I 1111111111111111 11111 1111111111 1111111111 1111111111 111111111111111 IIII IIII
`
`US007375609B2
`
`(IO) Patent No.: US 7,375,609 B2
`
`c12) United States Patent
`(45)Date of Patent:
`May 20, 2008
`
`
`Suzuki et al.
`
`(54)MULTILAYER LAMINATED CIRCUIT
`BOARD
`(75)
`Inventors: Yukiharu Suzuki, Tokyo (JP);
`
`
`
`
`
`Toshihiko Kobayashi, Tokyo (JP);
`
`Toshimi Mizoguchi, Tokyo (JP)
`
`(56)
`(73)
`
`Assignee: Tamura Corporation, Tokyo (JP)
`( *)
`
`Notice: Subject to any disclaimer, the term of this
`
`
`
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`(21)
`Appl. No.: 10/573,633
`
`(52)U.S. Cl. ....................... 336/200; 336/223; 336/232
`
`
`
`
`
`
`
`(58)Field of Classification Search ................ 336/200,
`336/232, 223
`
`
`
`See application file for complete search history.
`
`
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`6,573,821 B2 * 6/2003 Peels et al. ................. 336/200
`
`
`
`
`
`
`6,917,274 B2 * 7 /2005 Hong et al. ................. 336/200
`
`
`
`
`6,998,951 B2 * 2/2006 Itou et al .................... 336/200
`
`(22)
`PCT Filed: Sep. 29, 2003
`
`(86)
`PCT No.: PCT I JP03/12431
`
`* cited by examiner
`
`
`
`Primary Examiner-Anh T Mai
`
`
`
`(57)
`
`ABSTRACT
`
`§371 (c)(l),
`(2), ( 4) Date:Oct. 18, 2006
`
`(87)PCT Pub. No.: WO2005/032226
`
`PCT Pub. Date: Apr. 7, 2005
`
`A multi-layer laminated circuit board lOA of the present
`
`
`
`
`
`
`invention is formed by laminating together a multi-layer
`
`
`transformer 10, a multi-layer part sheet 30 formed with a
`
`
`multi-layer part, and a wiring sheet 50 formed with a circuit
`
`
`
`pattern. The multi-layer transformer 10 is incorporated into
`
`
`
`
`the multi-layer laminated circuit board l0A, and therefore a
`Prior Publication Data
`
`
`
`package for the multi-layer transformer 10 is omitted, and
`
`
`
`the wiring between the multi-layer transformer 10 and other
`
`components is reduced to a minimum.
`
`(65)
`
`
`
`US 2007/0030659 Al Feb. 8, 2007
`
`
`
`13 Claims, 14 Drawing Sheets
`
`
`
`(51)Int. Cl.
`H0JF 5100 (2006.01)
`
`130
`
`-�
`
`155
`
`Ex.1013
`APPLE INC. / Page 1 of 26
`
`

`

`U.S. Patent May 20, 2008
`Sheet 1 of 14
`
`
`US 7,375,609 B2
`
`FIG.1
`
`MULTI· LA YER
`LAMINATED
`
`CIRCUIT BOARD
`10A
`� WIRING SHEET
`50
`
`'\.
`MULTI· LA YER
`PART SHEET
`30
`MULTI·
`LAYER
`CAPACITOR
`
`21
`
`52
`
`13e
`
`13d
`
`11e
`
`11d
`
`13c
`
`13b
`
`11b
`
`13a
`
`34
`
`MULTI·
`LAYER
`INDUCTOR
`
`32
`
`I
`
`I
`
`: 18--<l,
`: 14b
`17 :
`
`I
`
`I
`I
`I
`
`15a
`
`J.Q/
`
`MULTI· LA YER
`TRANSFORMER
`
`Ex.1013
`APPLE INC. / Page 2 of 26
`
`

`

`U.S. Patent
`May 20, 2008
`Sheet 2 of 14
`
`
`US 7,375,609 B2
`
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`Ex.1013
`APPLE INC. / Page 3 of 26
`
`

`

`U.S. Patent
`May 20, 2008
`Sheet 3 of 14
`
`
`US 7,375,609 B2
`
`4-(Y)
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`Ex.1013
`APPLE INC. / Page 4 of 26
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`

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`PRINTING
`I >I BODYPASTE -
`RESISTIVE
`
`70
`
`£:!_
`
`THROUGHH·HOLES)
`SECONDARY
`WINDINGS,
`(PRIMARY
`AND
`PASTE PRINTING
`Ag GROUP CONDUCTOR
`�71
`
`Ip
`
`H
`
`1 I
`
`METHOD
`� USING PRINTING PRESSING
`ETC.
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`ON PET FILM FORMATION
`BY 1------3,,
`SHEET CREATION
`,(\-168 69 V\ \I/ \I/
`CREATION (ON PET FILM)
`BODY SLURRY MOLDING CUTTING
`NONMAGNETIC H BODYSHEET
`SHEET -
`NONMAGNETIC
`/V65 /V66
`CREATION (ON PET FILM)
`SLURRY SHEET MOLDING CUTTING -
`H
`MAGNETIC BODY H MAGNETIC BODY
`SHEET
`/V62 �3
`
`(GLASS PASTE)
`CREATION
`BODY PASTE
`NONMAGNETIC
`_d_67
`
`/V64
`
`/V61
`
`(ABOUT 900°C)
`PRESS) CUTTING FIRING
`STACKING H
`H SIMULTANEOUS
`(HYDROSTATIC
`fV 74
`fV 72
`
`INDIVIDUAL
`
`fV 73
`
`FIG. 4
`
`Ex.1013
`APPLE INC. / Page 5 of 26
`
`

`

`May 20,
`2008 Sheet 5 of 14
`U.S. Patent
`
`US 7,375,609
`B2
`
`MULTI· LA YER
`TRANSFORMER
`110
`
`MULTI· LA YER
`LAMINATED
`FIG.5
`CIRCUIT BOARD
`MAGNETIC SHEET
`100
`117
`
`/
`
`THROUGH-HOLE
`SHEET
`DIRLECTRIC
`111 b
`115
`
`SECONDARY
`114
`121�
`WINDING
`,THROUGH-HOLE:
`111a
`:
`
`I
`
`I
`I
`I
`I
`
`I
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`I
`
`I
`I
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`I
`
`<.j>--120
`
`SHEET
`DIRLECTRIC
`
`113
`
`PRIMARY
`WINDING
`112
`
`I
`I
`I
`I
`I
`I
`I
`
`118 ----f
`
`I
`I
`I
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`
`I
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`I
`
`MAGNETIC SHEET
`
`c:!:--119
`
`116
`
`-�VI WIRING SHEET
`
`101
`
`Ex.1013
`APPLE INC. / Page 6 of 26
`
`

`

`U.S. Patent May 20, 2008
`Sheet 6 of 14
`
`
`US 7,375,609 B2
`
`,,;:t __ _
`0 ----­
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`
`Ex.1013
`APPLE INC. / Page 7 of 26
`
`

`

`Sheet 7 of 14 US 7,375,609
`B2
`U.S. Patent May 20, 2008
`
`FIG. 7
`
`142
`
`148
`
`138
`
`134
`
`144
`
`147
`
`143b
`
`136b
`
`132b
`
`143a
`
`136a
`
`155
`
`Ex.1013
`APPLE INC. / Page 8 of 26
`
`

`

`= N
`
`= \0
`
`0--,
`"'U'I
`--...l
`w
`
`
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`
`141
`
`40b
`
`.... .i;...
`
`....
`
`0
`
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`
`.....
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`
`134
`
`135a 132a
`
`136a
`
`131a
`
`=-('D
`
`
`
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`
`QO
`0
`0
`N
`
`"'o
`N
`
`�
`�
`
`135b
`
`132a 135a
`
`151
`
`140b
`
`147-
`
`134
`
`=
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`�
`�
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`•
`
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`/
`
`130
`
`FIG. 8
`
`Ex.1013
`APPLE INC. / Page 9 of 26
`
`

`

`Sheet 9 of 14 US 7,375,609
`B2
`U.S. Patent May 20, 2008
`
`FIG. 9
`MULTI-LA
`YER
`TRANSFORMER
`210
`
`�
`
`MAGNETIC SHEET
`216b
`
`CENTER MAGNETIC PATTERN
`211b
`
`PATTERN
`DIRLECTRIC
`
`213b
`SHEET
`COMPOSITE
`214b
`
`215b
`WINDING
`SECONDARY
`
`I
`I
`I
`I
`I
`I
`I
`I
`
`221-<J.:> I
`
`212b
`PERIPHERAL
`MAGNETIC
`PATTERN
`,t,.-220
`PATTERN
`: DIRLECTRIC
`
`CENTER MAGNETIC PATTERN
`211a
`
`I
`I
`
`: 213a
`SHEET
`1 COMPOSITE
`
`i"\\/'.
`
`PRIMARY WINDING
`218�
`
`I
`
`I
`I
`
`214a
`
`212a
`PERIPHERAL
`MAGNETIC
`PATTERN
`
`I
`I
`I
`I
`
`d-219
`
`I
`I
`I
`I
`I
`I
`
`MAGNETIC SHEET
`
`216a
`
`225
`
`224
`
`Ex.1013
`APPLE INC. / Page 10 of 26
`
`

`

`U.S. Patent May 20, 2008
`Sheet 10 of 14
`
`
`US 7,375,609 B2
`
`.....
`
`N
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`
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`
`N
`
`Ex.1013
`APPLE INC. / Page 11 of 26
`
`

`

`U.S. Patent
`May 20, 2008
`Sheet 11 of 14
`
`
`US 7,375,609 B2
`
`FIG. 11
`
`233e
`
`235d
`
`233d
`
`235c
`
`235b
`
`233a
`
`234e
`
`234d
`
`234c
`
`I I
`
`I I
`I I
`
`I 9---245
`244� I I
`231b : :
`
`234b
`
`234a
`
`236a
`
`246
`
`Ex.1013
`APPLE INC. / Page 12 of 26
`
`

`

`N
`=
`
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`UI
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`
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`
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`
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`
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`
`233a
`
`231e
`
`FIG. 12
`
`232b
`
`232c
`
`232d
`
`232e
`
`Ex.1013
`APPLE INC. / Page 13 of 26
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`

`

`U.S. Patent May 20, 2008
`Sheet 13 of 14
`
`
`
`US 7,375,609 B2
`
`FIG. 13
`
`82g
`
`82f
`
`82e
`
`82d
`
`82c
`
`82b
`
`82a
`
`81d
`
`81c
`
`81b
`
`92�
`
`81a
`
`97
`
`I
`
`I 4>-- 95
`
`I
`I
`I
`I
`I
`I
`
`94------4
`
`I
`
`I
`I
`I
`I
`I
`
`I
`
`cl>-. 91
`
`I
`I
`I
`I
`
`I
`I
`
`I
`I
`I
`I
`I
`I
`
`96
`
`Ex.1013
`APPLE INC. / Page 14 of 26
`
`

`

`U.S. Patent May 20, 2008
`Sheet 14 of 14
`
`
`US 7,375,609 B2
`
`c.o
`co
`
`·•.(Y') m
`
`m·--
`
`ro
`
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`---CJ')
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`
`m
`
`Ex.1013
`APPLE INC. / Page 15 of 26
`
`

`

`
`
`US 7,375,609 B2
`
`2
`1
`coupling ary windings 81b and 81d is M, and a magnetic
`
`
`MULTILAYER LAMINATED CIRCUIT
`
`
`
`coefficient k is defined by the following equation:
`BOARD
`
`
`
`k�IMIJ(Ll-L2) (k;el)
`
`
`
`TECHNICAL FIELD
`
`indica-k is one of the 5 The magnetic coupling coefficient
`
`
`
`
`
`
`
`
`tors of the transformer function and the larger the magnetic
`
`
`
`
`The present invention relates to a multi-layer laminated
`
`
`
`
`coupling coefficient k, the smaller the leakage magnetic flux
`
`
`
`
`circuit board in the field of semiconductor technology, more
`
`
`
`(leakage inductance) becomes and, therefore, the power
`
`
`
`specifically, relates to that having an in-built multi-layer
`
`
`conversion efficiency is high.
`
`transformer in which a coil and core are formed by stacking
`10
`Problem to Solved
`
`
`
`sheets having electromagnetic characteristics.
`The multi-layer transformer 80 is mounted on a printed
`
`
`
`
`
`wiring board as an individual component, for example.
`
`
`
`However, it is becoming more and more difficult for such
`
`
`
`prior art to respond to demand for further reductions in the
`15
`
`
`
`In recent years, multi-layer transformers have attracted
`
`size of electronic equipment.
`
`
`
`attention that are thin, small, and lightweight in accordance
`
`
`
`Further, in the multi-layer transformer 80, a magnetic
`
`
`
`
`with rapid advances in the miniaturization of electronic
`
`
`
`layer (the magnetic sheets 82c to 82e) is formed between the
`
`
`
`devices. FIG. 13 is a disassembled perspective view of a
`
`primary windings and secondary windings
`81a, 81c
`81b,
`
`
`stacked body of a conventional multi-layer transformer. FIG.
`
`
`
`8ld, causing magnetic flux leakage 86 (FIG. 14), and hence
`20
`
`
`
`14 is a vertical cross-sectional view along the line XIV-XIV
`
`
`
`it is not possible to obtain a sufficient electromagnetic
`
`
`
`in FIG. 13 after stacking. The description below is based on
`
`
`
`coupling coefficient k. To solve this problem, a technique
`FIGS. 13 and 14.
`
`
`
`
`(referred to hereafter as a "conventional multi-layer trans­
`
`
`
`
`former") has been considered whereby a dielectric layer (not
`
`
`
`
`A conventional multi-layer transformer 80 comprises pri­
`
`82b and 82d on which pri­
`
`
`
`shown) is provided on the prima81a, 81c and ry windings
`mary -winding magnetic sheets
`25
`
`
`
`printing or secondary windings 81b, 81d by means of screen
`
`
`
`secondamary windings 81a and 81c are formed, ry -winding
`
`
`paste coating such that the magnetic permeability of the
`
`
`
`magnetic sheets 82c and 82e on which secondary windings
`
`
`
`
`magnetic layer is reduced by the substances which diffuse
`
`
`81b and 81d are formed, and magnetic sheets 82a and 82g
`
`
`from the dielectric layer.
`
`
`that hold the magnetic sheets 82b to 82e from both sides.
`However, in this conventional multi-layer transformer,
`
`
`
`
`
`
`Furthermore, a magnetic sheet 82/ for improving the 30
`
`
`
`
`conductive substances (Ag particles, for example) may
`magnetic saturation characteristic is inserted between the
`
`
`
`
`
`
`81a, 81c diffuse from the primary windings and secondary
`
`
`magnetic sheet 82e and magnetic sheet 82g. The magnetic
`
`
`
`
`windings 81b, 81d onto the dielectric paste coated on the
`
`sheets 82a to 82e are provided with through-holes 90, 91,
`
`
`
`primary windings and secondary windings
`81a, 81c
`81b,
`and 92 that connect the 81a and 81c and primary windings
`
`
`
`
`
`
`8ld, leading to a decrease in the insulating property between
`35
`
`
`
`through-holes 93, 94, and 95 that connect the seconda
`
`
`
`81c, the 81a, the primary windings the primary windings
`ry
`
`windings 81b and 81d. The lower face of the magnetic sheet
`
`
`secondary windings 81b, and the secondary windings
`81d.
`82a is provided
`
`
`96 with primary -winding external electrodes
`
`
`
`This is because the paste takes a liquid form due to an
`
`
`
`
`98 and external electrodes and 97 and secondary -winding
`
`
`
`
`organic solvent or the like, for example, and hence sub-
`
`
`99.The through-holes 90 to 96 are filled with a conductor.
`
`
`therefrom.40 stances diffuse easily
`
`
`
`The magnetic sheets 82a to 82g are the core of the multi­
`Moreover, when a dielectric layer is provided in order to
`
`
`
`
`layer transformer 80.
`
`
`
`
`reduce magnetic flux leakage, the gap between the prima
`ry
`
`
`
`Further, FIGS. 13 and 14 are schematic diagrams and,
`
`
`
`81b, 81d corre­windings 81a, 81c and secondary windings
`
`therefore, strictly speaking, the number of windings of the
`
`
`
`
`
`sponds to "the magnetic layer+the dielectric layer", and
`primary windings 81a and 81c and secondary windings
`
`
`81b
`
`
`
`flux becomes more 45 therefore widens. As a result, magnetic
`
`
`
`
`and 81d and the positions of the through-holes 90 to 96 do
`
`
`likely to leak into the gap, causing the electromagnetic
`
`
`not correspond in FIGS. 13 and 14.
`
`
`
`
`coupling coefficient k to decrease. Therefore, with this
`
`
`
`On the primary side of the multi-layer
`
`
`
`conventional transformer 80, the multi-layer transformer, it is extremely difficult
`
`
`current flows in the order of the external
`
`
`
`to increase electrode 96, the electromagnetic coupling coefficient k.
`
`
`81c, through-hole through-hole 92, primary winding
`
`
`91, 50
`
`
`
`90, and then the external primary winding 81a, through-hole
`
`
`
`
`
`electrode 97 or in the reverse order. On the other hand, on
`
`
`
`transformer 80, the the secondary side of the multi-layer
`It is therefore a principal object of the present invention
`
`
`
`
`
`
`
`
`current flows in the order of the external electrode 99, the
`
`
`
`
`to provide a technique for realizing a further decrease in the
`
`
`81d, the through-through-hole 95, the secondary winding
`
`
`size of electronic equipment by maximizing the advantages
`55
`
`
`93, 81b, the through-hole hole 94, the secondary winding
`
`
`
`
`of a small, light, thin multi-layer transformer. A further
`
`
`
`
`
`and then the external electrode 98 or in the reverse order.
`
`
`
`
`object of the present invention is to provide a multi-layer
`
`
`
`
`81a and The current flowing through the primary windings
`
`
`
`transformer in which an electromagnetic coupling coeffi­
`
`
`81c produces a magnetic flux 100 (FIG. 14) in the magnetic
`
`
`cient can be increased while maintaining an insulating
`
`
`sheets 82a to 82g. The magnetic flux 100 produces
`an 60
`
`property between windings.
`
`
`
`electromotive force corresponding with the winding ratio in
`
`
`trans­the secondary windings 81b and 81d. The multi-layer
`
`
`former 80 operates thus.
`A multi-layer laminated circuit board according to the
`
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`
`Here, supposing that the self-inductance of the prim
`ary
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`
`
`65 present invention comprises: an in-built multi-layer trans­
`
`
`windings 81a and 81c is Ll, the self-inductance of the
`
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`
`former formed by laminating a magnetic sheet, a prima
`
`81b and 81d is L2, the mutual induc­secondary windings
`
`ry
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`sheet and a dielectric winding and a secondary winding,
`
`tance of the primary windings 81a and 81c and the second-
`
`BACKGROUND ART
`
`OBJECT OF THE INVENTION
`
`DISCLOSURE OF THE INVENTION
`
`Ex.1013
`APPLE INC. / Page 16 of 26
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`

`

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`US 7,375,609 B2
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`3
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`4
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`
`
`constituted by a non-magnetic body; and a wiring sheet
`in the parts where a winding is present. (2) Since the
`
`
`
`
`
`formed with a circuit pattern. In a preferred embodiment, the
`
`matter dielectric sheet is not in paste form, very little
`
`
`
`wiring sheet may be laminated onto an upper surface or a
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`
`
`
`diffuses from the windings. As a result, the insulating
`
`lower surface of the multi-layer transformer, or the multi­
`
`
`
`
`
`
`the and between property between the primary windings
`layer transformer may be provided on apart of the wiring
`
`
`5 secondary windings does not deteriorate.
`
`
`
`
`sheet. The multi-layer laminated circuit board may further
`
`
`
`Further, a through hole is preferably formed in the center
`
`comprise a multi-layer part sheet formed with a multi-layer
`
`
`
`of the dielectric sheet, and the dielectric sheet is preferably
`
`
`
`part, or a thick film, a passive chip element, and an active
`
`formed to be smaller than the magnetic sheets. Thus, when
`
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`
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`chip element may be mounted on a top surface thereof. In
`
`
`
`the dielectric sheet is sandwiched between the pair of
`
`
`
`this case, either the thick film, or the passive chip element,
`10
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`
`
`magnetic sheets, the magnetic sheets contact each other in
`
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`
`or the active chip element may be mounted on the top
`
`
`
`the center and on the peripheral edge of the dielectric sheet
`
`
`
`surface. Note that here, the "non-magnetic body" is a
`
`
`
`such that the magnetic sheets form a core. Since the dielec­
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`
`
`
`substance having a smaller magnetic permeability than at
`
`
`
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`tric sheet is interposed between the primary winding and
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`
`
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`least the magnetic sheet. The "dielectric sheet" is a sheet
`
`
`
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`be insulating property can 15 secondary winding, an excellent
`
`
`
`having a greater resistivity than at least the magnetic sheet,
`realized.
`
`
`
`
`and may be referred to as either a dielectric sheet or an
`
`insulating sheet.
`The multi-layer transformer incorporated into the multi­
`
`In the prior art, the multi-layer transformer is mounted on
`
`
`
`
`
`
`layer laminated circuit board in a preferred embodiment of
`
`
`
`
`a printed wiring board as an individual component. How­
`
`
`
`
`the present invention comprises: a dielectric sheet consti­
`
`
`
`ever, limits have been reached in reducing the size of the
`20
`
`
`
`
`tuted by a non-magnetic body having a through hole formed
`
`
`
`
`multi-layer transformer package and reducing the amount of
`
`
`
`
`in the center thereof; a first winding positioned on one
`
`
`
`
`wiring between the multi-layer transformer and other com­
`
`
`
`
`surface of the dielectric sheet and around the through hole,
`
`
`ponents. Hence, in the present invention the multi-layer
`
`
`
`and constituted by one or both of a primaand a ry winding
`
`
`transformer is incorporated into the multi-layer laminated
`
`
`on the positioned secondary winding; a second winding
`
`
`
`circuit board. As a result, the multi-layer laminated circuit
`25
`
`
`
`other surface of the dielectric sheet and around the through
`
`
`
`board is packaged, and therefore the multi-layer transformer
`
`
`
`hole, and constituted by the other of, or both of, the prima
`ry
`
`
`
`
`
`package is omitted. Moreover, wiring can be provided in the
`
`
`pair of magnetic winding and the secondary winding; and a
`
`
`
`lamination direction, leading to a reduction in the surface
`
`
`
`
`sheets sandwiching the dielectric sheet, the first winding,
`
`
`
`area occupied by the wiring, and therefore the wiring
`
`
`and the second winding, and contacting each other on a
`
`
`
`between the multi-layer transformer and other components
`30
`
`
`
`peripheral edge of and through the through hole in the
`
`can be reduced to a minimum.
`
`dielectric sheet.
`
`
`The multi-layer transformer that is incorporated into the
`The dielectric sheet may be constituted by a single sheet
`
`
`
`
`
`
`multi-layer laminated circuit board in a preferred embodi­
`
`
`
`
`or a plurality of laminated sheets. By disposing the prima
`
`ment of the present invention is constituted by the following
`ry
`
`
`to face each other on winding and secondary winding so as
`
`
`laminated body. This laminated body comprises: a first
`35
`
`
`
`
`
`either side of the dielectric sheet, a primary winding and a
`
`
`magnetic sheet; a first dielectric sheet laminated onto the
`
`
`
`one secondary winding may be disposed alternately on
`
`
`
`
`first magnetic sheet and constituted by a non-magnetic body
`
`
`
`
`surface of the dielectric sheet, and a primary winding and a
`
`
`having a through hole formed in the center thereof; a first
`
`
`secondary winding may be disposed alternately on the other
`
`
`
`winding positioned around the through hole on the first
`
`
`
`
`
`surface of the dielectric sheet. When a plurality of dielectric
`
`
`
`dielectric sheet and constituted by one or both of a prim
`ary 40
`
`
`
`
`
`sheets are provided, a plurality of primary windings and
`
`
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`
`sheet second magnetic winding and a secondary winding; a
`
`
`
`sides of secondary windings may be provided on opposite
`
`
`laminated onto the first winding so as to contact the first
`
`
`
`
`the dielectric sheets. In this case, through holes connecting
`
`
`
`magnetic sheet on a peripheral edge of and through the
`
`
`the the primary windings to each other and connecting
`
`
`
`
`through hole in the first dielectric sheet; a second dielectric
`
`
`in the secondary windings to each other may be provided
`
`
`sheet laminated onto the second magnetic sheet and consti-45
`
`dielectric sheets.
`
`
`
`
`tuted by a non-magnetic body having a through hole formed
`In the conventional multi-layer transformer, a magnetic
`
`
`
`
`
`in the center thereof; a second winding positioned around
`
`
`
`secondalayer is formed between the primary winding and ry
`
`
`
`the through hole on the second dielectric sheet and consti­
`
`
`
`
`winding, and as a result, the electromagnetic coupling
`
`
`tuted by the other of, or both of, the primand the ary winding
`
`
`
`
`
`coefficient is reduced by magnetic flux leakage into the
`
`
`
`third magnetic sheet laminated secondary winding; and a
`50
`
`
`
`
`magnetic layer. Hence, in the multi-layer transformer of the
`
`
`
`onto the second winding so as to contact the second mag­
`
`
`
`
`present invention, a non-magnetic layer (the dielectric sheet)
`
`
`netic sheet on a peripheral edge of and through the through
`
`
`
`secondais formed between the primary winding and ry
`
`
`
`
`hole in the second dielectric sheet. Further, the multi-layer
`
`
`
`winding. However, a core is not formed simply by forming
`
`
`
`
`transformer is preferably formed by laminating together a
`
`
`
`
`a non-magnetic layer, and therefore a through hole is pro­
`
`
`plurality of these laminated bodies such that the third 55
`
`
`
`vided in the center of the dielectric sheet, and the pair of
`
`
`
`
`magnetic sheet, excluding the third magnetic sheet on an
`
`
`
`
`
`magnetic sheets are caused to contact each other through the
`
`
`upper end, doubles as the first magnetic sheet of the lami­
`
`
`
`through hole and on the peripheral edge of the dielectric
`
`
`nated body thereabove, and through holes respectively con­
`
`
`
`sheet, thereby forming a core. Thus, in the multi-layer
`
`
`
`to each other and necting the plurality of primary windings
`
`
`
`
`
`transformer of the present invention, a non-magnetic layer
`
`
`
`to each other are pref-60 the plurality of secondary windings
`
`
`
`
`(the dielectric sheet) is formed between the primary winding
`
`
`
`
`
`erably provided in the magnetic sheets and dielectric sheets.
`
`and as a result, magnetic flux and secondary winding,
`
`
`
`
`The dielectric sheet has the following advantages over a
`
`
`
`
`leakage can be suppressed. Moreover, in contrast to the
`
`
`
`dielectric layer which is formed by coating the winding with
`
`
`
`
`conventional multi-layer transformer, there is no need to
`
`
`
`
`a dielectric paste. (1) The dielectric sheet takes a solid form
`
`
`
`and form a dielectric layer by coating the primary winding
`
`
`
`rather than a paste form and therefore has a uniform film 65
`
`
`
`and hence the secondary winding with a dielectric paste,
`
`
`
`
`thickness regardless of the presence or absence of a winding.
`
`
`
`
`insulating property between the primary windings and
`
`
`
`As a result, a sufficient film thickness can be secured even
`
`Ex.1013
`APPLE INC. / Page 17 of 26
`
`

`

`
`
`US 7,375,609 B2
`
`5
`6
`and the does not deteriorate between the secondary windings
`
`
`
`
`to face each other on winding and secondary winding so as
`
`
`
`
`
`
`and secondagap between the primary winding ry winding
`
`
`
`
`
`either side of the dielectric pattern on the composite sheet,
`does not widen.
`
`
`dis­a primary winding and a secondary winding may be
`
`
`
`In a preferred embodiment, the multi-layer transformer
`
`
`
`
`posed alternately on one surface of the composite sheet, and
`
`
`
`may further comprise a maaligned with the gn etic frame
`
`
`may be dis­5 a primary winding and a secondary winding
`
`
`peripheral edge of the dielectric sheet and a magnetic core
`
`
`
`posed alternately on the other surface of the composite sheet.
`align ed with the through hole, and the pair of magnetic
`
`
`
`
`
`When a plurality of composite sheets are provided, a plu­
`
`
`
`
`sheets may sandwich the dielectric sheet and contact each
`
`
`
`
`may be rality of primary windings and secondary windings
`
`
`
`other via the magnetic frame and magnetic core. In this case
`
`
`
`
`provided on opposite sides of the composite sheets. In this
`
`
`
`
`also, the dielectric sheet may be constituted by a single sheet
`
`
`
`to each 10 case, through holes connecting the primary windings
`
`
`
`
`or a plurality of (laminated) sheets. When a plurality of
`
`
`to each other other and connecting the secondary windings
`
`
`
`
`dielectric sheets are provided, a plurality of primary wind­
`
`
`
`may be provided in the composite sheets.
`
`
`
`on either side of ings and secondary windings are provided
`
`
`In the conventional multi-layer transformer, a magn etic
`
`
`
`the dielectric sheets. In this case, through holes connecting
`
`
`
`and secondalayer is formed between the primary winding ry
`
`
`
`
`the each other and connecting the primary windings to
`
`
`
`15 winding, and as a result, the electromagnetic coupling
`
`
`
`
`be provided in the to each other may secondary windings
`
`
`
`
`coefficient is reduced by magnetic flux leakage into the
`
`dielectric sheets.
`
`
`
`of the multi-layer transformer magn etic layer. Hence, in the
`
`
`
`The dielectric sheet is preferably sandwiched between the
`
`
`
`
`present invention, a non-magnetic layer (the dielectric pat­
`
`
`
`and the first magnetic sheet and second magn etic sheet,
`
`
`and secondatern) is formed between the primary winding ry
`
`
`primary winding and secondary winding are preferably
`
`
`
`20 winding. However, a core is not formed simply by forming
`
`
`
`
`
`positioned respectively on either surface of the dielectric
`
`
`
`
`
`are magnetic patterns and therefore a non-magn etic layer,
`
`
`
`sheet. The magnetic frame is align ed with the peripheral
`
`
`
`
`provided in the center and on the peripheral edge of the
`
`
`edge of the dielectric sheet, and the magn etic core is align ed
`
`
`
`
`are caused composite sheet, and the pair of magn etic sheets
`
`
`
`
`
`with the through hole in the center of the dielectric sheet.
`
`
`to contact each other through the magn etic patterns, thereby
`
`
`
`
`
`Thus there is little sagging in the pair of magnetic sheets on
`
`
`
`
`25 forming a core. Thus, in the multi-layer transformer of the
`
`
`
`the peripheral edge and in the center of the dielectric sheet.
`
`
`
`
`present invention, a non-magnetic layer (the dielectric pat­
`
`
`
`
`As a result, the pair of magnetic sheets do not have to be bent
`
`
`and secondatern) is formed between the primary winding ry
`
`
`
`to a great extent, and therefore manufacture is easy. More­
`
`
`
`
`winding, and as a result magnetic flux leakage can be
`
`
`area can over, a magn etic path having a sufficient sectional
`
`
`
`
`suppressed. Moreover, in contrast to the conventional multi-
`
`
`be secured, leading to an improvement in the magnetic
`
`
`30 layer transformer, there is no need to form a dielectric layer
`
`
`
`saturation characteristic. This action becomes more striking
`
`
`
`
`with and secondaby coating the primary winding ry winding
`
`
`
`
`as the number of laminated dielectric sheets increases.
`
`
`
`a dielectric paste, and hence the insulating property between
`
`
`
`In particular, by matching the thickness of the magnetic
`
`
`
`
`the secondathe primaand between ry windings ry windings
`
`
`frame (the sum total thereof when a plurality of magnetic
`
`
`does not deteriorate and the gap between the prima
`ry
`
`
`
`
`frames are provided), the thickness of the magnetic core (the
`
`
`does not widen. 35 winding and secondary winding
`
`
`
`
`sum total thereof when a plurality of magnetic cores are
`
`
`
`In a preferred embodiment, the aforementioned composite
`
`
`
`
`provided), and the thickness of the dielectric sheet (the sum
`
`
`sheet may be interposed between the primary winding or
`
`
`
`
`total thereof when a plurality of dielectric sheets are pro­
`
`
`
`sheet. This composite secondary winding and the magnetic
`
`
`
`
`vided), an extremely even multi-layer transformer is
`
`sheet acts to enhance the insulating property of the prima
`ry
`
`
`
`
`obtained. Thus, when a wiring sheet is laminated onto the
`
`40 winding or secondary winding.
`
`
`
`multi-layer transformer, warping of the wiring sheet can be
`In a preferred embodiment, the film thickness of the
`
`
`
`
`
`
`
`suppressed, leading to an improvement in the reliability of
`
`
`
`film thickness of the magn etic patterns may be equal to the
`
`the wiring sheet.
`
`
`
`
`dielectric pattern on the composite sheet. In this case, the
`
`
`In a preferred embodiment, the magnetic frame and
`
`
`
`
`film thickness of the composite sheet is constant in all
`
`
`magnetic core may be connected to each other via a support
`
`
`
`
`
`45 locations, and therefore the pair of magnetic sheets sand­
`
`
`
`
`portion to form a magnetic sheet. In this case, the magnetic
`
`
`
`wiching the composite sheet are also even. Thus, when a
`
`
`frame and magnetic core can be formed simultaneously, and
`
`
`wiring sheet is laminated onto the multi-layer transformer,
`
`
`
`
`positioning thereof during lamination can also be performed
`
`
`
`
`
`warping of the wiring sheet can be suppressed, leading to an
`simultaneously.
`
`
`
`improvement in the reliability of the wiring sheet.
`
`
`
`
`According to the multi-layer laminated circuit board of
`
`
`The multi-layer transformer incorporated into the multi-50
`
`
`
`
`the present invention, the multi-layer transformer is in-built,
`
`layer laminated circuit board in a preferred embodiment of
`
`
`
`
`
`
`
`and therefore a multi-layer transformer package can be
`
`
`
`
`the present invention comprises: a composite sheet having a
`
`
`
`omitted and the wiring between the multi-layer transformer
`
`magnetic pattern in the center and on the peripheral edge
`
`
`
`
`
`and other components can be reduced to a minimum. As a
`thereof, and a dielectric pattern constituted by a non-mag­
`
`
`
`
`netic body in parts other than the center and the peripheral
`
`
`
`
`
`55 result, the advantages of a small, light, thin multi-layer
`
`
`
`
`edge; a first winding positioned on one surface of the
`
`
`
`
`transformer can be maximized, enabling a further decrease
`
`
`
`dielectric pattern and around the center, and constituted by
`
`
`in the size of electronic equipment.
`
`
`
`
`one or both of a primaand a secondary winding ry winding;
`
`
`
`According to the multi-layer transformer in the multi­
`
`
`a second winding positioned
`
`
`
`
`layer laminated on the other surface of the circuit board in a preferred embodiment of
`
`
`
`
`
`
`dielectric pattern and around the center, and constituted by 60 the present invention, the windings are disposed on the
`
`
`
`
`
`
`
`
`of the dielectric sheet, and hence the film thickness dielectric and the the other of, or both of, the primary winding
`
`
`
`
`
`
`
`
`in the parts where the sufficiently even sheets sandwich­layer can be secured and a pair of magnetic secondary winding;
`
`
`
`
`
`
`
`
`
`
`ing the composite sheet, the first winding, and the second windings are present. Moreover, the dielectric sheet takes a
`
`
`
`
`winding, and contacting each other via the magnetic pat­solid form rather than a paste form, and hence very little
`terns.
`
`
`
`65 matter is diffused from the winding into the dielectric sheet.
`
`
`
`
`
`
`
`
`The composite sheet may be constituted by a single sheet As a result, the insulating property between the prima
`ry
`
`
`
`
`
`
`
`
`does not or a plurality of laminated sheets. By disposing the primwindings and between the secondary windings
`
`ary
`
`Ex.1013
`APPLE INC. / Page 18 of 26
`
`

`

`
`
`US 7,375,609 B2
`
`8
`
`7
`deteriorate. Accordingly, a great improvement in the insu­
`
`
`
`center and winding, the maformed in the gn etic patterns are
`
`
`
`
`
`
`
`
`lating property between the windings can be achieved.
`
`
`
`
`on the peripheral edge of the composite sheet, and the pair
`
`
`
`Furthermore, the dielectric sheet having a through hole
`
`
`
`of magn etic sheets contact each other through the magn etic
`
`
`
`formed in its center is sandwiched between the pair of
`
`
`
`
`patterns to form a core. As a result, a multi-layer transformer
`
`
`
`
`contact each 5 magnetic sheets such that the magn etic sheets
`
`having a non-magn etic layer between the primary winding
`
`
`other in the center and on the peripheral edge of the
`
`
`
`
`and magnetic flux can be realized, and secondary winding
`
`
`
`
`
`dielectric sheet, and therefore the core constituted by the
`
`
`
`
`leakage can be suppressed. Moreover, in contrast to the
`
`
`
`magnetic sheets has a simple constitution and can be formed
`
`
`
`
`conventional multi-layer transformer, there is no need to
`
`
`by means of a straight forward method.
`
`
`
`and form a dielectric layer by coating the primary winding
`
`
`
`
`According to the multi-layer transformer in the multi-10
`
`
`
`and hence the secondary winding with a dielectric paste,
`
`
`
`
`layer laminated circuit board in a preferred embodiment of
`
`
`
`insulating property between the primary windings and
`
`
`
`the present invention, the dielectric sheet is provided
`
`
`
`
`and the does not deteriorate between the secondary windings
`
`
`
`and a and secondabetween the primary winding ry winding
`
`
`
`gap between the primary winding and secondary winding
`
`
`
`
`
`through hole is provided in the center of the dielectric sheet
`
`
`does not widen. As a result, the electromagnetic coupling
`
`
`
`
`such that the pair of magnetic sheets contact each other 15
`
`
`
`coefficient can be increased while maintaining the insulating
`
`
`
`through the through hole and on the peripheral edge of the
`
`
`
`
`property between the windings. In addition, the insulating
`
`
`
`
`
`dielectric sheet, thereby forming a core. As a result, a
`
`
`
`
`and the secondaproperty between the primary winding ry
`
`
`
`
`multi-layer transformer having a non-magnetic layer
`
`
`
`winding is enhanced by the interposition of the dielectric
`
`
`
`can be and secondabetween the primary winding ry winding
`
`
`
`pattern in p