of a magnetic component in accordance with one embodiment; 
         FIGS. 2A-2B  illustrate a top view and a sectional view of a substrate having a feature in accordance with one embodiment; 
         FIGS. 3A-3C  illustrate a top view, a section view, and a detail view of a substrate having a feature and a conductive pattern disposed within the feature in accordance with one embodiment; 
         FIG. 4  illustrates a perspective exploded view of a magnetic component in accordance with another embodiment; 
         FIG. 5  illustrates a schematic of a magnetic component in accordance with an embodiment; 
         FIG. 6  illustrates a schematic of a magnetic component in accordance with another embodiment; 
         FIG. 7  illustrates a schematic of a magnetic component in accordance with another embodiment; 
         FIG. 8  illustrates a schematic of a magnetic component in accordance with another embodiment; and 
         FIG. 9  illustrates a flow chart of one embodiment of a process for producing a magnetic component. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, embodiments will be disclosed. For purposes of explanation, specific numbers, materials, and/or configurations are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to those skilled in the art that the embodiments may be practiced without one or more of the specific details, or with other approaches, materials, components, etc. In other instances, well-known structures, materials, and/or operations are not shown and/or described in detail to avoid obscuring the embodiments. Accordingly, in some instances, features are omitted and/or simplified in order to not obscure the disclosed embodiments. Furthermore, it is understood that the embodiments shown in the figures are illustrative representations and are not necessarily drawn to scale. 
     References throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, material, and/or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” and/or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, and/or characteristics may be combined in any suitable manner in one or more embodiments. 
     For the purposes of the subject matter disclosed herein, substrates may include a wide range of substrates such as, but not limited to, plastic type substrates, metal type substrates, semiconductor type substrates, and so forth. Accordingly, it should appreciated by those skilled in the art that types of substrates may vary widely based at least in part on its application. However, for the purposes of describing the subject matter, references may be made to a substrate along with some example types, but the subject matter is not limited to a type of substrate. Additionally, for the purposes of describing various embodiments, references may be made to magnetic components. However, it should be appreciated by those skilled in the relevant art that magnetic components may include a wide variety of magnetic components such as, but not limited to transformer type components, inductor type components, filter type components, and so forth, and accordingly, the claimed subject matter is not limited in scope in these respects. 
     Turning now to the figures,  FIG. 1  illustrates a perspective exploded view of a magnetic component in accordance with one embodiment. As shown in  FIG. 1 , magnetic component  100  may comprise of a substrate  102  having a first surface  104  and a feature  106 . A first conductive pattern  108  may be disposed on the feature  106 . A permeability material  110  may be disposed within the feature  106 . Additionally, in the illustrated embodiment, a substrate material  112  may be disposed on the first surface  104  and on the feature  106 , thereby forming a second surface  114 . Disposed on the second surface  114  may be a second conductive pattern  116 . As will be further described in detail, first conductive pattern  108  and second conductive pattern  116  cooperate to be capable of facilitating magnetic properties of permeability material  110  in accordance with various embodiments. 
     It should be appreciated that  FIG. 1  illustrates an exploded view to describe an embodiment of the claimed subject matter, and accordingly, as will be described in further detail, magnetic component  100  may have permeability material  110  substantially enclosed within feature  106  with substrate material  112  substantially covering the permeability material  110 . First conductive pattern  106  and second conductive pattern  116  may substantially surround the permeability material, thereby forming a winding type relationship. 
     Continuing to refer to  FIG. 1 , substrate  102  is shown having a substantially rectangular type shape. However, it should be appreciated that substrate  102  may have any type of shape such as, but not limited to, substantially circular, substantially square, or any other type of polygonal shape. Additionally, substrate  102  may comprise of many types of material such as, but not limited to, material suitable for printed circuit boards (PCBs), various plastic type materials, material suitable for injection molding and so forth. For example, in one embodiment, substrate  102  may comprise of a thermoplastic type material such as, but not limited to, polyetherimide (PEI) type material. In another embodiment, substrate  102  may comprise of a resin type material that may be suitable for injection type molding such as, but not limited to, liquid crystal polymer type material. It should be appreciated by those skilled in the relevant art that the shape and materials described are merely examples, and the claimed subject matter is not limited in scope in these respects. 
     In  FIG. 1 , feature  106  is illustrated as a cup type feature below the first surface  104 . That is, feature  106  may comprise of a depression in the first surface  104  of substrate  102 . Further, in the illustrated embodiment of  FIG. 1 , feature  106  may comprise of a toroidal type shape depression below first surface  104  into the body of substrate  102 . However, it should be appreciated by those skilled in the relevant art that feature  106  may have a wide range of shapes such as, but not limited to, a rod type shape, oblong type shape, and so forth, and accordingly, the claimed subject matter is not limited in scope in these respects. 
     A variety of approaches may be utilized in order to facilitate formation of feature  106 . For example, in one embodiment, feature  106  may be formed by utilizing a lithography type process such as, but not limited to photolithography. In another embodiment, feature  106  may be formed by utilizing a machining type process such as, but not limited to, a micromachining process. Various approaches may be utilized to facilitate formation of a feature, and accordingly, the claimed subject matter is not limited to a particular approach. 
     As shown in  FIG. 1 , first conductive pattern  108  may be disposed in a pattern around the inside of feature  106 . In the illustrated embodiment, first conductive pattern  108  may be disposed in a manner whereby first conductive pattern  108  substantially lines portions of the inside surfaces of the feature  106 . Here too, a variety of approaches may be utilized in order to dispose the first conductive pattern  108 . In one embodiment, first conductive pattern  108  may be disposed by utilizing a stamping type approach such as, but not limited to, stamping a conductive pattern on a substrate. In another embodiment, first conductive pattern  108  may be disposed by utilizing a plating type approach such as, but not limited to, chemical and/or electroplating a conductive pattern on a substrate. In another embodiment, first conductive pattern  108  may be disposed by utilizing a lithography type approach such as, but not limited to, photolithography. In yet another embodiment, an structuring type approach such as, but not limited to, laser structuring type approach may be utilized to dispose first conductive pattern  108 . Various approaches may be utilized to dispose a conductive pattern, and accordingly, the claimed subject matter is not limited to a particular approach. 
     First conductive pattern  108  may comprise of a wide variety of materials such as, but not limited to, copper, aluminum, gold, and various types of conductive tracing materials. Accordingly, the claimed subject matter is not limited in scope in these respects. 
     Continuing to refer to  FIG. 1 , permeability material  110  is shown as having a shape based at least in part on the shape of the feature  106 . That is, permeability material  110  may have a substantially toroidal shape that may substantially fit within the feature  106 . In the embodiment of  FIG. 1 , permeability material  110  may be shown as a separate solid object, where the solid object may be placed within the feature  106  by various methods such as, but not limited to, utilizing a pick and place machine. However, in another embodiment, permeability material  110  may be of a liquid type form whereby the liquid type form may be poured into a feature. In another embodiment, permeability material  110  may be in the form of a powder type material whereby the powder type material may be disposed into a feature. In yet another embodiment, permeability material  110  may comprise of material that may be utilized with a vibration based type approach to facilitate placement of the permeability material substantially within the feature  106 . That is, a method by which a vibration type machine may be utilized. Accordingly, the claimed subject matter is not limited in scope in these respects. 
     Permeability material  110  may comprise of a wide variety of materials such as, but not limited to, ferromagnetic type materials that may include ferrite type materials, iron type material, metal type materials, metal alloy type materials, and so forth. Additionally, permeability material  110  may comprise of materials based at least in part on the particular utilization of a magnetic component. For example, a magnetic component to be utilized as an isolation transformer may include a permeability material having a relatively high permeability, such as, but not limited to 10000 Henry per meter. In another example, a magnetic component to be utilized as a common mode filter may include a permeability material having a moderate permeability such as, but not limited to, 1000 Henry per meter. Further, as previously alluded to, the size and shape of the permeability material  110  may be based at least in part on the utilization of the magnetic component as well. Accordingly, the claimed subject matter is not limited in scope in these respects. 
     In  FIG. 1 , for the purposes of describing the embodiment, substrate material  112  may be shown as a thin layer. However, the thin layer may be representative of one or more layers of printed circuit layers to be disposed on the first surface  104  of the substrate  102  and does not necessarily denote a single piece of substrate material, but it also could be a single piece of substrate material. Additionally, the substrate material  112  does not necessarily need to substantially match the material of the substrate  102  and may be of a different material. For example, in one embodiment, the substrate material  112  may include various lamination layers that facilitate build up of circuit layers. In another embodiment, a liquid type material may be disposed on the on a substrate such as, but not limited to, a liquid dielectric type material. For example, a liquid type dielectric type material may be disposed by utilizing at least one of a spray type, roller type, and/or a squeegee type approach. It should be appreciated by those skilled in the relevant art that the substrate material  112  may be disposed on the first surface  104  of the substrate  102  by a wide variety of approaches. Accordingly, the claimed subject matter is not limited to any one particular approach. 
     In the embodiment illustrated in  FIG. 1 , second conductive pattern  116  is shown on the second surface  114  of substrate material  112 . However, as previously described, second conductive pattern  116  may be disposed on the substrate material  112  utilizing a variety of approaches such as, but not limited to, a lamination approach, lithography approach, etching approach, a screen printing type approach, a laser structuring type approach, and so forth. That is, second conductive pattern  116  may be disposed as part of the process of providing substrate material  112 , and accordingly, the claimed subject matter is not limited in these respects. 
     In the embodiment of  FIG. 1 , second conductive pattern  116  substantially matches the pattern of the first conductive pattern  108  to facilitate wrapping of the permeability material  110  between the first conductive pattern  108  and the second conductive pattern  116 . Additionally, first conductive pattern  108  and second conductive pattern  116  may be electrically coupled by various vias and/or interconnects as will be described in detail. Together, first conductive pattern  108  and the second conductive pattern  116  cooperate to be capable of facilitating magnetic properties of the permeability material  110 . For example, first conductive pattern  108  and second conductive pattern  116  may cooperate to be capable of inducing a magnetic field upon the permeability material  110 . 
       FIGS. 2A-2B  illustrate a top view and a sectional view of a substrate having a feature in accordance with one embodiment. In  FIG. 2A , a substrate  200  may have a surface  202  and a feature  204 . As shown in  FIG. 2B , feature  204  may be formed into the substrate  204  below the surface  202 . In this embodiment, the feature  204  may have a substantially toroidal shape formed as a depression type feature into the substrate  200 . As previously described, feature  204  may be formed by utilizing a wide variety of approaches and may have a variety of shapes, and accordingly, the claimed subject matter is not limited in these respects. 
       FIGS. 3A-3C  illustrate a top view, a section view, and a detail view of a substrate having a feature and a conductive pattern disposed within the feature in accordance with one embodiment. Referring to  FIG. 3A , a substrate  300  may have a surface  302 , a feature  304 , and a conductive pattern  306 . As shown in  FIG. 3A , feature  304  may have a substantially toroidal type shape, and correspondingly, conductive pattern  306  may be patterned circumferentially around the feature  304  (i.e., a wheel type pattern radiating from the center of the toroid). Turning to  FIG. 3B , in the illustrated embodiment, conductive pattern  306  has a portion on the surface  302  and partly covers the walls of the feature  304  (i.e., feature areas below surface  302 ). Detail  308  is illustrated in  FIG. 3C , where conductive pattern  306  is shown provided on surface  302 , inside feature  304 , and back on surface  302 . 
     As previously described, once the conductive pattern  306  is disposed on the feature  304 , a permeability material may be disposed within the feature  304 . A substrate material may be disposed on the surface  302  having a second conductive pattern. Various conductive paths such as, but not limited to, vias and/or interconnects (not shown) may be formed and utilized to electrically couple the two conductive patterns, thereby forming a winding type structure around a permeability material. 
       FIG. 4  illustrates a perspective exploded view of a magnetic component in accordance with another embodiment. In  FIG. 4 , similar to magnetic component  100  (shown in  FIG. 1 ), magnetic component  400  may include a substrate  400 , a first surface  404 , a feature  406 , a first conductive pattern  408 , a substrate material  410 , a second surface  412 , and a second conductive pattern  414 . However, in this embodiment, a permeability material (not shown) may be relatively large based at least in part on its application. Accordingly, a second feature  416  may be formed on the substrate material  410  to facilitate accommodation of the permeability material. As shown, second conductive pattern  414  may be disposed to at least partially cover the surfaces of the second feature  416 . As previously described, substrate material  410  may be disposed on the substrate utilizing various approaches such as, but not limited to, a lamination type approach, where a sheet of substrate material having a second feature may be disposed on a substrate. Alternatively, substrate material may be disposed utilizing an etching type approach, where the second feature  416  may be the result of covering the permeability material that extends out of the surface  404 . Further, substrate material may be disposed utilizing a spray type, roller type, and/or a squeegee type approach. Accordingly, the claimed subject matter is not limited to a particular approach. 
     Here again, various approaches may be utilized for disposing conductive patterns. For example, one such approach may be a lithography type approach utilizing various etching methods, and another approach may be to utilize a stamping type approach, a laser structuring type approach, and so forth. 
     Conductive patterns may be patterned to facilitate various magnetic properties for various magnetic components based at least in part on their applications. Further, because an approach that may be utilized in providing the number of conductive patterns may be of a lithography type approach, laser structuring type approach, etc., precision of the conductive patterns may be relatively high based at least in part on the type approaches utilized such as, but not limited to, a high aspect lithography approach of ultraviolet photolithography, and accordingly, the claimed subject matter is not limited to a particular approach. 
     In various embodiments, one or more magnetic components may be formed on a single substrate. Additionally, because the magnetic properties of a magnetic component may be based at least in part on its conductive pattern, its feature size, permeability material utilized, and/or so forth, more than a single type of magnetic component may be formed from a single substrate, and accordingly, the claimed subject matter is not limited in these respects. 
     Examples of magnetic components may include a magnetic component including a substrate having a feature, a first conductive pattern, a permeability material, a substrate material, and a second conductive pattern, where the first conductive pattern and the second conductive pattern cooperate to be capable of facilitating magnetic properties of the permeability material for various applications. Various applications may include applications such as, but not limited to a dual common mode filter, a single common mode filter, a single inductor, an isolation transformer, and so forth, and accordingly, the claimed subject matter is not limited in these respects. Various embodiments of various magnetic components, without limitations, may be illustrated in  FIGS. 5-8 . 
     Turning now to  FIG. 5 , a magnetic component  500  may include a substrate (not shown) having a feature  502 , a first conductive pattern  504 , a permeability material  506 , a substrate material (not shown), and a second conductive pattern  508 . The first conductive pattern  504  and the second conductive pattern  508  cooperate to be capable of facilitating magnetic properties of the permeability material  506 , and in this particular embodiment, magnetic component  500  may be capable of being utilized as a dual common mode filter (i.e., a common mode filter type functionality) as shown by related circuit illustration  510 . It should be appreciated that the substrate and substrate material are not shown in order to better illustrate the embodiment. 
       FIG. 6  illustrates a schematic of a magnetic component in accordance with another embodiment. In  FIG. 6 , magnetic component  600  may include a substrate (not shown) having a feature  602 , a first conductive pattern  604 , a permeability material  606 , a substrate material (not shown), and a second conductive pattern  608 . The first conductive pattern  604  and the second conductive pattern  608  cooperate to be capable of facilitating magnetic properties of the permeability material  606 , and in this particular embodiment, magnetic component  600  may be capable of being utilized as a single common mode filter (i.e., a single common mode filter functionality) as shown by related circuit illustration  610 . 
       FIG. 7  illustrates a schematic of a magnetic component in accordance with another embodiment. In  FIG. 7 , magnetic component  700  may include a substrate (not shown) having a feature  702 , a first conductive pattern  704 , a permeability material  706 , a substrate material (not shown), and a second conductive pattern  708 . The first conductive pattern  704  and the second conductive pattern  708  cooperate to be capable of facilitating magnetic properties of the permeability material  706 , and in this particular embodiment, magnetic component  700  may be capable of being utilized as a single inductor (i.e., an inductor type functionality) as shown by related circuit illustration  710 . 
       FIG. 8  illustrates a schematic of a magnetic component in accordance with another embodiment. In  FIG. 8 , magnetic component  800  may include a substrate (not shown) having a feature  802 , a first conductive pattern  804 , a permeability material  806 , a substrate material (not shown), and a second conductive pattern  808 . The first conductive pattern  804  and the second conductive pattern  808  cooperate to be capable of facilitating magnetic properties of the permeability material  806 , and in this particular embodiment, magnetic component  800  may be capable of being utilized as an isolation transformer (i.e., a transformer type functionality) as shown by related circuit illustration  810 . 
       FIG. 9  illustrates a flow chart of one embodiment of a process for producing a magnetic component. As illustrated by flow chart  900  in  FIG. 9 , the process may start by providing a substrate, as indicated by block  902 . As previously described, substrate may be of wide variety of materials that may be utilized to PCBs. Further, substrate may have a feature formed on the substrate utilizing a wide variety of approaches as previously described. 
     In the embodiment of  FIG. 9 , a first conductive pattern may be disposed over the feature and the substrate, as indicated by block  904 . 
     At block  906 , a permeability material may be disposed within the feature. A substrate material may be disposed over the permeability material and the substrate at block  908 . At block  910 , a second conductive pattern may be disposed on the substrate material, thereby facilitating a winding of the conductive patterns around the permeability material. 
     While there has been illustrated and/or described what are presently considered to be example embodiments of claimed subject matter, it will be understood by those skilled in the art that various other modifications may be made, and/or equivalents may be substituted, without departing from the true scope of claimed subject matter. Additionally, many modifications may be made to adapt a particular situation to the teachings of claimed subject matter without departing from subject matter that is claimed. Therefore, it is intended that the patent not be limited to the particular embodiments disclosed, but that it covers all embodiments falling within the scope of the appended claims.