DETAILED ACTION
Notice of Pre-AIA or AIA Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Election/Restrictions
Applicant’s election without traverse of Group I in the reply filed on 03/19/2026 is acknowledged.
Claims 27-28 and 30 are withdrawn from further consideration pursuant to 37 CFR 1.142(b) as being drawn to a nonelected Group II, there being no allowable generic or linking claim. Election was made without traverse in the reply filed on 03/19/2026.
Applicant’s election of Species IV in the reply filed on 07/07/2026 is acknowledged. Because applicant did not distinctly and specifically point out the supposed errors in the restriction requirement for Species I, the election has been treated as an election without traverse (MPEP § 818.01(a)).
Claims 9, 15, 17-18, 20-21, and 25 are withdrawn from further consideration pursuant to 37 CFR 1.142(b) as being drawn to a nonelected Species I, there being no allowable generic or linking claim. Election was made without traverse in the reply filed on 07/07/2026.
Applicant's election with traverse of Species IV relative to Species II-V in the reply filed on 07/07/2026 is acknowledged. The traversal is on the ground(s) that Species II-V are not mutually exclusive. This is not found persuasive because Species II-V have special technical feature of one species is not present in other species. Therefore, these species are deemed to lack of unity of invention because they are not so linked as to form a single general inventive concept.
The requirement is still deemed proper and is therefore made FINAL.
Claim Objections
Claims 10-14 and 16 are objected to because of the following informalities:
Claim 10, line 20, “first lower conductive traces” should be --first lower traces--.
Appropriate correction is required.
Claim Rejections - 35 USC § 102
In the event the determination of the status of the application as subject to AIA 35 U.S.C. 102 and 103 (or as subject to pre-AIA 35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis (i.e., changing from AIA to pre-AIA ) for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
The following is a quotation of the appropriate paragraphs of 35 U.S.C. 102 that form the basis for the rejections under this section made in this Office action:
A person shall be entitled to a patent unless –
(a)(1) the claimed invention was patented, described in a printed publication, or in public use, on sale, or otherwise available to the public before the effective filing date of the claimed invention.
Claim(s) 19 is/are rejected under 35 U.S.C. 102(a)(1) as being anticipated by Li et al. [U.S. Pub. No. 2014/0116758].
Regarding Claim 19, Li et al. shows a device (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teachings from Fig. 1 or Fig. 14 and Drawings A, B, C, and D below) comprising:
a substrate (18, substrate S [see Drawing A below], 718, 1318, 1518) including a cavity (cavity C [see Drawing A below], 724, 1324, 1524);
a magnetic core (14, 714) in the cavity (apply element 14, 714 to Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24);
a first winding (16, 716) extending around the magnetic core (see Fig. 1 and apply element 16, 716 to Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24, Paragraph [0033]); and
a single channel (472, 760, 1360, or 1560) that extends between the cavity (cavity C [see Drawing A below], see also elements 724, 1324, 1524) and an exterior (edge E [see Drawings A and B below], see also elements 764a, 1364, 1564) of the device (see Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 and Drawings A, B, C, and D below), that defines an opening (472a, 766, 1366, 1566), and that includes a bottom wall with an open recess (open recess OR, see Drawings A, B, C, and D) adjacent to the opening (see Drawings A, B, C, and D).
Claim(s) 19 is/are rejected under 35 U.S.C. 102(a)(1) as being anticipated by Lloyd [U.S. Pub. No. 2016/0254090].
Regarding Claim 19, Lloyd shows a device (Figs. 3A-5B and Drawing E below) comprising:
a substrate (301) including a cavity (302);
a magnetic core (304) in the cavity (see Figs. 3A-5B);
a first winding (410) extending around the magnetic core (see Figs. 3A-5B, Paragraph [0059]); and
a single channel (channel C1, see Drawing E) that extends between the cavity 302) and an exterior (edge E) of the device (see Figs. 3A-5B), that defines an opening (see Figs. 3A-5B and Drawing E below), and that includes a bottom wall (top surface of element 330) with an open recess (open recess OR adjacent to element 330, see Drawing E) adjacent to the opening (see Drawing E).
Claim Rejections - 35 USC § 103
In the event the determination of the status of the application as subject to AIA 35 U.S.C. 102 and 103 (or as subject to pre-AIA 35 U.S.C. 102 and 103) is incorrect, any correction of the statutory basis (i.e., changing from AIA to pre-AIA ) for the rejection will not be considered a new ground of rejection if the prior art relied upon, and the rationale supporting the rejection, would be the same under either status.
The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections set forth in this Office action:
A patent for a claimed invention may not be obtained, notwithstanding that the claimed invention is not identically disclosed as set forth in section 102, if the differences between the claimed invention and the prior art are such that the claimed invention as a whole would have been obvious before the effective filing date of the claimed invention to a person having ordinary skill in the art to which the claimed invention pertains. Patentability shall not be negated by the manner in which the invention was made.
Claim(s) 1, 4-5, 7-8, 10, 13-14, 16, and 19 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Li et al. [U.S. Pub. No. 2014/0116758].
Regarding Claim 1, Quilici shows an embedded magnetic component device (Figs. 50a-50d and 51) comprising:
an insulating substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core) and opposing first (top side) and second (bottom side) sides (see Fig. 51);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51) and including an inner periphery (inner circumference, see Figs. 50-50d and 51) and an outer periphery (outer circumference, see Figs. 50-50d and 51);
first (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) and second (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) electrical windings that extend through the insulating substrate (FR-4 substrate) and around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51), each of the first and the second electrical windings including:
upper traces (Layer 3 Conductor, Layer 4 Conductor) located on the first side (top side) of the insulating substrate (see Figs. 50-50d and 51);
lower traces (Layer 2 Conductor, Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (see Figs. 50-50d and 51);
inner conductive connectors (inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the inner periphery of the magnetic core (see Figs. 50-50d and 51), the inner conductive connectors respectively defining electrical connections between respective upper traces and respective lower traces (see Figs. 50-50d and 51, inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1 respectively defining electrical connections between respective Layer 3 Conductor, Layer 4 Conductor and respective Layer 2 Conductor, Layer 1 Conductor); and
outer conductive connectors (outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the outer periphery of the magnetic core (see Figs. 50-50d and 51), the outer conductive connectors respectively define electrical connections between respective first upper traces and respective first lower traces (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1 respectively define electrical connections between respective first Layer 3 Conductor, first Layer 4 Conductor and respective first Layer 2 Conductor, first Layer 1 Conductor),
a top covering (Top, Cover-Lay or Solder Mask) on the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50-50d and 51);
a bottom covering (Bottom Cover-Lay of Solder Mask) on the lower traces of the second electrical winding (Layer 1 Conductor, see Figs. 50-50d and 51); and
the first electrical winding is closer to the magnetic core than the second electrical winding (see Figs. 50-50d and 51, Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3 is closer to Ferromagnetic Core than Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1).
Quilici does not explicitly show a channel located in the insulating substrate and defining an opening connecting the cavity to an exterior of the insulating substrate.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14 and Drawings 1, 2, 3, and 4 below) teaching and suggesting a channel (472, 760, 1360, or 1560) located in the insulating substrate (see substrate of Fig. 8a, see also elements 718, 1318, 1518) and defining an opening (472a, 766, 1366, 1566) connecting the cavity (cavity C [see Drawing 1 below], see also elements 724, 1324, 1524) to an exterior (edge E [see Drawing 1 below], see also elements 764a, 1364, 1564) of the insulating substrate (see Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14, Paragraphs [0071], [0077]).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a channel located in the insulating substrate and defining an opening connecting the cavity to an exterior of the insulating substrate as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Regarding Claim 4, Quilici shows the second electrical winding overlaps the first electrical winding (see Figs. 50a-50d, Layer 1 Conductor, Layer 4 Conductor overlaps Layer 2 Conductor, Layer 3 Conductor).
Regarding Claim 5, Quilici shows the upper traces of the first electrical winding (Layer 3 Conductor) are on a different layer of the insulating substrate (FR-4 Substrate) than the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51), and
the lower traces of the first electrical winding (Layer 2 Conductor) are on a different layer of the insulating substrate (FR-4 Substrate) than the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51).
Regarding Claim 7, Quilici shows a first isolation layer (HV Laminate between Layer 3 Conductor and Layer 4 Conductor) located on the first side (top side) of the insulating substrate (FR-4 Substrate) between the first electrical winding (Layer 3 Conductor) and the second electrical winding (Layer 4 Conductor, see Fig. 51); and
a second isolation layer (HV Laminate between Layer 2 Conductor and Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (FR-4 Substrate) between the first electrical winding (Layer 2 Conductor) and the second electrical winding (Layer 1 Conductor, see Fig. 51).
Regarding Claim 8, Quilici shows the first isolation layer and/or the second isolation layer include a single layer (HV Laminate between Layer 3 Conductor and Layer 4 Conductor is a single layer).
Regarding Claim 10, Quilici shows a method of manufacturing an embedded magnetic component device (Figs. 50a-50d and 51), the method comprising:
forming a cavity (cavity for Ferromagnetic Core) in an insulating substrate (FR-4 substrate, see Fig. 51) that includes a first side (top side) and a second side (bottom side) opposite to the first side (see Fig. 51);
installing a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51), the magnetic core including an inner periphery (inner circumference, see Figs. 50-50d and 51) and an outer periphery (outer circumference, see Figs. 50-50d and 51);
forming first (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) and second (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) electrical windings that extend through the insulating substrate (FR-4 substrate) and around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51), each of the first and the second electrical windings including:
upper traces (Layer 3 Conductor, Layer 4 Conductor) located on the first side (top side) of the insulating substrate (see Figs. 50-50d and 51);
lower traces (Layer 2 Conductor, Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (see Figs. 50-50d and 51);
inner conductive connectors (inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the inner periphery of the magnetic core (see Figs. 50-50d and 51), the inner conductive connectors respectively defining electrical connections between respective upper traces and respective lower traces (see Figs. 50-50d and 51, inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1 respectively defining electrical connections between respective Layer 3 Conductor, Layer 4 Conductor and respective Layer 2 Conductor, Layer 1 Conductor); and
outer conductive connectors (outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the outer periphery of the magnetic core (see Figs. 50-50d and 51), the outer conductive connectors respectively defining electrical connections between respective first upper traces and respective first lower conductive traces (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1 respectively define electrical connections between respective first Layer 3 Conductor, first Layer 4 Conductor and respective first Layer 2 Conductor, first Layer 1 Conductor);
forming a top covering (Top, Cover-Lay or Solder Mask) on the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50-50d and 51); and
forming a bottom covering (Bottom Cover-Lay of Solder Mask) on the lower traces of the second electrical winding (Layer 1 Conductor, see Figs. 50-50d and 51), wherein
the first electrical winding is closer to the magnetic core than the second electrical winding (see Figs. 50-50d and 51, Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3 is closer to Ferromagnetic Core than Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1).
Quilici does not explicitly show forming a channel between the cavity and an edge of the insulating substrate.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3 or Fig. 14 and see Drawings 1, 2, 3, and 4 below) teaching and suggesting forming a channel (472, 760, 1360 with 1382, or 1560 with 1582) between the cavity (cavity C [see Drawing 1 below], see also elements 724, 1324, 1524) and an edge (edge E [see Drawing 1 below], see also elements 764a, 1364, 1564) of the insulating substrate (see Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14, Paragraphs [0071], [0077]).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a channel between the cavity and an edge of the insulating substrate as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Regarding Claim 13, Quilici shows the second electrical winding overlaps the first electrical winding (see Figs. 50a-50d, Layer 1 Conductor, Layer 4 Conductor overlaps Layer 2 Conductor, Layer 3 Conductor).
Regarding Claim 14, Quilici shows the upper traces connected to the first electrical winding (Layer 3 Conductor) are on a different layer than the upper traces connected to the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51), and
the lower traces connected to the first electrical winding (Layer 2 Conductor) are on a different layer than the lower traces connected to the second electrical winding (Layer 1 Conductor, see Figs. 50a-50d and 51).
Regarding Claim 16, Li et al. shows a portion (portion P1) of a bottom of the channel is shorter than a top of the channel (portion P2, see Fig. 8a and see Drawing 1 below, portion P1 of a bottom is shorter than portion P2 or see Fig. 22 and see Drawing 2 below, portion P1 of a bottom is shorter than portion P2 or see Fig. 14 and see Drawing 3 below, portion P1 of a bottom is shorter than portion P2 or see Fig. 24 and see Drawing 4 below, portion P1 of a bottom is shorter than portion P2).
Regarding Claim 19, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (see Figs. 50a-50d and 51).
Quilici does not show a single channel that extends between the cavity and an exterior of the device, that defines an opening, and that includes a bottom wall with an open recess adjacent to the opening.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3 or Fig. 14 and Drawings A, B, C, and D below) teaching and suggesting a single channel (472, 760, 1360, or 1560) that extends between the cavity (cavity C [see Drawing A below], see also elements 724, 1324, 1524) and an exterior (edge E [see Drawings A and B below], see also elements 764a, 1364, 1564) of the device (see Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 and Drawings A, B, C, and D below), that defines an opening (472a, 766, 1366, 1566), and that includes a bottom wall with an open recess (open recess OR, see Drawings A, B, C, and D) adjacent to the opening (see Drawings A, B, C, and D).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device, that defines an opening, and that includes a bottom wall with an open recess adjacent to the opening as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Claim(s) 1-2, 4-5, 7-8, 10, 13-14, 16, and 19 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Lloyd [U.S. Pub. No. 2016/0254090].
Regarding Claim 1, Quilici shows an embedded magnetic component device (Figs. 50a-50d and 51) comprising:
an insulating substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core) and opposing first (top side) and second (bottom side) sides (see Fig. 51);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51) and including an inner periphery (inner circumference, see Figs. 50-50d and 51) and an outer periphery (outer circumference, see Figs. 50-50d and 51);
first (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) and second (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) electrical windings that extend through the insulating substrate (FR-4 substrate) and around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51), each of the first and the second electrical windings including:
upper traces (Layer 3 Conductor, Layer 4 Conductor) located on the first side (top side) of the insulating substrate (see Figs. 50-50d and 51);
lower traces (Layer 2 Conductor, Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (see Figs. 50-50d and 51);
inner conductive connectors (inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the inner periphery of the magnetic core (see Figs. 50-50d and 51), the inner conductive connectors respectively defining electrical connections between respective upper traces and respective lower traces (see Figs. 50-50d and 51, inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1 respectively defining electrical connections between respective Layer 3 Conductor, Layer 4 Conductor and respective Layer 2 Conductor, Layer 1 Conductor); and
outer conductive connectors (outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the outer periphery of the magnetic core (see Figs. 50-50d and 51), the outer conductive connectors respectively define electrical connections between respective first upper traces and respective first lower traces (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1 respectively define electrical connections between respective first Layer 3 Conductor, first Layer 4 Conductor and respective first Layer 2 Conductor, first Layer 1 Conductor),
a top covering (Top, Cover-Lay or Solder Mask) on the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50-50d and 51);
a bottom covering (Bottom Cover-Lay of Solder Mask) on the lower traces of the second electrical winding (Layer 1 Conductor, see Figs. 50-50d and 51); and
the first electrical winding is closer to the magnetic core than the second electrical winding (see Figs. 50-50d and 51, Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3 is closer to Ferromagnetic Core than Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1).
Quilici does not explicitly show a channel located in the insulating substrate and defining an opening connecting the cavity to an exterior of the insulating substrate.
Lloyd shows a magnetic component (Figs. 5A-5B) teaching and suggesting a channel (left element 303) located in the insulating substrate (301) and defining an opening (opening between element 302 and left element 322) connecting the cavity (302) to an exterior (left element 322) of the insulating substrate (see Figs. 5A-5B).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a channel located in the insulating substrate and defining an opening connecting the cavity to an exterior of the insulating substrate as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Regarding Claim 2, Lloyd shows a layer of adhesive (318) located on a floor of the cavity (302) to secure the magnetic core (304) in the cavity (see Figs. 5A-5B and Fig. 3C, Paragraph [0071]).
Regarding Claim 4, Quilici shows the second electrical winding overlaps the first electrical winding (see Figs. 50a-50d, Layer 1 Conductor, Layer 4 Conductor overlaps Layer 2 Conductor, Layer 3 Conductor).
Regarding Claim 5, Quilici shows the upper traces of the first electrical winding (Layer 3 Conductor) are on a different layer of the insulating substrate (FR-4 Substrate) than the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51), and
the lower traces of the first electrical winding (Layer 2 Conductor) are on a different layer of the insulating substrate (FR-4 Substrate) than the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51).
Regarding Claim 7, Quilici shows a first isolation layer (HV Laminate between Layer 3 Conductor and Layer 4 Conductor) located on the first side (top side) of the insulating substrate (FR-4 Substrate) between the first electrical winding (Layer 3 Conductor) and the second electrical winding (Layer 4 Conductor, see Fig. 51); and
a second isolation layer (HV Laminate between Layer 2 Conductor and Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (FR-4 Substrate) between the first electrical winding (Layer 2 Conductor) and the second electrical winding (Layer 1 Conductor, see Fig. 51).
Regarding Claim 8, Quilici shows the first isolation layer and/or the second isolation layer include a single layer (HV Laminate between Layer 3 Conductor and Layer 4 Conductor is a single layer).
Regarding Claim 10, Quilici shows a method of manufacturing an embedded magnetic component device (Figs. 50a-50d and 51), the method comprising:
forming a cavity (cavity for Ferromagnetic Core) in an insulating substrate (FR-4 substrate, see Fig. 51) that includes a first side (top side) and a second side (bottom side) opposite to the first side (see Fig. 51);
installing a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51), the magnetic core including an inner periphery (inner circumference, see Figs. 50-50d and 51) and an outer periphery (outer circumference, see Figs. 50-50d and 51);
forming first (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) and second (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) electrical windings that extend through the insulating substrate (FR-4 substrate) and around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51), each of the first and the second electrical windings including:
upper traces (Layer 3 Conductor, Layer 4 Conductor) located on the first side (top side) of the insulating substrate (see Figs. 50-50d and 51);
lower traces (Layer 2 Conductor, Layer 1 Conductor) located on the second side (bottom side) of the insulating substrate (see Figs. 50-50d and 51);
inner conductive connectors (inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the inner periphery of the magnetic core (see Figs. 50-50d and 51), the inner conductive connectors respectively defining electrical connections between respective upper traces and respective lower traces (see Figs. 50-50d and 51, inner Via Barrel Layer 2-3, inner Via Barrel Layer 4-1 respectively defining electrical connections between respective Layer 3 Conductor, Layer 4 Conductor and respective Layer 2 Conductor, Layer 1 Conductor); and
outer conductive connectors (outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1) extending through the insulating substrate (see Figs. 50-50d and 51) adjacent to the outer periphery of the magnetic core (see Figs. 50-50d and 51), the outer conductive connectors respectively defining electrical connections between respective first upper traces and respective first lower conductive traces (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3, outer Via Barrel Layer 4-1 respectively define electrical connections between respective first Layer 3 Conductor, first Layer 4 Conductor and respective first Layer 2 Conductor, first Layer 1 Conductor);
forming a top covering (Top, Cover-Lay or Solder Mask) on the upper traces of the second electrical winding (Layer 4 Conductor, see Figs. 50-50d and 51); and
forming a bottom covering (Bottom Cover-Lay of Solder Mask) on the lower traces of the second electrical winding (Layer 1 Conductor, see Figs. 50-50d and 51), wherein
the first electrical winding is closer to the magnetic core than the second electrical winding (see Figs. 50-50d and 51, Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3 is closer to Ferromagnetic Core than Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1).
Quilici does not explicitly show forming a channel between the cavity and an edge of the insulating substrate.
Lloyd shows a magnetic component (Figs. 5A-5B) teaching and suggesting forming a channel (left element 303) between the cavity (302) and an edge (left element 322) of the insulating substrate (301, see Figs. 5A-5B).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a channel between the cavity and an edge of the insulating substrate as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Regarding Claim 13, Quilici shows the second electrical winding overlaps the first electrical winding (see Figs. 50a-50d, Layer 1 Conductor, Layer 4 Conductor overlaps Layer 2 Conductor, Layer 3 Conductor).
Regarding Claim 14, Quilici shows the upper traces connected to the first electrical winding (Layer 3 Conductor) are on a different layer than the upper traces connected to the second electrical winding (Layer 4 Conductor, see Figs. 50a-50d and 51), and
the lower traces connected to the first electrical winding (Layer 2 Conductor) are on a different layer than the lower traces connected to the second electrical winding (Layer 1 Conductor, see Figs. 50a-50d and 51).
Regarding Claim 16, Lloyd shows a portion (portion P1) of a bottom of the channel is shorter than a top of the channel (portion P2, see Fig. 5A and see Drawing 5 below, portion P1 of a bottom adjacent to element 330 is shorter than portion P2 extending from element 302 to element 322).
Regarding Claim 19, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (see Figs. 50a-50d and 51).
Quilici does not show a single channel that extends between the cavity and an exterior of the device, that defines an opening, and that includes a bottom wall with an open recess adjacent to the opening.
Lloyd shows a magnetic component (Figs. 5A-5B) teaching and suggesting a single channel (channel C1, see Drawing E) that extends between the cavity 302) and an exterior (edge E) of the device (see Figs. 3A-5B), that defines an opening (see Figs. 3A-5B and Drawing E below), and that includes a bottom wall (top surface of element 330) with an open recess (open recess OR adjacent to element 330, see Drawing D) adjacent to the opening (see Drawing E).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device, that defines an opening, and that includes a bottom wall with an open recess adjacent to the opening as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Claim(s) 2 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. as applied to claim 1 above, and further in view of Lloyd [U.S. Pub. No. 2016/0254090].
Regarding Claim 2, Quilici in view of Li et al. shows the claimed invention as applied above but does not show a layer of adhesive located on a floor of the cavity to secure the magnetic core in the cavity.
Lloyd shows a layer of adhesive (318) located on a floor of the cavity (302) to secure the magnetic core (304) in the cavity (see Figs. 5A-5B and Fig. 3C, Paragraph [0071]).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a layer of adhesive located on a floor of the cavity to secure the magnetic core in the cavity as taught by Lloyd for the device as disclosed by Quilici in view of Li et al. to achieve a strong bond between the magnetic core and the cavity to prevent movement of the core and protects the cored from mechanical shock and/or vibration damage (Paragraph [0071]).
Claim(s) 3 and 11 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claims 1 and 11 above, and further in view of Wang et al. [U.S. Pub. No. 2016/0111966].
Regarding Claims 3 and 11, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the upper and the lower traces of the second electrical winding are wider than the upper and the lower traces of the first electrical winding.
Wang et al. shows a device (Fig. 4) teaching and suggesting the upper and the lower traces of the second electrical winding (323) are wider than the upper and the lower traces of the first electrical winding (313, see Fig. 4, Paragraphs [0081]-[0082]).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the upper and the lower traces of the second electrical winding are wider than the upper and the lower traces of the first electrical winding as taught by Wang et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to reduce resistance of the windings while increasing coupling (Paragraph [0091]).
Claim(s) 3 and 11 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claims 1 and 11 above, and further in view of Quilici [U.S. Pub. No. 2016/0093431] (hereinafter as “Quilici ‘431”) and Wang et al. [U.S. Pub. No. 2016/0111966] (for motivation purposes).
Regarding Claims 3 and 11, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the upper and the lower traces of the second electrical winding are wider than the upper and the lower traces of the first electrical winding.
Quilici ‘431 shows a device (Figs. 12-21) teaching and suggesting the upper and the lower traces of the second electrical winding (378, 368) are wider than the upper and the lower traces of the first electrical winding (308, 316, see Figs. 12-21).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the upper and the lower traces of the second electrical winding are wider than the upper and the lower traces of the first electrical winding as taught by Quilici ‘431 for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to reduce resistance of the windings while increasing coupling (Paragraph [0091] of Wang et al.).
Claim(s) 6 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claim 1 above, and further in view of Finnemore et al. [U.S. Patent No. 6,246,311].
Regarding Claim 6, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the magnetic core is octagonally shaped.
Finnemore et al. shows an inductive device (Figs. 1-5) teaching and suggesting the magnetic core is octagonally shaped (see Figs. 1-5, Col. 2, Lines 66-67 to Col. 3, Lines 1-17, claim 24).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the magnetic core is octagonally shaped as taught by Finnemore et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to facilitate geometry and placement of electronic components such as shields to reduce demagnetization and flux leakage (Col. 3, Lines 1-17).
Moreover, having the magnetic core is octagonally shaped would have been an obvious design choice based on intended and/or environmental use to achieve desirable operating characteristics. In re Dailey, 357 F.2d 669, 149 USPQ 47 (CCPA 1966) (The court held that the configuration of the claimed disposable plastic nursing container was a matter of choice which a person of ordinary skill in the art would have found obvious absent persuasive evidence that the particular configuration of the claimed container was significant.).
Claim(s) 6 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claim 1 above, and further in view of Lee et al. [KR 2004-0076510].
Regarding Claim 6, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the magnetic core is octagonally shaped.
Lee et al. shows an inductive device (Fig. 6b) teaching and suggesting the magnetic core (23) is octagonally shaped (see Fig. 6b, Paragraph [0052]).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the magnetic core is octagonally shaped as taught by Lee et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to achieve excellent properties (Paragraph [0084]).
Moreover, having the magnetic core is octagonally shaped would have been an obvious design choice based on intended and/or environmental use to achieve desirable operating characteristics. In re Dailey, 357 F.2d 669, 149 USPQ 47 (CCPA 1966) (The court held that the configuration of the claimed disposable plastic nursing container was a matter of choice which a person of ordinary skill in the art would have found obvious absent persuasive evidence that the particular configuration of the claimed container was significant.).
Claim(s) 6 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claim 1 above, and further in view of Hiatt et al. [U.S. Patent No. 7,107,666].
Regarding Claim 6, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the magnetic core is octagonally shaped.
Hiatt et al. shows an inductive device (Fig. 13) teaching and suggesting the magnetic core (12) is octagonally shaped (see Fig. 13).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the magnetic core is octagonally shaped as taught by Lee et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to increase number of turns to achieve desirable inductances and operating characteristics (Col. 9, Lines 28-30).
Moreover, having the magnetic core is octagonally shaped would have been an obvious design choice based on intended and/or environmental use to achieve desirable operating characteristics. In re Dailey, 357 F.2d 669, 149 USPQ 47 (CCPA 1966) (The court held that the configuration of the claimed disposable plastic nursing container was a matter of choice which a person of ordinary skill in the art would have found obvious absent persuasive evidence that the particular configuration of the claimed container was significant.).
Claim(s) 7-8 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claim 1 above, and further in view of Otsubo et al. [U.S. Pub. No. 2017/0018349].
Regarding Claim 7, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above.
In addition, Otsubo et al. shows (Fig. 18) a first isolation layer (220) located on the first side (top side) of the insulating substrate (31) between the first electrical winding (116) and the second electrical winding (316, see Fig. 18); and
a second isolation layer (layer between elements 16, 216) located on the second side (bottom side) of the insulating substrate (31) between the first electrical winding (16) and the second electrical winding (216, see Fig .18).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a first isolation layer located on the first side of the insulating substrate between the first electrical winding and the second electrical winding; and a second isolation layer located on the second side of the insulating substrate between the first electrical winding and the second electrical winding as taught by Otsubo et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to facilitate insulation to prevent unwanted connection such as shorting to achieve desirable coupling.
Regarding Claim 8, Otsubo et al. shows the first isolation layer and/or the second isolation layer include a single layer (element 220 is a single layer).
Claim(s) 12 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claims 1 and 11 above, and further in view of Quilici [U.S. Pub. No. 2016/0093431] (hereinafter as “Quilici ‘431”).
Regarding Claim 12, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the second electrical winding includes two outer conductive connectors between each respective first upper trace and respective first lower trace.
Quilici ‘431 shows a device (Figs. 12-21) teaching and suggesting the second electrical winding (378, 368) includes two outer conductive connectors (341) between each respective first upper trace (378) and respective first lower trace (368, see Figs. 12-21).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the second electrical winding includes two outer conductive connectors between each respective first upper trace and respective first lower trace as taught by Quilici ‘431 for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to achieve desirable electrical resistance and/or impedance (Paragraph [0182]).
Claim(s) 12 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. OR Quilici in view of Lloyd as applied to claims 1 and 11 above, and further in view of Altman et al. [U.S. Patent No. 5,055,816] and Quilici [U.S. Pub. No. 2016/0093431] (hereinafter as “Quilici ‘431”) (for motivation purposes).
Regarding Claim 12, Quilici in view of Li et al. OR Quilici in view of Lloyd shows the claimed invention as applied above but does not show the second electrical winding includes two outer conductive connectors between each respective first upper trace and respective first lower trace.
Altman et al. shows a device (Figs. 5a-5b) teaching and suggesting the second electrical winding (189, 192) includes two outer conductive connectors (194, 196) between each respective first upper trace (189) and respective first lower trace (192, see Figs. 5a-5b).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the second electrical winding includes two outer conductive connectors between each respective first upper trace and respective first lower trace as taught by Altman et al. for the device as disclosed by Quilici in view of Li et al. OR Quilici in view of Lloyd to obtain reliability and high inductance (Col. 1, Lines 44-52) and to achieve desirable electrical resistance and/or impedance (Paragraph [0182] of Quilici ‘431).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Li et al. [U.S. Pub. No. 2014/0116758] and Wang et al. [U.S. Pub. No. 2012/0025941] (hereinafter as “Wang ‘941”).
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14 and Drawings 1, 2, 3, 4, and Drawings I and II below) teaching and suggesting a single channel (472, 760, 1360, or 1560) that extends between the cavity (cavity C [see Drawing 1 below], see also elements 724, 1324, 1524) and an exterior (edge E [see Drawings 1 and 2 below], see also elements 764a, 1364, 1564) of the device and that defines an opening (472a, 766, 1366, 1566); the first winding (winding W1 or winding W2 of element 16 or 716) includes vias (vias V1 or vias V2, see Drawings I and II below) along an exterior periphery (outer circumference) of the magnetic core (14 or 714) opposite to the single channel (channel CH or 760, see Drawings I and II below, winding W1 or winding W2 of element 16 or 716 includes vias V1 or vias V2 along an outer circumference of element 14 or 714 opposite to the single channel CH or 760).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Quilici in view of Li et al. does not show the first and the second windings only extend around a same half of the magnetic core.
Wang ‘941 shows a coil assembly (Figs. 6-7) teaching and suggesting the first (one coil from element 143 to element 144) and the second (another coil from element 145 to element 146) windings only extend around a same half of the magnetic core (13, see Figs. 6-7, one coil from element 143 to element 144 and another coil from element 145 to element 146 only extend around a same half of element 13).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Wang ‘941 for the device as disclosed by Quilici in view of Li et al. to achieve desired number of turns and coupling to improve inductance; and achieve miniaturization such as reduced size (Paragraph [0011]).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Lloyd [U.S. Pub. No. 2016/0254090] and Wang et al. [U.S. Pub. No. 2012/0025941] (hereinafter as “Wang ‘941”).
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Lloyd shows a magnetic component (Figs. 4, Figs. 5A-5B, and Drawing III below) teaching and suggesting a single channel (channel CH) that extends between the cavity (302) and an exterior (edge E) of the device and that defines an opening (see Drawing III below, there is a single channel CH that extends between element 302 and edge E and that defines an opening); the first winding (winding W1 or winding W2 of element 410) includes vias (vias V1 or vias V2, see Drawing III below) along an exterior periphery (outer circumference) of the magnetic core (304) opposite to the single channel (see Drawing III below, winding W1 or winding W2 of element 410 includes vias V1 or vias V2 along an outer circumference of element 304 opposite to the single channel CH).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Quilici in view of Lloyd does not show the first and the second windings only extend around a same half of the magnetic core.
Wang ‘941 shows a coil assembly (Figs. 6-7) teaching and suggesting the first (one coil from element 143 to element 144) and the second (another coil from element 145 to element 146) windings only extend around a same half of the magnetic core (13, see Figs. 6-7, one coil from element 143 to element 144 and another coil from element 145 to element 146 only extend around a same half of element 13).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Wang ‘941 for the device as disclosed by Quilici in view of Lloyd to achieve desired number of turns and coupling to improve inductance; and achieve miniaturization such as reduced size (Paragraph [0011]).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Li et al. [U.S. Pub. No. 2014/0116758] and Hill et al. [U.S. Pub. No. 2020/0006250].
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14 and Drawings 1, 2, 3, 4, and Drawings I and II below) teaching and suggesting a single channel (472, 760, 1360, or 1560) that extends between the cavity (cavity C [see Drawing 1 below], see also elements 724, 1324, 1524) and an exterior (edge E [see Drawings 1 and 2 below], see also elements 764a, 1364, 1564) of the device and that defines an opening (472a, 766, 1366, 1566); the first winding (winding W1 or winding W2 of element 16 or 716) includes vias (vias V1 or vias V2, see Drawings I and II below) along an exterior periphery (outer circumference) of the magnetic core (14 or 714) opposite to the single channel (channel CH or 760, see Drawings I and II below, winding W1 or winding W2 of element 16 or 716 includes vias V1 or vias V2 along an outer circumference of element 14 or 714 opposite to the single channel CH or 760).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Quilici in view of Li et al. does not show the first and the second windings only extend around a same half of the magnetic core.
Hill et al. shows a coil assembly (Fig. 1) teaching and suggesting the first (111) and the second (121) windings only extend around a same half of the magnetic core (102, see Fig. 1, elements 111, 121 only extend around a same half of element 102).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Hill et al. for the device as disclosed by Quilici in view of Li et al. to achieve desired number of turns and coupling to improve inductance, achieve miniaturization, and facilitate mechanical rigidity to prevent or reduce warpage of the package (Paragraph [0056]).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Lloyd [U.S. Pub. No. 2016/0254090] and Hill et al. [U.S. Pub. No. 2020/0006250].
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Lloyd shows a magnetic component (Figs. 4, Figs. 5A-5B, and Drawing III below) teaching and suggesting a single channel (channel CH) that extends between the cavity (302) and an exterior (edge E) of the device and that defines an opening (see Drawing III below, there is a single channel CH that extends between element 302 and edge E and that defines an opening); the first winding (winding W1 or winding W2 of element 410) includes vias (vias V1 or vias V2, see Drawing III below) along an exterior periphery (outer circumference) of the magnetic core (304) opposite to the single channel (see Drawing III below, winding W1 or winding W2 of element 410 includes vias V1 or vias V2 along an outer circumference of element 304 opposite to the single channel CH).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Quilici in view of Lloyd does not show the first and the second windings only extend around a same half of the magnetic core.
Hill et al. shows a coil assembly (Fig. 1) teaching and suggesting the first (111) and the second (121) windings only extend around a same half of the magnetic core (102, see Fig. 1, elements 111, 121 only extend around a same half of element 102).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Hill et al. for the device as disclosed by Quilici in view of Lloyd to achieve desired number of turns and coupling to improve inductance, achieve miniaturization, and facilitate mechanical rigidity to prevent or reduce warpage of the package (Paragraph [0056]).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Li et al. [U.S. Pub. No. 2014/0116758] and Okuzawa et al. [U.S. Pub. No. 2007/0075819].
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Li et al. shows a magnetic component (Fig. 8a, Figs. 14-16, Fig. 22, or Fig. 24 with general teaching of Fig. 1, Fig. 3, or Fig. 14 and Drawings 1, 2, 3, 4, and Drawings I and II below) teaching and suggesting a single channel (472, 760, 1360, or 1560) that extends between the cavity (cavity C [see Drawing 1 below], see also elements 724, 1324, 1524) and an exterior (edge E [see Drawings 1 and 2 below], see also elements 764a, 1364, 1564) of the device and that defines an opening (472a, 766, 1366, 1566); the first winding (winding W1 or winding W2 of element 16 or 716) includes vias (vias V1 or vias V2, see Drawings I and II below) along an exterior periphery (outer circumference) of the magnetic core (14 or 714) opposite to the single channel (channel CH or 760, see Drawings I and II below, winding W1 or winding W2 of element 16 or 716 includes vias V1 or vias V2 along an outer circumference of element 14 or 714 opposite to the single channel CH or 760).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Li et al. for the device as disclosed by Quilici to obtain vent openings are open to atmosphere such that the vent openings fluidly connect the recesses to the atmosphere to prevent undesired air burst and/or enabling air, moisture, and/or other fluids trapped within the recess to exhaust from the recess to the atmosphere (Paragraph [0032]).
Quilici in view of Li et al. does not show the first and the second windings only extend around a same half of the magnetic core.
Okuzawa et al. shows a device (Fig. 1) teaching and suggesting the first (11) and the second (12) windings only extend around a same half of the magnetic core (141, see Fig. 1, elements 11, 12 only extend around a same half of element 141).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Okuzawa et al. for the device as disclosed by Quilici in view of Li et al. to achieve desired number of turns and coupling to improve inductance, achieve miniaturization/low profile with small size and low cost, high electrical characteristics and obtain high permeability where leakage of magnetic flux can be prevented (Paragraph [0013], [0279], [0280]).
Claim(s) 23 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici [U.S. Pub. No. 2019/0333674] in view of Lloyd [U.S. Pub. No. 2016/0254090] and Okuzawa et al. [U.S. Pub. No. 2007/0075819
Regarding Claim 23, Quilici shows a device (Figs. 50a-50d and 51) comprising:
a substrate (FR-4 substrate, see Fig. 51) including a cavity (cavity for Ferromagnetic Core);
a magnetic core (Ferromagnetic Core) in the cavity (see Fig. 51);
a first winding (Layer 2 Conductor, Layer 3 Conductor, Via Barrel Layer 2-3) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51);
a second winding (Layer 1 Conductor, Layer 4 Conductor, Via Barrel Layer 4-1) extending around the magnetic core (Ferromagnetic Core, see Figs. 50-50d and 51) and around a portion of the first winding (see Figs. 50-50d and 51);
a first covering (Top, Cover-Lay or Solder Mask) located on a first surface (top surface) of the substrate (FR-4 substrate) and covering a first portion (Layer 4 Conductor) of the second winding (see Figs. 50-50d and 51); and
a second covering (Bottom Cover-Lay of Solder Mask) located on a second surface (bottom surface) of the substrate (FR-4 substrate) and covering a second portion (Layer 1 Conductor) of the second winding (see Figs. 50-50d and 51); wherein
the first winding includes vias (outer Via Barrel Layer 2-3) along an exterior periphery (outer circumference) of the magnetic core (see Figs. 50-50d and 51, outer Via Barrel Layer 2-3 along an outer circumference of Ferromagnetic Core).
Quilici does not show a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel; and the first and the second windings only extend around a same half of the magnetic core.
Lloyd shows a magnetic component (Figs. 4, Figs. 5A-5B, and Drawing III below) teaching and suggesting a single channel (channel CH) that extends between the cavity (302) and an exterior (edge E) of the device and that defines an opening (see Drawing III below, there is a single channel CH that extends between element 302 and edge E and that defines an opening); the first winding (winding W1 or winding W2 of element 410) includes vias (vias V1 or vias V2, see Drawing III below) along an exterior periphery (outer circumference) of the magnetic core (304) opposite to the single channel (see Drawing III below, winding W1 or winding W2 of element 410 includes vias V1 or vias V2 along an outer circumference of element 304 opposite to the single channel CH).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have a single channel that extends between the cavity and an exterior of the device and that defines an opening; the first winding includes vias along an exterior periphery of the magnetic core opposite to the single channel as taught by Lloyd for the device as disclosed by Quilici to aids with cooling of the component during operation (Paragraph [0074]).
Quilici in view of Lloyd does not show the first and the second windings only extend around a same half of the magnetic core.
Okuzawa et al. shows a device (Fig. 1) teaching and suggesting the first (11) and the second (12) windings only extend around a same half of the magnetic core (141, see Fig. 1, elements 11, 12 only extend around a same half of element 141).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have the first and the second windings only extend around a same half of the magnetic core as taught by Okuzawa et al. for the device as disclosed by Quilici in view of Lloyd to achieve desired number of turns and coupling to improve inductance, achieve miniaturization/low profile with small size and low cost, high electrical characteristics and obtain high permeability where leakage of magnetic flux can be prevented (Paragraph [0013], [0279], [0280]).
Claim(s) 24 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. as applied to claim 23 above, and further in view of Noguchi et al. [U.S. Patent No. 5,959,846].
Regarding Claim 24, Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. shows a module comprising: the device of claim 23 (see claim 23 rejection above).
Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. does not explicitly show electronic components mounted on the first covering and/or the second covering; and a conformal coating or molding covering the electronic components.
Noguchi et al. shows a device (Figs. 1-15) teaching and suggesting a module comprising a device (see Figs. 1-15) and electronic components (26, 28 or 35, 36, 37) mounted on the first covering (2a or 2d) and/or the second covering; and a conformal coating or molding (30) covering the electronic components (see Figs. 1-15).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have electronic components mounted on the first covering and/or the second covering; and a conformal coating or molding covering the electronic components as taught by Noguchi et al. for the device as disclosed by Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. to shield and protect the electronic components to prevent damage and achieve desirable operating characteristics (Col. 6, Lines 1-13, Col. 9, Lines 11-17).
Claim(s) 24 is/are rejected under 35 U.S.C. 103 as being unpatentable over Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. as applied to claim 23 above, and further in view of Otsubo [KR 2016-0001626].
Regarding Claim 24, Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. shows a module comprising: the device of claim 23 (see claim 23 rejection above).
Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. does not explicitly show electronic components mounted on the first covering and/or the second covering; and a conformal coating or molding covering the electronic components.
Otsubo shows a device (Fig. 1) teaching and suggesting a module comprising a device (see Fig. 1) and electronic components (3) mounted on the first covering (top or middle layer of element 20) and/or the second covering; and a conformal coating or molding (4) covering the electronic components (see Fig. 1).
Before the effective filing date of the claimed invention, it would have been obvious to a person of ordinary skill in the art to have electronic components mounted on the first covering and/or the second covering; and a conformal coating or molding covering the electronic components as taught by Otsubo for the device as disclosed by Quilici in view of Li et al. and Wang ‘941 OR Quilici in view of Lloyd and Wang ‘941 OR Quilici in view of Li et al. and Hill et al. OR Quilici in view of Lloyd and Hill et al. OR Quilici in view of Li et al. and Okuzawa et al. OR Quilici in view of Lloyd and Okuzawa et al. to shield and protect the electronic components to prevent damage and achieve desirable operating characteristics (Paragraph [0045]).
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Conclusion
Any inquiry concerning this communication or earlier communications from the examiner should be directed to TSZFUNG J CHAN whose telephone number is (571)270-7981. The examiner can normally be reached M-TH 8:00AM-6:00PM.
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If attempts to reach the examiner by telephone are unsuccessful, the examiner’s supervisor, Shawki Ismail can be reached at (571)272-3985. The fax phone number for the organization where this application or proceeding is assigned is 571-273-8300.
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/TSZFUNG J CHAN/Primary Examiner, Art Unit 2837
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