EP0439389B1 - Verfahren zur Herstellung von elektromagnetischen Spulen - Google Patents

Verfahren zur Herstellung von elektromagnetischen Spulen Download PDF

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Publication number
EP0439389B1
EP0439389B1 EP19910400104 EP91400104A EP0439389B1 EP 0439389 B1 EP0439389 B1 EP 0439389B1 EP 19910400104 EP19910400104 EP 19910400104 EP 91400104 A EP91400104 A EP 91400104A EP 0439389 B1 EP0439389 B1 EP 0439389B1
Authority
EP
European Patent Office
Prior art keywords
patterns
loops
coil
over
sheet
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
EP19910400104
Other languages
English (en)
French (fr)
Other versions
EP0439389A1 (de
Inventor
Albert Barre
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.)
Airbus Group SAS
Original Assignee
Airbus Group SAS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Airbus Group SAS filed Critical Airbus Group SAS
Publication of EP0439389A1 publication Critical patent/EP0439389A1/de
Application granted granted Critical
Publication of EP0439389B1 publication Critical patent/EP0439389B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • 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

Definitions

  • the present invention relates to a method for producing electromagnetic coils, as well as the coils obtained by implementing this method and the electromagnetic components comprising such coils.
  • the windings of the invention are useful for producing electromagnetic components, such as inductors and transformers, intended for switching power supplies and DC-DC converters. These have experienced significant development in recent years because of the indisputable advantages they offer, especially in terms of efficiency which can reach 70 to 90% depending on the value of the output voltage and power. To reduce their volume and weight, the production of these products increasingly calls on technological sectors such as hybrid circuits with thick layers or surface mountable components ("CMS”) on special printed circuits. This miniaturization has led to the production of power supplies or converters operating at high frequency to reduce the size of the electromagnetic components and filtering capacitors.
  • CMS surface mountable components
  • the windings consist of flat copper spirals, laminated on dielectric substrates, and cut copper sheets.
  • the layers, separated by an insulator, are assembled by bonding and mounted in an E-shaped ferrite core, thus producing a transformer having a particularly flat housing profile.
  • the product of the second manufacturer comprises a stack of independent open rigid turns, which are interconnected via the printed circuit or the substrate, requiring specific connections which complicate the production of the windings.
  • the cost price of this product is high taking into account the specificity of the constituents, in particular the turns, the number of which is also limited, which does not make it possible in particular to produce transformers with high secondary voltage.
  • mounting the component directly on the surface of the substrate only by brazed joints can cause problems during vibration and / or shock due to the mass of the component and its height relative to the substrate.
  • the object of the present invention is to avoid the drawbacks of the state of the art and relates to a method making it possible to produce, in a simple, perfectly reproducible and economical manner, electromagnetic coils which can be used in particular in electromagnetic components operating at high frequency, all while retaining the properties of the coils with known flat turns, indicated above.
  • the method of the invention makes it possible to obtain, in a reproducible and economical manner, electromagnetic coils, each of which is formed in one piece by simple folding of a flat strip, or by folding of several of said flat strips previously superimposed.
  • said metal sheet is cut so as to obtain pairs of facing patterns, the patterns of each pair being connected, at least at their ends, by strips of material intended to form connection tabs of said winding. Then, said pattern pairs can be separated into individual single thickness patterns by cutting said strips, or can be folded back to form individual double thickness patterns.
  • said sheet is cut by chemical etching. Furthermore, a protective metallic coating, obtained in particular by electrolytic deposition, and / or an electrically insulating coating, obtained in particular by sublimation under vacuum, can be applied to said patterns.
  • Figure 1 shows, in top view, a sheet of electrically conductive material, in which has been cut a plurality of patterns whose loops have a first shape, for the production of electromagnetic coils according to the invention.
  • Figure 2 is a figure similar to Figure 1, illustrating a second form of the pattern loops.
  • Figures 3 and 4 show, in top view, pairs of patterns of Figures 1 and 2, respectively, separated from the sheet of conductive material.
  • Figures 5 and 6 show individual patterns obtained from the pairs of patterns in Figures 3 and 4.
  • Figures 7a-c and 8a-c show, in front, side and top views, the patterns of Figures 5 and 6 folded to each provide a winding according to the invention.
  • Figure 9 is an exploded view of a transformer comprising two primary and secondary windings of the invention, each in accordance with the embodiment of Figures 7a-7c.
  • Figures 10a-c show, in top and side view, the transformer of Figure 9, in the assembled state.
  • Figures 1 and 2 show, in top view, a sheet 100,200 of electrically conductive material, in particular copper or the like, in which a plurality of patterns 101,201 have been produced, each of which represents the flat development of an electromagnetic coil according to l 'invention. It should be noted that the thickness of the sheet can vary from 50 micrometers to one millimeter depending on the requirements.
  • Each pattern 101,201 consists of a plurality of open loops 102,202 connected to each other, at their ends 103,104; 203.204, by connecting bridges 105.205.
  • the shapes of the loops 102, 202 shown in FIGS. 1 and 2 constitute exemplary embodiments among others, and the invention is in no way limited to these particular shapes, shapes which are more suited to specific electromagnetic components than the we want to manufacture.
  • the open loops 102 In a first case ( Figures 1,3,5,7), the open loops 102 have a generally circular shape, analogous to the Greek letter ⁇ , while, in the second case ( Figures 2,4,6,8), the loops 202 have a generally rectangular shape. It will be noted that this latter form makes it possible to arrange the loops of two adjacent patterns in staggered rows, as shown in the lower part of FIG. 2.
  • the patterns 101,201 are produced by chemical etching. This makes it possible to produce, at the same time, a large number of patterns of suitable shape, and this in a reproducible, precise and economical manner.
  • the patterns are protected by a metallic coating (tin, tin / lead or the like) with a thickness of 10 to 20 micrometers, which can be obtained by electrolytic deposition. This coating moreover ensures good weldability when brazing the output connection lugs on the substrate.
  • Each motif 101,201 then forms a bar (double thickness or single thickness) made up of a plurality loops 102,202 connected to each other by bridges 105,205, and comprising, at its ends, connection lugs 106a, 107a; 206a, 207a, as well as possibly a central connection tab 107b of angled shape.
  • connection lugs 106a, 107a, 107b; 206a, 207a can be protected by a film of electrically insulating thermoplastic resin, applied to a uniform thickness of about 30 to 40 micrometers, except of course at the ends 109,209 ( Figures 7a and 8a) connection lugs 106a, 107a, 107b; 206a, 207a.
  • the resin layer can be deposited by vacuum sublimation of a physico-chemically transformed dimer to obtain an appropriate polymer.
  • FIGs 9 and 10a-c there is shown an embodiment of a transformer using windings made in accordance with the present invention, that is to say, in this particular case, the windings, shown in the figures 1,3,5,7, with circular loops.
  • the primary 108a and secondary 108b windings executed according to the invention are interposed so as to optimize the coupling. They can also be fitted with a galvanic screen. In this case, the primary and secondary windings are superimposed and isolated by a flat turn provided with an outlet connection to allow a connection to ground.
  • the ferrite cores 2a, 2b are standard products, having diametrically opposite openings for the passage of the connection tabs of the primary and secondary windings.
  • the sheath 4 and the washers 3a, 3b provide satisfactory electrical insulation, while being good thermal conductors. Thus, heat losses are reduced, thanks to the heat exchanges between the cores and the windings.
  • connection tabs of the windings are curved to allow surface mounting on a substrate.
  • the connection tabs can also be provided with pins (not shown) intended to be inserted into holes in the substrate.
  • the ferrite cores 2a, 2b and the windings 108a, 108b are held together by the fixing clips 5a, 5b placed on either side of the cores. The ends of the clips can be bent for flat mounting on a substrate.
  • the windings of the invention adapt to the ferrite cores existing on the market, the dimensions of which are chosen as a function of the power and the output voltage, and make it possible to make transformers with high secondary voltage, each winding being able to include a large number of turns.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)

Claims (13)

  1. Verfahren zur Herstellung elektromagnetischer Wicklungen mit jeweils einer Vielzahl von aneinanderliegenden Flachwindungen, bei dem aus einer Folie (100,200) aus einem elektrisch leitenden Material eine Vielzahl von Mustern (101,201) ausgeschnitten wird, wobei jedes der Muster die flache Ausführung einer Wicklung darstellt und eine Leiste bildet,
    dadurch gekennzeichnet, daß:
    - die Leiste eine Vielzahl offener Schleifen (102,202) hat, wobei die benachbarten Schleifen miteinander an ihren Enden durch Verbindungsbrücken (105,205) verbunden sind und die Windungen der Wicklung darstellen sollen,
    - die Leisten (101,201) von der Folie (100,200) getrennt werden, und
    - zur Herstellung der Wicklung die Schleifen (102,202) jeder Leiste (101,201) aufeinandergebogen werden, indem die Verbindungsbrücke zwischen zwei Schleifen auf eine der Schleifen und die andere Schleife auf die Gesamtheit aus der ersten Schleife und der auf diese umgeschlagenen Verbindungsbrücke umgeschlagen wird, und so fort für jede weitere Schleife der Leiste.
  2. Verfahren nach Anspruch 1,
    dadurch gekennzeichnet, daß mindestens zwei Leisten (101,201) übereinandergelegt werden, bevor deren Schleifen (102,202) aufeinandergebogen werden.
  3. Verfahren nach Anspruch 1 oder Anspruch 2,
    dadurch gekennzeichnet, daß beim Ausschneiden der Muster Materialstreifen (106,107; 206,207) erhalten bleiben, durch die mindestens bestimmte entsprechende Schleifen (102,202) benachbarter Muster (101,201) miteinander verbunden werden.
  4. Verfahren nach Anspruch 3,
    dadurch gekennzeichnet, daß die Folie (100,200) so ausgeschnitten wird, daß sich gegenüberliegende Musterpaare (101,201) ergeben, wobei die Muster jedes Paars mindestens an ihren Enden durch Materialstreifen (106,107; 206,207)) miteinander verbunden sind, die die Anschlußlaschen der Wicklung darstellen.
  5. Verfahren nach Anspruch 4,
    dadurch gekennzeichnet, daß die Musterpaare (101,201) durch Zerschneiden der Streifen (106,107; 206,207) in Einzelmuster getrennt werden.
  6. Verfahren nach Anspruch 4,
    dadurch gekennzeichnet, daß die Muster eines Musterpaares (101,201) aufeinandergebogen werden und ein zweilagiges Einzelmuster bilden.
  7. Verfahren nach einem der Ansprüche 1 bis 6,
    dadurch gekennzeichnet, daß die Folie (100) chemisch ausgeätzt wird.
  8. Verfahren nach einem der Ansprüche 1 bis 7,
    dadurch gekennzeichnet, daß auf die Muster ein metallischer Schutzüberzug aufgetragen wird.
  9. Verfahren nach Anspruch 8,
    dadurch gekennzeichnet, daß der Schutzüberzug durch Galvanisation erzielt wird.
  10. Verfahren nach einem der Ansprüche 1 bis 9,
    dadurch gekennzeichnet, daß auf die Muster ein elektrisch isolierender Überzug aufgetragen wird.
  11. Verfahren nach Anspruch 10,
    dadurch gekennzeichnet, daß der isolierende Überzug durch Vakuumsublimation erzielt wird.
  12. Elektromagnetische Wicklung,
    dadurch gekennzeichnet, daß sie durch Anwendung des Verfahrens nach einem der Ansprüche 1 bis 11 verwirklicht wird.
  13. Elektromagnetischer Bauteil, insbesondere Transformator,
    dadurch gekennzeichnet, daß er mindestens eine durch Anwendung des Verfahrens nach einem der Ansprüche 1 bis 11 verwirklichte Wicklung (108a,108b) auf einem Magnetkern (2a,2b) hat.
EP19910400104 1990-01-23 1991-01-18 Verfahren zur Herstellung von elektromagnetischen Spulen Expired - Lifetime EP0439389B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9000747 1990-01-23
FR9000747A FR2657454B1 (fr) 1990-01-23 1990-01-23 Procede pour la realisation de bobinages electromagnetiques.

Publications (2)

Publication Number Publication Date
EP0439389A1 EP0439389A1 (de) 1991-07-31
EP0439389B1 true EP0439389B1 (de) 1994-09-14

Family

ID=9393022

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19910400104 Expired - Lifetime EP0439389B1 (de) 1990-01-23 1991-01-18 Verfahren zur Herstellung von elektromagnetischen Spulen

Country Status (4)

Country Link
EP (1) EP0439389B1 (de)
DE (1) DE69103920T2 (de)
ES (1) ES2063454T3 (de)
FR (1) FR2657454B1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9318251B2 (en) 2006-08-09 2016-04-19 Coilcraft, Incorporated Method of manufacturing an electronic component

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5042139A (en) * 1990-03-14 1991-08-27 General Electric Company Method of making an excitation coil for an electrodeless high intensity discharge lamp
FR2721431B1 (fr) * 1994-06-20 1996-09-06 Ies Procédé pour réaliser des composants magnétiques à bobinages simplifiés, et composants ainsi réalisés.
US7034645B2 (en) 1999-03-16 2006-04-25 Vishay Dale Electronics, Inc. Inductor coil and method for making same
US6198375B1 (en) 1999-03-16 2001-03-06 Vishay Dale Electronics, Inc. Inductor coil structure
US7921546B2 (en) 1995-07-18 2011-04-12 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US7263761B1 (en) 1995-07-18 2007-09-04 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
GB2332100A (en) * 1997-12-02 1999-06-09 David Vail An insulated winding arrangement
DE50000916D1 (de) * 1999-03-03 2003-01-23 Abb Patent Gmbh Magnetischer auslöser, insbesondere für einen leitungsschutzschalter, und leitungsschutzschalter mit einem solchen magnetauslöser

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB292741A (en) * 1927-05-05 1928-06-28 Ig Farbenindustrie Ag Manufacture of vat-dyestuffs
GB1145265A (en) * 1965-06-03 1969-03-12 Eisler Paul Methods of producing helicoids
DE3143210A1 (de) * 1981-10-30 1983-05-11 Max-E. Dipl.-Ing. 7320 Göppingen Reeb "elektrisches bauteil"
FR2586135A1 (fr) * 1985-08-06 1987-02-13 Dumont Alain Electro-aimants juxtaposes et alignes et procede de realisation de tels electro-aimants

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9318251B2 (en) 2006-08-09 2016-04-19 Coilcraft, Incorporated Method of manufacturing an electronic component

Also Published As

Publication number Publication date
DE69103920D1 (de) 1994-10-20
ES2063454T3 (es) 1995-01-01
FR2657454B1 (fr) 1995-07-13
DE69103920T2 (de) 1995-01-05
EP0439389A1 (de) 1991-07-31
FR2657454A1 (fr) 1991-07-26

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