DEVICES USING METALLIZED MAGNETIC SUBSTRATES

摘要

The present invention provides novel devices including magnetic components and novel methods for making them. In a first aspect, the invention provides a device comprising a metallized magnetic substrate (e.g., 5) having an aperture (e.g., 50). At least one metallized path (e.g., 20) passes through the aperture and around a portion of the substrate to define a magnetic component which has a flux path in the plane of the substrate and substantially confined within the substrate. The winding can pass around a substrate edge or through a second aperture. Advantageously, other circuit elements such as metallized interconnects (e.g., 55) and electronic components (e.g., 401) are disposed on the substrate to form a device. In a further aspect, the invention provides methods for metallizing magnetic substrate to form devices including magnetic components. In one embodiment, a green ceramic body (e.g., 5) comprising at least one ceramic layer is provided in an unfired state. At least one aperture (e.g., 50) having at least one conductively coated side wall pathway (e.g., 56) is formed within each ceramic layer. Top and bottom surface portions of the ceramic body are metallized such that the metallized surface portions (e.g., 20) form a continuous conductive region with the side wall conductive pathway to create a conductive winding about the ceramic body. The ceramic body with the conductive winding formed thereon is fired to yield a substrate including a magnetic component. Preferably after sintering, additional metal is plated on the conductive regions to enhance current-carrying capacity.