DE102007045946A1 - Coil e.g. rectangular coil, producing method for generating spatially defined, controllable magnetic field, involves rolling flexible, electrical insulating substrate on which conductor is superimposed or in which conductor is placed - Google Patents

Abstract

The method involves rolling a flexible, electrical insulating substrate (3) on which a conductor (2) is superimposed or in which the conductor is placed, such that the conductor forms a three dimensional conductor structure. A single layer is superimposed on a side of the flexible, electrical insulating substrate, before the rolling of the conductor. A flat coil is generated on a layer of the substrate. The flat coil is executed as a spiral coil (8), a meander coil or a helix coil with a magnetic conductor.

Description

The The invention relates to a method for producing a coil and a coil.

in the State of the art is a generation of spatially defined, controllable Magnetic fields by means of excitation coils, which consist of one or more arranged appropriately electrical conductors, z. As metal wires or metal foils exist and electric currents be flowed through.

Usually electric coils consist of one with a defined number of turns wrapped around a magnetic or non-magnetic core material, high quality electrical conductor, z. B. a metal wire or a Metal foil. The wires or foils are either free or defined wound on a bobbin and by means of an insulating layer, e.g. As a paint, electrically isolated.

Do the washing up can for example, according to a coil shape, z. B. cylindrical coils, rectangular coils, form coils, after a coil execution, z. B. wire coils, foil coils, after a coil winding, z. B. In-line winding, orthocyclic winding, disordered winding, or a number of coils, z. B. with a coil, with several coils, whose electric fields overlap, to be grouped.

Farther Foil or tape reels are known in the art, in which with the goal of a high conductor fill factor a film or tape material is wound, with individual Layers of the film or strip material by means of an introduced Insulation layer are executed electrically isolated from each other.

adversely is, however, that in coil systems, such. B. stator windings in electric motors or multipole coils in electron-optical devices, the previously described classic winding the coil is very expensive. It must Single coils wound according to a defined winding scheme be that when an energization of the coils with an electric Power is generated a three-dimensional magnetic field, its field strength and Induction distribution is precisely defined. For small production quantities is common an elaborate one manual winding necessary, with large production quantities mechanical devices are used with which the electrical conductor, z. B. the metal wire, wound and passed through a Statorhohlkörper.

The The object of the invention is an improved method to provide for the preparation of a coil and a coil, in particular the overcome disadvantages indicated in the prior art.

The solution The object succeeds according to the invention by a method with the Feature combination according to claim 1 and by a coil with the combination of features according to claim 21st

advantageous Embodiments of the invention are the subject of the dependent claims.

at the method according to the invention For producing a coil is a flexible, electrically insulating Substrate on which a current conductor is applied or in which the conductor is inserted, rolled. It is necessary that also conductor material of the conductor is made flexible, d. H. is formed such that a rolling of the electrically insulating Substrates with applied or introduced conductor none damage or destruction caused a structure of the conductor.

there becomes the flexible, electrically insulating substrate with the applied or introduced conductor so rolled that the coil a has cylindrical shape. This may, for example, to a circular cylinder, a cuboid or a prism with a different one Number of lateral surfaces act.

Based the rolling of the flexible, electrically insulating substrate with the applied or introduced conductor is a three-dimensional Achieved ladder structure, so that when subjected to a Electric current advantageously a magnetic field with a exactly defined, predetermined field structure can be generated.

Especially It is advantageous that from the rolling of the flexible, electric insulating substrate with applied or introduced conductors a coil results in comparison to conventional wire windings a improved thermal conductivity having. This improved thermal conductivity is achieved in particular by the fact that the individual layers of Coil, for example by pressing, are interconnected, that no air pockets exist within the coil. Alternatively or additionally between the individual layers an intermediate layer, in particular a thermal conductor, z. B. a thermally conductive adhesive, be introduced. Thus, despite a low conductor fill factor, which leads advantageously to a low weight of the coil, a high permissible Current density can be achieved. The conductor fill factor gives the proportion the conductor volume, z. As the volume of copper to the total volume to the coil.

Furthermore, in the inventive Method before rolling a conductor applied at least one layer on or in at least one side of the flexible, electrically insulating substrate or introduced. This means that the flexible, electrically insulating substrate is either applied or introduced on one or both sides of the current conductors, wherein the current conductors are designed in one or more layers. The current conductors can be applied or introduced in such a way that one or more flat coils are produced on one layer. The flat coils can be designed, for example, as a spiral coil, meander coil or as a helix coil with a magnetic conductor.

The flexible, electrically insulating substrate becomes multiple layers Rolled up with layers of corresponding sections of conductors. The Layerwise corresponding sections of conductors can thereby be arranged in a row and / or parallel on the substrate. The application of the current conductor is in particular a lithographic Produced manufacturing process, which It is easy to reorient and precise positioning of the conductors allows.

there can the conductors of a layer with each other and / or layers corresponding sections of conductors of a layer and / or different layers of contact surfaces electrically be connected to each other. Thus, it is possible the power conductors depending on preset requirements so electrically connect, for example in a cyclic arrangement of the layerwise corresponding Power conductor a multipole, z. A dipole, a cross dipole, a quadrupole or a hexapole can be realized with the rolled coil. These Circuit arrangements are with conventional coil arrangements very expensive, in contrast, with the present invention, simple and inexpensive to implement.

Farther can from the contact surfaces via a longitudinal edge protruding from the substrate Flags be formed by means of which the corresponding layers Sections of conductors of different layers electrically connected be and the coil from the outside can be electrically contacted in a simple manner.

The supernumerary Flags are used for electrical contacting of the layers corresponding sections of conductors of different layers or to an external electrical contact by means of a soldering, bonding, Adhesive and / or a clamping method electrically connected.

The different layers of the coil are additionally punctiform and / or surface cohesive, non-positive or a form fit, z. B. by riveting, welding, Soldering or Bonding techniques linked together. Furthermore, distances between the sections of conductors designed so enlarging, that when rolling with layer by layer increasing extent of the layers corresponding Sections of conductors lie one above the other without offset. The lithographic Manufacturing process allows that the position of each conductor can be specified precisely. Thus, a via of the layerwise corresponding Sections of conductors of different layers at the contact surfaces allows.

Farther gets a layer by layer check up Offset the one above the other lying, corresponding sections of conductors based a use of markings, in particular a mark per scope, reached. For this purpose, in particular on the flat substrate Adjustment marks or alignment holes introduced, in addition to a use as a marker in advantageous Way at the same time as connecting points of the individual layers means Rivet, welding, Soldering or gluing techniques used can be.

One Offset one above the other lying corresponding sections of conductors is in layers balanced by means of a correction, this correction being specific based on a variation of a strength an intermediate layer arranged between the individual layers is made. For this, for example, a lot of glue between the individual layers are varied.

In the coil can additionally Cavities incorporated in which soft magnetic and / or hard magnetic elements can be arranged. These cavities arise either before rolling through the introduction of cavities in the flexible, electrically insulating substrate or can after the Roles, z. B. by means of a drill or a laser, in the coil be introduced.

Farther can Ironwork parts partially and / or completely incorporated. These are completely wrapped or rolled in rolls from the substrate after rolling in cavities, in accordance with the cavities for the soft magnetic and / or hard magnetic elements are introduced introduced.

Out the targeted introduction of soft and / or hard magnetic elements As well as iron parts, the advantage that a course and the size of a influenced or magnetic flux during the production of the coil can be specified.

While rolling the coil can electrical components, eg. As ohmic resistors, capacitors or transistors, incorporated into the coil and are electrically connected to the contact surfaces of the conductors. Thus, in the manufacture of the coil complex electrical circuits can be realized physically small. As an alternative and / or in addition, the electrical components can also be arranged on the coil after rolling such that they are electrically connectable to the conductors by means of the projecting lugs.

The Invention will be explained in more detail below with reference to exemplary embodiments.

there demonstrate:

1 schematically a conductor applied as a flat coil on a substrate conductor,

2 schematically a periodic arrangement of applied as a flat coil on a substrate conductors,

3 schematically a rolled coil,

4 schematically a helical coil,

5 schematically a rolled coil with cavities,

6A schematically a possible embodiments of a rolled coil as a prism, and

6B schematically a possible embodiments of a rolled coil as a cuboid.

each other corresponding parts are in all figures with the same reference numerals Mistake.

1 shows a flat coil on a flexible, electrically insulating substrate 3 applied conductor 2 , In one embodiment of the invention, the current conductor 2 alternatively in the flexible, electrically insulating substrate 3 be introduced. As 1 shows, the flat coil is a spiral coil 8th educated. The conductor 2 is one-sided and one-layer, in particular by means of a lithographic process, on the substrate 3 applied. In one embodiment of the invention, the current conductor 2 but also on both sides and / or multi-layered on the substrate 3 be applied.

Shown is a layer of the substrate 3 with applied conductor 2 , For producing the coil according to the invention 1 become one or more layers of the substrate 3 with applied conductors 2 rolled up. It is necessary that also the conductor material of the conductor 2 is designed to be flexible, that is designed such that a rolling of the substrate 3 with applied conductor 2 no damage or destruction of a structure of the conductor 2 caused. On every layer of the substrate 3 can be a conductor 2 or what 2 shows, several conductors 2 be arranged in a row. It is alternatively or additionally possible that the conductors 2 are arranged in parallel.

The power conductors 2 have contact surfaces 4 on which several power conductors 2 a single layer, a group of conductors 2 a single layer or conductor 2 various layers are electrically connected together. To the contact surfaces 4 several conductors 2 on different layers of the substrate 3 electrically connect to each other, a via 9 (= Via, from English: Vertical Interconnect Access) used.

To an application of the via 9 it is necessary that contact surfaces 4 the conductor 2 lie one above the other without offset. These are in the substrate 3 at the end of a position (= 360 °) markings 10 arranged, which are designed in particular as Justagemarken or Justagelöcher. Thus, in the rolling of the substrate 3 be sure that the power conductors 2 lie one above the other without offset. The marks 10 can simultaneously as a connection point of a non-illustrated selective connection of the individual nen layers of the substrate 3 be used by riveting, welding, soldering or gluing techniques.

A correction of the arrangement of the individual layers can be achieved by means of a variation of a thickness of a 4 illustrated intermediate layer 7 be performed so that a possibly occurring offset of the superposed conductor 2 is compensated.

In the substrate 3 can cavities before rolling 5 are introduced, in which not shown soft magnetic and / or hard magnetic elements and / or iron circuit parts can be arranged. These cavities 5 may alternatively and / or additionally after rolling in the coil 1 be introduced.

Furthermore, at the contact surfaces 4 the conductor 2 not shown electrical components, such as capacitors, ohmic resistors or transistors electrically connected to the conductors 2 get connected. The components are used in rolling the substrate 3 and the conductor 2 with rolled up and are thus in the coil 1 integrated.

2 represents a periodic arrangement of as a flat coil on the substrate 3 applied conductors 2 There are four as a meander coil 11 formed flat coils in a row on a layer of the substrate 3 arranged. However, the flat coils can alternatively also be used as a spiral coil 8th according to 1 or as a helix coil 12 according to 4 be educated.

The production of the coil 1 is carried out according to the in 1 shown coil 1 with the difference that to the in 1 shown position of the substrate 3 with applied conductor 2 the contact surfaces 4 as flags 13 over a longitudinal edge 14 of the substrate 3 are formed protruding. By means of these flags 13 can the power conductors 2 and / or groups of conductors 2 on a layer or on different layers of the substrate 3 electrically connected to each other. Furthermore, it is possible to use the flags 13 the rolled up coil 1 to the outside, z. B. with an electrical circuit or with electrical components to connect. The electrical connection is carried out, for example, by means of a soldering, bonding, bonding process and / or a clamping method.

Based on the illustrated periodic / cyclic arrangement of the flat coils can in the rolling of the substrate 3 and the conductor 2 in a simple manner, a multipole, in particular a quadrupole, are produced. By a variation of the number of flat coils and a variation of the electrical interconnection of the individual flat coils, it is possible to use various other multipoles, for. B. dipoles, cross dipoles or hexapoles produce.

3 shows a rolled coil 1 which has a circular basic shape. Here are the substrate 3 and the conductors 2 around a cylindrical base body 6 rolled. The rolled coil 1 may alternatively be formed as a circular cylinder as a cuboid, according to 6b , or as a prism with a different number of lateral surfaces, according to 6a be trained.

Between the individual layers of the substrate 3 with applied conductors 2 is an intermediate layer 7 arranged. Based on a variation of the thickness of the intermediate layer 7 On the one hand, an offset of the superposed conductor 2 , by checking the markings 10 to be compensated. On the other hand, by means of the intermediate layer 7 a flat connection of the individual layers possible. For this purpose, the intermediate layer is formed, for example, as a thermally conductive adhesive, the same time a thermal energy of the conductors 2 and absorbs this to the environment of the coil 1 emits. Thus, despite a low conductor fill factor of the coil 1 an impingement of the conductors 2 with a high electric current, ie a high current density can be realized.

By rolling a three-dimensional conductor structure is further achieved, so that when subjected to the current conductor 2 with the electric current in an advantageous manner by means of the coil 1 a magnetic field with a well-defined, predetermined field structure can be generated.

4 shows a flat coil acting as a helix coil 12 is executed. The helix coil 12 created by a winding of conductors 2 around a flexible trained magnetic conductor 15 , The resulting flat coil, in particular helix coil 12 , will, as under 1 and 2 described on the substrate 3 applied and to a coil 1 rolled.

5 represents a rolled coil 1 with introduced cavities 5 dar. The rolled coil 1 will according to the descriptions of the 1 to 4 produced. In the cavities introduced before rolling or after rolling 5 soft and / or hard magnetic materials and / or iron circuit parts can be arranged and thus advantageously predetermined and / or influenced a magnetic flux of the coil.

6a put the coil 1 according to the descriptions of the 1 to 5 was prepared in the form of a prism with three lateral surfaces. In this case, the individual layers of the substrate 3 with applied conductors 2 around a magnetic or non-magnetic prismatic body 6 wound. However, in a further embodiment of the invention, the prism can also have more than three lateral surfaces. Also, additionally not shown cavities 5 in the coil 1 are introduced, the soft and / or hard magnetic elements and / or Eisenkreileile record.

6b put the coil 1 according to the descriptions of the 1 to 5 in the form of a cuboid. In this case, the individual layers of the substrate 3 with applied conductors 2 around a magnetic or non-magnetic cuboid base body 6 wound. Again, not shown cavities 5 in the coil 1 are introduced, the soft and / or hard magnetic elements and / or Eisenkreileile record.

1

Kitchen sink

2

conductor

3

substratum

4

contact area

5

cavity

6

body

7

interlayer

8th

spiral coil

9

via

10

marks

11

meandering

12

helix coil

13

Banner, flag

14

longitudinal edge

15

magnetic ladder

Claims (36)

Method for producing a coil 1 , characterized in that a flexible, electrically insulating substrate 3 on which a current conductor 2 applied or in which the current conductor 2 is introduced, is rolled. A method according to claim 1, characterized in that before rolling the current conductor 2 at least one layer on at least one side of the flexible, electrically insulating substrate 3 is applied. A method according to claim 1 or 2, characterized in that the current conductor 2 before rolling on the flexible, electrically insulating substrate 3 is applied, that a flat coil or more flat coils on a layer of the substrate 3 is generated or will be. A method according to claim 3, characterized in that the flat coil as a spiral coil 8th , Meander coil 11 or as a helix coil 12 is performed with a magnetic conductor. Method according to one of claims 1 to 4, characterized in that a plurality of layers with layerwise corresponding sections of conductors 2 to be rolled. Method according to claim 5, characterized in that that several layers connected point and / or area become. Method according to claim 5 or 6, characterized that for a compound of the layers cohesive, non-positive or positive connection techniques, in particular riveting techniques, welding techniques, bonding techniques, Soldering techniques and / or Adhesive techniques are used. Method according to one of claims 5 to 7, characterized in that between the layers an intermediate layer 7 , in particular a thermal conductor and / or an adhesive is introduced. Method according to one of claims 5 to 8, characterized in that distances between sections of conductors 2 be formed such enlarging that when rolling with layers of wise enlarging perimeter of the layers corresponding sections of conductors 2 superimposed on each other without offset. Method according to one of Claims 5 to 9, characterized in that a layer-by-layer check for offset of the corresponding, corresponding sections of current conductors is provided 2 using a label 10 , in particular a marker 10 per scope is reached. A method according to claim 10, characterized in that an offset of superposed, corresponding portions of conductors 2 in layers by means of a correction, in particular by means of a variation of a thickness of the intermediate layer 7 , is compensated. Method according to one of claims 1 to 11, characterized in that current conductors 2 each one layer of contact surfaces 4 electrically connected to each other. Method according to one of claims 5 to 12, characterized in that the layer-wise corresponding sections of conductors 2 each one layer of contact surfaces 4 electrically connected to each other. Method according to one of claims 5 to 13, characterized in that the layer-wise corresponding sections of conductors 2 different layers based on vias 9 at contact surfaces 4 vertical to the contact surfaces 4 electrically connected to each other. Method according to one of claims 12 to 14, characterized in that of the contact surfaces 4 from over a longitudinal edge 14 of the substrate 3 protruding flags 13 are formed, by means of which the layers corresponding sections of conductors 2 various layers are electrically connected together. Method according to one of claims 12 to 15, characterized in that of the contact surfaces 4 from over a longitudinal edge 14 of the substrate 3 protruding flags 13 are formed, by means of which the coil 1 is electrically contacted from the outside. Method according to one of claims 1 to 16, characterized in that during rolling in the coil 13 incorporated electrical components and / or after rolling from the outside of the coil 1 be arranged, the electrical components with the conductors 2 electrically at the contact surfaces 4 and / or the overhanging flags 13 get connected. A method according to claim 17, characterized in that the projecting flags 13 with each other and / or to an electrical contact from the outside, the vias 9 and the introduced electrical components are electrically connected by soldering, bonding, gluing and / or clamping methods. Method according to one of claims 5 to 18, characterized in that before rolling into individual layers and / or after rolling into several layers of the coil 1 cavities 5 eingear be processed, in which soft magnetic and / or hard magnetic elements are introduced. Method according to one of claims 5 to 19, characterized in that during rolling in the coil 1 Ironing parts are fully incorporated and / or that during rolling into individual layers and / or after rolling in multiple layers of the coil 1 cavities 5 are incorporated, in which after rolling iron circuit parts are introduced. Kitchen sink 1 , in particular produced by a process according to one of claims 1 to 20, characterized in that a flexible, electrically insulating substrate 3 on which a current conductor 2 applied or in which the current conductor 2 is rolled in such a way that current conductors 2 form a three-dimensional conductor structure, so that when subjected to the current conductor 2 With an electric current, a magnetic field with a predetermined field structure can be generated. Kitchen sink 1 according to claim 21, characterized in that the flexible, electrically insulating substrate 3 and the applied conductor 2 rolled so that the coil 1 has a cylindrical shape. Kitchen sink 1 according to claim 21 or 22, characterized in that a layer with one or more layerwise corresponding sections of conductors 2 is executed, wherein the layer-wise corresponding sections of conductors 2 arranged in a row and / or in parallel. Kitchen sink 1 according to claim 23, characterized in that a plurality of layers with layerwise corresponding sections of conductors 2 are rollable, so over the circumference of the coil 1 one or more corresponding sections of conductors 2 are arranged on each layer. Kitchen sink 1 according to one of claims 21 to 24, characterized in that cyclically on the electrically insulating substrate 3 applied layerwise corresponding sections of conductors 2 a multipole can be realized. Kitchen sink 1 according to claim 25, characterized in that the multipole is designed as a dipole, cross dipole, quadrupole or hexapole. Kitchen sink 1 according to one of claims 23 to 26, characterized in that several layers are punctiform and / or surface by means of riveting techniques, welding techniques, bonding techniques, soldering techniques and / or bonding techniques connected to each other. Kitchen sink 1 according to one of claims 23 to 27, characterized in that between the layers an intermediate layer 7 In particular, a thermal conductor for receiving and dissipating thermal energy is arranged. Kitchen sink 1 according to any one of claims 21 to 28, characterized in that a mark 10 , in particular a marker 10 per circumference on the substrate 3 which is a layer-by-layer check for displacement of the superimposed, corresponding sections of conductors 2 allows. Kitchen sink 1 according to claim 29, characterized in that an intermediate layer 7 is arranged with variable thickness, so that the offset of superimposed, corresponding portions of conductors 2 is compensable in layers. Kitchen sink 1 according to one of claims 21 to 30, characterized in that based on contact surfaces 4 the conductors 2 and / or the corresponding sections of conductors 2 layerwise electrically connectable. Kitchen sink 1 according to claim 31, characterized in that plated-through holes 9 at the contact surfaces 4 vertical to the contact surfaces 4 the layerwise corresponding sections of conductors 2 electrically connect different layers. Kitchen sink 1 according to claim 31 or 32, characterized in that by means of a longitudinal edge 14 of the substrate 3 protruding flags 13 layer by section corresponding sections of conductors 2 various layers are electrically connected. Kitchen sink 1 according to claim 33, characterized in that by means of the flags 13 the sink 1 From the outside is electrically contacted. Kitchen sink 1 according to one of claims 21 to 34, characterized in that based on in cavities 5 used soft magnetic and / or hard magnetic elements, a magnetic River is controllable. Kitchen sink 1 according to one of claims 21 to 35, characterized in that a magnetic flux is controllable on the basis of rolling elements integrated or used in cavities Eisencreisteilen.