EP3754677A1 - Verfahren zur herstellung einer induktiven vorrichtung - Google Patents

Verfahren zur herstellung einer induktiven vorrichtung Download PDF

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Publication number
EP3754677A1
EP3754677A1 EP20180391.3A EP20180391A EP3754677A1 EP 3754677 A1 EP3754677 A1 EP 3754677A1 EP 20180391 A EP20180391 A EP 20180391A EP 3754677 A1 EP3754677 A1 EP 3754677A1
Authority
EP
European Patent Office
Prior art keywords
support
winding
conductive material
electrically conductive
recessed
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.)
Withdrawn
Application number
EP20180391.3A
Other languages
English (en)
French (fr)
Inventor
Dominique BERGOGNE
Hamilton QUERINO DE CARVALHO
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.)
Commissariat a lEnergie Atomique et aux Energies Alternatives CEA
Original Assignee
Commissariat a lEnergie Atomique CEA
Commissariat a lEnergie Atomique et aux Energies Alternatives CEA
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 Commissariat a lEnergie Atomique CEA, Commissariat a lEnergie Atomique et aux Energies Alternatives CEA filed Critical Commissariat a lEnergie Atomique CEA
Publication of EP3754677A1 publication Critical patent/EP3754677A1/de
Withdrawn legal-status Critical Current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
    • H01F17/06—Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • H01F17/062—Toroidal core with turns of coil around it
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/0006—Printed inductances
    • H01F17/0033—Printed inductances with the coil helically wound around a magnetic core
    • 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
    • H01F27/2804—Printed windings
    • 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
    • H01F27/2895—Windings disposed upon ring cores
    • 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
    • H01F41/041—Printed circuit coils
    • H01F41/043—Printed circuit coils by thick film techniques
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/003—Printed circuit coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/02—Coils wound on non-magnetic supports, e.g. formers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/0006—Printed inductances
    • H01F2017/004—Printed inductances with the coil helically wound around an axis without a core

Definitions

  • the present invention relates to a method for producing an inductive device.
  • Inductive devices are used, for example, in very high frequency converters and switching power supplies for power electronics and in high frequency transformers.
  • An inductive device is a device comprising an electric circuit forming a winding so that when an electric current flows in the electric circuit, a magnetic flux appears inside the winding.
  • the inductive device may include a core arranged in an area where the winding creates the magnetic flux.
  • Inductive devices or coils are generally made by winding a wire conductor around a core.
  • the current flowing in the conductor is a high-frequency alternating current
  • a skin effect appears, i.e. the current tends to circulate only on the outer periphery of the wire, a tendency which increases with the increase in frequency .
  • Windings with flat conductors i.e. having a small thickness compared to their width can then be used to mitigate the appearance of this phenomenon.
  • One solution is to produce such a winding with microelectronic techniques, ie by implementing layers, in which the conductors are made by conductive tracks in different planes connected to each other. by via. However, a phenomenon of proximity between the conductors and stray capacitance appears.
  • the document US 9754714 describes an exemplary embodiment of an inductive device comprising flat conductors.
  • the device comprises a first substrate provided with a face in which is formed an annular recess in which are arranged flat first flat conductive elements next to each other. Each first flat conductive element is disposed on the two annular edges and the bottom of the recess and has two tabs at each of its ends lying flat on the face of the first substrate.
  • the device comprises a second substrate comprising second electrical conductors arranged so as to form a winding with the first conductive elements.
  • a core is disposed in the annular recess within the first conductive elements.
  • the method according to the invention makes it possible to produce, relatively easily, a conductive winding of complex shape.
  • the support provided with the recessed path is produced for example directly by molding, by machining, by engraving or by printing in three dimensions.
  • the at least partial filling of the recess is for example carried out by dipping the support in a bath of molten metal, such as copper.
  • the withdrawal of the electrical conductor outside the recess is for example obtained by abrasion.
  • a structured support is used, for example grooved, having the profile of a winding around the support, on which a layer of electrically conductive material is formed. There is then an intimate contact between the support and the material of the winding, since it comes from a layer formed on the outer surface of the core.
  • step c) is carried out mechanically.
  • step a) comprises the simultaneous production of the support and of the recessed path in the outer surface of the support.
  • Step a) can be carried out by molding.
  • step b) the application of a conductive material can for example be done in several sub-steps.
  • step b) comprises soaking the support in a bath of electrically conductive material.
  • step a) comprises a first sub-step of dipping the support in the bath of electrically conductive material and one or more sub-steps for increasing the thickness of the layer of electrically conductive material.
  • the method may comprise, prior to step b), the application of a layer of an electrically insulating material on the support.
  • the method may comprise, after step c), the application of a layer of an electrically insulating material on at least the first electrically conductive winding and the repetition of steps b) and c) to produce a second electric winding.
  • the recessed path has a depth P and a width L, the depth to width ratio P / L being between 0.001 and 0.8, preferably between 0.01 and 0.1.
  • At least one tool provided with at least one blade intended to come into contact with the layer of electrically conductive material is used.
  • the support may comprise at least two parallel surfaces and in which the tool comprises two parallel blades arranged with respect to one another so as to each come into contact with one of said parallel surfaces.
  • the support has the shape of a ring having two concentric radial surfaces and two parallel planar end faces.
  • Step a) may include the provision of a support comprising several distinct recessed paths.
  • the electrically conductive material is copper
  • the support may be made of a magnetic material so as to form a magnetic core of the inductive device.
  • a subject of the present invention is also a process for manufacturing a transformer comprising the process for producing an inductive device according to the invention comprising several electrically conductive windings and the connection of the windings to at least one electric circuit.
  • the aim of the manufacturing process is to manufacture an inductive device.
  • inductive device is understood to mean a device comprising an electric circuit forming a winding comprising at least one turn so that, when an electric current flows in the electric circuit, a magnetic flux appears inside. winding.
  • the inductive device may include a magnetic core or an electrical insulating core.
  • a turn designates a path wound in a helix during one turn.
  • An electrical coil is an electrically conductive element wound in a helix during one turn.
  • the supports are parts of revolution generated by the rotation of a rectangle around an axis external to the rectangle and located in its plane. This shape will be referred to as a “ring”.
  • Supports 2.1, to 2.3 have two parallel plane faces F1, F2 and concentric F3 and F4 faces ( figures 5 and 6 ). This form has the advantage of simplifying step c) as will be described below.
  • the supports 2.1, 2.2, 2.3 have a recessed path C1, C2, C3 respectively.
  • the support can be a torus.
  • the support 2.4 has the shape of a rectangular frame.
  • the support 2.5 has the shape of a block. As a variant, it may be a bar of revolution.
  • the support 2.6 has the shape of a cylinder whose directing curve is arbitrary.
  • the supports 2.4, 2.5, 2.6 have a recessed path respectively C4, C5, C6.
  • the support is made of magnetic material and also fulfills the function of a magnetic core guiding the flux generated by the winding of the inductive device, in addition to the function of mechanical support for the winding.
  • the magnetic material is for example an iron-based material, such as ferrite, a nickel or chromium-based material.
  • the magnetic material may include one or more layers of magnetic material forming a laminated material.
  • the support is made of a non-magnetic material.
  • the support only has the function of mechanical support for the winding.
  • the support is for example made of plastic material such as acrylonitrile butadiene styrene or ABS, polyetheretherketone, wood, glass, SiO 2 .
  • the supports have for example produced by molding, for example by injection, by machining in a solid part or by 3D printing, for example by a process by powder bed fusion or PBF (Powder Bed Fusion in English terminology) and by a process for the deposition of matter under concentrated energy or DED (Directed Energy Deposition in English terminology). Manufacturing by 3D printing is preferably used for small series.
  • the support 2.2 comprises an outer surface 4 in which is formed at least one recessed path C2 forming a winding with at least one turn.
  • the hollow path comprises a single winding comprising several turns rotating around the support.
  • the support comprises several separate windings intended to form several electrical windings electrically separated from one another.
  • the recessed path 6 can be obtained directly during the molding of the support or subsequently by structuring the outer surface 4 of the support.
  • the structuring of the outer surface 4 is for example carried out by mechanical machining, laser machining or by chemical etching, such as implemented in microelectronic processes.
  • the recessed path has a depth P and a width L ( figure 4 ).
  • the P / L ratio is less than 1, preferably the P / L ratio is between 0.001 and 0.8, more preferably between 0.01 and 0.1.
  • the recessed path can be distributed over the entire support or be located in an area of the support.
  • a layer of electrically insulating material is formed on the outer surface of the support in order to move away the electric turn or turns which will be formed in step b) of the magnetic support.
  • the electrically insulating layer is for example produced by dipping the support in a bath for example of electrically insulating varnish.
  • the electrically insulating layer is produced by covering the support with an insulating lacquer, for example of polyurethane, with a liquid or powder paint, for example of PVC, which is then heated.
  • the support is covered with a layer of ceramic or of a polyester-imide and / or polyamide-imide in a manner similar to the conductive threads called enameled threads.
  • the electrically insulating layer then covers the bottom and the side edges of the recessed path and the areas outside the recessed path.
  • the recessed path C2 is at least partially filled with an electrically conductive material so as to form a continuous conductive path intended to form a winding around the support 2.
  • Layer 8 is formed, for example, in a bath of molten conductive material, for example copper or by sputtering.
  • Layer 8 can be produced in a single dipping step or in several dipping steps.
  • a first thin layer is formed, for example by dipping or spraying, and in a second sub-step, the thickness of the layer 8 is increased, for example by electrolytic deposition, for example in a copper sulphate bath to make a layer of copper.
  • the layer 8 has a thickness greater than the depth P, for example 200 ⁇ m.
  • Layer 8 can be a thick layer formed in a single pass, with a thickness greater than P or of several thin layers superimposed until the desired thickness greater than P.
  • each angular zone is covered with a layer of conductive material 8 different from those of the other angular zones.
  • the dimensions of the electrical conductors of the windings can vary from one another.
  • step c a step of partial removal of the conductive material takes place in order to keep the conductive winding in the recessed path. During this step, the material deposited on the outside of the recessed path is removed.
  • the material is removed for example by mechanical abrasion or by scraping.
  • the tool T1 is suitable for removing the conductive material on the faces F3 and F4 simultaneously.
  • the tool has two pairs of scrapers R1, each pair enclosing an area of the support.
  • the scrapers R1 come into contact with the faces F1 and F2 and are rotated to ensure scraping on all of the faces.
  • a tool having a suitable shape performs the removal operation in a single translation.
  • Another tool T2 is provided to remove the material 8 on the faces F1 and F2. It also comprises a pair of scrapers R2 enclosing the two faces F1 and F2, which comes into contact with the latter. The scrapers are then rotated around the axis of the support.
  • the scrapers are for example made of steel, tungsten, ceramic or aluminum loaded with diamond.
  • the tools for removing the electrically conductive material can be simplified and the removal step can be faster.
  • the tool or tools for removing the conductive material are adapted to the shape of the support.
  • the spacing of the scrapers is variable to adapt to different dimensions of the supports.
  • the spacing of the blades and / or the pressure exerted by them on the layer 8 is or are adapted to remove all the material 8 in the zones outside the hollow path (s) and not to attack the material of the support.
  • the material is removed on one side at a time.
  • one or more tools carried by a robotic arm mobile in the three directions of space is or can be envisaged.
  • material outside of the recessed path is removed by means of at least one abrasive tool, for example an abrasive disc or an abrasive roller moved over the outer surface of the carrier, for example the abrasive disc is carried by an arm robotic.
  • abrasive tool for example an abrasive disc or an abrasive roller moved over the outer surface of the carrier, for example the abrasive disc is carried by an arm robotic.
  • the material outside the recessed path is removed by chemical etching using techniques well known for the manufacture of printed circuits.
  • an inductive device DI obtained by means of the method according to the invention comprising a conductive winding forming an electromagnetic winding. If the support is of a magnetic material, it forms a magnetic core guiding the magnetic flux.
  • the method according to the invention also makes it possible to produce several superimposed windings.
  • the method comprises after step c), a step d) of coating the winding already produced, a step e) of making one or more recessed paths and repeating steps b) and c ).
  • An inductive device with more than two superimposed windings separated by an electrical insulating layer can be manufactured.
  • the inductive device produced by the method according to the invention can be mounted on a printed circuit PCB and the winding is electrically connected to the circuit by its two terminal terminals B1, B2.
  • the inductive device makes it possible to easily produce transformers with at least two windings.
  • Winding E1 has terminals B1, B2, winding E2 has terminals B3, B4 and winding E3 has terminals B5, B6.
  • FIG. 10A we can see a transformer with two windings E1 ', E2' each arranged on an angular sector ⁇ 1 ', ⁇ 2' respectively.
  • the winding E1 ' has the terminals B1', B2 '
  • the winding E2' has the terminals B3 ', B4'.
  • FIG. 10B we can see the electrical diagram of this transformer.
  • the support does not have a recessed path
  • the winding is obtained by structuring the layer 10 so as to form a winding.
  • the tool may include a scraper moving helically around the body and removing the layer material 10 so that only a continuous winding is left.
  • the carrier is removed after removing the conductive material out of the recessed path, resulting in a hollow winding. Removal of the support is for example obtained by etching.
  • the inductive devices thus produced offer good performance in conduction and good performance in heat dissipation, since the production method makes it possible to simply produce a thin electrical conductor wound up.
  • the skin effect phenomenon is appreciably reduced, and the device is not subject to the proximity effect which appears when the winding is carried out by conductive tracks in different planes connected to one another by via. The risks of parasitic capacitance appearing are therefore appreciably reduced.
  • the manufacturing process makes it possible to produce an inductive device offering the advantage of a flat conductor without the proximity phenomenon which appears in inductive devices obtained by stacking layers.
  • the method makes it possible to produce inductive devices having a wide variety of configurations, with one or more windings, superimposed or not.
  • the inductive device according to the invention can be used to manufacture inductive components with a magnetic core, very high frequency converters and switching power supplies for power electronics and power transformers and inductors.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
EP20180391.3A 2019-06-17 2020-06-16 Verfahren zur herstellung einer induktiven vorrichtung Withdrawn EP3754677A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR1906443A FR3097366A1 (fr) 2019-06-17 2019-06-17 Procede de fabrication d’un dispositif inductif

Publications (1)

Publication Number Publication Date
EP3754677A1 true EP3754677A1 (de) 2020-12-23

Family

ID=68501697

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20180391.3A Withdrawn EP3754677A1 (de) 2019-06-17 2020-06-16 Verfahren zur herstellung einer induktiven vorrichtung

Country Status (2)

Country Link
EP (1) EP3754677A1 (de)
FR (1) FR3097366A1 (de)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3319207A (en) * 1963-07-18 1967-05-09 Davis Jesse Grooved toroidal body with metal filling
JPH07130544A (ja) * 1993-10-29 1995-05-19 Tokin Corp 棒状インダクタ及びその製造方法
EP0747913A1 (de) * 1995-06-05 1996-12-11 Motorola, Inc. Oberflächenmontiertes elektronisches Bauelement mit gerilltem Kern und Verfahren zu seiner Herstellung
US9754714B2 (en) 2009-07-31 2017-09-05 Radial Electronics, Inc. Embedded magnetic components and methods

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1994767A (en) * 1934-06-27 1935-03-19 Heintz & Kaufman Ltd Method of making inductances
JPS5878402A (ja) * 1981-11-04 1983-05-12 Yagi Antenna Co Ltd インダクタンス素子

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3319207A (en) * 1963-07-18 1967-05-09 Davis Jesse Grooved toroidal body with metal filling
JPH07130544A (ja) * 1993-10-29 1995-05-19 Tokin Corp 棒状インダクタ及びその製造方法
EP0747913A1 (de) * 1995-06-05 1996-12-11 Motorola, Inc. Oberflächenmontiertes elektronisches Bauelement mit gerilltem Kern und Verfahren zu seiner Herstellung
US9754714B2 (en) 2009-07-31 2017-09-05 Radial Electronics, Inc. Embedded magnetic components and methods

Also Published As

Publication number Publication date
FR3097366A1 (fr) 2020-12-18

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