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Flake composite
1.
© TOKIN 2019 Soft
magnetic Metal-flake Composite Material Suitable for High Frequiency Power Modules 19 Mar. 2019 Ken’ichi Chata’ni TOKIN Corporation
2.
© TOKIN 2019 Ken’ichi
Chata’ni, Ph.D.(Physics) Manager, Advanced Materials R&D Division TOKIN Corporation kenichichatani@kemet.com
3.
© TOKIN 2019 Demands:
Shorten the distance from DC/DC converter to the load. Higher DC current / Higher switching frequency Motivation Back surface mount Processer Inductor Inductor Inductor Processer PCB embedding Processer 3D mount Processer Conventional Spread of GaN Integratable L, C Low-profiled inductor for integrated DC/DC converter is required. PCB embed enabling magnetic material will also be required in future. Inductor
4.
© TOKIN 2019 FlakeCompositeConventional Metal
composite Permeability 300 (Same as ferrite) < 40 Metal-flake Compacting Technology Thickness >0.5mm Brittle >50μm Flexible Heat durability <200℃ Organic binder >200℃ Inorganic binder Enable PCB Embedding Suitable for Automotive Smaller component's volume What is FlakeCompositeTM?
5.
© TOKIN 2019 Conventional metal
composite 0.0 0.5 1.0 1.5 2.0 100 100010 Bs(T) MnZn NiZn CoZrO(film) CoZrTa(film) CoNiFe(film) Fe nano crystal Permalloy FeSiAl FeSi Fe amorphous Permeability (1MHz) Low permeability ferrite Deposited Film Brittle Difficult to increase the core volume. PCB embedded Magnetic Material High permeability (300 at 1 MHz.) 50m to 2mm thickness Thin, Flexible(Rigid) FlakeComposite Comparison of Magnetic Materials for PCB Embedding
6.
© TOKIN 2019 0 100 200 300 400 0.1
1 10 100 Permeability(Re,Im) Frequency(MHz) NiZn ferrite FlakeComposite μ’// = 300 μ≦ 5 Comparable to NiZn ferrite for MHz power application. Frequency dispersion of complex permeability Limitation Lower Out-plane permeability. Permeability(Re,Im) Frequency (MHz) Permeability vs Frequency
7.
© TOKIN 2019 0 500 1000 1500 -50
-25 0 25 50 75 100 125 150 175 Pcv(mW/cc,1MHzBm25mT) Temp (℃) 0 1000 2000 0 1 2 3 4 5 Pcv(mW/cc) f(MHz) f×Bm=25MHz・mT 23℃ Core loss of FlakeComposite is comparable to NiZn ferrite, but much larger than MnZn ferrite. NiZn ferrite MnZn ferrite Conventional Metal Composite Core Loss vs Temp. FlakeComposite FlakeComposite Core Loss
8.
© TOKIN 2019 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) Soft-saturation in FlakeComposite. Smaller drop of saturated magnetic moment against temperature, comparing to MnZn ferrite. 125℃ 25℃ MnZn ferrite FlakeComposite Conventional Metal Composite Magnetic Saturation (BH curve)
9.
© TOKIN 2019 0 10 20 30 40 50 60 70 80 0
2000 4000 6000 8000 Permeability Hdc(A/m) 125℃ 25℃ MnZn ferrite FlakeComposite Conventional Metal Composite In metals, permeability under DC-bias field is insensitive to temperature. 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 Permeability under DC-bias Field
10.
© TOKIN 2019 0 50 100 150 200 250 300 0.1
1 10 100 Permeability(Re,Im) Frequency(MHz) 0 10 20 30 40 50 60 70 80 90 100 0 500 1000 PermeabilityChange(%) Plane Pressure(kgf/cm2) Only 7.6% permeability decrease under 1000kgf/cm2 compression. Plane Pressure(kgf/cm2) -7.6% FlakeComposite Apply 1000kgf/cm2 plane pressure on the toroidal core. After 1000kgf/cm2 compression Initial Only 2.7% permeability decrease after 1000kgf/cm2 compression. No apparent damage was found. Effect of Plane Compression
11.
© TOKIN 2019 10 100 1000 10000 0
200 400 600 Permeability(25℃) Curie Temperature(℃) Higher Curie temperature than ferrites. NiZn ferrite MnZn ferrite FlakeComposite 0 50 100 150 200 250 300 -50 0 50 100 150 RealPermeability Temp(℃) FlakeComposite Curie Temperature
12.
© TOKIN 2019 Material
characteristics of FlakeCompositeTM , in comparison with existing magnetic materials. -Permeability, magnetic saturation, core loss, etc. Inductor performance benchmarking. PCB embedded inductor test fabrication result.
13.
© TOKIN 2019 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 the Efficiency and Dynamics of 3D Integrated POL”, IEEE Applied Power Electronics Conference and Exposition (APEC), 2015, pp. 1011 – 1017. FlakeComposite is suitable to demonstrate the proposed advantage of “Lateral flux” inductor design. As inductor goes thinner, the advantage of “Lateral flux” inductor structure should be more prominent. Lateral Flux Inductor Structure
14.
© TOKIN 2019 0 10000 20000 30000 0
1 2 3 4 5 6 LxImax/DCR(nH・A/mΩ) Inductor Height(mm) Imax≧20A FlakeComposite Lateral flux The advantage of FlakeComposite Lateral flux inductor becomes prominent as the inductor height goes lower. Benchmarking Result
15.
© TOKIN 2019 Storage
Result (N=22) -50℃ 1000h Pass 150℃ 1000h Pass Unbiased Hast With MSL 3 Pre-Conditioning 130℃85% 96h Pass 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 192h Reflow 260℃ x 3 J-STD-020E Sample Structure ・Tin plated lead frame and Cu pins (without insulation coating) are attached on the FlakeComposite core. Image Hi Temp and Humidity 85℃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 AEC-Q200 compatible. (RoHS2.0, Halogen free, REACH compliant.) 13mm Reliability Test Example (On samples to CPES)
16.
© TOKIN 2019 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 Application Target
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© TOKIN 2019 Material
characteristics of FlakeCompositeTM , in comparison with existing magnetic materials. -Permeability, magnetic saturation, core loss, etc. Inductor performance benchmarking. PCB embedded inductor test fabrication result.
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© TOKIN 2019 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. Under the testing of similar prototypes. PCB Embedded Inductor Demonstrated by CPES
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© TOKIN 2019 2
turn Upside Downside DCR 2.8mΩ 3 turn Upside Downside DCR 4.4mΩ With inserted pins 0.8mΩ With inserted pins 2.1mΩ 0 50 100 150 200 250 300 350 0 10 20 30 40 L(nH)@1MHz Idc(A) 2 turn 3 turn t2.5mm 12mm Embedded core size 9 x 8 x t1.5mm PCB Embedded Inductor Prototype
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© TOKIN 2019 0 10 20 30 235
255 275 295 315 Count L(nH, 1MHz) 0 10 20 30 105 115 125 135 145 Count L(nH, 1MHz) 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 Tight tolerance of inductance is readily achieved in test fabrication. Dispersion of Inductance , |Z|
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© TOKIN 2019
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. We believe this material will contribute to the miniturization of electronic circuits, especially in: - DC/DC converters, - Wireless Power Transfer system. We are continuing to scale-up this technology for use in several applications. Summary
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© TOKIN 2019 Thank
you very much for your attention.
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© TOKIN 2019 Back
Ups
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© TOKIN 2019 Applied
Power Electronics Conference and Exposition (APEC), 2015 Thirtieth Annual IEEE, 2015, pp. 140-145.
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