PATENT DOCUMENT

Publication Number: US-11430606-B2
Application Number: US-201716335075-A
Country: US
Kind Code: B2

Title: Coupled inductor structures utilizing magnetic films

Abstract:
An inductor is disclosed, including a first wire, a non-conductive material, and a shell. The non-conductive material may cover the first wire, with a portion of each end of the first wire uncovered. The shell may include a top portion and a bottom portion and include at least one magnetized layer and at least one gap between the first portion and the second portion. The shell may also surround a portion of the non-conductive material.

Claims:
What is claimed is: 
     
       1. An apparatus, comprising:
 an inductor, including:
 a first wire; 
 a second wire, parallel to the first wire; 
 a non-conductive material covering the first wire and the second wire; and 
 a shell, including an upper portion and a lower portion, surrounding a portion of the non-conductive material, wherein the shell includes at least one magnetized layer and at least one gap between the upper portion and the lower portion, and wherein an end of the upper portion of the shell extends past an end of the lower portion of the shell at an edge of the inductor where the at least one gap is formed. 
 
 
     
     
       2. The apparatus of  claim 1 , wherein the upper portion of the shell includes a first portion and a second portion with another gap between the first portion and the second portion. 
     
     
       3. The apparatus of  claim 1 , wherein the upper portion of the shell includes a plurality of magnetized layers, wherein each layer is separated by a layer of non-conductive material, and wherein magnetic properties of each magnetized layer are different from one another. 
     
     
       4. The apparatus of  claim 1 , wherein a cross section of both the first wire and the second wire each corresponds to a rectangular shape. 
     
     
       5. The apparatus of  claim 1 , wherein a cross section of both the first wire and the second wire each correspond to a pentagonal shape, and wherein at least one adjacent side of the first wire is oblique to a closest side of the second wire. 
     
     
       6. The apparatus of  claim 1 , wherein parts of the upper portion and the lower portion of the shell are coplanar. 
     
     
       7. An apparatus, comprising:
 an inductor, including:
 a first wire; 
 a second wire, parallel to the first wire; 
 a non-conductive material covering the first wire and the second wire; and 
 a shell, including an upper portion and a lower portion, surrounding a portion of the non-conductive material, wherein the shell includes at least one magnetized layer and at least one gap between the upper portion and the lower portion, and wherein a cross section of the upper portion of the shell includes a channel formed between the first wire and the second wire, and wherein an end of the upper portion of the shell extends past an end of the lower portion of the shell at an edge of the inductor where the at least one gap is formed. 
 
 
     
     
       8. The apparatus of  claim 7 , wherein a depth and a width of the channel are selected to impart a particular amount of inductance to the first wire and to the second wire. 
     
     
       9. The apparatus of  claim 7 , wherein parts of the upper portion and the lower portion of the shell are coplanar. 
     
     
       10. The apparatus of  claim 7 , wherein the upper portion of the shell includes a plurality of magnetized layers, wherein each layer is separated by a layer of non-conductive material, and wherein magnetic properties of each magnetized layer are different from one another. 
     
     
       11. The apparatus of  claim 10 , wherein a strength of a magnetic field of a first magnetized layer of the plurality of magnetized layers is greater than a strength of a magnetic field of a second magnetized layer of the plurality of magnetized layers that is closer to the first and second wires than the first magnetized layer. 
     
     
       12. The apparatus of  claim 7 , wherein a cross section of both the first wire and the second wire each correspond to a pentagonal shape, and wherein at least one adjacent side of the first wire is oblique to a closest side of the second wire. 
     
     
       13. The apparatus of  claim 7 , wherein a cross section of both the first wire and the second wire each corresponds to a hexagonal shape. 
     
     
       14. An apparatus, comprising:
 a first inductor, including:
 a first wire; 
 a second wire, parallel to the first wire; 
 a first non-conductive material covering the first wire and the second wire; and 
 a first upper shell surrounding a portion of the first non-conductive material, wherein the first upper shell includes at least one magnetized layer, and wherein the first upper shell includes a first portion and a second portion with a gap between the first portion and the second portion, the gap located between the first and second wires; and 
 
 a second inductor, including:
 a third wire; 
 a fourth wire, parallel to the third wire; 
 a second non-conductive material covering the third wire and the fourth wire; and 
 a second upper shell surrounding a portion of the second non-conductive material, wherein the second upper shell includes at least one magnetized layer; 
 
 wherein the second inductor is inverted and attached on a bottom of the first inductor to form an inductive device, wherein the first wire and the third wire are parallel to each other. 
 
     
     
       15. The apparatus of  claim 14 , wherein the first wire is conductively coupled to the third wire and the second wire is conductively coupled to the fourth wire. 
     
     
       16. The apparatus of  claim 15 , wherein a cross section of the conductively coupled first wire and third wire corresponds to an octagonal shape. 
     
     
       17. The apparatus of  claim 14 , wherein a cross section of the first upper shell includes a channel formed between the first wire and the second wire. 
     
     
       18. The apparatus of  claim 17 , wherein a cross section of the second upper shell includes a channel formed between the third wire and the fourth wire. 
     
     
       19. The apparatus of  claim 14 , wherein the first upper shell and the second upper shell each include a plurality of magnetized layers, wherein each layer is separated by a layer of non-conductive material, and wherein magnetic properties of each magnetized layer are different from one another. 
     
     
       20. The apparatus of  claim 14 , further comprising a gap between the first upper shell and the second upper shell.

Description:
PRIORITY INFORMATION 
     This application claims priority to U.S. provisional patent application Ser. No. 62/398,352, entitled “COUPLED INDUCTOR STRUCTURES UTILIZING MAGNETIC FILMS,” filed Sep. 22, 2016, which is hereby incorporated by reference in its entirety as though fully and completely set forth herein. 
    
    
     BACKGROUND 
     Technical Field 
     Embodiments described herein are related to the field of magnetic passive circuit components. More particularly, these embodiments relate to a structure for and method of creating inductive devices. 
     Description of the Related Art 
     Magnetic devices, such as, for example, inductors, may be used in a variety of circuits. Inductors may be used to resist fluctuations of an electric current. The current stabilizing property of inductors makes them useful in power supply circuits and voltage regulating circuits, helping to generate low noise power signals. Inductors may also be used in wireless circuits, particularly as part of an antenna circuit. 
     Inductor designs may be consume a significant amount of circuit board space when compared to other circuit components. Due to this, some electronic devices, in particular, small portable devices such as smartphones, for example, may use a minimal number of inductors to save space. Limiting a number of inductors may result in more complex circuit designs with reduced performance. An inductor design is desired which can be implemented into circuits without consuming significant space. 
     SUMMARY OF THE EMBODIMENTS 
     Various embodiments of an inductive device are disclosed. Broadly speaking, an inductor is disclosed, including a first wire, a non-conductive material, and a shell. The non-conductive material may cover the first wire, with a portion of each end of the first wire uncovered. The shell may include a top portion and a bottom portion and include at least one magnetized layer and at least one gap between the first portion and the second portion. The shell may also surround a portion of the non-conductive material. 
     In a further embodiment, a cross section of the first wire may include at least four sides. In another embodiment, the top portion of the shell may include a plurality of magnetized layers, wherein each layer is separated by a layer of non-conductive material, and wherein magnetic properties of each magnetized layer are different from one another. 
     In one embodiment, a second wire may be surrounded by the non-conductive material. The second wire may be parallel to the first wire, and the non-conductive material may fill a region between the second wire and the shell and between the second wire and the first wire. 
     In another embodiment, a cross section of both the first wire and the second wire may each correspond to a pentagonal shape. At least one adjacent side of the first wire may be oblique to a closest side of the second wire. 
     In a further embodiment, a cross section of the top portion of the shell may include a channel formed between the first wire and the second wire. A depth of the channel may be configured to impart a predetermined amount of inductance to the first wire and to the second wire. In an embodiment, the top portion of the shell may include a first portion and a second portion with another gap between the first portion and the second portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description makes reference to the accompanying drawings, which are now briefly described. 
         FIG. 1  illustrates two views of an embodiment of an inductor: (a) a three dimensional view, and (b) a cross sectional view. 
         FIG. 2  illustrates a cross section of another embodiment of an inductor. 
         FIG. 3  includes two figures.  FIG. 3( a )  depicts a cross section of a further embodiment of an inductor.  FIG. 3( b )  depicts a cross section of a similar embodiment of an inductor including a channel in a magnetic shell. 
         FIG. 4  illustrates a cross section of a portion of an embodiment of an inductor with a graded magnetic shell. 
         FIG. 5  illustrates an embodiment of an inductor with wires of a different shape. 
         FIG. 6  illustrates an embodiment of another inductor with a channel in a magnetic shell. 
         FIG. 7  shows an embodiment of an inductor created by combining two similar inductive structures. 
         FIG. 8  depicts another embodiment of an inductor created by combining two similar inductive structures with a reduced number of wires. 
         FIG. 9  includes two figures.  FIG. 9( a )  illustrates an embodiment of an inductor created by combining two similar inductive structures, including a gap between the two structures.  FIG. 9( b )  illustrates a similar embodiment of an inductor created using two similar inductive structures, without a gap between the two structures. 
         FIG. 10  illustrates alignment of an embodiment of an inductor created by combining two similar inductive structures. 
         FIG. 11  shows a flow diagram of an embodiment of a method for constructing an inductor. 
         FIG. 12  shows a flow diagram of another embodiment of a method for constructing an inductor. 
     
    
    
     While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form illustrated, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including, but not limited to. 
     Various units, circuits, or other components may be described as “configured to” perform a task or tasks. In such contexts, “configured to” is a broad recitation of structure generally meaning “having circuitry that” performs the task or tasks during operation. As such, the unit/circuit/component can be configured to perform the task even when the unit/circuit/component is not currently on. In general, the circuitry that forms the structure corresponding to “configured to” may include hardware circuits. Similarly, various units/circuits/components may be described as performing a task or tasks, for convenience in the description. Such descriptions should be interpreted as including the phrase “configured to.” Reciting a unit/circuit/component that is configured to perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112, paragraph (f) interpretation for that unit/circuit/component. More generally, the recitation of any element is expressly intended not to invoke 35 U.S.C. § 112, paragraph (f) interpretation for that element unless the language “means for” or “step for” is specifically recited. 
     DETAILED DESCRIPTION 
     Due to size and cost restraints, inductors may be under-utilized in small portable electronics. Inductors can improve the performance of some power supply, voltage regulation, wireless, and current regulation designs. Advantages, therefore, may exist in having an inductor design that is small and cost efficient for use in portable electronics. In some embodiments, it may be advantageous to include one or more inductive circuit elements coupled to an integrated circuit (IC), mounted either on or within the packaging of the IC, thereby freeing space on a circuit board. 
     It is noted that an “inductor” refers to an electronic component that resists changes in a current flowing through it. As current flows through an inductor, some energy resulting from the flow of current is temporarily stored in a magnetic field. When current passing through the inductor changes, the resulting change in the magnetic field induces a voltage in the inductor, which opposes the change in current. The amount of the opposition to current changes imparted by the magnetic field is characterized by a ratio of the voltage to the rate of change of the current, which is commonly referred to as inductance. Inductors may be employed in a variety of circuit applications and may be constructed using various manufacturing methods in order to achieve a desired inductance value. 
     Two views of an embodiment of an inductor are presented in  FIG. 1 . A three dimensional view of Inductor  100  is shown in  FIG. 1 a   , while a cross-sectional view is shown in  FIG. 1 b   . Inductor  100  includes Wires  101   a  and  101   b  surrounded by Non-Conductive Material  104 . A magnetized shell is created from Upper Magnetized Shell Segment  102  and Lower Magnetized Shell Segment  103 . Magnetized Shell Segments  102  and  103  are separated from each other by Shell Gaps  105   a  and  105   b . Each end of Wires  101   a  and  101   b  extends past Non-Conductive Material  104  and Magnetized Shell Segments  102  and  103 , and may be coupled to respective circuit nodes, thereby adding inductance to signals transmitted via Wires  101   a - b . In some embodiments, terminals may be coupled to each end of Wires  101   a - b , providing connection points from Inductor  100  to the respective circuit nodes. 
     Wires  101   a - b  may consist of any suitable conductive material, such as, but not limited to, gold, copper, aluminum, and the like. Wires  101   a - b  are shown as being approximately equal in shape. In other embodiments, however, Wire  101   b  may have different shape than Wire  101   a . Although two Wires  101  are shown, any suitable number may be used, such as one wire, or three or more wires. Non-Conductive Material  104  may include any suitable substance, such as, but not limited to, silicon dioxide (i.e., glass), rubber, plastic, or combination thereof. Non-Conductive Material  104  may be used to fill the space between Wires  101   a - b  and Magnetized Shell Segments  102   a - b  and  103   a - b  providing support for Wires  101   a - b  and conductively isolating Wires  101   a - b  from each other as well as from the Magnetized Shell Segments  102  and  103 . Upper Magnetized Shell Segment  102  and Lower Magnetized Shell Segment  103  collectively form a magnetized shell along a length of Wires  101   a - b , increasing an amount of inductance associated with Wires  101   a - b . Magnetized Shell Segments  102  and  103  may consist of any suitable compound capable of being magnetized, including, but not limited to, materials made with iron, cobalt, or nickel. 
     The amount of inductance in each of Wires  101   a - b  may be determined based on several properties of Inductor  100 . For example, the length of Magnetized Shell Segments  102  and  103 , as well as the magnetic properties of Magnetized Shell Segments  102  and  103 , may influence a magnetic field generated by current flowing in either of Wires  101   a - b . A surface area of each of Wires  101   a - b  that is exposed to the magnetic field may further influence the amount of inductance, as well as a distance between the outer surface of each of Wires  101   a - b  and the inner surface of Magnetized Shell Segments  102  and  103 . 
     In the illustrated embodiment, Wires  101   a - b  are conductively isolated from each other, but are inductively coupled. A current running through Wire  101   a  may increase or decrease the inductance on Wire  101   b , and vice versa. If currents in each wire are in the same direction, then an amount of inductance may be increased on each wire. Conversely, if the currents are in opposite directions, then the amount of inductance may be decreased in each wire. 
     Shell Gaps  105   a - b  may be included to control a saturation current of Inductor  100 . As used herein, a “saturation current” corresponds to an amount of current through either Wire  101   a  or Wire  101   b  that results in either or both of Magnetized Shell Segments  102  and  103  to reach a magnetic field limit. A current through either Wire  101   a  or Wire  101   b  increases a magnetic field in Magnetized Shell Segments  102  and  103 . As the current through the wire increases, so does the magnetic field of the shell segments. The saturation current corresponds to the amount of current through the wire that causes either Magnetized Shell Segment  102  or  103  (or both) to reach a limit of magnetization, i.e., the magnetic field in the Magnetized Shell Segment  102  or  103  ceases to increase at the same rate. If current through either wire of Inductor  100  reaches the saturation current, then a signal traveling through Inductor  100  may not be subjected to the expected amount of inductance and operation of a circuit coupled to Inductor  100  may be negatively impacted. 
     The shape and relative separations of Shell Gaps  105   a - b  may be adjusted during the manufacturing of Inductor  100  to modify the saturation current level. For example, increasing the width of Shell Gap  105   a  and/or Shell Gap  105   b  may increase the saturation current, allowing Inductor  100  to pass higher current values. Shell Gaps  105   a  and  105   b  may also make the manufacturing of Inductor  100  easier, as a slight misalignment between Magnetized Shell Segments  102  and  103  may not have a significant impact to the properties of Inductor  100 . 
     It is noted that inductor  100  of  FIG. 1  is merely an example for demonstration of disclosed concepts. The illustrated components are not necessarily shown to scale. The illustrated shapes, although shown with straight lines, may include curves and jagged edges consistent with a manufacturing process, such as a semiconductor fabrication process. 
     Moving to  FIG. 2 , a cross section of an embodiment of another inductor is illustrated. Inductor  200  is a variation of Inductor  100  of  FIG. 1 , and includes Wires  201   a  and  201   b  surrounded by Non-Conductive Material  204 . A magnetized shell is created from Upper Magnetized Shell Segments  202   a  and  202   b  and Lower Magnetized Shell Segments  203   a  and  203   b . Each of Magnetized Shell Segments  202   a - b  and  203   a - b  are separated from the closest adjacent Shell Segment by one of Shell Gaps  205   a - d . Like Inductor  100 , each end of Wires  201   a  and  201   b  may be coupled to respective circuit nodes, thereby adding inductance to signals transmitted via Wires  201   a  and  201   b . Components of Inductor  200  correspond to the descriptions of the similarly named and numbered components of Inductor  100 , except for differences as described below. 
     Shell gaps  205   c  and  205   d  may be added to further control a saturation current of Inductor  200 . Similar to the description of Inductor  100 , gaps between Magnetized Shell Segments  202   a - b  and  203   a - b  may increase a saturation current of Inductor  200 . Adding Shell Gaps  205   c - d  to Shell Gaps  205   a - b  may further increase saturation current levels, allowing Inductor  200  to pass higher current than without Shell Gaps  205   c - d.    
     Additionally, in some manufacturing processes, the widths of Shell Gaps  205   c - d  may be easier to control than the widths of Shell Gaps  205   a - b . Although four gaps are illustrated, any suitable number of Shell Gaps  205  may be included, such as, e.g., removing Shell Gap  205   d  such that only three gaps are included. Moreover, Shell Gaps  205   c - d  may be placed at any suitable point along Magnetized Shell Segments  202   a - b  and  203   a - b . An asymmetrical alignment of Shell Gaps  205   c - d , may, however, result in different saturation currents for Wire  201   a  compared to Wire  201   b.    
     It is noted that inductor  200  of  FIG. 2  is one example for demonstration purposes. Some operational details have been omitted to focus on the disclosed subject matter. The illustrated components may not be shown to scale. Other embodiments may include more components. 
     Turning to  FIG. 3 , two similar embodiments of an inductor are shown.  FIG. 3( a )  depicts a cross section of a further embodiment of an inductor, and  FIG. 3( b )  depicts a cross section of a similar embodiment of an inductor including a channel in a magnetic shell. Inductor  300  is another embodiment of Inductor  100  in  FIG. 1  and includes Wires  301   a  and  301   b  surrounded by Non-Conductive Material  304 . As with Inductor  100 , a magnetized shell is created from Upper Magnetized Shell Segment  302   a  and Lower Magnetized Shell Segment  303 . Magnetized Shell Segments  302   a  and  303  are separated from each other by Shell Gaps  305   a  and  305   b . Each end of Wires  101   a  and  101   b  extends past Non-Conductive Material  104  and Magnetized Shell Segments  102  and  103 , and may be coupled to respective circuit nodes. 
     In the illustrated embodiment, the form and function of Inductor  300  is similar to the description of Inductor  100 . Compared to Inductor  100 , Inductor  300  includes extensions of Upper Magnetized Shell Segment  302   a  next to Shell Gaps  305   a  and  305   b . These extensions may provide additional control for setting a desired saturation current in Inductor  300 . 
     In addition, Wires  301   a  and  301   b  have a hexagonal shape, created by eliminating the top two corners of each wire to create a chamfered or beveled edge. The two beveled edges near the center of Inductor  300  may, in some embodiments, reduce an amount of inductive coupling between Wire  301   a  and Wire  301   b  by reducing a surface area of the adjacent facing sides of each of Wires  301   a  and  301   b . The two beveled edges nearest the outside edges of Inductor  300  allow for Upper Magnetized Shell Segment  302   a  to be brought in closer to each of Wires  301   a - b . Bringing the magnetized shell closer to the wires may allow Wires  301   a - b  to be in a stronger portion of a magnetic field from Upper Magnetized Shell Segment  302   a , thereby creating a higher level of inductance through Wires  301   a - b.    
     Inductor  310  of  FIG. 3( b )  includes the features of Inductor  300 , with an addition of Channel  306  to Upper Magnetized Shell Segment  302   b . Like Inductor  300 , Inductor  310  includes Wires  301   a - b , Non-Conducting Material  304 , and Lower Magnetized Shell Segment  303 . 
     Compared to Inductor  300 , Inductor  310  includes Channel  306  running parallel to Wires  301   a - b . In the illustrated embodiment, Channel  306  allows portions of Upper Magnetized Shell Segment  302   b  to be closer to each of Wires  301   a - b , thereby increasing the inductive coupling between Upper Magnetized Shell Segment  302   b  and Wires  301   a - b . The addition of Channel  306  may, in some embodiments, benefit further when combined with the beveled edge design of Wires  301   a - b , by allowing Channel  306  to come closer to each of Wires  301   a - b  without making electrical contact. 
     A depth, denoted by the label “d” in  FIG. 3( b ) , of Channel  306  may be adjusted to impart particular properties into Inductor  310 . A greater depth may provide more coupling between Upper Magnetized Shell Segment  302   b  and Wires  301   a - b , but reduce inductive coupling between Wire  301   a  and Wire  301   b . A width (labeled “h” in  FIG. 6 ) of Channel  306  may likewise be adjusted to modify particular properties of Inductor  310 . 
     It is noted that Inductors  300  and  310  in  FIG. 3  are examples for demonstration purposes. Some operational details have been omitted to focus on the disclosed subject matter. In other embodiments, additional components may be included, such as additional Wires  301 . Relative sizes and shapes of the illustrated components are not intended to be shown to scale, and may differ based on a fabrication process used in the construction of each Inductor  300  and  310 . Although Inductor  310  shows Channel  306  as a part of Upper Magnetized Shell Segment  302   b , in other embodiments, another channel may be created as a part of Lower Magnetized Shell Segment  303  in addition to, or in place of, Channel  306 . 
     Proceeding to  FIG. 4 , a cross section of a portion of an embodiment of an inductor with a graded magnetic shell is depicted. Inductor  400  may correspond to a portion of Inductor  100  or Inductor  200 , and illustrates a more detailed embodiment of a magnetized shell. Inductor  400  includes Wire  401  and Lower Magnetized Shell Segment  403 . Multiple Magnetized Shell Segment Layers  402   a - d  are placed between multiple Non-Conductive Material Layers  404   a - 404   d.    
     In the illustrated embodiment, an upper shell segment is created by layering Magnetized Shell Segment Layers  402   a - d  with Non-Conductive Material Layers  404   b - 404   d  separating each magnetized layer. Each of Magnetized Shell Segment Layers  402   a - d  may, in some embodiments, have different magnetic properties. A magnetic field of a magnetized object is weaker at increasing distances from the object. If the magnetic field from Magnetized Shell Segment Layer  402   a  is the same as Magnetized Shell Segment Layer  402   d , then Wire  401  would be subjected to more of the magnetic field of Layer  402   a  than of Layer  402   d . By increasing the strength of the magnetic field of Magnetized Shell Segment Layer  402   d  relative to Layer  402   a , Wire  401  may be subjected to similar amounts of magnetic field from each magnetized layer. 
     In the illustrated embodiment, the magnetic field of each Magnetized Shell Segment Layer  402   a - d  is increased corresponding to its respective distance from Wire  401 . In some embodiments, the magnetic field of each of Magnetized Shell Segment Layers  402   a - d  may be determined by adjusting a thickness of the Layer  402 , by using a different material to create each Layer  402 , by subjecting each layer to a different magnetization process, or any combination thereof. In addition, the thickness and/or composition of each Non-Conductive Material Layer  404   a - 404   d  may be adjusted to produce the desired properties of Inductor  400 . 
     The layered magnetic shell may provide a process for adjusting an amount of inductance through Wire  401  as well as a process for adjusting a saturation current for Inductor  400 . Although not illustrated, Lower Magnetized Shell Segment  403  may also be created using this layered approach. 
     It is noted that the embodiment illustrated in  FIG. 4  is an example structure. Only a portion of Inductor  400  is shown to highlight particular aspects of the disclosed subject matter. In other embodiments, any suitable number of layers may be used. The illustrated embodiment may be used in combination with the other inductor structures disclosed herein. 
     Moving now to  FIG. 5 , an embodiment of an inductor with wires of a different shape is shown. Inductor  500  is another variation of Inductor  100  in  FIG. 1 . Similar to Inductor  100 , Inductor  500  includes two Wires  501   a - b  surrounded by Non-Conductive Material  504 . Upper and Lower Magnetized Shell Segments  502  and  503 , respectively, collectively form magnetized shell around Wires  501   a - b . Descriptions of Inductor  100  apply to Inductor  500 , with exceptions noted below. 
     In the illustrated embodiment, Inductor  500  differs from Inductor  100  by the cross-sectional shape of Wires  501   a - b . Whereas the cross-section of Wires  101   a - b  of Inductor  100  are shown as rectangles, the cross-section of Wires  501   a - b  are illustrated as asymmetric pentagonal shapes. The facing Sides  506  of Wires  501   a - b  are angled away from each other, e.g., are oblique to each other, thereby reducing an amount of inductive coupling between Wire  501   a  and Wire  501   b . The angles of Sides  506  may be adjusted to achieve a desired amount of coupling between Wires  501   a - b.    
     The other sides of Wires  501   a - b  may be created approximately parallel to corresponding sides of Upper and Lower Magnetized Shell Segments  502  and  503 . By making the sides of Wires  501   a - b  parallel to the corresponding sides of the magnetized shell, the magnetic fields coupled between Wires  501   a  and  501   b  and Upper and Lower Magnetized Shell Segments  502  and  503  may be increased and, in some embodiments, may be more uniform as compared to Inductor  100 . Wires  501   a - b  are shown as being approximately equal in shape. In other embodiments, however, Wire  501   b  may have different size and/or shape than Wire  501   a.    
     It is noted that, as used herein, “parallel” is not intended to imply two perfectly equidistant objects. Instead, “parallel” is intended to describe two or more objects that are approximately uniform in distance from one another, within the limits of contemporary manufacturing capabilities. It is noted that one of ordinary skill in the art would understand that parallel wires, as used herein, refer to two or more wires that are substantially parallel to each other, but may run askew of one another by several degrees due to limitations of the manufacturing capabilities. 
     It is further noted that  FIG. 5  is merely an example. In other embodiments, the structure of inductor  500  may differ from the structure illustrated. For example, although five sides for each wire are shown, any suitable number of sides may be utilized to correspond to various shapes of the corresponding magnetic shell. 
     Turning now to  FIG. 6 , another embodiment of an inductor with a channel in a magnetic shell is shown. Inductor  600  is similar in structure to Inductor  310  in  FIG. 3( b ) . Components of Inductor  600  are as described above in regards to Inductor  310 , except where noted. Inductor  600  includes Wires  601   a - b , Non-Conducting Material  604 , and Upper and Lower Magnetized Shell Segments  602  and  603 . Channel  606  is included in Upper Magnetized Shell  602 . Inductor  600  differs from Inductor  310  by excluding the extensions of Upper Magnetized Shell Segment  302   a , leaving Shell Gaps  605   a  and  605   b  similar to Shell Gaps  105   a  and  105   b  described in regards to Inductor  100  in  FIG. 1 . Excluding these extensions may simplify a process for manufacturing Inductor  600 . 
     It is noted that Inductor  600  in  FIG. 6  is one example for demonstration purposes. Some operational details have been omitted to focus on the disclosed subject matter. The illustrated structures may not be shown to scale. Other embodiments may include more components. 
     Turning to  FIG. 7 , an embodiment of an inductor created by combining two similar inductive structures is illustrated. First Inductive Structure  700   a  includes Wires  701   a - b  surrounded by Non-Conductive Material  704   a  and partially covered by Magnetized Shell Segment  702   a . Second Inductive Structure  700   b  includes Wires  701   c - d  surrounded by Non-Conductive Material  704   b  and partially covered by Magnetized Shell Segment  702   b.    
     Inductor  700  is formed by combining Inductive Structures  700   a  and  700   b  by inverting Structure  700   b  and attaching it to the bottom of Structure  700   a . Both Inductive Structures  700   a  and  700   b  may, in some embodiments, be created in a semiconductor fabrication process. Structure  700   a  may be attached to Structure  700   b  using any suitable adhesive, such as, for example, a non-conductive epoxy. Gap  703  may include the adhesive as well as additional non-conductive material. Similar to the Shell Gaps  105   a - b  discussed in regards to Inductor  100  in  FIG. 1 , Gap  703  between Structures  700   a  and  700   b  may be adjusted to achieve desired properties, such as an amount of inductance and control a level of saturation current through Wires  701   a - d . In some embodiments, Wires  701   a - d  may be conductively isolated from one another, resulting in Inductor  700  being capable of passing four separate signals. In other embodiments, Wires  701   a  and  701   b  may be conductively coupled to Wires  701   c  and  701   d , respectively, resulting in Inductor  700  capable of passing two signals. In such embodiments, Wires  701   a  and  701   c , as well as Wires  701   b  and  701   d , may be attached using any suitable method, such as metal vias, metal bumps on the adjoining sides, and the like. 
     It is noted that  FIG. 7  is merely an example. Although two wires are shown in each of Structures  700   a  and  700   b , any suitable number of wires may be used. Other inductive structures disclosed herein may be used in combination with the concepts disclosed in regards to Inductor  700 . 
     Moving to  FIG. 8 , another embodiment of an inductor created by combining two similar inductive structures with a reduced number of wires is illustrated. A first Inductive Structure  800   a  includes Wire  801   a  surrounded by Non-Conductive Material  804   a  and partially covered by Magnetized Shell Segment  802   a . Second Inductive Structure  800   b  includes Wire  801   b  surrounded by Non-Conductive Material  804   b  and partially covered by Magnetized Shell Segment  802   b.    
     Inductor  800  is similar in design to Inductor  700  and the description of Inductor  700  may, therefore, apply to Inductor  800 . Inductor  800  demonstrates use of a different number of wires per each of Structures  800   a  and  800   b . Instead of two wires per structure, Structures  800   a  and  800   b  each include Wire  801   a  and  801   b , respectively. Wires  801   a - b  may be attached to form a single conductor through Inductor  800 , or may be isolated so Inductor  800  includes two conductors. As described for Inductor  700  above, a width of a gap between Structures  800   a  and  800   b  (Gap  803 ), may be adjusted to modify inductive parameters of Inductor  800 . 
     It is noted that  FIG. 8  is an example for demonstrating disclosed concepts. Relative sizes and shapes of the illustrated components are not intended to be shown to scale, and may differ based on a fabrication process used in the construction of Inductor  800 . 
     Turning now to  FIG. 9 , two figures are shown.  FIG. 9( a )  illustrates an embodiment of an inductor created by combining two similar inductive structures, including a gap between the two structures, while  FIG. 9( b )  illustrates a similar embodiment of an inductor without a gap between the two structures. Inductor  900  is another variation of Inductor  700  shown in  FIG. 7 . Inductor  900  includes a first Inductive Structure  900   a  including Wires  901   a - b  surrounded by Non-Conductive Material  904   a  and partially covered by Magnetized Shell Segment  902   a . A second Inductive Structure  900   b  includes Wires  901   c - d  surrounded by Non-Conductive Material  904   b  and partially covered by Magnetized Shell Segment  902   b . Inductive Structures  900   a  and  900   b  also include Channels  905   a  and  905   b , respectively. 
     Inductor  900  may be created as described above in regards to Inductor  700 . The addition of Channels  905   a  and  905   b  may provide further capabilities for controlling parameters of Inductor  900 , such as a level of inductance on Wires  901   a - 901   d  and a saturation current level. Although Channels  905   a - b  are shown as having similar shapes, including width and depth, each channel may be shaped independently to achieve desired properties. In some embodiments, either of Channels  905   a - b  may be omitted, leaving a single channel on one side of Inductor  900 . 
     Similar to Gap  703  discussed in regards to Inductor  700  in  FIG. 7 , Gap  903  between Structures  900   a  and  900   b  may be adjusted, in combination with Channels  905   a  and  905   b , to further achieve desired properties. Wires  901   a - d  may be conductively isolated from one another, resulting in Inductor  900  being capable of passing four separate signals. 
     Similar to Inductor  900 , Inductor  910  in  FIG. 9( b ) , includes Inductive Structures  910   a  and  910   b , each with a respective magnetized shell, Magnetized Shell Segment  902   c  and Magnetized Shell Segment  902   d . Magnetized Shell Segments  902   c  and  902   d  each include a respective one of Channel  905   c  and Channel  905   d . Inductor  910  differs from Inductor  900  by elimination of Gap  903 . Wires  901   a  and  901   c , as well as Wires  901   b  and  901   d  of Inductor  900  are joined to create Wires  901   e  and  901   f , respectively. The two halves of Wires  901   e  and  901   f , each included in Inductive Structures  910   a  and  910   b , may be attached using any suitable method, such as metal vias, metal bumps on the adjoining sides, and the like. Similarly, Non-Conductive Material  904   a  and  904   b  are joined to form a single Non-Conductive Material  904   c , surrounding both Wire  901   e  and  901   f.    
     Magnetized Shells  902   c  and  902   d  are illustrated as touching. In other embodiments, however, Magnetized Shells  902   c  and  902   d  may be trimmed, or otherwise shortened, to leave a gap between the two magnetized shells on one or both sides of Inductor  910 . Additionally, Inductor  910  differs from Inductor  900  in regards to the shape of Wires  901   e  and  901   f , which are beveled at the corners, similar to Wires  301   a  and  301   b  of  FIG. 3 . Beveling these corners of Wires  901   e  and  901   f , may increase an inductive coupling to Magnetized Shell Segments  902   c  and  902   d.    
     Inductor  910  may, in some embodiments, provide a higher amount of inductance than some of the other embodiments disclosed herein, for inductors of a similar size. The adjacent sides of Wires  901   e  and  901   f  may provide a greater amount of inductive coupling between the two wires, than, for example, Wires  301   a  and  301   b  in  FIG. 3 . In addition, an ability to change the widths and depths of each of Channels  905   c  and  905   d  may provide capability to adjust an amount of inductance coupled to each of Wires  901   e  and  901   f  from Magnetized Shells  902   c  and  902   d.    
     It is noted that Inductors  900  and  910  in  FIG. 9  are merely examples. Relative shapes and sizes of components may also differ for various embodiments, including, for example, the various geometries shown elsewhere herein. For example, the beveled corners of Wires  901   e  and  901   f  may be omitted, leaving the wires in a rectangular shape. In other embodiments, the number of Wires  901  included in Inductor  900  may vary. 
     Moving now to  FIG. 10 , alignment of an embodiment of an inductor created by combining two similar inductive structures is illustrated. Inductor  1000  is a further variation of the concepts disclosed for Inductor  700  in  FIG. 7 . Inductor  1000  includes a first Inductive Structure  1000   a , including Wires  1001   a - b , Non-Conductive Material  1004   a , Magnetic Shell Segment  1002   a , and Channel  1005 . A second Inductive Structure  1000   b  includes Wires  1001   c - d , Non-Conductive Material  1004   b , and Magnetic Shell Segment  1002   b.    
     It is noted that, in the illustrated embodiment, Inductive Structures  1000   a - b  are dissimilar, in that Structure  1000   a  includes Channel  1005 , while Structure  1000   b  does not include a channel. Additionally, Wires  1001   a - b  are approximately pentagonally shaped while Wires  1001   c - d  are rectangular in shape. The dissimilarities are included to demonstrate that Inductive Structures are not required to be “mirror images” of each other to be joined into a single inductor. 
     Expanded View  1003  illustrates a detailed image of a misalignment of Structure  1000   a  to Structure  1000   b . In the illustrated embodiment, misalignment of the two structures, in particular Magnetic Shell Segments  1002   a  to  1002   b , may result in undesired properties for Inductor  1000 . The amount of inductance through Inductor  1000  may, in some embodiments, be reduced due to misalignment. Other adjustments, as disclosed herein, may be used to mitigate potential reductions due to misalignment. For example, any combination of sizes and shapes of Wires  1001   a - d , widths and depths of Channel  1005 , the thickness of Magnetic Shell Segments  1002   a  to  1002   b , along with other properties, may be adjusted to compensate for potential reductions in the amount of inductance due to tolerances of the manufacturing process. 
     It is noted that Inductor  1000  does not include extensions of Magnetized Shell Segments  1002   a - b  at their closest points. Referring to Inductor  100  in  FIG. 1 , both Upper Magnetized Shell Segment  102  and Lower Magnetized Shell Segment  103  extend outward, away from Wires  101   a - b  and approximately parallel to each other. If the Magnetized Shell Segments  102  and  103  are created using a layered process as described in regards to  FIG. 4 , then the outside layers are farther apart than the inside layers at Shell Gaps  105   a - b . This unequal distance may cause losses in the magnetic fields generated when current flows through either Wire  101   a  or  101   b.    
     In contrast, Magnetized Shell Segments  1002   a - b  end askew to each other. As shown in Expanded View  1003 , if Magnetized Shell Segments  1002   a - b  are layered, then each layer is approximately the same distance from a corresponding layer in the opposing Magnetized Shell Segment  1002 . Even if Structure  1000   a  is misaligned to Structure  1000   b , distances between respective layers of Magnetized Shell Segments  1002   a - b  may be similar for each layer. Compared to Inductor  100 , this higher level of consistency between the layers of Magnetized Shell Segments  1002   a - b  may result in reduced losses in the magnetic fields generated when current flows through any of Wires  101   a - d.    
     It is noted that  FIG. 10  is merely one embodiment. Elements of the inductive device  1000  may be combined with other concepts disclosed herein. Relative scales of the illustrated components may differ in other embodiments. 
     It is also noted that any suitable combination of the inductor structures disclosed herein are contemplated. For example, the shell gaps shown in Inductor  200  in  FIG. 2  may be combined with the shaped wires of Inductor  500  in  FIG. 5  and combined with a second such structure to form a mirrored inductor design similar to Inductor  900  in  FIG. 9 . One or more channels could also be added to the magnetized shells. 
     Moving to  FIG. 11 , a flow diagram of an embodiment of a method for constructing an inductor is shown. Method  1100  may be applied to a manufacturing process for creating an inductive structure, such as, for example, any of Inductors  100  to  1000  presented herein. Referring collectively to  FIG. 1  and the flow diagram of  FIG. 11 , Method  1100  begins in block  1101 . 
     A top portion of a shell is created (block  1102 ). A top portion of a magnetized shell is formed in a shape such as Upper Magnetized Shell Segment  102 . Various methods may be utilized for creating the top portion of the magnetized shell, such as, e.g., a depositing a magnetic material via a physical vapor deposition (PVD) process or chemical vapor deposition (CVD) process. The magnetic material may include iron, nickel, cobalt, or other magnetic substance. The magnetic material may be magnetized before it is deposited, or may be magnetized after deposition. In some embodiments, the top portion of the magnetized shell may be created as described for Magnetized Shell Segment Layers  402   a - d  in  FIG. 4 , by alternating layers of magnetic material with layers of a non-magnetic, non-conductive material. The top portion of the magnetic shell may correspond to any suitable shape, including any shape of Upper Magnetized Shell Segments illustrated herein. One or more shell gaps, in some embodiments, may be created in the magnetized shell after the shell has been created by etching a gap into the shell to create a top portion of the magnetic shell similar to Upper Magnetic Shell Segments  202   a - b  in  FIG. 2 . 
     A non-conductive material is placed within the top portion of the magnetic shell (block  1104 ). A non-conductive material, such as, for example, silicon oxide (glass), nitride, plastic, rubber, and the like, is placed within the previously formed top portion of the magnetic shell. Plastic or rubber compounds may be deposited with a similar CVD or PVD process. A glass material may be created by first placing a silicon layer (e.g., a polysilicon layer) and exposing it to high oxygen levels under high temperatures. A nitride layer may be created in a similar process by replacing the oxygen with nitrogen. When complete, the non-conductive material may fill all or most of a space within the top portion of the magnetic shell. 
     One or more wires are created within the non-conductive material (block  1106 ). Before a conductive metal may be added to form the wire, channels may need to be etched into the non-conductive material. Referring to  FIG. 1 , after the non-conductive material is added, the space occupied by Wires  101   a - b  may be filled by the non-conductive material. An etch process may be used to form channels corresponding to a desired shape for the wires, including shapes corresponding to Wires  101   a - b , Wires  301   a - b  in  FIG. 3 , or Wires  501   a - b  in  FIG. 5 . After channels are created for the one or more wires, a conductive metal, such as, for example, aluminum, copper, or gold, is placed into the channels, using, for example, a deposition process. In some embodiments, additional non-conductive material may be added to cover the newly formed wires. 
     A bottom portion of the magnetic shell is created (block  1108 ). The bottom portion of the magnetic shell is formed using a similar process as used to create the top portion, as described in block  1102 . In some embodiments, a planarization step may be performed prior to creating the bottom portion of the magnetic shell. If an inductor structure such as shown in  FIGS. 7-10  is being manufactured, then the bottom portion of the magnetic shell may be omitted, and instead, two structures are created using operations  1102  through  1106 , and then the two structures are joined using an adhesive. The method ends in block  1110 . 
     It is noted that Method  1100  in  FIG. 11  is an example process for manufacturing an embodiment of an inductor. The operations have been simplified for clarity. In other embodiments, more or fewer operations may be included. 
     Proceeding to  FIG. 12 , a flow diagram of an embodiment of a method for constructing an inductor is shown. Method  1200 , similar to Method  1100  in  FIG. 11 , may be applied to a process for manufacturing an inductive structure, such as, for example, any of Inductors  100  to  600  presented herein. Referring collectively to  FIG. 1  and the flow diagram of  FIG. 12 , Method  1200  begins in block  1201 . 
     A lower portion of a shell is created (block  1202 ). A lower portion of a magnetized shell is formed in a shape such as Lower Magnetized Shell Segment  103 . The lower portion of the magnetized shell may be created from similar materials, using similar processes as described above in block  1102  of Method  1100 . As previously disclosed, the magnetic material may be magnetized before it is deposited, or may be magnetized after deposition. In some embodiments, the lower portion of the magnetized shell may be created as described for Magnetized Shell Segment Layers  402   a - d  in  FIG. 4 , by alternating layers of magnetic material with layers of a non-magnetic, non-conductive material. The lower portion of the magnetic shell may or may not include a channel gap as described in regards to  FIG. 6 . One or more shell gaps, in some embodiments, may be created in the magnetized shell after the shell has been created by etching a gap into the shell to create a lower portion of the magnetic shell similar to Lower Magnetic Shell Segments  203   a - b  in  FIG. 2 . 
     A non-conductive material is placed on top of the lower portion of the magnetic shell (block  1204 ). A non-conductive material, such as, for example, silicon oxide, nitride, plastic, or rubber, is placed on top of the previously formed lower portion of the magnetic shell. Any suitable process such as disclosed above in regards to block  1104  of Method  1100  may be used to place the non-conductive material. The non-conductive material may be placed with a thickness corresponding to a desired width of a gap such as, for example, Shell Gap  205   a - b  in  FIG. 2 . In other embodiments, the non-conductive material may be placed thicker than the desired width of the gap and then the excess removed using a process such as, e.g., an etch or a planarization process. 
     One or more wires are created on top of the non-conductive material (block  1206 ). A conductive metal, such as, for example, aluminum, copper, or gold, is placed on top of the non-conductive material, using, for example, a deposition process. In some embodiments, the metal may be deposited over all of the non-conductive material, and then the excess metal etched away to leave the wires in a desired shape. In addition, the non-conductive material may be shaped to support a non rectangular wire shape, such as shown in  FIG. 5 , by Wires  101   a - b  and Non-Conductive Material  504 . 
     Additional non-conductive material is placed on top of and around the one or more wires (block  1208 ). Additional non-conductive material is placed around the one or more wires created in block  1206 . In some embodiments, the non-conductive material is etched after being placed to conform to a desired shape for an upper portion of the magnetized shell. 
     A upper portion of the magnetic shell is created (block  1210 ). The upper portion of the magnetic shell is formed using a similar process as used to create the lower portion, as described in block  1202 . The non-conductive material surrounding the one or more wires may be etched prior to creating the upper portion of the magnetic shell in order to establish a shape for the upper portion. For example, referring to  FIG. 6 , a channel may be etched into the non-conductive material to create Channel  605 . The upper magnetic shell is created using one or more layers of a magnetic material such as, for example, iron, nickel, cobalt, or other magnetic substance. As described above, the upper magnetized layer may be magnetized before application or after being created. The method ends in block  1212 . 
     It is noted that Method  1200  in  FIG. 12  is an example process for manufacturing an embodiment of an inductor. The operations have been simplified for clarity. In other embodiments, more or fewer operations may be included. 
     Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure. 
     The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of this application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.

Metadata:
Filing Date: 20170824
Publication Date: 20220830
Grant Date: 20220830
Priority Date: 20160922
Inventors: CAPPABIANCA, DAVID P.
DIBENE, II, JOSEPH T.
SEARLES, SHAWN
WANG, LE
YANG, YIZHANG
O'MATHUNA, SEAN CIAN
KULKARNI, SANTOSH
MCCLOSKEY, PAUL
PAVLOVIC, ZORAN
LAWTON, WILLIAM
MAXWELL, GRAEME
O'BRIEN, JOSEPH
SMIDDY, Hugh Charles
Assignee: APPLE INC
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Family ID: 59966820