SBIR Phase I: Ultra-Miniature Transformer and Inductor Design and Manufacture

该小型企业创新研究一期项目致力于高频（5 MHz至1 GHz）变压器和电感器的自动化制造开发。目前的制造过程是劳动密集型的。磁芯和导线直径非常小（2.5毫米和0.075毫米），使机器组装不切实际。所提出的方法使用类似于半导体制造的自动化技术来沉积、蚀刻和涂覆磁性、导电和绝缘材料的图案层。这种自动化将大大减少劳动力含量，进一步缩小设备尺寸，并使美国而不是海外的经济生产成为可能。研究目标包括完成机电变压器的设计和样机的制作。设备操作和电气性能的基本现象将被评估。商业应用包括用于数据和视频传输的高频变压器和电感器、混合电路和相关电路。在现有市场之外，这种新方法将使数据和个人通信领域的微型产品得以发展。＊＊＊

*** ABSTRACT 9660219 DeCramer This Small Business lnnovation Research Phase I project addresses the development of automated manufacturing for high frequency (5 MHz to 1 GHz) transformers and inductors. Current manufacturing processes are labor intensive. Magnetic core and wire diameters are very small (2.5 mm and 0.075 mm) making machine assembly impractical. The proposed approach uses automated techniques similar to semiconductor manufacturing to deposit, etch, and coat patterned layers of magnetic, conductive and insulating materials. This automation will significantly reduce labor content, further reduce device size, and enable economic production in the United States rather than offshore. Research objectives include completion of electrical and mechanical transformer design and fabrication of prototypes. Fundamental phenomena underlying device operation and electrical performance will be evaluated. Commercial applications include high frequency transformers and inductors for data and video transmissions, hybrid circuits, and related circuitry. Beyond existing markets, this new approach will enable development of miniature products in data and personal communications. ***