EP0439389B1 - Method of making electromagnetic coils - Google Patents

Method of making electromagnetic coils Download PDF

Info

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
German (de)
French (fr)
Other versions
EP0439389A1 (en
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/en
Application granted granted Critical
Publication of EP0439389B1 publication Critical patent/EP0439389B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

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
    • 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)

Description

La présente invention concerne un procédé pour la réalisation de bobinages électromagnétiques, ainsi que les bobinages obtenus par mise en oeuvre de ce procédé et les composants électromagnétiques comportant de tels bobinages.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.

Les bobinages de l'invention sont utiles pour réaliser des composants électromagnétiques, comme des inducteurs et transformateurs, destinés aux alimentations à découpage et convertisseurs continu-continu. Ceux-ci ont connu un développement important au cours de ces dernières années du fait des avantages incontestables qu'ils offrent, notamment au niveau du rendement qui peut atteindre 70 à 90% selon la valeur de la tension de sortie et de la puissance. Pour réduire leur volume et leur poids, la réalisation de ces produits fait de plus en plus appel à des filières technologiques telles que les circuits hybrides à couches épaisses ou les composants montables en surface ("CMS") sur des circuits imprimés spéciaux. Cette miniaturisation a conduit à réaliser des alimentations ou des convertisseurs fonctionnant à fréquence élevée pour réduire l'encombrement des composants électromagnétiques et des condensateurs de filtrage.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.

De façon générale, les composants électromagnétiques à fréquence élevée se distinguent des composants classiques par le fait que les enroulements sont constitués, non pas par des fils ronds, mais par des spires planes empilées sur des noyaux par exemple de ferrite. Par rapport aux composants classiques, ils présentent les avantages suivants :

  • hauteur réduite des noyaux,
  • bon rendement à fréquence élevée,
  • reproductibilité de fabrication,
  • faible inductance de fuite,
  • effet de peau réduit.
In general, high frequency electromagnetic components are distinguished from conventional components by the fact that the windings are formed, not by round wires, but by flat turns stacked on cores, for example of ferrite. Compared to conventional components, they have the following advantages:
  • reduced core height,
  • good performance at high frequency,
  • manufacturing reproducibility,
  • low leakage inductance,
  • reduced skin effect.

Plus particulièrement, comme indiqué dans la revue "Electronique Hebdo" n° 113 du 11 mai 1989, page 18 et n° 108 du 6 Avril 1989, page 38, deux fabricants proposent des produits fonctionnant à fréquence élevée.More particularly, as indicated in the review "Electronique Hebdo" n ° 113 of May 11, 1989, page 18 and n ° 108 of April 6, 1989, page 38, two manufacturers offer products operating at high frequency.

Pour réaliser les enroulements, on utilise, dans les produits d'un premier fabricant, la technologie des circuits imprimés. En effet, les enroulements sont constitués par des spirales planes en cuivre, laminées sur des substrats diélectriques, et des feuilles de cuivre découpées. Les couches, séparées par un isolant, sont assemblées par collage et montées dans un noyau de ferrite en E, en réalisant ainsi un transformateur ayant un profil de boîtier particulièrement plat.To make the windings, we use, in the products of a first manufacturer, the technology of the printed circuits. In fact, 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.

Cependant, de tels produits sont onéreux et ne permettent pas de réaliser des transformateurs à tension secondaire élevée du fait du nombre limité de spires. De plus, ils nécessitent des noyaux spécifiques de forme particulière et, par ailleurs, leur tenue en environnement mécanique vibratoire impose une adaptation particulière.However, such products are expensive and do not make it possible to produce transformers with a high secondary voltage because of the limited number of turns. In addition, they require specific cores of particular shape and, moreover, their behavior in a vibratory mechanical environment requires special adaptation.

Le produit du second fabricant comporte un empilage de spires rigides ouvertes indépendantes, qui sont interconnectées par l'intermédiaire du circuit imprimé ou du substrat, en nécessitant des connexions spécifiques qui compliquent la réalisation des bobinages.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.

En outre, le prix de revient de ce produit est élevé compte tenu de la spécificité des constituants, notamment les spires, dont le nombre est en outre limité, ce qui ne permet pas de réaliser, en particulier, des transformateurs à tension secondaire élevée. De plus, le montage du composant directement à la surface du substrat uniquement par des joints brasés peut poser des problèmes lors de vibrations et/ou de chocs en raison de la masse du composant et de sa hauteur par rapport au substrat.In addition, 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. In addition, 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.

On connaît par ailleurs, par le brevet US-A-3 495 327, qui divulgue les caractéristiques techniques telles qu'énoncées dans le préambule de la revendication 1 un bobinage formé à partir d'une bande continue de feuille métallique, présentant des boucles successives, reliées par des lignes transversales de pliage, autour desquelles la bande peut être pliée en accordéon.We also know from US-A-3,495,327, which discloses the technical characteristics as stated in the preamble of claim 1, a winding formed from a continuous strip of metal foil, having successive loops , connected by transverse fold lines, around which the strip can be folded in accordion.

La présente invention a pour but d'éviter les inconvénients de l'état de la technique et concerne un procédé permettant de réaliser, de façon simple, parfaitement reproductible et économique, des bobinages électromagnétiques utilisables notamment dans des composants électromagnétiques fonctionnant à fréquence élevée, tout en conservant les propriétés des bobinages à spires planes connus, indiquées ci-dessus.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.

A cet effet, le procédé pour la réalisation de bobinages électromagnétiques, comportant chacun une pluralité de spires planes accolées les unes aux autres, dans lequel, dans une feuille de matière électriquement conductrice, on découpe une pluralité de motifs, chacun desdits motifs représentant le développement à plat d'un bobinage et formant une barrette, est remarquable, selon l'invention, en ce que :

  • ladite barrette comporte une pluralité de boucles ouvertes, les boucles voisines étant reliées les unes aux autres, à leurs extrémités, par des ponts de liaison, et destinées à constituer les spires dudit bobinage,
  • on sépare les barrettes de ladite feuille, et
  • pour former ledit bobinage, on replie les boucles de chaque barrette les unes sur les autres en rabattant le pont de liaison réunissant deux boucles sur l'une desdites boucles et en rabattant l'autre desdites boucles sur l'ensemble constitué par la première boucle et le pont de liaison rabattu sur celle-ci, et ainsi de suite pour chaque boucle suivante de la barrette.
To this end, the method for producing electromagnetic coils, each comprising a plurality of flat turns joined to one another, in which, in a sheet of electrically conductive material, a plurality of patterns are cut, each of said patterns representing the development flat of a winding and forming a bar, is remarkable, according to the invention, in that:
  • said strip comprises a plurality of open loops, the neighboring loops being connected to each other, at their ends, by connecting bridges, and intended to constitute the turns of said winding,
  • the strips of said sheet are separated, and
  • to form said winding, the loops of each bar are folded over one another by folding down the connecting bridge bringing together two loops on one of said loops and by folding the other of said loops onto the assembly formed by the first loop and the link bridge folded over it, and so on for each subsequent loop of the bar.

En particulier, avant de replier leurs boucles les unes sur les autres en zigzag, on peut superposer au moins deux barrettes l'une sur l'autre.In particular, before folding their loops over each other in a zigzag, it is possible to superimpose at least two bars one on the other.

Ainsi, le procédé de l'invention permet d'obtenir, de façon reproductible et économique, des bobinages électromagnétiques dont chacun est formé en une seule pièce par simple pliage d'une barrette plane, ou par pliage de plusieurs desdites barrettes planes préalablement superposées.Thus, 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.

Par ailleurs, lors de la découpe desdits motifs, on peut conserver des bandes de matière reliant au moins certaines boucles respectives de motifs adjacents.Furthermore, when cutting said patterns, it is possible to keep strips of material connecting at least certain respective loops of adjacent patterns.

De préférence, on découpe ladite feuille métallique de façon à obtenir des paires de motifs en vis-à-vis, les motifs de chaque paire étant reliés, au moins à leurs extrémités, par des bandes de matière destinées à former des pattes de connexion dudit bobinage. Ensuite, lesdites paires de motifs peuvent être séparées en motifs individuels à simple épaisseur en coupant lesdites bandes, ou peuvent être repliées pour former des motifs individuels à double épaisseur.Preferably, 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.

Avantageusement, ladite feuille est découpée par gravure chimique. Par ailleurs, un revêtement métallique protecteur, obtenu en particulier par dépôt électrolytique, et/ou un revêtement électriquement isolant, obtenu notamment par sublimation sous vide, peuvent être appliqués sur lesdits motifs.Advantageously, 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.

Les figures du dessin annexé feront bien comprendre comment l'invention peut être réalisée.The figures of the appended drawing will make it clear how the invention can be implemented.

La figure 1 montre, en vue de dessus, une feuille de matière électriquement conductrice, dans laquelle a été découpée une pluralité de motifs dont les boucles présentent une première forme, pour la réalisation de bobinages électromagnétiques selon l'invention.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.

La figure 2 est une figure analogue à la figure 1, illustrant une seconde forme des boucles des motifs.Figure 2 is a figure similar to Figure 1, illustrating a second form of the pattern loops.

Les figures 3 et 4 montrent, en vue de dessus, des paires de motifs des figures 1 et 2, respectivement, séparées de la feuille de matière conductrice.Figures 3 and 4 show, in top view, pairs of patterns of Figures 1 and 2, respectively, separated from the sheet of conductive material.

Les figures 5 et 6 montrent des motifs individuels obtenus à partir des paires de motifs des figures 3 et 4.Figures 5 and 6 show individual patterns obtained from the pairs of patterns in Figures 3 and 4.

Les figures 7a-c et 8a-c montrent, en vues de face, de côté et de dessus, les motifs des figures 5 et 6 repliés pour fournir chacun un bobinage selon l'invention.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.

La figure 9 est une vue éclatée d'un transformateur comportant deux bobinages primaire et secondaire de l'invention, conformes, chacun, à l'exemple de réalisation des figures 7a-7c.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.

Les figures 10a-c montrent, en vue de dessus et de côté, le transformateur de la figure 9, à l'état monté.Figures 10a-c show, in top and side view, the transformer of Figure 9, in the assembled state.

Les figures 1 et 2 montrent, en vue de dessus, une feuille 100,200 de matériau électriquement conducteur, notamment en cuivre ou analogue, dans laquelle on a réalisé une pluralité de motifs 101,201 dont chacun représente le développement à plat d'un bobinage électromagnétique selon l'invention. On notera que l'épaisseur de la feuille peut varier de 50 micromètres à un millimètre selon les exigences. Chaque motif 101,201 est constitué d'une pluralité de boucles ouvertes 102,202 reliées les unes aux autres, à leurs extrémités 103,104 ; 203,204, par des ponts de liaison 105,205.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.

Les formes des boucles 102,202 montrées sur les figures 1 et 2 constituent des exemples de réalisation parmi d'autres, et l'invention n'est en aucun cas limitée à ces formes particulières, formes qui sont plutôt adaptées aux composants électromagnétiques spécifiques que l'on souhaite fabriquer. Dans un premier cas (figures 1,3,5,7), les boucles ouvertes 102 présentent une forme générale circulaire, analogue à la lettre grecque Ω, tandis que, dans le second cas (figures 2,4,6,8), les boucles 202 présentent une forme générale rectangulaire. On remarquera que cette dernière forme permet d'agencer les boucles de deux motifs adjacents en quinconce, comme montré sur la partie inférieure de la figure 2.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. In a first case (Figures 1,3,5,7), the open loops 102 have a generally circular shape, analogous to the Greek letter Ω, 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.

La disposition des motifs 101,201 reliés deux à deux, au niveau de chaque boucle 102,202, par des bandes de matière 106,107 ; 206,207 prolongeant les extrémités respectives 103,104 ; 203,204 des boucles ouvertes 102,202 et pouvant constituer des pattes de connexion notamment aux extrémités, permet d'assurer une qualité de fabrication et un rendement élevés.The arrangement of the patterns 101,201 connected two by two, at each loop 102,202, by strips of material 106,107; 206.207 extending the respective ends 103.104; 203,204 open loops 102,202 and which can constitute connection lugs, in particular at the ends, makes it possible to ensure high quality of manufacture and efficiency.

Avantageusement, les motifs 101,201 sont réalisés par gravure chimique. Cela permet de réaliser, à la fois, un grand nombre de motifs de forme adaptée, et cela de façon reproductible, précise et économique. Pour permettre leur stockage, les motifs sont protégés par un revêtement métallique (étain, étain/plomb ou analogue) d'une épaisseur de 10 à 20 micromètres, pouvant être obtenu par dépôt électrolytique. Ce revêtement permet de plus d'assurer une bonne soudabilité au moment de braser les pattes de connexion de sortie sur le substrat.Advantageously, 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. To allow their storage, 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.

Sur les figures 3 et 4, et 4 et 5, on a représenté deux étapes successives de la séparation des motifs 101,201 de la feuille 100,200. Par découpe des bandes 106,107 ; 206,207 à éliminer, à l'aide d'une pince coupante d'angle (cas de la petite série) ou d'une machine à découper (cas des moyenne ou grande séries), et en conservant les bandes destinées à servir de pattes de connexion d'extrémité 106a,107a ; 206a,207a, plus la patte de connexion centrale 107b dans le cas de la figure 3, on obtient tout d'abord des paires de motifs 101,201 (figures 3 et 4), lesquels sont ensuite soit repliés l'un sur l'autre par pliage des pattes 106a, 107a, 107b ; 206a, 207a autour d'un axe médian X-X parallèle aux ponts de liaison 105;205, pour former des motifs à double épaisseur, soit séparés les uns des autres pour former des motifs individuels 101,201 à simple épaisseur (figures 5 et 6). Chaque motif 101,201 forme alors une barrette (à double épaisseur ou à simple épaisseur) constituée d'une pluralité de boucles 102,202 reliées les unes aux autres par des ponts 105,205, et comportant, à ses extrémités, des pattes de connexion 106a,107a ; 206a,207a, ainsi qu'éventuellement une patte de connexion centrale 107b de forme coudée.In Figures 3 and 4, and 4 and 5, there are shown two successive steps of the separation of the patterns 101,201 of the sheet 100,200. By cutting strips 106,107; 206,207 to be eliminated, using angle cutters (case of the small series) or of a cutting machine (case of the medium or large series), and keeping the strips intended to serve as tabs end connection 106a, 107a; 206a, 207a, plus the central connection tab 107b in the case of FIG. 3, we first obtain pairs of patterns 101,201 (FIGS. 3 and 4), which are then either folded over one another by folding the legs 106a, 107a, 107b; 206a, 207a around a median axis XX parallel to the connecting bridges 105; 205, to form patterns with double thickness, or separated from each other to form individual patterns 101,201 with single thickness (Figures 5 and 6). 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.

En se référant maintenant aux figures 7a-c et 8a-c, on obtient un bobinage, à partir de la barrette 101,201, en repliant les boucles (à simple ou double épaisseur) 102,202 de cette dernière les unes sur les autres en zigzag de façon à former un "empilage" de spires accolées constituant ledit bobinage 108,208. Pour cela, on rabat le pont de liaison réunissant deux boucles sur l'une desdites boucles, et on rabat l'autre desdites boucles sur l'ensemble constitué par la première boucle et le pont de liaison rabattu sur celle-ci, et ainsi de suite pour chaque boucle suivante de la barrette. Ces doubles cambrages successifs, qui apparaissent clairement sur les figures 7c et 8c, permettent d'établir le sens d'enroulement des spires.Referring now to Figures 7a-c and 8a-c, we obtain a winding, from the strip 101,201, by folding the loops (single or double thickness) 102,202 of the latter one on the other in a zigzag so forming a "stack" of contiguous turns constituting said coil 108,208. To do this, the connecting bridge bringing together two loops is folded down on one of said loops, and the other of said loops is folded back over the assembly constituted by the first loop and the connecting bridge folded over on this one, continued for each subsequent loop of the bar. These successive double bends, which appear clearly in FIGS. 7c and 8c, make it possible to establish the direction of winding of the turns.

On pourrait également, comme déjà indiqué, superposer plusieurs barrettes 101,201, de faible épaisseur, après avoir séparé les barrettes de la feuille 100,200 et avant de replier les boucles 102,202 de celles-ci les unes sur les autres en zigzag, de façon à former un bobinage à plusieurs épaisseurs.We could also, as already indicated, superimpose several strips 101,201, of small thickness, after having separated the strips from the sheet 100,200 and before folding the loops 102,202 of these one on the other in a zigzag, so as to form a winding with several thicknesses.

Pour isoler les spires l'une de l'autre, on peut les protéger par une pellicule de résine thermoplastique électriquement isolante, appliquée à une épaisseur uniforme d'environ 30 à 40 micromètres, sauf bien sûr aux extrémités 109,209 (figures 7a et 8a) des pattes de connexion 106a, 107a,107b ; 206a,207a. La couche de résine peut être déposée par sublimation sous vide d'un dimère physico-chimiquement transformé pour obtenir un polymère approprié.To isolate the turns from one another, they 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.

Sur les figures 9 et 10a-c, on a représenté un exemple de réalisation d'un transformateur utilisant des bobinages réalisés conformément à la présente invention, c'est-à-dire, dans ce cas particulier, les bobinages, montrés sur les figures 1,3,5,7, à boucles circulaires.In Figures 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.

En se référant notamment à la vue éclatée de la figure 9, le transformateur 1 comprend les éléments suivants :

  • deux enroulements primaire 108a et secondaire 108b,
  • deux noyaux en ferrite 2a,2b,
  • deux rondelles isolantes 3a,3b,
  • une gaine isolante 4, et
  • deux clips de fixation 5a,5b
Referring in particular to the exploded view of FIG. 9, the transformer 1 comprises the following elements:
  • two primary windings 108a and secondary 108b,
  • two ferrite cores 2a, 2b,
  • two insulating washers 3a, 3b,
  • an insulating sheath 4, and
  • two fixing clips 5a, 5b

Les enroulements primaire 108a et secondaire 108b exécutés selon l'invention sont intercalés de façon à optimiser le couplage. Ils peuvent être également munis d'un écran galvanique. Dans ce cas, les enroulements primaire et secondaire sont superposés et isolés par une spire plane munie d'une connexion de sortie pour permettre une liaison à la masse.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.

Les noyaux en ferrite 2a,2b sont des produits standard, possédant des ouvertures diamétralement opposées pour le passage des pattes de connexion des enroulements primaire et secondaire.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.

La gaine 4 et les rondelles 3a,3b assurent un isolement électrique satisfaisant, tout en étant de bons conducteurs thermiques. Ainsi, on réduit les pertes thermiques, grâce aux échanges thermiques entre les noyaux et les enroulements.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.

Sur les figures 10a-c, on a représenté le transformateur 1 assemblé. Les pattes de connexion des enroulements sont courbées pour permettre le montage en surface sur un substrat. Les pattes de connexion peuvent être également munies de broches (non représentées) destinées à être insérées dans des trous du substrat. Les noyaux en ferrite 2a,2b et les enroulements 108a,108b sont maintenus ensemble par les clips de fixation 5a,5b placés de part et d'autre des noyaux. Les extrémités des clips peuvent être recourbées pour le montage à plat sur un substrat.In Figures 10a-c, there is shown the transformer 1 assembled. The 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.

Outre les propriétés déjà mentionnées propres aux enroulements à spires planes, les bobinages de l'invention s'adaptent aux noyaux en ferrite existant sur le marché, dont les dimensions sont choisies en fonction de la puissance et de la tension de sortie, et permettent de réaliser des transformateurs à tension secondaire élevée, chaque bobinage pouvant comporter un grand nombre de spires.In addition to the properties already mentioned specific to windings with flat turns, 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.

Claims (13)

  1. Method of making electromagnetic coils, each being composed of a plurality of flat turns placed facing each other, in which method a plurality of patterns (101, 201) is cut out from a sheet (100, 200) of electrically conducting material, each of the said patterns representing the opened-out flat configuration of a coil and forming a linear array, characterized in that:
    - the said linear array is composed of a plurality of open loops (102, 202), the adjacent loops being connected to each other, at their ends, by connecting bridges (105, 205), and intended to constitute the turns of the said coil,
    - the linear arrays (101, 201) are separated from the said sheet (100, 200), and
    - in order to form the said coil, the loops (102, 202) of each linear array (101, 201) are bent back over each other by folding back the connecting bridge joining two loops over one of the said loops and by folding back the other of the said loops over the assembly constituted by the first loop and the connecting bridge folded back over the latter, and so on for each following loop of the linear array.
  2. Method according to Claim 1, characterized in that, before bending back their loops (102, 202) over each other, at least two linear arrays (101, 201) are superimposed, one on the other.
  3. Method according to Claim 1 or Claim 2, characterized in that, when cutting out the said patterns, strips of material (106, 107; 206, 207) are left connecting at least some of the respective loops (102, 202) of adjacent patterns (101, 201).
  4. Method according to Claim 3, characterized in that the said sheet (100, 200) is cut out so as to obtain pairs of patterns (101, 201) facing each other, the patterns of each pair being connected, at least at their ends, by strips of material (106, 107; 206, 207) which are intended to form connection leads of the said coil.
  5. Method according to Claim 4, characterized in that the said pairs of patterns (101, 201) are separated into individual patterns by cutting the said strips (106, 107; 206, 207).
  6. Method according to Claim 4, characterized in that the patterns of one pair of patterns (101, 201) are bent back, one over the other, in order to form an individual pattern having a double thickness.
  7. Method according to any one of Claims 1 to 6, characterized in that the said sheet (100) is cut out by chemical etching.
  8. Method according to any one of Claims 1 to 7, characterized in that a protective metal coating is applied to the said patterns.
  9. Method according to Claim 8, characterized in that the said protective coating is obtained by electro-plating.
  10. Method according to any one of Claims 1 to 9, characterized in that an electrically insulating coating is applied to the said patterns.
  11. Method according to Claim 10, characterized in that the said insulating coating is obtained by vacuum sublimation.
  12. Electromagnetic coil, characterized in that it is made by implementation of the method according to any one of Claims 1 to 11.
  13. Electromagnetic component, especially a transformer, characterized in that it comprises at least one coil (108a, 108b), made by implementation of the method according to any one of Claims 1 to 11, mounted on a magnetic core (2a, 2b).
EP19910400104 1990-01-23 1991-01-18 Method of making electromagnetic coils Expired - Lifetime EP0439389B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9000747 1990-01-23
FR9000747A FR2657454B1 (en) 1990-01-23 1990-01-23 PROCESS FOR THE PRODUCTION OF ELECTROMAGNETIC WINDINGS.

Publications (2)

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

Family

ID=9393022

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19910400104 Expired - Lifetime EP0439389B1 (en) 1990-01-23 1991-01-18 Method of making electromagnetic coils

Country Status (4)

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

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 (en) * 1994-06-20 1996-09-06 Ies Method for producing magnetic components with simplified windings, and components thus produced.
US7034645B2 (en) 1999-03-16 2006-04-25 Vishay Dale Electronics, Inc. Inductor coil and method for making same
US7263761B1 (en) 1995-07-18 2007-09-04 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
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
GB2332100A (en) * 1997-12-02 1999-06-09 David Vail An insulated winding arrangement
ATE229692T1 (en) * 1999-03-03 2002-12-15 Abb Patent Gmbh MAGNETIC TRIGGER, IN PARTICULAR FOR A CIRCUIT CIRCUIT BREAKER, AND LINE CIRCUIT CIRCUIT BREAKER HAVING SUCH A MAGNETIC TRIGGER

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 (en) * 1981-10-30 1983-05-11 Max-E. Dipl.-Ing. 7320 Göppingen Reeb Electrical component
FR2586135A1 (en) * 1985-08-06 1987-02-13 Dumont Alain Juxtaposed and aligned electromagnets and method of producing such electromagnets

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
DE69103920T2 (en) 1995-01-05
FR2657454B1 (en) 1995-07-13
FR2657454A1 (en) 1991-07-26
ES2063454T3 (en) 1995-01-01
EP0439389A1 (en) 1991-07-31
DE69103920D1 (en) 1994-10-20

Similar Documents

Publication Publication Date Title
EP0523588B1 (en) Transformer winding composed of an insulating tape comprising electrically conductive patterns for realizing a parallel arrangement of the patterns when zigzag folding this tape
EP0439389B1 (en) Method of making electromagnetic coils
EP2313948B1 (en) Insert and method of assembling such an insert
FR2727785A1 (en) INDUCTANCE COMPONENT / EXTRA-FLAT TRANSFORMER
FR2771843A1 (en) INTEGRATED CIRCUIT TRANSFORMER
WO1998019361A1 (en) Armoured magnetic field antenna in printed circuit
FR2568414A1 (en) ELECTROMAGNETIC RESONATORS AND FILTERS MADE THEREFROM THESE RESONATORS.
FR2593320A1 (en) METHOD OF MANUFACTURING AN INDUCTIVE COMPONENT FOR FLAT REPORT
EP1022750A1 (en) Discrete electronic inductive component, and method of manufacture of such components
EP0191668B1 (en) Hf ceramic multilayer capacitor with a high capacity
FR2926159A1 (en) CAPACITOR WITH LOW INDUCTANCE.
FR2721431A1 (en) Automated mfg. process for transformer used in motor vehicle electronics
TWI462131B (en) Production method of chip coil
FR2550026A1 (en) Stator for high-voltage electrical machine.
EP0120754B1 (en) Polarized electronic component, and method for its manufacture
EP0204636A1 (en) Strong current capacitor and process for making such a capacitor
FR3103625A1 (en) Winding, corresponding production method and aircraft comprising such a winding
FR2536901A1 (en) MULTI-LAYERED CAPACITOR
WO2021116632A1 (en) Electrotechnical device for an aircraft
WO2021116599A1 (en) Electrotechnical device for an aircraft, comprising low-frequency coil components
WO2004068632A2 (en) Antenna and production method thereof
JP2000058369A (en) Film capacitor
FR2823365A1 (en) Inductance electrical winding having continuous wire with first direction wire emanating central point/second wire opposite direction with both wires having same electrical sense
WO2023232437A1 (en) Planar electrical transformer and assembly
EP3792941A1 (en) Component forming at least one inductance for an electrical circuit

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): BE CH DE ES GB GR IT LI NL SE

17P Request for examination filed

Effective date: 19910809

17Q First examination report despatched

Effective date: 19920115

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): BE CH DE ES GB GR IT LI NL SE

REF Corresponds to:

Ref document number: 69103920

Country of ref document: DE

Date of ref document: 19941020

GBT Gb: translation of ep patent filed (gb section 77(6)(a)/1977)

Effective date: 19940922

REG Reference to a national code

Ref country code: GR

Ref legal event code: FG4A

Free format text: 3013251

ITF It: translation for a ep patent filed
REG Reference to a national code

Ref country code: ES

Ref legal event code: FG2A

Ref document number: 2063454

Country of ref document: ES

Kind code of ref document: T3

EAL Se: european patent in force in sweden

Ref document number: 91400104.5

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

26N No opposition filed
NLT2 Nl: modifications (of names), taken from the european patent patent bulletin

Owner name: AEROSPATIALE SOCIETE NATIONALE INDUSTRIELLE

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: CH

Payment date: 20001227

Year of fee payment: 11

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: SE

Payment date: 20001229

Year of fee payment: 11

Ref country code: GR

Payment date: 20001229

Year of fee payment: 11

Ref country code: DE

Payment date: 20001229

Year of fee payment: 11

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: BE

Payment date: 20010110

Year of fee payment: 11

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: ES

Payment date: 20010112

Year of fee payment: 11

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: GB

Payment date: 20010118

Year of fee payment: 11

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: NL

Payment date: 20010131

Year of fee payment: 11

REG Reference to a national code

Ref country code: GB

Ref legal event code: IF02

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GB

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020118

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020119

Ref country code: ES

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020119

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LI

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020131

Ref country code: CH

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020131

Ref country code: BE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020131

BERE Be: lapsed

Owner name: AEROSPATIALE SOC. NATIONALE INDUSTRIELLE

Effective date: 20020131

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: NL

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020801

Ref country code: DE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020801

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GR

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20020812

EUG Se: european patent has lapsed

Ref document number: 91400104.5

GBPC Gb: european patent ceased through non-payment of renewal fee

Effective date: 20020118

REG Reference to a national code

Ref country code: CH

Ref legal event code: PL

NLV4 Nl: lapsed or anulled due to non-payment of the annual fee

Effective date: 20020801

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IT

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES;WARNING: LAPSES OF ITALIAN PATENTS WITH EFFECTIVE DATE BEFORE 2007 MAY HAVE OCCURRED AT ANY TIME BEFORE 2007. THE CORRECT EFFECTIVE DATE MAY BE DIFFERENT FROM THE ONE RECORDED.

Effective date: 20050118