New Soft Magnetic FlakeComposite2 · 2018. 10. 16. · Efficiency and Dynamics of 3D Integrated...

© TOKIN 2018 Confidential

Soft magnetic Metal-flake Composite Material Suitable for Highly Integrated Power Modules

26 June. 2018

Ken’ichi Chata’niTOKIN Corporation


Outline

n Material characteristics of FlakeCompositeTM ,in comparison with existing magnetic materials.

-Permeability, magnetic saturation, core loss, etc.

n Inductor performance benchmarking.

n PCB embedded inductor test fabrication result.


What is FlakeCompositeTM?

FlakeCompositeConventional Metal composite

Permeability 300(Same as ferrite)

< 40

Metal-flakeCompactingTechnology

Thickness >0.5mmBrittle

>50μmFlexible

Heat resistance <200℃℃Organic binder

>200℃℃Inorganic binder

Enable PCB Embedding

Suitable for Automotive

Smaller component's volume


Comparison of Magnetic Materials for PCB Embedding

Conventional metal composite

0.0

0.5

1.0

1.5

2.0

100 100010

Bs(T

)

MnZnNiZn

CoZrO(film)

CoZrTa(film)

Fla

keC

om

posite

Co Fe(film)

Fe nanocrystal

Permalloy

FeSiAl

FeSi

Fe amorphous

Permeability(1MHz)

ØLow permeability

ferrite

Deposited Film

ØBrittle

ØDifficult to increase the core volume.PCB embedded

Magnetic Material

ØHigh permeability (300 at 1 MHz.)

Ø50µm to 2mm thickness

ØThin, Flexible(Rigid)

FlakeComposite


Permeability vs Frequency

NiZn ferrite

FlakeComposite

μ’// = 300

μ^̂≦≦ 5

Ø Comparable to NiZn ferrite for MHz powerapplication.

Frequency dispersion of complex permeability

LimitationLower Out-plane

permeability.

Per

mea

bilit

y (R

e, Im

)

Frequency (MHz)


0

1000

2000

0 1 2 3 4 5

Pcv(mW/cc)

f(MHz)

f Bm=25MHz mT23

Core Loss

Ø Core loss of FlakeComposite is comparable to NiZn ferrite,but much larger than MnZn ferrite.

NiZn ferrite

MnZn ferrite

ConventionalMetal Composite

Core Loss vs Temp.

FlakeComposite

FlakeComposite


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 2000 4000 6000 8000

B (T

)

H (A/m)

Magnetic Saturation (BH curve)

Ø Soft-saturation in FlakeComposite.

Ø Smaller drop of saturated magnetic moment against temperature, comparing to MnZn ferrite.

125℃℃

25℃℃

MnZn ferrite

FlakeComposite



Deduction of Permeability under DC-bias Field from BH curve

Hm3Hm2Hm1

dB/dH3

dB/dH2

dB/dH1

Bm3

Bm2

Bm1

(Hm1, Bm1, dB/dH1)

(Hm2, Bm2, dB/dH2)

(Hm3, Bm3, dB/dH3)

DemagnetizingCoefficient N

(H1, µ1)

(H2, µ2)

(H3, µ3)

!" ≅ !$" − &×($"

)" = 1 + ⁄.( .!" − 11 + & ⁄.( .!" − 1

Ø From the set of partial BH curve

and slope value at Hm,

permeability under DC-bias field

with arbitral demagnetizing

coefficient

can be deduced.


0

10

20

30

40

50

60

70

80

0 2000 4000 6000 8000

Permeability

Hdc(A/m)

Permeability under DC-bias Field

125℃℃

25℃℃

MnZn ferrite

FlakeComposite


Ø In metals, permeability under DC-bias field is insensitive to temperature.

Ø In metals, permeability survives under high DC-bias field.

In MnZn ferrite and FlakeComposite, effective permeability under zero bias field is tuned to be 70 by corresponding demagnetizing coefficient, i.e, air-gap.

N=0.01384

N=0.01091

N=0


0

50

100

150

200

250

300

0.1 1 10 100

Perm

eabi

lity(

Re,

Im)

Frequency(MHz)

0102030405060708090100

0 500 1000

Perm

eabi

lity

Chan

ge(%

)

Plane Pressure(kgf/cm2)

Effect of Plane Compression

Ø Only 7.6 permeability decreaseunder 1000kgf/cm2 compression.

Plane Pressure(kgf/cm2)

-7.6%

FlakeComposite

Ø Apply 1000kgf/cm2 plane pressureon the toroidal core.

After 1000kgf/cm2compression

Initial

Ø Only 2.7% permeability decreaseafter 1000kgf/cm2 compression.

Ø No apparent damage was found.


10

100

1000

10000P

erm

eabi

lity

(25

)

Curie Temperature( )

Curie Temperature

Ø Higher Curie temperature than ferrite.

NiZn ferrite

MnZn ferrite

FlakeComposite

0

50

100

150

200

250

300

-50 0 50 100 150

Real

Per

mea

bilit

y

Temp( )

FlakeComposite







Lateral Flux Inductor Structure

Qiang Li, Fred C. Lee, “High Inductance Density Low-Profile Inductor Structure for Integrated Point-of-Load Converter”, 2009 IEEE Applied

Power Electronics Conference and Exposition (APEC), Washington, District of Columbia, Feb. 15 – 19, 2009, pp. 1011 – 1017.

Dongbin Hou, Yipeng Su, Qiang Li, Fred C. Lee, “Improving theEfficiency and Dynamics of 3D Integrated POL”, IEEE AppliedPower Electronics Conference and Exposition (APEC), 2015,pp. 1011 – 1017.

Ø FlakeComposite is suitable to demonstrate the proposed advantage of “Lateral flux” inductor design.

Ø As inductor goes thinner, the advantage of “Lateral flux” inductor structure should be more prominent.


0

10000

20000

30000

0 1 2 3 4 5 6

L x

Imax

/ DC

R(nH

A/m

Ω)

Inductor Height(mm) Imax 20A

Benchmarking Result

Met

alCo

mpo

site

FlakeCompositeLateral flux

MnZ

nFe

rrite

Good

Ø The advantage of FlakeComposite Lateral flux inductor becomes prominent as the inductor height goes lower.


Storage Result (N=22)

-50℃ 1000h Pass

150℃ 1000h Pass

Unbiased HastWith MSL 3Pre-Conditioning

130℃85% 96hPass

33.3psia(2.3atm)

JESD22-A119 JESD22-A103 Condition B

Heat Cycle-65⇔150℃ 500cycle Pass

JESD22-A104 Condition C Soak Mode 4

JESD22-A118

MSL test (Level 1)Pre-bake 125℃ 24h

PassMoisture Soak 85℃85%RH 192hReflow 260℃ x 3

J-STD-020E

Reliability Test Example (On samples to CPES)Sample StructureTin plated lead frame and Cu pins

(without insulation coating) are attached on the FlakeComposite core. Image

Hi Temp and Humidity85℃85% 1000h Pass

MIL-STD-202 Method 103

• Acceptance Criteria: Change of Ls, Rs and

DCR<10% pre-test to post-test.No cracks, chips or

discoloration

Ø AEC-Q200 compatible.(RoHS2.0, Halogen free, REACH compliant.)

13mm


Application Target

PCB embedded inductor to minimize:- PCB board area.- parasitic inductance of Cu trace.

Power Inductors

Ferrite FlakeCompositeTM

40% height reduction with FlakeComposite inductor.

Embedded noise shielding layer

Flexible shielding layer (for WPT)- Combined with PCB embedding technology.

FlexSuppressor® Flex "Embedded" Suppressor

Magnetic Sheets







Y. Su, W. Zhang, Q. Li, F. C. Lee, and M. Mu, "High frequency integrated Point of Load (POL) module with PCB embedded inductor substrate," in Energy Conversion Congress and Exposition (ECCE), 2013 IEEE, 2013, pp. 1243-1250.

PCB Embedded Inductor Demonstrated by CPES

Ø Under the testing of similar prototypes.


PCB Embedded Inductor Prototype

2 turn

Upside Downside

DCR2.8mΩ

3 turn

Upside Downside

DCR4.4mΩ

With insertedpins

0.8mΩ

With insertedpins

2.1mΩ

0

50

100

150

200

250

300

350

0 10 20 30 40L(

nH)

@1M

Hz

Idc(A)

2 turn

3 turn

t2.5mm11

mm

12mm

Embedded core size9 x 8 x t1.5mm


0

10

20

30

Cou

nt

L(nH, 1MHz)

0

10

20

30

Cou

nt

L(nH, 1MHz)

Dispersion of Inductance , |Z|

0

25

50

75

100

125

150

1 10 100 1000

L(nH)

Frequency(MHz)

1

10

100

1000

1 10 100 1000

|Z|(Ω)

Frequency(MHz)

0

100

200

300

1 10 100 1000

L(nH)

Frequency(MHz)

1

10

100

1000

1 10 100 1000

|Z|(Ω)

Frequency(MHz)

2 turn (n=100)

3 turn (n=100)

10%

3σ

3σ

+10%Ave.

125nH

Ave.277nH

10% +10%

SRF=400MHz

SRF=250MHz

Ø Tight tolerance of inductance is readily achieved in test fabrication.


Summary

Ø FlakeCompositeTM is:-Thin, Flexible, PCB-embed-enabling, -High permeability at multi-MHz swithcing frequency,-High-saturated magnetic moment than ferrite,-High temperature tolerant

soft magnetic material for power supply application.

Ø We believe this material will contribute to the miniturization of electronic circuits, especially in:

- DC/DC converters,- Wireless Power Transfer system.

Ø We are continuing to scale-up this technology for use in several applications.


Thank you very much for your attention.


Back Ups


MnZn ferrite NiZn ferrite FlakeComposite

Permeability 1000~10000 50~1000 300

Bs (T) <0.55 <0.5 >0.7

Core loss(kW/m3)(1MHz,Bm20mT)

<50 500(typ) 500

Resistivity (Ω cm) <1k >100M >100k

Curie Temperature(℃℃) <250 <300 >450

Specific weight(g/cc) 4.8~5.0 4.9~5.1 5.0

CTE (10-7/℃℃) 120 150 100 In-plane120, Out- 90

CTC (W/m k) 10 16 In-plane18, Out- 2

Magnetic anisotropy None None High µ only in-plane

Comparison to ferrite

PCB embed No. (Brittle) Yes. (Flexible)

Plane compression tolerance No >0.7t/cm2

RoHS2.0, Halogen free,REACH compliant.


Applied Power Electronics Conference and Exposition (APEC), 2015 Thirtieth Annual IEEE, 2015, pp. 140-145.



105min 4 presenters25min/man

New Soft Magnetic FlakeComposite2 · 2018. 10. 16. · Efficiency and Dynamics of 3D Integrated...

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Transcript of New Soft Magnetic FlakeComposite2 · 2018. 10. 16. · Efficiency and Dynamics of 3D Integrated...