EP0217219B1 - Miniature induction coil and method of making the same - Google Patents

Miniature induction coil and method of making the same Download PDF

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Publication number
EP0217219B1
EP0217219B1 EP86112759A EP86112759A EP0217219B1 EP 0217219 B1 EP0217219 B1 EP 0217219B1 EP 86112759 A EP86112759 A EP 86112759A EP 86112759 A EP86112759 A EP 86112759A EP 0217219 B1 EP0217219 B1 EP 0217219B1
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EP
European Patent Office
Prior art keywords
skids
metal strip
cover
central opening
support
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP86112759A
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German (de)
French (fr)
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EP0217219A1 (en
Inventor
Guy Barbier
Jean-Paul Amory
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Alcatel CIT SA
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Alcatel CIT SA
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Publication date
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Publication of EP0217219A1 publication Critical patent/EP0217219A1/en
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Publication of EP0217219B1 publication Critical patent/EP0217219B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/027—Casings specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10—Connecting leads to windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F2017/048—Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49799—Providing transitory integral holding or handling portion

Definitions

  • the present invention relates to a miniature electronic component having an adjustable inductance consisting of a winding associated with a ferromagnetic plunger core whose penetration depth is adjustable.
  • this kind of miniature inductance sometimes has surface defects: small craters due to air bubbles trapped along the walls of the mold during the pouring of the resin or undesirable bosses due to the deterioration of the flexible mold. These surface defects in addition to the fact that they are unsightly can adversely affect the quality of the component because they can cause pockets of retention for the corrosive products of the solder flux used during the mounting of the component.
  • the object of the present invention is to remedy these various drawbacks while retaining a low cost price.
  • a miniature inductance formed by a winding welded to a pair of connection pads, a ferromagnetic plunger core threaded at least in part and a cover made of pressure-molded plastic material having two opposite side walls on the edge of which the connection pads are stapled, which are traversed by a central orifice serving as housing for the plunger core and which are separated by a solid part in which said orifice is tapped in a manner complementary to the thread of the plunger core and by a hollow part in which said winding is arranged in the axis of said orifice and embedded in a resin.
  • the miniature inductance in the form of a rectangular parallelepiped. It comprises a cover 1 carrying connection pads 2, 3 and enclosing a cylindrical winding 4 embedded in resin and provided with a plunger core 5.
  • the cover 1 has the general shape of a hollow die opened by its bottom. It has two opposite side walls 6, 7 which bear on their edge the connection pads 2, 3 and which are traversed right through by a central orifice serving as housing for the plunger core 5. These two side walls 6, 7 are separated by a solid part 8 of the cover in which the central orifice is provided with a thread 9 and by a hollow part 10 which serves as a housing for the cylindrical winding 4 centered on the central orifice.
  • Grooves 11, 12, 13 formed around the solid part 8, along the side walls of the cover 1 allow the fitting of a connection pad 3 on the edge of the side wall 6 adjacent to the solid part 8 as well as the housing for the electrical connection of the winding 4 to this pad 3 and the supply of resin from the hollow part to reinforce the fixing of this pad 3.
  • connection pads 2, 3 are identical. Their shape appears more clearly in Figures 2 and 3. Each of them consists of a metal tongue folded longitudinally in a U shape with two wings approximately the same height 15, 16 joined by a base 17 placed astride a ledge of the hood wall. One of the wings, 15, coming outside the hood, has a rectangular profile started in the middle by a large rounded notch 18 ensuring the release of the central orifice serving as housing for the plunger core.
  • the other wing, 16 has two tabs 19, 20 with a dovetail profile which come inside the cover and serve to anchor the pad in the plastic coating material and one of which, 19 , is extended on the side of a folded finger 21 used for fixing one end of the winding 4.
  • the plunger core 5 shown in FIG. 1 consists of a ferromagnetic rod 24 provided with a threaded head 25 adapted to the internal thread 9 of the central orifice and hollowed out with a diametrical actuation slot 26.
  • the adjustable miniature inductor which has just been described connects to the tracks of a printed circuit or of a hybrid circuit on ceramic wafer in the manner of small electronic components appearing in the form of a block with connection terminals embedded in their side faces that is to say, either by forming a weld fillet to the surfaces in contact with its connection pads or by placing spacer parts therein.
  • connection pads are produced in pairs from a cut and folded metal strip.
  • This strip is for example a 0.1 mm thick copper strip cut by a photoengraving technique, tinned by an electrolytic technique and then folded.
  • FIG. 2 represents such a strip after cutting and before folding.
  • Several pairs of pads are cut from this strip and separated by centering clips 30. Within each pair, the pads are constituted by bridges thrown through openings 31 and placed face to face in the width direction. the strip, at their final distance. These bridges are attached to the edges of the openings 31 by throttles 32, 33 facilitating their subsequent separation.
  • the covers with their central orifice tapped in the solid part, are obtained by injection molding of a thermosetting plastic material such as for example diallylphthalate in a rigid mold designed in several parts and polished internally in the direction of extraction of the part made to facilitate demolding.
  • a thermosetting plastic material such as for example diallylphthalate
  • This die casting technique eliminates appearance defects, blistering and cra tées, thanks to the rigidity of the mold and the good evacuation of the air included in the mold made possible by the injection pressure. In addition, it does not use a mold release agent.
  • the assembly of the miniature inductors begins by welding the ends of the windings 4 to the fingers 21 of the pairs of pads still attached to their original metal edge which temporarily keeps them in correct positioning.
  • the windings 4 are oriented parallel to the width of the metal strip.
  • One of their ends 35 is not arched, it escapes tangentially and arrives perpendicularly to the finger 21 of one of the connecting pads 2 while their other end 36 is arched parallel to their axis after having escaped tangentially and arrives in the axis of the finger 21 of the other connection pad 3.
  • This arrangement allows the winding of one of the pads to be brought closer so that it is facing the hollow part of the cover and leaves relative to the other shoe sufficient space to accommodate the solid part 8 of the cover supporting the thread in which the plunger core is screwed.
  • a rigid, elongated hood support This, shown in Figure 4, has a series of housings 40 aligned with the same spacing as the pairs of connecting pads on the metal strip and centering pins 41 having the same relative arrangement as the centering clips 30 of the metal strip.
  • Each housing 40 is designed to receive a cover 1 arranged upside down, its central orifice oriented in the width direction of the support, and has in its side walls a hole 42 centered on the central orifice of the cover allowing the introduction a pin 43 saving the clearance space of the plunger core.
  • This pin 43 has a smooth end rod 44 extending through a shoulder a threaded portion 45 of larger diameter suitable for tapping 9 of the covers, itself followed by a non-threaded portion 46 ending in a gripping head 47.
  • the covers 1, produced by injection molding, are arranged upside down in the housings 40, their central orifice in the extension of the hole 42 of the support.
  • the metal strip with the pairs of connection pads fitted with their windings is then brought opposite the support and then lowered so that the windings 4 penetrate into the hollow parts of the covers 1 and that the pads are fitted on the edges of the side walls of the covers, the precise positioning resulting from the guidance of the end chamfers of the centering pins 41 of the support in the centering clips 30 of the metal strip.
  • the pins 43 are introduced into the openings 42 of the support by screwing them into the threads 9 of the covers to save the clearance space of the plunger cores inside the windings 4 then the hollow part of the covers is filled with a thermosetting plastic coating material which bypasses by grooves 11, 12, 13 the solid part 8 of the cover and reaches the base of the connection pads embedding their anchoring lugs and penetrating by cappillarity between them and the wall of the hood.
  • the pins 43 are removed, the metal strip unclipped from the cover support and the miniature inductors come out of their housing, separated from the metal strip and equipped with their plunger cores.

Description

La présente invention concerne un composant électronique miniature présentant une self inductance ajustable constituée d'un enroulement associé à un noyau plongeur ferromagnétique dont la profondeur de pénétration est réglable.The present invention relates to a miniature electronic component having an adjustable inductance consisting of a winding associated with a ferromagnetic plunger core whose penetration depth is adjustable.

Pour simplifier la fabrication de ce genre de composant et en améliorer les caractéristiques électriques il importe de rendre minimum le nombre de petites pièces accessories à l'enroulement et au noyau plongeur, et notamment d'éviter l'utilisation d'embase de fixation, de bornes de raccordement, de mandrin support d'enroulement, d'entretoises de montage de la bobine sur l'embase et autres pièces supportant le noyau et permettant son coulissement.To simplify the manufacture of this type of component and improve its electrical characteristics, it is important to minimize the number of small accessory parts to the winding and the plunger, and in particular to avoid the use of a mounting base, connection terminals, winding support mandrel, spacers for mounting the coil on the base and other parts supporting the core and allowing it to slide.

Il est connu pour ce faire, par le brevetfrançais n° 2.486.704 d'utiliser un bobinage en fil thermoadhérent, sans support d'enroulement, soudé à une paire de patins de raccordement emboutie dans une bande métallique et enrobé dans une résine coulée à froid et polymérisée à chaud dans une moule souple traversé par une broche ménageant une cavité axiale partiellement filetée pour le logement d'un noyau plongeur formé d'un bâtonnet ferromagnétique avec une vis sans tête surmoulée à une extrémité.It is known to do this, by French patent n ° 2,486,704 to use a coil of thermoadherent wire, without winding support, welded to a pair of connection pads stamped in a metal strip and coated in a resin cast at cold and hot-polymerized in a flexible mold traversed by a spindle providing a partially threaded axial cavity for housing a plunger core formed by a ferromagnetic rod with a grub screw overmolded at one end.

ce genre d'inductance miniature présente parfois des défauts de surface: petits cratères dus à des bulles d'air emprisonnées le long des parois du moule lors du coulage de la résine ou bossages indésirables dus à la détérioration du moule souple. Ces défauts de surface outre le fait qu'ils sont inesthétiques peuvent nuire à la qualité du composant car ils peuvent engendrer des poches de rétention pour les produits corrosifs du flux de soudure utilisé lors du montage du composant.this kind of miniature inductance sometimes has surface defects: small craters due to air bubbles trapped along the walls of the mold during the pouring of the resin or undesirable bosses due to the deterioration of the flexible mold. These surface defects in addition to the fact that they are unsightly can adversely affect the quality of the component because they can cause pockets of retention for the corrosive products of the solder flux used during the mounting of the component.

Son moulage est peu pratique car il nécessite un centrage individuel de chaque composant. En effet, le moule souple se rétracte à chaud lors de la polymérisation de la résine ce qui modifie la distance entre deux empreintes successives de composant et oblige à utiliser chaque paire de patins de raccordement séparément c'est-à-dire à fractionner la bande métallique dans laquelle elles sont embouties au lieu de la conserver pour bénéficier des facilités de centrage qu'elle pourrait apporter. En outre le taraudage de la broche utilisée lors du montage pour ménager le logement du noyau plongeur s'encrasse fréquemment de résidus de résine ce qui rend nécessaires des opérations de nettoyage et de contrôle délicates étant donné les dimensions de la pièce concernée.Its molding is impractical because it requires individual centering of each component. Indeed, the flexible mold shrinks hot during the polymerization of the resin which modifies the distance between two successive impressions of component and obliges to use each pair of connection pads separately that is to say to split the strip metal in which they are stamped instead of keeping it to benefit from the centering facilities that it could provide. In addition, the thread of the spindle used during assembly to save the housing of the plunger core is frequently clogged with resin residues, which makes delicate cleaning and control operations necessary given the dimensions of the part concerned.

La présente invention a pour but de remédier à ces différents inconvénients tout en conservant un faible coût de revient.The object of the present invention is to remedy these various drawbacks while retaining a low cost price.

Elle a pour objet une inductance miniature formée d'un enroulement soudé à une paire de patins de raccordement, d'un noyau plongeur ferromagnétique fileté au moins en partie et d'un capot en matériau plastique moulé sous pression ayant deux parois latérales opposées sur le bord desquels sont agraffés les patins de raccordement, qui sont traversées par un orifice central servant de logement au noyau plongeur et qui sont séparées par une partie pleine dans laquelle ledit orifice est taraudé de manière complémentaire au filetage du noyau plongeuret par une partie creuse dans laquelle ledit bobinage est disposé dans l'axe dudit orifice et noyé dans une résine.It relates to a miniature inductance formed by a winding welded to a pair of connection pads, a ferromagnetic plunger core threaded at least in part and a cover made of pressure-molded plastic material having two opposite side walls on the edge of which the connection pads are stapled, which are traversed by a central orifice serving as housing for the plunger core and which are separated by a solid part in which said orifice is tapped in a manner complementary to the thread of the plunger core and by a hollow part in which said winding is arranged in the axis of said orifice and embedded in a resin.

Elle a également pour objet un procédé de fabrication de plusieurs de ces inductances consistant à:

  • bobiner, sous aur chaud, sur des mandrins provisoires, des enroulements de fil conducteur revêtu d'un isolant thermoadhérent et retirer les mandrins provisoires,
  • étamer et cambrer les extrémités des enroulements,
  • réaliser des noyaux plongeurs par surmoulage de vis sans tête en matière plastique à l'une des extrémités de bâtonnets ferromagnétiques de diamètre inférieur à celui des enroulements,
  • réaliser des paires de patins de raccordements par emboutissage dans une bande métallique sans séparation de la bande, les patins d'une paire se faisant face sur deux bords opposés de la bande, à leur distance définitive, et les paires étant séparées par des clips de centrage,
  • réaliser des capots en matière plastique injectée sous pression de la forme d'un dé creux avec deux parois opposées de même écartement que les patins d'une paire sur la bande métallique, percées d'un orifice central aux dimensions d'un noyau plongeur et séparées par une partie pleine dans laquelle ledit orifice est taraudé de manière complémentaire au filetage des noyaux plongeurs et par une partie creuse aux dimensions des bobinages,
  • placer les enroulements sur les paires de patins de raccordement, dans le sens de la largeur de la bande en y soudant leurs extrémités,
  • placer les capots dans un support de forme allongée comme la bande metallique avec une série de logements espacés comme les paires de patins sur la bande métallique et séparés par des pions de centrage de même disposition relative que les clips de centrage de la bande métallique, chauque capot étant disposé tête en bas, son orifice central perpendiculaire à la longueur du support,
  • introduire les enroulements montés sur les paires de patins de la bande métallique dans les capots disposés dans le support en veillant à l'encastrement des patins sur les arêtes des parois latérales de chaque capot et au positionnement correct des pions dans les clips,
  • disposer une broche à l'intérieur de chaque logement du support par un trou latéral pratiqué dans l'axe de l'orifice central des capots, ladite broche ayant une partie filetée se vissant dans la partie taraudée de l'orifice central des capots prolongée par une extrémité lisse de diamètre supérieur à celui d'un bâtonnet ferromagnétique s'enfilant dans les enroulements,
  • remplir la partie creuse de chaque capot d'une résine d'enrobage,
  • retirer les broches par dévissage après durcissement de la résine d'enrobage, retirer les capots du support,
  • séparer les patins de raccordement de la bande métallique et
  • monter les noyaux plongeurs dans les logements laissés par les broches.
It also relates to a process for manufacturing several of these inductors, consisting of:
  • wind, under hot air, on temporary mandrels, windings of conductive wire coated with thermoadherent insulation and remove the temporary mandrels,
  • tin and arch the ends of the windings,
  • producing plunger cores by overmoulding of plastic headless screws at one end of ferromagnetic rods with a diameter smaller than that of the windings,
  • make pairs of connection pads by stamping in a metal strip without separation of the strip, the pads of a pair facing each other on two opposite edges of the strip, at their final distance, and the pairs being separated by clips centering,
  • make covers of plastic material injected under pressure in the form of a hollow die with two opposite walls of the same spacing as the pads of a pair on the metal strip, pierced with a central orifice with the dimensions of a plunger core and separated by a solid part in which said orifice is tapped in a manner complementary to the threading of the plunger cores and by a hollow part to the dimensions of the windings,
  • place the windings on the pairs of connection pads, across the width of the strip, welding their ends to them,
  • place the covers in an elongated support like the metal strip with a series of spaced housings like the pairs of pads on the metal strip and separated by centering pins of the same relative arrangement as the centering clips of the metal strip, each hood being disposed upside down, its central orifice perpendicular to the length of the support,
  • introduce the windings mounted on the pairs of pads of the metal strip into the covers arranged in the support, taking care to embed the pads on the edges of the side walls of each cover and the correct positioning of the pins in the clips,
  • have a pin inside each housing of the support by a lateral hole made in the axis of the central hole of the hoods, said pin having a threaded part screwing into the tapped part of the central hole of the hoods extended by a smooth end with a diameter greater than that of a ferromagnetic rod threading through the windings,
  • fill the hollow part of each cover with a coating resin,
  • remove the pins by unscrewing after hardening of the coating resin, remove the covers from the support,
  • separate the connection pads from the metal strip and
  • mount the plunger cores in the housings left by the pins.

D'autres caractéristiques et avantages de l'invention ressortiront de la description ci-après d'un mode de réalisation donné à titre d'exemple. Cette description sera faite en regard du dessin annexé dans lequel:

  • la figure 1 est une vue de dessous, en perspective et en transparence d'une inductance miniature ajustable selon l'invention avec son noyau plongeur sorti,
  • la figure 2 représente une bande métallique prédécoupée à partir de laquelle sont obtenues par pliage les patins de raccordement de l'inductance miniature représentée à la figure 1,
  • la figure 3 illustre la présentation en cours de montage du capot de l'inductance miniature de la figure 1 devant son enroulement fixé au préalable sur une pair de patins de raccordement toujours solidaire de la bande métallique et
  • la figure 4 représente le support utilisé pour l'enrobage des enroulements dans les capots à un stade préparatoire avant le positionnement des capots et de la bande métallique supportant les enroulements fixés aux patins de raccordement.
Other characteristics and advantages of the invention will emerge from the description below of an embodiment given by way of example. This description will be made with reference to the appended drawing in which:
  • FIG. 1 is a bottom view, in perspective and in transparency of an adjustable miniature inductor according to the invention with its plunger core extended,
  • FIG. 2 represents a precut metal strip from which the connection pads of the miniature inductance shown in FIG. 1 are obtained by bending,
  • FIG. 3 illustrates the presentation during assembly of the cover of the miniature inductor of FIG. 1 in front of its winding fixed beforehand on a pair of connection pads still integral with the metal strip and
  • FIG. 4 represents the support used for the coating of the windings in the covers at a preparatory stage before the positioning of the covers and of the metal strip supporting the windings fixed to the connection pads.

Pour une meilleure clarté des figures, les différents éléments de l'inductance miniature ont été représentés à des échelles agrandies. Dans la réalité leurs dimensions réelles sont inférieures au centimètre.For better clarity of the figures, the various elements of the miniature inductance have been represented on enlarged scales. In reality their actual dimensions are less than a centimeter.

Comme on peut le voir sur la figure 1, l'inductance miniature à la forme d'un parallèlépipède rectangle. Elle comporte un capot 1 portant des patins de raccordement 2, 3 et renfermant un enroulement cylindrique 4 noyé dans de la résine et pourvu d'un noyau plongeur 5.As can be seen in Figure 1, the miniature inductance in the form of a rectangular parallelepiped. It comprises a cover 1 carrying connection pads 2, 3 and enclosing a cylindrical winding 4 embedded in resin and provided with a plunger core 5.

Le capot 1 à la forme générale d'un dé creux ouvert par son fond. Il présente deux parois latérales opposées 6, 7 qui portent sur leur rebord les patins de raccordement 2, 3 et qui sont traversées de part en part par un orifice central servant de logement au noyau plongeur 5. Ces deux parois latérales 6, 7 sont séparées par une partie pleine 8 du capot dans laquelle l'orifice central est pourvu d'un taraudage 9 et par une partie creuse 10 qui sert de logement à l'enroulement cylindrique 4 axé sur l'orifice central. Des rainures 11, 12, 13 pratiquées autour de la partie pleine 8, le long des parois latérales du capot 1 permettent l'emboîtage d'un patin de raccordement 3 sur le rebord de la paroi latérale 6 adjacente à la partie pleine 8 ainsi que le logement du raccordement électrique de l'enroulement 4 à ce patin 3 et l'amenée de résine depuis la partie creuse pour renforcer la fixation de ce patin 3.The cover 1 has the general shape of a hollow die opened by its bottom. It has two opposite side walls 6, 7 which bear on their edge the connection pads 2, 3 and which are traversed right through by a central orifice serving as housing for the plunger core 5. These two side walls 6, 7 are separated by a solid part 8 of the cover in which the central orifice is provided with a thread 9 and by a hollow part 10 which serves as a housing for the cylindrical winding 4 centered on the central orifice. Grooves 11, 12, 13 formed around the solid part 8, along the side walls of the cover 1 allow the fitting of a connection pad 3 on the edge of the side wall 6 adjacent to the solid part 8 as well as the housing for the electrical connection of the winding 4 to this pad 3 and the supply of resin from the hollow part to reinforce the fixing of this pad 3.

Les patins de raccordement 2, 3 sont identiques. Leur forme apparaît plus clairement aux figures 2 et 3. Chacun d'eux est constitué d'une languette métallique pliée longitudinalement en forme de U avec deux ailes approximativement de même hauteur 15, 16 réunies par une base 17 se plaçant à cheval sur un rebord de paroi du capot. L'une des ailes, 15, venant à l'extérieur du capot, a un profil rectangulaire entamé en son milieu par une large encoche arrondie 18 assurant le dégagement de l'orifice central servant de logement au noyau plongeur. L'autre aile, 16, présente deux pattes 19, 20 à profil en queue d'aronde qui viennent à l'intérieur du capot et servent à l'ancrage du patin dans la matière plastique d'enrobage et dont l'une, 19, est prolongée sur le côté d'un doigt replié 21 servant à la fixation d'une extrémité de l'enroulement 4.The connection pads 2, 3 are identical. Their shape appears more clearly in Figures 2 and 3. Each of them consists of a metal tongue folded longitudinally in a U shape with two wings approximately the same height 15, 16 joined by a base 17 placed astride a ledge of the hood wall. One of the wings, 15, coming outside the hood, has a rectangular profile started in the middle by a large rounded notch 18 ensuring the release of the central orifice serving as housing for the plunger core. The other wing, 16, has two tabs 19, 20 with a dovetail profile which come inside the cover and serve to anchor the pad in the plastic coating material and one of which, 19 , is extended on the side of a folded finger 21 used for fixing one end of the winding 4.

Le noyau plongeur 5, représenté figure 1, est constitué d'un bâtonnet ferromagnétique 24 pourvu d'une tête filetée 25 adaptée au taraudage 9 de l'orifice central et creusée d'une fente diamétrale d'actionnement 26.The plunger core 5, shown in FIG. 1, consists of a ferromagnetic rod 24 provided with a threaded head 25 adapted to the internal thread 9 of the central orifice and hollowed out with a diametrical actuation slot 26.

L'inductance miniature ajustable qui vient d'être décrite se connecte aux pistes d'un circuit imprimé ou d'un circuit hybride sur plaquette céramique à la manière des petits composants électroniques se présentant sous forme de pavé avec des bornes de raccordement noyées dans leur faces latérales c'est-à-dire, soit en formant un congé de soudure aux surfaces en contact avec ses patins de raccordement soit en y plaçant des pièces entretoises.The adjustable miniature inductor which has just been described connects to the tracks of a printed circuit or of a hybrid circuit on ceramic wafer in the manner of small electronic components appearing in the form of a block with connection terminals embedded in their side faces that is to say, either by forming a weld fillet to the surfaces in contact with its connection pads or by placing spacer parts therein.

La fabrication peut se dérouler de la manière suivante:

  • L'enroulement 4 est réalisé par bobinage sous air chaud et sur un mandrin provisoire d'un fil conducteur revêtu d'un isolant thermoadhérent. Le mandrin provisoire est retiré en fin de bobinage et les extrémités de l'enroulement 4 étamées, l'une d'entre elles étant en outre cambrée.
  • Le noyau plongeur est réalisé à partir d'un bâtonnet ferromagnétique d'un diamètre inférieur à celui de l'enroulement à l'extrémité duquel est surmoulée une vis sans tête en matière plastique.
Manufacturing can take place as follows:
  • The winding 4 is produced by winding in hot air and on a temporary mandrel of a conductive wire coated with a thermoadherent insulator. The temporary mandrel is removed at the end of the winding and the ends of the winding 4 tinned, one of them being furthermore bent.
  • The plunger core is made from a ferromagnetic rod with a diameter less than that of the winding at the end of which is screwed a plastic headless screw.

Les patins de raccordement sont fabriqués par paires à partir d'une bande métallique découpée et pliée. Cette bande est par exemple une bande de cuivre de 0,1 mm d'épaisseur découpée par une technique de photogravure, étamée par une technique électrolytique puis pliée. La figure 2 représente une telle bande après découpage et avant pliage. Plusieurs paires de patins sont découpées sur cette bande et séparées par des clips de centrage 30. Au sein de chaque paire, les patins sont constitués par des pontets jetés au travers d'ouvertures 31 et placés face à face dans la sens de la largeur de la bande, à leur distance définitive. Ces pontets sont rattachés aux bords des ouvertures 31 par des étranglements 32, 33 facilitant leur séparation ultérieure.The connection pads are produced in pairs from a cut and folded metal strip. This strip is for example a 0.1 mm thick copper strip cut by a photoengraving technique, tinned by an electrolytic technique and then folded. FIG. 2 represents such a strip after cutting and before folding. Several pairs of pads are cut from this strip and separated by centering clips 30. Within each pair, the pads are constituted by bridges thrown through openings 31 and placed face to face in the width direction. the strip, at their final distance. These bridges are attached to the edges of the openings 31 by throttles 32, 33 facilitating their subsequent separation.

Les capots, avec leur orifice central taraudé dans la partie pleine sont obtenus par moulage par injection d'un matériau plastique thermodurcissable tel que par exemple du diallylphtalate dans un moule rigide conçu en plusieurs parties et poli intérieurement dans le sens de l'extraction de la pièce réalisée pour en faciliter le démoulage. Cette technique de moulage sous pression élimine les défauts d'aspect, boursouflures et cratères, grâce à la rigidité du moule et à la bonne évacuation de l'air inclus dans le moule rendue possible par la pression d'injection. En outre, elle ne fait pas appel à un agent de démoulage.The covers, with their central orifice tapped in the solid part, are obtained by injection molding of a thermosetting plastic material such as for example diallylphthalate in a rigid mold designed in several parts and polished internally in the direction of extraction of the part made to facilitate demolding. This die casting technique eliminates appearance defects, blistering and cra tères, thanks to the rigidity of the mold and the good evacuation of the air included in the mold made possible by the injection pressure. In addition, it does not use a mold release agent.

Les différentes pièces étant réalisées, l'assemblage des inductances miniatures commence par le soudage des extrémités des enroulements 4 aux doigts 21 des paires de patins toujours attachées à leur bord métallique d'origine qui les maintient de façon provisoire dans un positionnement correct.The different parts being produced, the assembly of the miniature inductors begins by welding the ends of the windings 4 to the fingers 21 of the pairs of pads still attached to their original metal edge which temporarily keeps them in correct positioning.

Comme on peut le voir sur la figure 3, les enroulements 4 sont orientés parallèlement à la largeur de la bande métallique. L'une de leurs extrémités 35 n'est pas cambrée, elle s'échappe tangentiellement et arrive perpendiculairement au doigt 21 de l'un des patins de raccordement 2 tandis que leur autre extrémitée 36 est cambrée parallélement à leur axe après s'être échappée tangentiellement et arrive dans l'axe du doigt 21 de l'autre patin de raccordement 3. Cette disposition permet de rapprocher l'enroulement de l'un des patins pour qu'il se présente en vis-à-vis de la partie creuse du capot et laisse par rapport à l'autre patin un espace suffisant pour loger la partie pleine 8 du capot supportant le taraudage dans lequel se visse le noyau plongeur.As can be seen in Figure 3, the windings 4 are oriented parallel to the width of the metal strip. One of their ends 35 is not arched, it escapes tangentially and arrives perpendicularly to the finger 21 of one of the connecting pads 2 while their other end 36 is arched parallel to their axis after having escaped tangentially and arrives in the axis of the finger 21 of the other connection pad 3. This arrangement allows the winding of one of the pads to be brought closer so that it is facing the hollow part of the cover and leaves relative to the other shoe sufficient space to accommodate the solid part 8 of the cover supporting the thread in which the plunger core is screwed.

L'assemblage se poursuit en utilisant un support de capot rigide et de forme allongée. Celui-ci, représenté à la figure 4, comporte une série de logements 40 alignés avec le même espacement que les paires de patins de raccordement sur la bande métallique et des pions de centrage 41 ayant même disposition relative que les clips de centrage 30 de la bande métallique. Chaque logement 40 est prévu pour recevoir un capot 1 disposé la tête en bas, son orifice central orienté dans le sens de la largeur du support, et comporte dans ses parois latérales un trou 42 axé sur l'orifice central du capot permettant l'introduction d'une broche 43 sauvegardant l'espace de débattement du noyau plongeur. Cette broche 43 possède une tige d'extrémité lisse 44 prolongeant par l'intermédiaire d'un épaulement une partie filetée 45 de plus grand diamètre adaptée au taraudage 9 des capots, elle-même suivie d'une partie non filetée 46 se terminant par une tête de préhension 47.Assembly continues using a rigid, elongated hood support. This, shown in Figure 4, has a series of housings 40 aligned with the same spacing as the pairs of connecting pads on the metal strip and centering pins 41 having the same relative arrangement as the centering clips 30 of the metal strip. Each housing 40 is designed to receive a cover 1 arranged upside down, its central orifice oriented in the width direction of the support, and has in its side walls a hole 42 centered on the central orifice of the cover allowing the introduction a pin 43 saving the clearance space of the plunger core. This pin 43 has a smooth end rod 44 extending through a shoulder a threaded portion 45 of larger diameter suitable for tapping 9 of the covers, itself followed by a non-threaded portion 46 ending in a gripping head 47.

les capots 1, issus de moulage par injection, sont disposés la tête en bas dans les logements 40, leur orifice central dans le prolongement du trou 42 du support. La bande métallique avec les paires de patins de raccordement équipées de leurs enroulements est ensuite amenée en vis-à-vis du support puis descendue de manière que les enroulements 4 pénétrent dans les parties creuses des capots 1 et que les patins s'encastrent sur les arêtes des parois latérales des capots, le positionnement précis résultant du guidage des chanfreins d'extrémité des pions de centrage 41 du support dans les clips de centrage 30 de la bande métallique. Une fois l'assemblage réalisé entre les pions 41 et les clips 30, on introduit les broches 43 dans les ouvertures 42 du support en les vissant dans les taraudages 9 des capots pour sauvegarder l'espace de débattement des noyaux plongeurs à l'intérieur des enroulements 4 puis on remplit la partie creuse des capots à l'aide d'un matériau plastique d'enrobage thermodurcissable qui contourne par les rainures 11, 12, 13 la partie pleine 8 du capot et parvient à la base des patins de raccordement noyant leurs pattes d'ancrage et pénétrant par cappillarité entre eux et la paroi du capot.the covers 1, produced by injection molding, are arranged upside down in the housings 40, their central orifice in the extension of the hole 42 of the support. The metal strip with the pairs of connection pads fitted with their windings is then brought opposite the support and then lowered so that the windings 4 penetrate into the hollow parts of the covers 1 and that the pads are fitted on the edges of the side walls of the covers, the precise positioning resulting from the guidance of the end chamfers of the centering pins 41 of the support in the centering clips 30 of the metal strip. Once the assembly has been made between the pins 41 and the clips 30, the pins 43 are introduced into the openings 42 of the support by screwing them into the threads 9 of the covers to save the clearance space of the plunger cores inside the windings 4 then the hollow part of the covers is filled with a thermosetting plastic coating material which bypasses by grooves 11, 12, 13 the solid part 8 of the cover and reaches the base of the connection pads embedding their anchoring lugs and penetrating by cappillarity between them and the wall of the hood.

Après durcissement du matériau plastique d'enrobage, les broches 43 sont retirées, la bande métallique déclipsée du support de capot et les inductances miniatures sorties de leur logement, séparées de la bande métallique et équipées de leurs noyaux plongeurs.After the plastic coating material has hardened, the pins 43 are removed, the metal strip unclipped from the cover support and the miniature inductors come out of their housing, separated from the metal strip and equipped with their plunger cores.

Il faut remarquer que dans ce mode de fabrication les défauts éventuels d'aspect extérieur ne peuvent être dus qu'au moulage du capot et n'entraînent par conséquent que le rebut de celui-ci.It should be noted that in this manufacturing method any defects in external appearance can only be due to the molding of the cover and consequently only cause the scrap of the latter.

Claims (4)

1. A miniature variable inductance inductor made of a coil (4) soldered to a pair of connecting skids (2, 3), and of a movable ferromagnetic core (5) having a screwthread on at least part of the core, characterized in that it comprises an injection-molded plastics cover (1) in the form of a hollow die with two oppositely disposed lateral walls (6, 7), to the edges of which are clipped the connecting skids (2, 3), which are traversed by a central opening used for accommodating the movable core (5) and which are separated by a solid part (8), in which the central opening is provided with a screwthread (9) adapted to the thread of the movable core (5), and by a hollow space (10), within which said coil (4) is disposed coaxially with the central opening and encapsulated within a resin.
2. An inductor according to claim 1, characterized in that the solid part (8) of the cover (1) is separated from the lateral walls of the cover (1) by grooves (11, 12, 13) so as to enable a connecting skid (3) to be clipped over the edge of the lateral wall (6) adjacent to the solid part (8), to accommodate the electrical connection between the coil (4) and said connecting skid (3), and to permit ingress of resin from the hollow space (10), in order to strengthen the attachment of said same connecting skid (3).
3. An inductor according to claim 1, characterized in that the connecting skids (2, 3) have dovetail-shaped lugs (19, 20) whereby they are anchored in the encapsulating resin.
4. A method of manufacturing an inductor according to claim 1, which comprises the steps of:
winding coils (4) of conductive wire coated with a thermo-adherent insulative material in a hot air atmsophere onto temporary formers and then removing the temporary formers,
tinning and bending the ends (35, 36) of the coils (4),
and making cores by overmoulding grub screws at one end of ferromagnetic rods (24) the diameter of which is less than the diameter of the coils, characterized in that the method further comprises the steps of:
making pairs of connecting skids (2, 3) by stamping a metal strip without separating them from the strip, with the skids of a pair being on opposite sides of the strip at a distance corresponding to their final distance, and the pairs being separated by centering clips (30),
making covers (1) by way of injection moulding in the shape of a hollow die with two oppositely disposed walls (6, 7) the same distance apart as the skids (2, 3) of a pair in the metal strip, said walls being pierced by a central opening having the dimensions of the movable core (5) and being separated by a solid part (8) in which said orifice is threaded in a manner complementary to the thread of the movable cores, and a hollow part (10) which is adapted to accommodate a coil (4) coaxially with the central opening, said solid part (8) being separated from said lateral walls of the cover (1) by grooves (11, 12, 13) which expose the edges of said walls,
placing the coils (4) on the pairs of connecting skids of the metal strip in the direction of the width of the latter, and soldering their ends to the skids,
placing the covers (1) in a support having the same elongate shape as the metal strip and comprising a series of cover housings (40) with the same spacing as the pairs of skids in the metal strip and separated by centering pins (41) having the same relative disposition as the centering clips (30) on the metal strip, each cover (1) being disposed upside-down with its central opening perpendicular to the length of the support,
inserting the coils (4) mounted on the pairs of connecting skids on the metal strip into the hollow parts (10) of the covers (1) placed in the support, ensuring that the pins (41) are located correctly in the clips (30),
placing a pin (43) inside each housing (40) of the support through a lateral opening (42) coaxial with the central opening of the covers, said pin being adapted to include the clearance required for the movable core,
filling the hollow part (10) of each cover with an encapsulating resin, removing the pin (43) after the encapsulating resin has hardened,
removing the covers (1) from the support, separating the skids from the metal strip, and fitting the cores into the openings made by the pins.
EP86112759A 1985-09-19 1986-09-16 Miniature induction coil and method of making the same Expired - Lifetime EP0217219B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR8513918 1985-09-19
FR8513918A FR2587537B1 (en) 1985-09-19 1985-09-19 MINIATURE INDUCTANCE AND MANUFACTURING METHOD THEREOF

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EP0217219B1 true EP0217219B1 (en) 1991-01-02

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EP (1) EP0217219B1 (en)
CN (1) CN1006745B (en)
BR (1) BR8604468A (en)
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FR (1) FR2587537B1 (en)
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CA2180992C (en) * 1995-07-18 1999-05-18 Timothy M. Shafer High current, low profile inductor and method for making same
US7921546B2 (en) * 1995-07-18 2011-04-12 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
JP3449222B2 (en) * 1998-06-23 2003-09-22 株式会社村田製作所 Method of manufacturing bead inductor and bead inductor
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CN102610365A (en) * 2011-07-19 2012-07-25 深圳市研通高频技术有限公司 Variable inductor
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CN102789877A (en) * 2012-07-30 2012-11-21 昆山达功电子有限公司 Miniature inductor
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JP2016187364A (en) * 2013-09-20 2016-11-04 第一高周波工業株式会社 Magnetic flux irradiation device
JP6332073B2 (en) * 2015-02-13 2018-05-30 株式会社村田製作所 Coil parts
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BR8604468A (en) 1987-05-19
IN166417B (en) 1990-05-05
US4736513A (en) 1988-04-12
MX168164B (en) 1993-05-07
CN1006745B (en) 1990-02-07
US4706058A (en) 1987-11-10
CN86106038A (en) 1987-03-18
DE3676407D1 (en) 1991-02-07
FR2587537A1 (en) 1987-03-20
FR2587537B1 (en) 1987-10-30
EP0217219A1 (en) 1987-04-08

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