EP1019926A1 - Inductive component and method for making same - Google Patents

Inductive component and method for making same

Info

Publication number
EP1019926A1
EP1019926A1 EP97943031A EP97943031A EP1019926A1 EP 1019926 A1 EP1019926 A1 EP 1019926A1 EP 97943031 A EP97943031 A EP 97943031A EP 97943031 A EP97943031 A EP 97943031A EP 1019926 A1 EP1019926 A1 EP 1019926A1
Authority
EP
European Patent Office
Prior art keywords
coil
core
winding
elements
inductive component
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.)
Granted
Application number
EP97943031A
Other languages
German (de)
French (fr)
Other versions
EP1019926B1 (en
Inventor
Jean-François KUMMEL
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.)
Microspire SA
Original Assignee
Microspire SA
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 Microspire SA filed Critical Microspire SA
Publication of EP1019926A1 publication Critical patent/EP1019926A1/en
Application granted granted Critical
Publication of EP1019926B1 publication Critical patent/EP1019926B1/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
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/043—Fixed inductances of the signal type  with magnetic core with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
    • 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
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices
    • 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
    • H01F41/12—Insulating of windings
    • H01F41/127—Encapsulating or impregnating

Definitions

  • the present invention relates to inductive components, of the type comprising one or more windings, and which can therefore be used depending on the case of inductance or alternating current transformer.
  • inductors are generally used to perform in electrical or electronic circuits filtering or smoothing functions, or energy storage, by being conventionally traversed by currents having a continuous component to which is superimposed an alternative component.
  • a common range of operating frequencies is 10 KHz to 3 MHz.
  • Such components are for example commonly used in switching power supplies, or direct current converters. These components are moreover conventionally produced so as to be able to be mounted on printed circuits, in a manner known per se.
  • the known inductors of the type mentioned above are generally formed from one or more coils of enamelled copper wire produced on a toroidal core carried by a support base comprising connection pins.
  • the toroidal windings are arranged vertically on the base, so as to extend perpendicular to the surface of the printed circuit.
  • the ends of the wires are connected to the connection pins, or themselves form the so-called pins, which are intended to be inserted into holes in the printed circuit and soldered thereto, in a conventional manner.
  • CMS surface-mounted component
  • the magnetic materials used for the toric core are generally based on iron powder, for example iron-silicon, when the intended frequency of use is low, up to about 100 KHz, or, when the frequencies are higher. high, up to around 200 kHz, made of ferronickel alloy such as permalloy, for example the material commonly known as Moly-Permalloy or MPP, which is an 80 or 50% sintered powder of iron and nickel of nickel.
  • iron powder for example iron-silicon
  • permalloy for example the material commonly known as Moly-Permalloy or MPP, which is an 80 or 50% sintered powder of iron and nickel of nickel.
  • toroidal type windings are not waterproof, the wire windings being simply produced around the toric core without external protection.
  • the present invention aims to solve these problems and aims particularly to provide an inductive component of reduced weight and volume, limiting losses during use at high frequency, and whose assembly can be facilitated and automated by allowing the production of these components in the form of surface mount components (CMS).
  • CMS surface mount components
  • the invention relates to an inductive component intended to be mounted on a printed circuit, comprising at least one coil of an electrically conductive wire and a magnetic core, characterized in that: the coil consists of '' a conductive wire wound in the form of a flat coil and the ends of which are connected to the internal ends of connection pads,
  • a body formed of a block of insulating material having a lower face substantially orthogonal to the axis of the coil, is molded onto the coil and on said internal ends of the studs, the body comprising a central opening which passes through it according to 1 axis of the coil, the core is made of ferrite and surrounds the body in a median plane containing the axis of the coil and has a central element passing through the opening of the body.
  • a component according to the invention occupies for example a volume of 1200 mm while an equivalent inductance with an O-ring has a volume of the order of 3240 mm.
  • the body for example in thermosetting epoxy resin, molded directly on the coil and the connections, ensures high mechanical resistance, good dissipation of losses generated by the passage of current in the winding, and a good seal allowing use of the component. in a humid environment.
  • the core is formed by two elements extending respectively on each of the faces of the body, at least one of the said elements having an E shape, the central branch of which passes through the opening of the body and the extreme branches pass on two opposite sides of said body.
  • This arrangement offers, at identical volume, compared to a use of ferrite cores produced in known forms, for example a toric shape, a much larger section of iron. At equivalent induction level, the number of turns of the winding can therefore be reduced, which reduces losses in the conductive wire, and consequently authorizes a higher current.
  • This realization of the ferrite cores allows by elsewhere to easily provide in the magnetic circuit an air gap between the two constituent elements of the core, at the end faces of at least one of the branches of the E.
  • This air gap can be adapted for example by playing on the respective lengths of the branches of E.
  • This air gap makes it possible to support the nucleus a large continuous field, and correspondingly, for a given field, to reduce the volume of the nucleus.
  • the two elements of the core are glued to each other, when they are placed on either side of the body.
  • the adhesive joint produced by a non-magnetic adhesive at the interface between the two elements of the core can also be placed in the air gap mentioned above, at one or more of the branches of the E.
  • the retention of the core on the body can be completed by an additional adhesive joint disposed between the edges of the core elements and the body, in particular on the sides of the component.
  • connection pads emerge from the body at the level of the lower face of the body, on two sides of the body opposite with respect to said median plane.
  • These studs are secured to the body by overmolding.
  • the external ends of these studs can be shaped to form studs for conventional mounting on a printed circuit.
  • the tabs In addition to their mechanical fixing function by soldering on the printed circuit, the tabs, at least those to which the ends of the winding (s) are connected, are of course used for their electrical connection.
  • a particular advantage resulting from the implementation of the CMS type according to the invention, which resides in the large possible contact surface between the tabs and the printed circuit, which makes it possible to obtain very low connection resistances and important currents. This advantage is even more marked when, as can be achieved in the case where the component has only one coil, this coil is connected to connections which extend over the entire length of the sides of the component.
  • inductive components according to the invention can be packaged in strips for use by automatic laying machines, their flattened format and their low weight allowing automatic laying by suction or by claws.
  • the subject of the invention is also a method of manufacturing an inductive component intended to be mounted on a printed circuit and comprising at least one coil and a magnetic core, this method being characterized in that:
  • the winding is carried out in the form of a flat coil by winding a wire without using a carcass, - the winding is placed on a grid, the axis of the winding being perpendicular to the grid, and the ends of the wire are welded on the said grid,
  • a body of insulating material is overmolded on the assembly thus obtained, so as to leave a central opening in the axis of the coil and to leave apparent the edges of the grid on two opposite sides of the body, two ferrite core elements are placed on either side of the body, at least one of which has an E shape, the central branch of the E being inserted in said central opening of the body and the two other branches passing over two opposite sides of the body, and the two core elements are fixed to each other.
  • the winding is carried out with a wire comprising an external thermo-adherent layer, and, after winding, an electric current is passed through the wire of sufficient intensity to heat it and obtain the adhesion of the turns between them.
  • FIG. 1 is a perspective view of an inductor according to the invention
  • FIGS. 2 and 3 illustrate two other alternative embodiments
  • FIGS. 4 and 5 illustrate, respectively in view front and from above, mounting the winding on a grid intended to subsequently form the connection tabs
  • FIG. 6 is a top view of the component after molding the body
  • FIG. 7 is a side view of the body
  • FIG. 8 is a sectional view along the line VIII-VIII of FIG. 6,
  • FIG. 10 shows a side view of the finished component
  • FIG. 11 is a sectional view of the component along the line XI -XI of Figure 9, with the complete core.
  • the inductance shown in Figure 1 has a body 1, from which emerge on each side of the connection lugs
  • the body is for example made of thermosetting epoxy resin, or a similar material suitable for shaping by overmolding on a coil 4, as seen in particular in FIGS. 8 and 11.
  • the core is composed of two elements 31 having a cross section E shape, placed on either side of the body.
  • the ferrite used is for example of the power ferrite type, having low losses, with a frequency of use of 10 KHz to 5 MHz and a relative permeability of 200 to 2500, or any type of ferrite with high relative permeability, of l '' from 3000 to 15000.
  • the winding 4 is produced with an insulated conductive wire and comprising a coating of thermoadherent resin, such as for example an enameled copper wire of the Thermibond R type.
  • This wire is wound in the form of a coil of rectangular shape, as seen. Figure 5, by winding the wire on a mandrel of suitable size. Maintaining the shape of the turns and the connection of the turns to each other to obtain mechanical resistance of the coil is ensured by thermo-adhesion, by passing a calibrated electric current through the wire which makes it possible to raise its temperature by Joule effect at a temperature of the order of 180 ° C., so as to ensure the melting of the coating and the connection of the turns after cooling. The coil can then be removed from the mandrel without deforming.
  • This type of winding without the use of a support carcass makes it possible to reduce the size of the coil as much as possible and ensures better heat dissipation during use.
  • the coil 4 is then mounted on a grid 21 of conductive metal, for example of tinned copper alloy.
  • the grid 21 is shaped so as to present elements 22 extending on each side of the coil and intended to form the connection lugs 2 as will be seen later.
  • the ends 41 of the wire are welded to internal ends 24 of the elements 22 by adding tin at high temperature, around 300 ° C., to a soldering iron or any equivalent process.
  • the elements 22 located on the same side of the coil can be interconnected.
  • the elements 22 would then be separated, each element 22 being able to receive one end of a winding.
  • Glue dots 23 also temporarily maintain the winding on the grid.
  • the body 1 is then molded onto the assembly thus obtained, so as to drown the winding and the fittings of the coil on the grid in the resin, as shown in FIGS. 6 to 8, and to obtain the body 1 having two parts lateral 11, located symmetrically with respect to the median plane P and from which the elements 22 of the grid emerge, and two transverse parts 12 providing a central opening 13 which passes through the body in the direction of the axis of the coil.
  • the two elements 31 of the core are then placed on either side of the body, as indicated in FIG. 11, the extreme branches 32 of the E passing outside the transverse parts 12 of the body, and the central branches 33 passing through the opening 13.
  • the ferrite elements 31 are held in place by adhesive joints 34, 35 disposed respectively between the end faces of the branches of the E and on the sides between the ferrite elements and the body, as shown in FIGS. 10 and 11.
  • connection tabs 2 are also cut and shaped by folding to form the connection tabs 2, which extend substantially in the plane of the underside 18 of the inductor.
  • Figure 2 illustrates an alternative embodiment usable in the case of an inductor comprising a single winding.
  • the tabs 2 located on the same side are then replaced by a bar 2 'which extends in the corner of the component, over the entire length of the latter.
  • connection pads 2 '' are arranged only on the edges of the lateral parts 11 of the body, such a component being able in particular to be mounted perpendicular to the surface of the printed circuit.
  • the winding may include several elements, separated or connected together, to produce various types of transformers or inductors.
  • the core can be formed from a single E-shaped part having longer branches and the other part being planar.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

The invention concerns an inductive component designed to be mounted on a printed circuit, comprising: at least a winding (4) of an electrically conductive wire coiled in the form of a flat winding whereof the ends (41) are connected to the inner ends (24) of bonding pads (2); a body (1), formed of an insulating material block over-moulded on the winding and on said inner ends of the pads, the body comprising a central opening (13) running through it along the winding axis; a ferrite magnetic core (3) enclosing the body in a median plane (P) containing the winding axis and a central element (33) passing in the body opening.

Description

Composant inductif et procédé de fabrication d'un tel composant . Inductive component and method of manufacturing such a component.
La présente invention concerne les composants inductifs, du type comportant un ou plusieurs bobinages, et pouvant donc servir selon le cas d'inductance ou de transformateur de courant alternatif. De tels composants, en tant qu'inductances, sont généralement utilisés pour réaliser dans des circuits électriques ou électroniques des fonctions de filtrage ou lissage, ou de stockage d'énergie, en étant classiquement parcourues par des courants ayant une composante continue à laquelle se superpose une composante alternative. Une gamme courante de fréquences d'utilisation est de 10 KHz à 3 MHz. De tels composants sont par exemple couramment utilisés dans des alimentations à découpage, ou convertisseurs de courant continu. Ces composants sont par ailleurs classiquement réalisés de manière à pouvoir être montés sur des circuits imprimés, de manière connue en soi.The present invention relates to inductive components, of the type comprising one or more windings, and which can therefore be used depending on the case of inductance or alternating current transformer. Such components, as inductors, are generally used to perform in electrical or electronic circuits filtering or smoothing functions, or energy storage, by being conventionally traversed by currents having a continuous component to which is superimposed an alternative component. A common range of operating frequencies is 10 KHz to 3 MHz. Such components are for example commonly used in switching power supplies, or direct current converters. These components are moreover conventionally produced so as to be able to be mounted on printed circuits, in a manner known per se.
Les inductances connues du type mentionné ci-dessus sont généralement formées d'un ou plusieurs bobinages en fil de cuivre émaillé réalisés sur un noyau de forme torique porté par une embase de support comportant des picots de connexion. Classiquement, notamment pour réduire l'encombrement surfacique sur le circuit imprimé, les bobinages toriques sont disposés verticalement sur l'embase, de manière à s'étendre perpendiculairement à la surface du circuit imprimé. Les extrémités des fils sont reliées aux picots de connexion, ou forment elles même les dits picots, qui sont destinés à être insérés dans des perçages du circuit imprimé et soudés sur celui-ci, de manière classique. Bien qu'il soit possible d'adopter également une réalisation du type composant monté en surface (CMS) , qui se prête mieux à un montage automatique, le volume et le poids importants de ces composants interdit généralement une telle réalisation, et ces composants doivent être reportés manuellement sur le circuit imprimé avant soudure. De plus, la tenue mécanique en cas de fortes vibrations n'est pas très fiable, du fait du poids important et de 1 ' éloignement relatif du tore par rapport au circuit imprimé, en comparaison avec les relativement petites dimensions de 1 ' embase .The known inductors of the type mentioned above are generally formed from one or more coils of enamelled copper wire produced on a toroidal core carried by a support base comprising connection pins. Conventionally, in particular to reduce the overall surface area on the printed circuit, the toroidal windings are arranged vertically on the base, so as to extend perpendicular to the surface of the printed circuit. The ends of the wires are connected to the connection pins, or themselves form the so-called pins, which are intended to be inserted into holes in the printed circuit and soldered thereto, in a conventional manner. Although it is also possible to adopt an embodiment of the surface-mounted component (CMS) type, which lends itself better to automatic assembly, the large volume and weight of these components generally prohibits such an embodiment, and these components must be transferred manually to the printed circuit before soldering. In addition, the mechanical strength in the event of strong vibrations is not very reliable, due to the large weight and the relative distance of the toroid from the printed circuit, in comparison with the relatively small dimensions of the base.
Par ailleurs, les matériaux magnétiques utilisés pour le noyau torique sont généralement à base de poudre de fer, par exemple fer-silicium, lorsque la fréquence d'utilisation prévue est faible, jusqu'à environ 100 KHz, ou, lorsque les fréquences sont plus élevées, jusqu'à environ 200 KHz, en alliage de ferronickel tel que du permalloy, par exemple le matériau connu couramment sous le nom de Moly-Permalloy ou encore MPP, qui est une poudre frittée de fer et de nickel à 80 ou 50 % de nickel .Furthermore, the magnetic materials used for the toric core are generally based on iron powder, for example iron-silicon, when the intended frequency of use is low, up to about 100 KHz, or, when the frequencies are higher. high, up to around 200 kHz, made of ferronickel alloy such as permalloy, for example the material commonly known as Moly-Permalloy or MPP, which is an 80 or 50% sintered powder of iron and nickel of nickel.
Ces deux matériaux présentent 1 ' avantage de supporter un champ magnétique continu de valeur importante, ce qui permet de réduire la section du noyau et donc 1 ' encombrement global du composant .These two materials have the advantage of supporting a continuous magnetic field of significant value, which makes it possible to reduce the section of the core and therefore the overall size of the component.
Mais ils présentent des pertes élevées lorsqu'ils sont utilisés en haute fréquence, c'est à dire de l'ordre de quelques centaines de KHz à plusieurs MHz, et de ce fait sont mal adaptés à des utilisations telles que dans des circuits d'alimentation à découpage qui utilisent de plus en plus des fréquences très élevées.But they have high losses when used at high frequency, that is to say of the order of a few hundred KHz to several MHz, and are therefore unsuitable for uses such as in circuits of switching power supplies which increasingly use very high frequencies.
Un autre inconvénient des bobinages de type torique est qu'ils ne sont pas étanches, les enroulements de fil étant simplement réalisés autour du noyau torique sans protection extérieure.Another drawback of toroidal type windings is that they are not waterproof, the wire windings being simply produced around the toric core without external protection.
La présente invention a pour but de résoudre ces problèmes et vise particulièrement à fournir un composant inductif de poids et volume réduits, limitant les pertes lors d'une utilisation en haute fréquence, et dont le montage puisse être facilité et automatisé en autorisant la réalisation de ces composant sous la forme de composants à monter en surface (CMS) .The present invention aims to solve these problems and aims particularly to provide an inductive component of reduced weight and volume, limiting losses during use at high frequency, and whose assembly can be facilitated and automated by allowing the production of these components in the form of surface mount components (CMS).
Avec ces objectifs en vue, l'invention a pour objet un composant inductif destiné à être monté sur un circuit imprimé, comportant au moins un bobinage d'un fil électriquement conducteur et un noyau magnétique, caractérisé en ce que : le bobinage est constitué d'un fil conducteur enroulé sous forme d'une bobine plate et dont les extrémités sont reliées à des extrémités internes de plots de connexion,With these objectives in view, the invention relates to an inductive component intended to be mounted on a printed circuit, comprising at least one coil of an electrically conductive wire and a magnetic core, characterized in that: the coil consists of '' a conductive wire wound in the form of a flat coil and the ends of which are connected to the internal ends of connection pads,
- un corps, formé d'un bloc de matière isolante présentant une face inférieure sensiblement orthogonale à l'axe de la bobine, est surmoulé sur la bobine et sur les dites extrémités internes des plots, le corps comportant une ouverture centrale qui le traverse selon 1 ' axe de la bobine, le noyau est réalisé en ferrite et entoure le corps dans un plan médian contenant 1 ' axe de la bobine et présente un élément central passant dans l'ouverture du corps .- A body, formed of a block of insulating material having a lower face substantially orthogonal to the axis of the coil, is molded onto the coil and on said internal ends of the studs, the body comprising a central opening which passes through it according to 1 axis of the coil, the core is made of ferrite and surrounds the body in a median plane containing the axis of the coil and has a central element passing through the opening of the body.
La combinaison de caractéristiques selon l'invention présente notamment l'avantage d'un gain important en volume et en poids par rapport à des composants inductifs ayant des propriétés équivalentes réalisées sous forme d'inductances à noyau torique : un composant selon 1 ' invention occupe par exemple un volume de 1200 mm alors qu'une inductance équivalente avec noyau torique a un volume de l'ordre de 3240 mm . Ces avantages résultent notamment de l'utilisation d'un bobinage de faible hauteur et d'un noyau magnétique en ferrite qui permet, grâce à ses caractéristiques magnétiques, d'en diminuer la section. Les ferrites présentent de faibles pertes en haute fréquence et un tel matériau est donc particulièrement adapté pour les applications visées par le composant selon l'invention, c'est à dire pour des fréquences pouvant aller jusqu'à 3 MHz, tel que par exemple dans des alimentations à découpage dans lesquelles les fréquences de découpage tendent à être de plus en plus élevées. De plus, la faible hauteur du composant permet de réduire 1 ' encombrement en épaisseur du circuit imprimé sur lequel il est monté.The combination of characteristics according to the invention has in particular the advantage of a significant gain in volume and in weight compared to inductive components having equivalent properties produced in the form of toroidal core inductors: a component according to the invention occupies for example a volume of 1200 mm while an equivalent inductance with an O-ring has a volume of the order of 3240 mm. These advantages result in particular from the use of a low-height winding and a ferrite magnetic core which, thanks to its magnetic characteristics, makes it possible to reduce its section. Ferrites have low losses at high frequency and such a material is therefore particularly suitable for the applications targeted by the component according to the invention, that is to say for frequencies up to 3 MHz, such as for example in switching power supplies in which the switching frequencies tend to be higher and higher. In addition, the low height of the component makes it possible to reduce the overall thickness of the printed circuit on which it is mounted.
Le corps, par exemple en résine époxy ther odurcissable, surmoulé directement sur la bobine et les connexions, assure une grande résistance mécanique, une bonne dissipation des pertes engendrées par le passage du courant dans le bobinage, et une bonne étanchéité permettant une utilisation du composant en milieu humide. Le fait de ne pas inclure le noyau de ferrite dans le moulage, mais de le rapporter autour du corps, et apparent extérieurement, améliore encore, la dissipation de l'énergie thermique, générée notamment par les courants de Foucault, ceci grâce à un contact direct d'une grande aire des surfaces externes du noyau avec l'extérieur et la possibilité d'y associer aisément un drain thermique .The body, for example in thermosetting epoxy resin, molded directly on the coil and the connections, ensures high mechanical resistance, good dissipation of losses generated by the passage of current in the winding, and a good seal allowing use of the component. in a humid environment. The fact of not including the ferrite core in the molding, but of bringing it around the body, and apparently externally, further improves, the dissipation of thermal energy, generated in particular by the eddy currents, this thanks to a contact direct from a large area of the external surfaces of the core with the outside and the possibility of easily associating a heat drain.
Selon une disposition particulière de 1 ' invention, le noyau est formé de deux éléments s ' étendant respectivement sur chacune des faces du corps, l'un au moins des dits éléments ayant une forme en E dont la branche centrale passe dans 1 ' ouverture du corps et les branches extrêmes passent sur deux cotés opposés du dit corps. Cette disposition offre, à volume identique, par rapport à une utilisation de noyaux en ferrite réalisés sous des formes connues, par exemple une forme torique, une section de fer beaucoup plus importante. A niveau d'induction équivalent, le nombre de spires du bobinage peut donc être réduit, ce qui diminue les pertes dans le fil conducteur, et autorise en conséquence un courant plus important.According to a particular arrangement of the invention, the core is formed by two elements extending respectively on each of the faces of the body, at least one of the said elements having an E shape, the central branch of which passes through the opening of the body and the extreme branches pass on two opposite sides of said body. This arrangement offers, at identical volume, compared to a use of ferrite cores produced in known forms, for example a toric shape, a much larger section of iron. At equivalent induction level, the number of turns of the winding can therefore be reduced, which reduces losses in the conductive wire, and consequently authorizes a higher current.
Cette réalisation des noyaux en ferrite permet par ailleurs de ménager aisément dans le circuit magnétique un entrefer entre les deux éléments constitutifs du noyau, au niveau des faces d'extrémité d'au moins une des branches du E. Cet entrefer peut être adapté par exemple en jouant sur les longueurs respectives des branches du E. Cet entrefer permet de faire supporter au noyau un champ continu important, et corrélativement, pour un champ donné, de réduire le volume du noyau.This realization of the ferrite cores allows by elsewhere to easily provide in the magnetic circuit an air gap between the two constituent elements of the core, at the end faces of at least one of the branches of the E. This air gap can be adapted for example by playing on the respective lengths of the branches of E. This air gap makes it possible to support the nucleus a large continuous field, and correspondingly, for a given field, to reduce the volume of the nucleus.
Préférentiellement , les deux éléments du noyau sont collés l'un sur l'autre, lors de leur mise en place de part et d'autre du corps. Le joint de colle, réalisé par une colle amagnétique à l'interface entre les deux éléments du noyau peut par ailleurs être placé dans l'entrefer mentionné ci-dessus, au niveau de l'une ou de plusieurs des branches du E . Le maintien du noyau sur le corps peut être complété par un joint de colle supplémentaire disposé entre les bords des éléments du noyau et le corps, en particulier sur les côtés du composant . Selon une autre disposition particulière, des plots de connexion émergent du corps au niveau de la face inférieure du corps, sur deux côtés du corps opposés par rapport au dit plan médian. Ces plots sont solidarisés avec le corps par le surmoulage . Les extrémités externes de ces plots peuvent être conformés pour former des picots pour un montage classique sur circuit imprimé. Ils seront toutefois préférentiellement conformés de manière à former des pattes s ' étendant dans le plan de la surface inférieure du corps, ou légèrement au-delà de celle-ci, permettant de fixer le composant sur le circuit imprimé par soudage de ces pattes à la surface du dit circuit, selon la technique connue pour les composants CMS.Preferably, the two elements of the core are glued to each other, when they are placed on either side of the body. The adhesive joint, produced by a non-magnetic adhesive at the interface between the two elements of the core can also be placed in the air gap mentioned above, at one or more of the branches of the E. The retention of the core on the body can be completed by an additional adhesive joint disposed between the edges of the core elements and the body, in particular on the sides of the component. According to another particular arrangement, connection pads emerge from the body at the level of the lower face of the body, on two sides of the body opposite with respect to said median plane. These studs are secured to the body by overmolding. The external ends of these studs can be shaped to form studs for conventional mounting on a printed circuit. They will however preferably be shaped so as to form tabs extending in the plane of the lower surface of the body, or slightly beyond the latter, making it possible to fix the component on the printed circuit by welding these tabs to the surface of said circuit, according to the technique known for SMD components.
La faible hauteur du composant associée à des dimensions transversales nettement plus grandes, notamment la distance entre les pattes situées de chaque côté du composant, ainsi qu'à un faible poids, améliore considérablement la tenue au vibrations lorsque le composant est soudé sur le circuit.The low height of the component associated with significantly larger transverse dimensions, in particular the distance between the legs located on each side of the component, as well as a low weight, improves considerably the resistance to vibrations when the component is welded on the circuit.
Outre leur fonction de fixation mécanique par soudure sur le circuit imprimé, les pattes, au moins celles auxquelles sont raccordées les extrémités de la ou des bobinages, servent bien sûr à leur connexion électrique. On notera à ce sujet un avantage particulier, résultant de la réalisation du type CMS selon l'invention, qui réside dans la grande surface de contact possible entre les pattes et le circuit imprimé, qui permet d'obtenir des résistances de connexion très faibles et des courants importants. Cet avantage est encore plus marqué, lorsque, comme cela peut être réalisé dans le cas où le composant ne comporte qu'un seul bobinage, ce bobinage est raccordé à des connexions qui s ' étendent sur toute la longueur des côtés du composant .In addition to their mechanical fixing function by soldering on the printed circuit, the tabs, at least those to which the ends of the winding (s) are connected, are of course used for their electrical connection. Note in this regard a particular advantage, resulting from the implementation of the CMS type according to the invention, which resides in the large possible contact surface between the tabs and the printed circuit, which makes it possible to obtain very low connection resistances and important currents. This advantage is even more marked when, as can be achieved in the case where the component has only one coil, this coil is connected to connections which extend over the entire length of the sides of the component.
Un autre avantage encore des composants inductifs selon l'invention est qu'ils peuvent être conditionnés en bande pour être utilisés par les machines de pose automatique, leur format aplati et leur faible poids autorisant une pose automatique par aspiration ou par griffes .Yet another advantage of the inductive components according to the invention is that they can be packaged in strips for use by automatic laying machines, their flattened format and their low weight allowing automatic laying by suction or by claws.
L'invention a aussi pour objet un procédé de fabrication d'un composant inductif destiné à être monté sur un circuit imprimé et comportant au moins un bobinage et un noyau magnétique, ce procédé étant caractérisé en ce que :The subject of the invention is also a method of manufacturing an inductive component intended to be mounted on a printed circuit and comprising at least one coil and a magnetic core, this method being characterized in that:
- on réalise le bobinage sous forme d'une bobine plate par enroulement d'un fil sans utiliser de carcasse, - on place le bobinage sur une grille, l'axe du bobinage étant perpendiculaire à la grille, et on soude les extrémités du fil sur la dite grille,- the winding is carried out in the form of a flat coil by winding a wire without using a carcass, - the winding is placed on a grid, the axis of the winding being perpendicular to the grid, and the ends of the wire are welded on the said grid,
- on surmoule sur l'ensemble ainsi obtenu un corps en matière isolante, de manière à laisser une ouverture centrale dans l'axe de la bobine et à laisser apparent les bords de la grille sur deux cotés opposés du corps, on place de part et d'autre du corps deux éléments de noyau en ferrite, dont l'un au moins a une forme en E, la branche centrale du E étant insérée dans la dite ouverture centrale du corps et les deux autres branches passant sur deux côtés opposés du corps, et on fixe les deux éléments de noyau l'un sur l'autre.- a body of insulating material is overmolded on the assembly thus obtained, so as to leave a central opening in the axis of the coil and to leave apparent the edges of the grid on two opposite sides of the body, two ferrite core elements are placed on either side of the body, at least one of which has an E shape, the central branch of the E being inserted in said central opening of the body and the two other branches passing over two opposite sides of the body, and the two core elements are fixed to each other.
Préférentiellemen , le bobinage est réalisé avec un fil comportant une couche externe thermo-adhérente, et, après bobinage, on fait passer dans le fil un courant électrique d'intensité suffisante pour l'échauffer et obtenir 1 ' adhérence des spires entre elles .Preferably, the winding is carried out with a wire comprising an external thermo-adherent layer, and, after winding, an electric current is passed through the wire of sufficient intensity to heat it and obtain the adhesion of the turns between them.
D'autres caractéristiques et avantages apparaîtront dans la description qui va être faite d'un composant conforme à l'invention et de son procédé de fabrication. On se reportera aux dessins annexés dans lesquels : la figure 1 est une vue en perspective d'une inductance conforme à l'invention, les figures 2 et 3 illustrent deux autres variantes de réalisation, - les figure 4 et 5 illustrent, respectivement en vue frontale et de dessus, le montage du bobinage sur une grille destinée à former par la suite les pattes de connexion,Other characteristics and advantages will appear in the description which will be given of a component according to the invention and of its manufacturing process. Reference will be made to the appended drawings in which: FIG. 1 is a perspective view of an inductor according to the invention, FIGS. 2 and 3 illustrate two other alternative embodiments, - FIGS. 4 and 5 illustrate, respectively in view front and from above, mounting the winding on a grid intended to subsequently form the connection tabs,
- la figure 6 est une vue de dessus du composant après moulage du corps,FIG. 6 is a top view of the component after molding the body,
- la figure 7 est une vue latérale du corps,FIG. 7 is a side view of the body,
- la figure 8 est une vue en coupe selon la ligne VIII-VIII de la figure 6,FIG. 8 is a sectional view along the line VIII-VIII of FIG. 6,
- la figure 9 montrent le composant après mise en place d'un des deux éléments du noyau,- Figure 9 shows the component after placing one of the two core elements,
- la figure 10 montre en vue de côté le composant terminé,FIG. 10 shows a side view of the finished component,
- la figure 11 est une vue en coupe du composant selon la ligne XI -XI de la figure 9, avec le noyau complet.- Figure 11 is a sectional view of the component along the line XI -XI of Figure 9, with the complete core.
L'inductance représentée figure 1 comporte un corps 1, d'où émergent de chaque côté des pattes de connexionThe inductance shown in Figure 1 has a body 1, from which emerge on each side of the connection lugs
2, et un noyau magnétique 3 en ferrite. Le corps est par exemple en résine époxy thermodurcissable , ou en un matériau similaire adapté pour une mise en forme par surmoulage sur un bobinage 4 , comme on le voit notamment figures 8 et 11. Le noyau est composé de deux éléments 31 ayant une section de forme en E, placés de part et d'autre du corps. La ferrite utilisée est par exemple du type ferrites de puissance, présentant de faibles pertes, avec une fréquence d'utilisation de 10 KHz à 5 MHz et une perméabilité relative de 200 à 2500, ou tout type de ferrite à forte perméabilité relative, de l'ordre de 3000 à 15000.2, and a magnetic core 3 made of ferrite. The body is for example made of thermosetting epoxy resin, or a similar material suitable for shaping by overmolding on a coil 4, as seen in particular in FIGS. 8 and 11. The core is composed of two elements 31 having a cross section E shape, placed on either side of the body. The ferrite used is for example of the power ferrite type, having low losses, with a frequency of use of 10 KHz to 5 MHz and a relative permeability of 200 to 2500, or any type of ferrite with high relative permeability, of l '' from 3000 to 15000.
Le bobinage 4 est réalisé avec un fil conducteur isolé et comportant un enrobage de résine thermoadhérente, tel que par exemple un fil de cuivre émaillé de type Thermibond R. Ce fil est bobiné sous forme d'une bobine de forme rectangulaire, comme on le voit figure 5, par enroulement du fil sur un mandrin de dimension adaptée. Le maintien en forme des spires et la liaison des spires entre elles pour obtenir une résistance mécanique de la bobine est assuré par thermo-adhérence , en faisant passer dans le fil un courant électrique calibré qui permet d'élever sa température par effet Joule à une température de l'ordre de 180°C, de manière .à assurer la fusion de l'enrobage et la liaison des spires après refroidissement. La bobine peut ensuite être retirée du mandrin sans se déformer. Ce type de bobinage sans utilisation d'une carcasse de support permet de réduire au maximum l'encombrement de la bobine et assure une meilleure dissipation thermique en cours d' utilisation.The winding 4 is produced with an insulated conductive wire and comprising a coating of thermoadherent resin, such as for example an enameled copper wire of the Thermibond R type. This wire is wound in the form of a coil of rectangular shape, as seen. Figure 5, by winding the wire on a mandrel of suitable size. Maintaining the shape of the turns and the connection of the turns to each other to obtain mechanical resistance of the coil is ensured by thermo-adhesion, by passing a calibrated electric current through the wire which makes it possible to raise its temperature by Joule effect at a temperature of the order of 180 ° C., so as to ensure the melting of the coating and the connection of the turns after cooling. The coil can then be removed from the mandrel without deforming. This type of winding without the use of a support carcass makes it possible to reduce the size of the coil as much as possible and ensures better heat dissipation during use.
Comme on le voit figures 4 et 5 , le bobinage 4 est ensuite monté sur une grille 21 en métal conducteur, par exemple en alliage cuivreux étamé . La grille 21 est conformée de manière à présenter des éléments 22 s ' étendant de chaque côté de la bobine et destinés à former les pattes de connexion 2 comme on le verra par la suite. Les extrémités 41 du fil sont soudés sur des extrémités internes 24 des éléments 22 par apport d'étain à haute température, d'environ 300°C, au fer à souder ou tout procédé équivalent. Dans l'exemple représenté, où une seule bobine est ainsi montée, les éléments 22 situés d'un même côté de la bobine peuvent être reliés entre eux. Dans le cas où le composant comporterait plusieurs bobinages, les éléments 22 seraient alors séparés, chaque élément 22 pouvant recevoir une extrémité d'un bobinage. Des points de colle 23 assurent par ailleurs le maintien temporaire du bobinage sur la grille.As seen in Figures 4 and 5, the coil 4 is then mounted on a grid 21 of conductive metal, for example of tinned copper alloy. The grid 21 is shaped so as to present elements 22 extending on each side of the coil and intended to form the connection lugs 2 as will be seen later. The ends 41 of the wire are welded to internal ends 24 of the elements 22 by adding tin at high temperature, around 300 ° C., to a soldering iron or any equivalent process. In the example shown, where a single coil is thus mounted, the elements 22 located on the same side of the coil can be interconnected. In the case where the component comprises several windings, the elements 22 would then be separated, each element 22 being able to receive one end of a winding. Glue dots 23 also temporarily maintain the winding on the grid.
On réalise ensuite le surmoulage du corps 1 sur l'ensemble ainsi obtenu, de manière à noyer le bobinage et les raccords de la bobine sur la grille dans la résine, comme représenté figures 6 à 8, et à obtenir le corps 1 présentant deux parties latérales 11, situées symétriquement par rapport au plan médian P et d'où émergent les éléments 22 de la grille, et deux parties transversales 12 ménageant une ouverture centrale 13 qui traverse le corps dans la direction de 1 ' axe de la bobine .The body 1 is then molded onto the assembly thus obtained, so as to drown the winding and the fittings of the coil on the grid in the resin, as shown in FIGS. 6 to 8, and to obtain the body 1 having two parts lateral 11, located symmetrically with respect to the median plane P and from which the elements 22 of the grid emerge, and two transverse parts 12 providing a central opening 13 which passes through the body in the direction of the axis of the coil.
Les deux éléments 31 du noyau sont ensuite placés de part et d'autre du corps, comme indiqué figure 11, les branches extrêmes 32 des E passant à l'extérieur des parties transversales 12 du corps, et les branches centrales 33 passant dans l'ouverture 13. Le maintien des éléments 31 de ferrite est assuré par des joints de colle 34, 35 disposés respectivement entre les faces d'extrémité des branches des E et sur les côtés entre les éléments de ferrite et le corps, comme indiqué figures 10 et 11.The two elements 31 of the core are then placed on either side of the body, as indicated in FIG. 11, the extreme branches 32 of the E passing outside the transverse parts 12 of the body, and the central branches 33 passing through the opening 13. The ferrite elements 31 are held in place by adhesive joints 34, 35 disposed respectively between the end faces of the branches of the E and on the sides between the ferrite elements and the body, as shown in FIGS. 10 and 11.
Les éléments 22 de grille sont par ailleurs coupés et conformés par pliage pour constituer les pattes de connexion 2, qui s'étendent sensiblement dans le plan de la face inférieure 18 de l'inductance.The grid elements 22 are also cut and shaped by folding to form the connection tabs 2, which extend substantially in the plane of the underside 18 of the inductor.
Le dessin de la figure 2 illustre une variante de réalisation utilisable dans le cas d'une inductance comportant un seul bobinage. Les pattes 2 situées d'un même côté sont alors remplacées par une barrette 2 ' qui s'étend dans l'angle du composant, sur toute la longueur de celui-ci.The drawing of Figure 2 illustrates an alternative embodiment usable in the case of an inductor comprising a single winding. The tabs 2 located on the same side are then replaced by a bar 2 'which extends in the corner of the component, over the entire length of the latter.
Le dessin de la figure 3 illustre encore une autre variante, dans laquelle les plots de connexion 2' ' sont aménagés uniquement sur les bords des parties latérales 11 du corps, un tel composant pouvant notamment être monté perpendiculairement à la surface du circuit imprimé .The drawing of FIG. 3 illustrates yet another variant, in which the connection pads 2 '' are arranged only on the edges of the lateral parts 11 of the body, such a component being able in particular to be mounted perpendicular to the surface of the printed circuit.
La fabrication de ces composants peut être réalisée comme indiqué précédemment, en adaptant simplement la forme de la grille de manière adéquate.The manufacture of these components can be carried out as indicated above, by simply adapting the shape of the grid adequately.
L'invention n'est pas limité aux modes de réalisation décrits ci-dessus uniquement à titre d'exemple. En particulier, le bobinage pourra comporter plusieurs éléments, séparés ou connectés entre eux, pour réaliser divers types de transformateurs ou d'inductances. Egalement, le noyau pourra être formé d'une seule partie en forme de E ayant des branches plus longues et l'autre partie étant plane. The invention is not limited to the embodiments described above only by way of example. In particular, the winding may include several elements, separated or connected together, to produce various types of transformers or inductors. Also, the core can be formed from a single E-shaped part having longer branches and the other part being planar.

Claims

REVENDICATIONS
1. Composant inductif destiné à être monté sur un circuit imprimé, comportant au moins un bobinage (4) d'un fil électriquement conducteur et un noyau magnétique (3), caractérisé en ce que : - le bobinage (4) est constitué d'un fil enroulé sous forme d'une bobine plate et dont les extrémités (41) sont reliées à des extrémités internes (24) de plots de connexion (2) ,1. Inductive component intended to be mounted on a printed circuit, comprising at least one coil (4) of an electrically conductive wire and a magnetic core (3), characterized in that: - the coil (4) consists of a wire wound in the form of a flat coil and the ends (41) of which are connected to internal ends (24) of connection pads (2),
- un corps (1), formé d'un bloc de matière isolante présentant une face inférieure sensiblement orthogonale à l'axe de la bobine (4) , est surmoulé sur la bobine et sur les dites extrémités internes des plots, le corps comportant une ouverture centrale (13) qui le traverse selon l'axe de la bobine, - le noyau (3) est réalisé en ferrite, et entoure le corps dans un plan médian (P) contenant l'axe de la bobine et présente un élément central (33) passant dans 1 ' ouverture du corps .- A body (1), formed of a block of insulating material having a lower face substantially orthogonal to the axis of the coil (4), is molded onto the coil and on said internal ends of the studs, the body comprising a central opening (13) which passes through it along the axis of the coil, - the core (3) is made of ferrite, and surrounds the body in a median plane (P) containing the axis of the coil and has a central element (33) passing through the opening of the body.
2. Composant inductif selon la revendication 1, caractérisé en ce que des plots de connexion (2) émergent du corps (1) au niveau de la face inférieure (18) , sur deux cotés du corps opposés par rapport au dit plan médian.2. Inductive component according to claim 1, characterized in that connection pads (2) emerge from the body (1) at the lower face (18), on two sides of the body opposite with respect to said median plane.
3. Composant inductif selon la revendication 1, caractérisé en ce que le noyau (3) est formé de deux éléments (31) s ' étendant respectivement sur chacune des faces du corps, l'un au moins des dits éléments ayant une forme en E dont la branche centrale (33) passe dans l'ouverture du corps et les branches extrêmes (32) passent sur deux cotés opposés du dit corps.3. Inductive component according to claim 1, characterized in that the core (3) is formed of two elements (31) extending respectively on each of the faces of the body, at least one of said elements having an E shape whose central branch (33) passes through the opening of the body and the end branches (32) pass on two opposite sides of said body.
4. Composant inductif selon la revendication 3 , caractérisé en ce que un entrefer magnétique est ménagé entre les deux éléments constituant le noyau.4. Inductive component according to claim 3, characterized in that a magnetic gap is formed between the two elements constituting the core.
5. Composant inductif selon la revendication 3, caractérisé en ce que les deux éléments (31) du noyau sont assemblés par collage.5. Inductive component according to claim 3, characterized in that the two elements (31) of the core are assembled by gluing.
6. Procédé de fabrication d'un composant inductif destiné à être monté sur un circuit imprimé et comportant au moins un bobinage (4) et un noyau magnétique (3) , caractérisé en ce que :6. Method of manufacturing an inductive component intended to be mounted on a printed circuit and comprising at least one coil (4) and a magnetic core (3), characterized in that:
- on réalise le bobinage sous forme d'une bobine plate (4) par enroulement d'un fil sans utiliser de carcasse, - on place le bobinage (4) sur une grille (21) , l'axe du bobinage étant perpendiculaire à la grille, et on soude les extrémités du fil sur la dite grille,- the winding is carried out in the form of a flat coil (4) by winding a wire without using a carcass, - the winding (4) is placed on a grid (21), the axis of the winding being perpendicular to the grid, and the ends of the wire are welded to said grid,
- on surmoule sur l'ensemble ainsi obtenu un corps (1) en matière isolante, de manière à laisser une ouverture centrale (13) dans l'axe de la bobine et à laisser apparent les bords de la grille sur deux cotés opposés du corps, on place de part et d'autre du corps deux éléments de noyau (31) en ferrite , dont l'un au moins a une forme en E, la branche centrale (33) du E étant insérée dans la dite ouverture centrale du corps et les deux autres branches passant sur deux côtés opposés du corps, et on fixe les deux éléments de noyau l'un sur 1 ' autre . - A body (1) of insulating material is molded onto the assembly thus obtained, so as to leave a central opening (13) in the axis of the coil and to leave visible the edges of the grid on two opposite sides of the body , two ferrite core elements (31) are placed on either side of the body, at least one of which has an E shape, the central branch (33) of the E being inserted in said central opening of the body and the other two branches passing on two opposite sides of the body, and the two core elements are fixed to one another.
7. Procédé selon la revendication 6, caractérisé en ce que le bobinage (4) est réalisé avec un fil comportant une couche externe thermo-adhérente, et, après bobinage, on fait passer dans le fil un courant électrique d'intensité suffisante pour l'échauffer et obtenir l'adhérence des spires entre elles.7. Method according to claim 6, characterized in that the winding (4) is produced with a wire comprising an external thermo-adhesive layer, and, after winding, an electric current of sufficient intensity is passed through the wire '' warm up and obtain the adhesion of the turns between them.
8. Procédé selon la revendication 6, caractérisé en ce que la bobine (4) est collée sur la grille (21) .8. Method according to claim 6, characterized in that the coil (4) is bonded to the grid (21).
9. Procédé selon la revendication 6, caractérisé en ce que les deux éléments (31) du noyau sont assemblés l'un sur l'autre par collage avec un adhésif amagnétique. 9. Method according to claim 6, characterized in that the two elements (31) of the core are assembled one on the other by bonding with a non-magnetic adhesive.
EP97943031A 1997-10-01 1997-10-01 Inductive component and method for making same Expired - Lifetime EP1019926B1 (en)

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WO1999017318A1 (en) 1999-04-08
US6486763B1 (en) 2002-11-26
DE69729127T2 (en) 2004-10-28
EP1019926B1 (en) 2004-05-12
DE69729127D1 (en) 2004-06-17

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