Magneto-dielectric substrate, circuit material, and assembly having the same

Patent metadata

Field	Value
Publication number	US-2016099498-A1
Application number	US-201514870273-A
Country	US
Kind code	A1
Filing date	Sep 30, 2015
Priority date	Oct 2, 2014
Publication date	Apr 7, 2016
Grant date	—

Abstract

A magneto-dielectric substrate includes a first dielectric layer, a second dielectric layer spaced apart from the first dielectric layer, and at least one magnetic reinforcing layer disposed between and in intimate contact with the first dielectric layer and the second dielectric layer.

First claim

I/we claim:

1 . A magneto-dielectric substrate, comprising:
a first dielectric layer; a second dielectric layer spaced apart from the first dielectric layer; and at least one magnetic reinforcing layer disposed between and in intimate contact with the first dielectric layer and the second dielectric layer.

2 . The magneto-dielectric substrate of claim 1 , wherein the magnetic reinforcing layer comprises fibers, wherein the fibers are ferrite fibers, ferrite alloy fibers, cobalt fibers, cobalt alloy fibers, iron fibers, iron alloy fibers, nickel fibers, nickel alloy fibers, polymer fibers comprising particulate ferrite, a particulate ferrite alloy, particulate cobalt, a particulate cobalt alloy, particulate iron, a particulate iron alloy, particulate nickel, a particulate nickel alloy, or a combination comprising at least one of the foregoing, preferably hexaferrite, magnetite, or MFe 2 O 4 , wherein M is at least one of Co, Ni, Zn, V, or Mn.

3 . The magneto-dielectric substrate of claim 1 , wherein the magnetic reinforcing layer comprises polymer or glass fibers coated with ferrite, a ferrite alloy, cobalt, a cobalt alloy, iron, an iron alloy, nickel, a nickel alloy, or a combination comprising at least one of the foregoing magnetic materials, or a combination comprising at least one of the foregoing fibers, preferably hexaferrite, magnetite, or MFe 2 O 4 , wherein M is at least one of Co, Ni, Zn, V, or Mn.

4 . The magneto-dielectric substrate of claim 1 , wherein the magnetic reinforcing layer comprises polymer fibers comprising particulate ferrite, a ferrite alloy, cobalt, a cobalt alloy, iron, an iron alloy, nickel, a nickel alloy, or a combination comprising at least one of the foregoing magnetic materials preferably hexaferrite, magnetite, or MFe 2 O 4 , wherein M is at least one of Co, Ni, Zn, V, or Mn.

5 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer and the second dielectric layer each independently comprises 1,2-polybutadiene, polyisoprene, polybutadiene-polyisoprene copolymers, polyetherimide, fluoropolymers such as polytetrafluoroethylene, polyimide, polyetheretherketone, polyamidimide, polyethylene terephthalate, polyethylene naphthalate, polycyclohexylene terephthalate, polyphenylene ethers, allylated polyphenylene ethers or a combination comprising at least one of the foregoing.

6 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer and the second dielectric layer each independently comprises a polybutadiene and/or a polyisoprene; optionally an ethylene-propylene liquid rubber having a weight average molecular weight of less than or equal to 50,000 g/mol as measured by gel permeation chromatography based on polycarbonate standards; optionally, a dielectric filler; and optionally, a flame retardant.

7 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer fully impregnates one side of the magnetic reinforcing layer; and the second dielectric layer fully impregnates an opposing side of the magnetic reinforcing layer.

8 . The magneto-dielectric substrate of claim 1 , wherein the magnetic reinforcing layer comprises:
a first magnetic layer; a second magnetic layer uniformly spaced apart from the first magnetic layer; and a dielectric reinforcement layer disposed between and in intimate contact with the first magnetic layer and the second magnetic layer.

9 . The magneto-dielectric substrate of claim 8 , wherein the first magnetic layer and the second magnetic layer each comprise thin film ferrite.

10 . The magneto-dielectric substrate of claim 8 , wherein:
the first magnetic layer has a first-magnetic-layer thickness; the second magnetic layer has a second-magnetic-layer thickness; the reinforcement layer has a reinforcement-layer thickness; a ratio of the reinforcement-layer thickness to the first-magnetic-layer thickness is equal to or greater than 25; and a ratio of the reinforcement-layer thickness to the second-magnetic-layer thickness is equal to or greater than 25.

11 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer has a first thickness; and the second dielectric layer has a second thickness substantially equal in thickness to the first thickness.

12 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer has a first thickness; and the second dielectric layer has a second thickness substantially equal in thickness to the first thickness.

13 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer is structurally macroscopically in-plane continuous; and the second dielectric layer is structurally macroscopically in-plane continuous.

14 . The magneto-dielectric substrate of claim 1 , wherein:
the magnetic reinforcing layer is at least partially structurally macroscopically in-plane continuous.

15 . The magneto-dielectric substrate of claim 1 , wherein:
the magnetic reinforcing layer has in-plane magnetic anisotropy.

16 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer has outer dimensions that define a first footprint; the second dielectric layer has outer dimensions that define a second footprint substantially equal in size to the first footprint; and the magnetic reinforcing layer has outer dimensions that define a third footprint substantially equal in size to the first and second footprints.

17 . The magneto-dielectric substrate of claim 1 , wherein:
the first dielectric layer, the second dielectric layer, and the magnetic reinforcing layer, are each planar in structure.

18 . The magneto-dielectric substrate of claim 1 , further comprising:
a conductive ground layer disposed on an outer surface of the first dielectric layer; and a conductive element disposed on an outer surface of the second dielectric layer, the conductive element being spaced apart from the conductive ground layer.

19 . The magneto-dielectric substrate of claim 18 , wherein:
the first dielectric layer has outer dimensions that define a first footprint; the second dielectric layer has outer dimensions that define a second footprint substantially equal in size to the first footprint; the magnetic reinforcing layer has outer dimensions that define a third footprint substantially equal in size to the first and second footprints; the conductive ground layer has outer dimensions that define a fourth footprint substantially equal in size to the first footprint; and the conductive element has outer dimensions that define a fifth footprint that is smaller in size than the second footprint.

20 . The magneto-dielectric substrate of claim 19 , wherein:
a ratio of an area of the fifth footprint to an area of the second footprint is equal to or less than 0.3.

21 . The magneto-dielectric substrate of claim 20 , wherein:
the conductive element is centrally disposed on the second dielectric layer.

22 . The magneto-dielectric substrate of claim 18 , further comprising:
a signal line disposed in signal communication with the conductive element.

23 . The magneto-dielectric substrate of claim 22 , wherein:
the signal line comprises a coaxial cable having a central signal conductor disposed in signal communication with the conductive element, and a ground sheath disposed in electrical ground communication with the conductive ground layer.

Assignees

• Rogers Corp

Inventors

• Pance Kristi
• Sprentall Karl
• Sethumadhavan Murali

Classifications

• H01Q15/004

  using superconducting materials or magnetised substrates · CPC title

• H01F1/344

  Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4 · CPC title

• H05K1/036

  Multilayers with layers of different types · CPC title

• H01Q9/0407

  Substantially flat resonant element parallel to ground plane, e.g. patch antenna (dipole H01Q9/285; monopole H01Q9/40) · CPC title

• H01Q1/38 Primary

  formed by a conductive layer on an insulating support {(patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface  H01Q15/142)} · CPC title