JPH0869935A - Manufacture of multilayered printed coil board, printed coil board, and multilayered printed coil board - Google Patents

Abstract

PURPOSE: To manufacture a planar magnetic product at a low cost by easily changing the number of turns and turn ratio of a printed coil in a developing and designing stages similarly to a winding type magnetic product. CONSTITUTION: After preparing in advance a plurality of kinds of printed coil boards having different coil patterns, such as the number of turns, wound shape, etc., a plurality of suitable printed coil boards 1a, 1b, 1c, 1d, and 1e are selected and laminated (a) and a printed coil 3 is formed by uniting the laminated boards 1a, 1b, 1c, 1d, and 1e in one body. Then a planar type magnetic product is manufactured by respectively putting the central projecting parts of cores 11 and 12 in the hole 2 of the coil 3 from the top and bottom sides (b).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multilayer printed coil board used for a planar magnetic product and having one or a plurality of printed coil boards.

[0002]

2. Description of the Related Art As magnetic products for transformers and choke coils used in electronic circuits such as switching power supplies, wound wire type magnetic products have been generally used. The wound wire type magnetic product has a structure in which a wire such as an enamel wire is wound around a bobbin provided with a lead terminal. With this wound-wire type magnetic product, the circuit engineer can easily change the number of turns of the coil, the number of turns of the coil, etc. at the time of circuit design / development. There is an advantage that it is easy to manufacture.

Nowadays, there is an increasing demand for miniaturization and weight reduction of electronic circuits, and miniaturization of electronic parts constituting the electronic circuits is required. Under such circumstances, in place of the above-mentioned wound type magnetic product, a planar type magnetic product having a structure suitable for high frequency, miniaturization and low profile of an electronic circuit such as a switching power supply has been put into practical use. It is (special public Sho 39
-6921, Japanese Patent Publication No. 41-10524, or Japanese Patent Laid-Open No. 48
−51250 publication). The planar type magnetic product does not form a coil by a wound wire, but forms a spiral or U-shaped thin film conductor pattern on one surface or both surfaces of a flat insulating substrate or a multilayer surface including the inner layer surface, for example. A single printed coil board formed or a multilayer printed coil board formed by laminating a plurality of such printed coil boards is sandwiched between magnetic material cores. There is a physical (area) limit to the number of turns of a coil formed of a conductor pattern formed on one printed coil board. Therefore, several printed coil boards are laminated in a transformer of a switching power supply. The use of multilayer printed coil boards is common.

In such a planar type magnetic product, of course, it is possible to realize the miniaturization and the low profile, and since the interlinking area of the magnetic flux can be increased as compared with the wound type magnetic product, the leakage inductance becomes small. Features that can achieve a high degree of secondary-to-secondary coupling, features that the increase in copper loss due to the skin effect can be suppressed to a minimum, and a coil of a conductor pattern can be formed using pattern etching, so that unstable wire winding Compared to the wound-wire type magnetic products that require treatment, the reproducibility is good and the quality reliability and stability are improved. Of these features, the first two features become more apparent as the high-frequency current increases. As magnetic products used for switching power supplies that aim to increase the switching frequency, planar magnetic products are increasingly being used. It is in the spotlight.

Here, the conventional planar type magnetic product already disclosed will be briefly described. FIG. 24 is a diagram showing a conventional example disclosed in, for example, Japanese Patent Application Laid-Open Nos. 61-74311 and 61-75510, and FIG. (B) is a cross-sectional view of the main part of the plane, FIG.
24 (c) shows a side view thereof. In FIG. 24, a laminated wiring board 41 is a multilayer laminated sheet coil in which a conductor pattern 45 of a coil is formed on a thin insulating sheet, and constitutes a multilayer printed coil board of a transformer as a whole. A through hole 42 is formed in the multilayer printed coil board, a terminal pin 43 is inserted into this through hole 42, and the conductor pattern 45 of each sheet coil is electrically connected to each other by soldering the terminal pin 43 and the through hole 42. Connected to each other. A part of the terminal pin 43 is extended in the longitudinal direction, and the extended portion serves as a connecting means to an external conductor of a printed wiring board (not shown) and a fixing means for the transformer. The cores 44 and 46 are manufactured in a vertically divided shape, and both cores 4 and
The magnetic circuit of the transformer is configured by putting the laminated wiring boards 41 and 46 together.

FIG. 25 is an exploded perspective view showing another conventional planar type magnetic product disclosed in, for example, Japanese Utility Model Laid-Open No. 4-103612. In FIG. 25, a coil pattern 52 is spirally formed on a printed wiring board 51, and core mounting holes 53, 54, 55 are formed at the center and both sides thereof.
Then, by the two ferrite cores 56 and 57 having a shape that penetrates through the core mounting holes 53, 54 and 55 and is bonded to each other,
Printed wiring board 51 in the portion where the coil pattern 52 is formed
The magnetic circuit of the transformer is constructed by sandwiching the

26 and 27 show, for example, an actual flat blade 4-105512.
FIG. 26 is a diagram showing still another example of the related art disclosed in Japanese Patent Application Laid-Open No. 5-291062, Japanese Patent Application Laid-Open No. 6-163266, etc., and FIG. 26 is a perspective view showing the overall configuration of a transformer, Figure 27
FIG. 3 is an exploded perspective view showing each component. This conventional thin transformer is a multilayer printed coil board formed by stacking a plurality of printed coil boards having conductor patterns formed on the surface thereof.
Place 62 on the terminal block 63 with a plurality of terminal pins 65,
The I-type core 64 and the E-type core 61 sandwich this structure vertically. Each terminal pin 65 provided on the terminal block 63 is an insertion portion 65a that is inserted into the through hole 66 of the multilayer printed coil board 62, and a mounting portion that is bent in series with the insertion portion 65a and extends parallel to the mounting surface. It is divided into part 65b. Then, the insertion portion 65a of each terminal pin 65 and the through hole 66 of the multilayer printed coil board 62 are electrically connected by soldering. The electrical connection with the external conductor is made via the mounting portion 65b of each terminal pin 65.

[0008]

Such a planar type magnetic product has the above-mentioned excellent advantages, but when the number of turns or the turn ratio of the coil is changed, the coil pattern is redesigned. There is a problem that it is difficult to easily change these as in a wound-type magnetic product, because a new printed coil board has to be manufactured again. Therefore, the development and design requires a great number of steps and days, and the cost is high, and the number of windings and the winding number ratio are predetermined, and the special magnetic product as a magnetic product of an electronic circuit does not change. Its use is limited to the field,
At present, the advantages of planar magnetic products have not been fully utilized.

The present invention has been made in view of the above circumstances. A plurality of types of printed coil boards having different coil patterns such as the number of windings and the winding shape are prepared in advance, and an appropriate plurality is selected from these. Then, by stacking them together to produce a multilayer printed coil board, the number of turns and the number of turns ratio can be easily changed at the development / design stage like the conventional wound-type magnetic products. An object of the present invention is to provide a method for manufacturing a multilayer printed coil board which can reduce the design cost and a plurality of printed coil boards used for the method.

Another object of the present invention is to provide a method for producing a multilayer printed coil board capable of producing a large quantity of the same multilayer printed coil board as a prototype developed / designed prototype at low cost, and It is to provide a set of a plurality of printed coil boards used for this.

[0011]

A method for manufacturing a multilayer printed coil board according to claim 1 of the present application is a multilayer method in which a plurality of printed coil boards each having a coil formed of a conductor pattern of one layer or a plurality of layers are laminated. In a method of manufacturing a printed coil board, a step of preparing a plurality of kinds of printed coil boards having different conductor patterns, a step of selecting a plurality of printed coil boards from the prepared kinds of printed coil boards, and a plurality of selected prints Laminating the coil substrates to produce a multilayer printed coil substrate.

A method for manufacturing a multilayer printed coil board according to claim 2 of the present application is the method according to claim 1, wherein each of the plurality of kinds of printed coil boards has a coil formed on both sides or one side with a conductor pattern. Is characterized by.

A method for manufacturing a multilayer printed coil board according to claim 3 of the present application is the method of manufacturing a multilayer printed coil board according to claim 1, wherein the plurality of types of printed coil boards include at least the number of windings, the winding shape, the width, and the thickness of the conductor pattern. One of them is different from each other.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a multilayer printed coil board according to the first aspect, wherein each of the plurality of types of printed coil boards has through holes for obtaining electrical connection on the front and back sides of the printed coil board. It is characterized by being formed.

According to a fifth aspect of the present invention, there is provided a method for manufacturing a multilayer printed coil board according to the first aspect, wherein each of the plurality of types of printed coil boards is electrically connected to another printed coil board when laminated. A connecting member for obtaining or for making an electrical connection with an external conductor is provided.

A method for manufacturing a multilayer printed coil board according to claim 6 of the present application is the method according to claim 5, wherein the connecting member is a clip lead, and the clip lead is provided at an end portion of each of the plurality of kinds of printed coil boards. It is characterized in that terminals are formed.

According to claim 7 of the present application, in the method for manufacturing a multilayer printed coil board according to claim 5, the connecting member is a terminal pin, and the terminal pin is inserted into an end portion of each of the plurality of kinds of printed coil boards. It is characterized in that a through hole is formed to allow it.

In the method for producing a multilayer printed coil board according to claim 8 of the present application, a multilayer printed coil board is produced by laminating a plurality of printed coil boards each having a coil formed of a conductor pattern of one layer or a plurality of layers. In the method, a step of preparing a plurality of types of printed coil boards having different conductor patterns, a step of selecting a plurality of printed coil boards from the prepared plurality of types of printed coil boards, and stacking the selected plurality of printed coil boards The steps of making a multilayer printed coil board as a prototype, the steps of making a plurality of printed coil boards having the same characteristics as the plurality of printed coil boards used for the prototype multilayer printed coil board, and the plurality of made prints. By stacking the coil boards, it can be used as a prototype multi-layer printed coil board. There characterized by a step of producing a multilayer printed coil substrate as a product of the same.

The method for producing a multilayer printed coil board according to claim 9 of the present application is the film for pattern used in producing a plurality of printed coil boards used for a multilayer printed coil board as a prototype according to claim 8. Is used to form a plurality of printed coil boards having the same characteristics as the plurality of printed coil boards.

A set of a plurality of printed coil boards according to claim 10 of the present application is a set of a plurality of printed coil boards used for producing a multilayer printed coil board, in which a coil is formed by a conductor pattern of one layer or a plurality of layers. The printed coil board of the present invention is characterized by having a plurality of types of printed coil boards in which at least one of the number of turns, the winding shape, the width, and the thickness of the conductor pattern is different from each other.

According to claim 11 of the present application, a set of a plurality of printed coil boards according to claim 10 is characterized in that a coil is formed in a conductor pattern on both sides or one side thereof.

According to a twelfth aspect of the present invention, a set of a plurality of printed coil boards is characterized in that, in the tenth aspect, through holes for forming electrical connection on the front and back sides are formed.

According to claim 13 of the present application, a set of a plurality of printed coil boards according to claim 10 is provided with a connecting member for obtaining each electrical connection or for obtaining an electrical connection with an external conductor. It is characterized by being provided.

According to a fourteenth set of printed coil boards according to the present invention, in the thirteenth aspect, the connecting member is a clip lead, and a terminal for a clip lead is formed at an end thereof. Characterize.

According to a fifteenth aspect of the present invention, in a set of a plurality of printed coil boards, the connecting member is a terminal pin, and a through hole for inserting the terminal pin is formed at an end portion thereof. It is characterized by

According to claim 16 of the present application, the set of a plurality of printed coil boards according to claim 10 is characterized in that the number of turns of the conductor pattern in all of the plurality of kinds of printed coil boards included is an integer. To do.

According to a seventeenth aspect of the present invention, a set of a plurality of printed coil boards according to the tenth aspect includes the printed coil board having a small number of turns of the conductor pattern.

The multilayer printed coil board according to claim 18 of the present application is prepared as a multilayer printed coil board in which a plurality of printed coil boards each having a coil formed of a conductor pattern of one layer or a plurality of layers are laminated. It is characterized in that a plurality of printed coil boards selected from a plurality of types of printed coil boards having different conductor patterns are laminated and integrally formed.

[0029]

In the method of manufacturing a multilayer printed coil board according to the present invention, the number of turns, the winding shape, and
Prepare multiple types of printed coil boards with different widths and thicknesses in advance. Then, based on the characteristics of the magnetic product to be produced, a desired combination of a plurality of printed coil boards is selected from these plurality of types of printed coil boards. A plurality of selected printed coil boards are integrally laminated to form a multilayer printed coil board.

In this way, after the multilayer printed coil board as a prototype having desired characteristics is manufactured, the pattern etching film used for forming the conductor pattern of the selected plural printed coil boards is used. A plurality of printed coil boards on which conductor patterns are formed are laminated according to the prototype, and a large number of multilayer printed coil boards as products having the same characteristics as the prototype are manufactured.

In the method for producing a multilayer printed coil board according to the present invention, by arbitrarily changing the combination of a plurality of types of printed coil boards, the winding of the produced multilayer printed coil board is carried out like a conventional wound wire type magnetic product. The number, winding ratio, winding order, etc. can be easily changed. In addition, since a plurality of printed coil boards to be laminated when manufacturing a multilayer printed coil board as a product is created by using an existing film, there is no need to redesign, and a new film is created. It is possible to mass-produce a multi-layer printed coil board having the same characteristics as the prototype easily and at low cost without any need.

[0032]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to the drawings showing the embodiments.

1 (a) and 1 (b) are exploded perspective views showing the steps for producing a planar type magnetic product based on the method for producing a multilayer printed coil board of the present invention. In advance
A large number of types of printed coil boards are prepared in which a coil having different numbers of turns (the number of turns) is formed on one surface or both surfaces of an insulating board by a conductor pattern. A desired plurality of (five in this example) printed coil boards 1a, 1b, 1c, 1d, 1e are selected from these so that the predetermined characteristics of the planar magnetic product to be produced can be obtained. Then, as shown in FIG. 1A, the selected five printed coil boards 1a, 1b, 1c, 1d, 1e are laminated. 11, 12
Is a core for sandwiching the laminated body (multilayer printed coil board 3) of the printed coil boards 1a, 1b, 1c, 1d, 1e from the upper surface and the lower surface. Each of the cores 11 and 12 is an E-shaped core having convex portions formed on both ends and the center thereof. A rectangular hole 2 is formed in the center of all of the printed coil boards prepared in advance so that the central protrusions of the cores 11 and 12 can be fitted therein.

Laminated printed coil boards 1a, 1b, 1c,
1d and 1e are integrated to produce a multilayer printed coil board 3 as shown in FIG. Then, the central protrusions of the cores 11 and 12 are fitted into the hole 2 from above and below, and the opposing protrusions of the cores 11 and 12 are brought into contact with each other to produce a planar magnetic product.

Next, a specific example of the present invention will be described.
FIG. 2 is a circuit diagram of a forward type switching power supply to which the multilayer printed coil board of the present invention is applied. The multilayer printed coil board of the present invention is used for a transformer 13 and a choke 14 in the circuit diagram. This switching power supply has 36 ~ 72
It can handle V input voltage. The output voltage is divided by a resistor, is amplified by comparison with the reference voltage of the variable Zener diode 19, and is input to the feedback voltage terminal of the PWM IC 15, which is the controller, via the photodiode 17 and the phototransistor 18. In the forward type switching power supply, the output voltage and the duty ratio of the MOSFET switch 16 (the proportion of the on-time to the pulse period) are in proportion to each other.
Can control the duty ratio of the pulse output from the MOSFET drive pulse according to the voltage of the feedback voltage terminal to stabilize the output voltage to a desired value. In this switching power supply, the emission intensity of the photodiode 17 increases (decreases) when the output voltage rises (decreases), and the voltage at the feedback voltage terminal connected to the emitter of the phototransistor 18 rises (decreases).
The duty ratio of the MOSFET drive pulse of the PWM IC15, which is a negative logic, decreases (up), and as a result, the output voltage is stabilized at a desired value.

In order to manufacture magnetic products used for the transformer 13 and the choke 14, six kinds of printed coil boards having different numbers of windings were prepared. Each of the prepared printed coil boards was formed with a coil of a conductor pattern on both surfaces thereof, and the number of windings on the front surface and the back surface was the same. This 6
The number of turns on each side of each type of printed coil board was as follows. L1: 2 turns, L2: 3 turns, L3:
4 turns, L4: 5 turns, L5: 6 turns,
L6: 7 turns

Since the height of the planar magnetic product including the core needs to be 5 mm or less, the maximum number of print coil substrates that can be stacked is six. Table 1 below shows examples of the printed coil boards selected for the transformer 13 and the choke 14 from the above-mentioned six types of printed coil boards. The number of laminated printed coil boards is five as shown in FIG. In Table 1, the first sheet is the printed coil board 1a shown in FIG. 1A, and the second, third, fourth, and fifth sheets are the printed coil boards 1b and 1c shown in FIG. 1A, respectively. , 1d, 1e are supported. Also, 1
Next / secondary indicates the primary side coil or the secondary side coil. In this example, primary-side coils and secondary-side coils are alternately laminated to enhance the coupling between the primary and secondary sides.

[0038]

[Table 1]

FIG. 2 shows a case where a planar type magnetic product having a core of a multilayer printed coil board in which five printed coil boards of a combination as shown in Table 1 are laminated and integrated is used for a transformer 13 and a choke 14. We were able to maximize the efficiency of the switching power supply shown to 85%. This is 1
It is largely due to the characteristic of the planar type magnetic product, that is, the high coupling between the secondary and the secondary.

Generally, when a 10-layer multi-layer printed coil board is prototyped, a cost of about 500,000 to 600,000 yen and a day of about one month are required, and coil winding in a transformer or a choke is required. It is necessary to change the number several times. Therefore, conventionally, a desired one must be selected from a plurality of types of multilayer printed coil boards whose number of turns and a number of turns are predetermined, and the application range of the planar type magnetic product is limited to a special field. Therefore, it was hard to say that the advantages of the planar magnetic product were maximized.
However, in the present invention, a multilayer printed coil board can be produced by arbitrarily selecting a plurality of printed coil boards having different numbers of windings. Therefore, even when the input / output voltage of the switching power supply is changed, the same as the wound wire type magnetic product is obtained. It is possible to flexibly respond with some degree of freedom, and the trial production cost and trial production time can be greatly reduced.

In the above example, the case where the printed coil board in which the coils (conductor patterns) with the same number of turns are formed is used on both sides has been described, but a coil (conductor with different numbers of turns on the front surface and the back surface) is used. A printed coil board on which a pattern is formed may be used. Further, only a printed coil board having a coil (conductor pattern) formed on only one side may be used, or a printed coil board having a coil (conductor pattern) formed on one side or both sides may be mixed and used.

Further, in the above-mentioned example, a case has been described in which a plurality of types of printed coil boards differing only in the number of windings are prepared and used, but a coil (conductor pattern) is used.
It is also possible to prepare in advance a plurality of types of printed coil boards having different winding shapes or different widths, thicknesses, etc., and select and use the required printed coil board from these. If a large number of printed coil boards with different parameters of such a coil (conductor pattern) are prepared in advance, the degree of freedom in producing a multilayer printed coil board will be further increased, and a multilayered board that is more suitable for use characteristics will be obtained. It goes without saying that the printed coil board can be easily manufactured.

Next, an example of the electrical connection member of the printed coil board will be described. FIG. 3 is an exploded perspective view showing a plurality of printed coil boards to be laminated together with a core. In FIG. 3, 1a, 1b, 1c, 1d and 1e are five printed coil boards selected from the prepared plural kinds of printed coil boards. In addition, 11 and 12 are E type cores similar to FIG.

Each printed coil board 1a, 1b, 1c, 1d, 1e
A spiral conductor pattern 4 is formed on both surfaces of the coil so as to form a coil with a predetermined number of turns. Each printed coil board 1a, 1b, 1c, 1d, 1e is formed with a through hole 5 for obtaining electrical connection between the front and back of the printed coil board. In addition, a part of each printed coil board 1a, 1b, 1c, 1d, 1e in the short side direction is projected, and a clip lead terminal 6 is formed on the projecting portion, and this terminal 6 can be automatically inserted. Possible clip leads 7 are extended downward and connected. The clip lead 7 is for obtaining an electrical connection between the respective printed coil boards and for connecting to an external pattern of the mounting board to obtain an electrical connection with the outside.

FIG. 4 is an exploded perspective view showing another example of the electrical connecting member of the printed coil board. In FIG.
The same parts as those in FIG. 3 are designated by the same reference numerals and the description thereof will be omitted.
In this example, each printed coil board 1a, 1b, 1c, 1d, 1e
Has a part projecting in the short side direction, and a through hole 8 is formed in the projecting part.
Is inserted. The method of using the terminal pin 9 is the same as the method of using the clip lead 7 in the above-described example.

By the way, unlike the wound wire type coil,
In the multilayer printed coil board, when the total number of printed coil boards to be stacked increases, the design cost and the initial cost such as a film cost for pattern etching increase in proportion to the total number. Therefore, when manufacturing a multilayer printed coil board as a product having the same characteristics as the prototype manufactured in the development / design stage as described above, the manufacturing cost can be reduced by reducing these costs. . Hereinafter, examples in which the manufacturing cost is reduced will be described.

First, the types of printed coil boards will be described. FIG. 5 shows an example of the printed coil board 1 in which coils having conductor patterns are formed on both sides and the number of terminals is four on each side. FIG. 5 shows an example of such three types of printed coil substrates (substrate A, substrate B, substrate A '), and FIG. 5 shows the front surface and the back surface of each printed coil substrate 1, respectively. In addition, in FIG. 5, the back view is a front perspective view of the front view. In FIG. 5, a conductor pattern 4 serving as a coil having a predetermined number of turns is formed on the front surface and the back surface of the printed coil board 1. Further, through holes 5 for obtaining electrical connection between the front surface and the back surface are formed as needed. Four pin pads 10 are formed on each end of each printed coil board 1 in a row at equal pitch.
Each pin pad 10 is formed with a through hole 8 for inserting a terminal pin for obtaining electrical connection between the printed coil boards.

These three types of printed coil boards 1 can be classified according to which through hole 8 the winding start position and the winding end position of the coil 4 correspond to. First, the substrate A is the first through hole 8 from the lower left of FIG.
Corresponds to the winding start position of the coil 4, and the second through hole 8 also corresponds to the winding end position of the coil 4. In addition, the board B is the second through hole 8 from the lower left of FIG.
Corresponds to the winding start position of the coil 4, and the third through hole 8 also corresponds to the winding end position of the coil 4. In the board A ′, the third through hole 8 from the lower left of FIG. 5 corresponds to the winding start position of the coil 4, and the fourth through hole 8 also corresponds to the winding end position of the coil 4.
Since the substrate A'is obtained by turning the substrate A over, the substrates A and A'are substantially the same. As a result, the number of terminals is 4
In the case of individual pieces, the printed coil board 1 is classified into two types, that is, boards A and B. For these two types, the printed coil board 1 having a plurality of types of turns is prepared. An example is shown in Table 2 below. Here, there are 1 to 6 turns for each printed coil board 1, and there are a total of 12 types.

[0049]

[Table 2]

Each of the printed coil boards 1 is generally designed in a multiple pattern as shown in FIG. 6, for example. FIG. 6 shows an example of taking nine pieces, and all nine pieces are the same substrate (for example, A1 in Table 2). Further, the V cut line in the drawing is inserted so that the printed coil board 1 can be easily divided into individual parts. For example, the 12 types of printed coil boards shown in Table 2 used to fabricate a multilayer printed coil board as a prototype in the development / design stage are shown in FIG. 7 (board type A) and FIG. 8 (board type B). The hatched portion is cut off, as shown in FIG. FIG. 9 shows the front surface and the back surface of each of the cut-out printed coil boards 1. In addition, in FIG. 9, the back view is a perspective view of the front view. Further, in FIG. 9, the same parts as those in FIG.

The reason why the hatched portion is cut off is that when a plurality of printed coil boards 1 are stacked and the terminal pins are inserted into the through holes 8 in order to obtain electrical conduction between the printed coil boards 1, the printed wiring board and the terminal pins are printed. This is because soldering with the pin pad 10 of the coil substrate 1 can be performed easily and reliably. Of course, if there is no problem, it is not necessary to cut off the hatched portion.

A plurality of printed coil boards 1 for initial development design prepared in this way are selected and laminated to form a multilayer printed coil board as a prototype, and then through holes 8 are formed. To terminal pin 9
And the E-type cores 11 and 12 are sandwiched between them to produce a planar type transformer. FIG. 10 is an exploded perspective view of such a planar type transformer, and FIGS. 11 (a) and 11 (b) are side views thereof. In this example, five selected printed coil boards are shown.
1a, 1b, 1c, 1d, 1e are laminated. The terminal pin 9 and the pin pad 10 inserted into the through hole 8 are solder fillets.
Connected at 20.

The characteristics of the manufactured multilayer printed coil boards of a plurality of prototypes are evaluated. Then, based on the evaluation result, the types of the plurality of printed coil boards 1 used for the multilayer printed coil board to be actually manufactured and the stacking order thereof are determined. After that, a multilayer printed coil board as an actual product is manufactured as follows.

First, a plurality of printed coil boards 1 used for a multilayer printed coil board as an actual product are prepared. Here, the printed coil board 1 for initial development design
Using the film for pattern used when creating
A plurality of the printed coil boards 1 to be used are prepared in a size of a large number shown in FIG. Since the existing pattern film can be used, it is not necessary to prepare a new pattern film, and the manufacturing cost can be reduced. Then, a predetermined number of printed coil boards 1 are laminated and integrated in a multi-sized printed circuit board to produce a multilayer printed coil board 3. At this time, an insulating sheet containing an adhesive resin is inserted between the adjacent printed coil boards 1 to insulate and bond the printed coil boards 1 together. After that, the terminal pin 9 is inserted into the through hole 8 and sandwiched between the E-shaped cores 11 and 12 to manufacture a planar transformer. FIG. 12 is an exploded perspective view of such a planar transformer, and FIG. 13 is a side view thereof.

In the above-mentioned example, the printed coil boards 1 separated from the multiple-sized size are laminated to produce a multilayer printed coil board as a prototype, but in the case of producing a multilayer printed coil board as a product, Similarly, a plurality of printed coil boards 1 may be stacked as they are to produce a multilayer printed coil board as a prototype.

Although the terminal pin 9 is used as the connecting member in the above-mentioned example, the clip lead 7 cheaper than the terminal pin 9 may be used as the connecting member as in the embodiment shown in FIG. Of course good things.

By the way, in the above-described embodiment, the number of turns of the conductor pattern (coil) 4 formed on the printed coil board 1 is an integer, but a decimal number of turns such as 0.75 and 0.5 is possible in addition to the integer. Fig. 14 (a) shows a pattern example of the conductor pattern (coil) 4 when the number of turns is 0.75.
14 (b) shows examples of the conductor pattern (coil) 4 when the number of turns is 0.5. When electrically connecting the terminals (pin pads 10) facing each other with the E-shaped core 11 sandwiched in one printed coil board 1, the conventional example uses the outer conductor 101 as shown in FIG. In the printed coil board 1 provided with the conductor pattern (coil) 4, the terminals (pin pads 10) facing each other can be electrically connected while increasing the number of turns, as shown in FIG.

When the number of turns of the conductor pattern (coil) 4 formed on each printed coil board 1 is an integer and four terminals are provided on one side, as described above, the winding start position and winding of the coil 4 are performed. There are two types of substrates depending on the end position. Table 3 shows the relationship between the number of terminals and the number of types according to the terminal positions of the winding start and the winding end of the printed coil board 1 (however, the number of turns of the conductor pattern (coil) 4 is an integer). 14 (a) and (b)
When the printed coil board 1 with a small number of turns as shown in Table 3 is included, the number of types of the printed coil board 1 is shown in Table 3.
Increase from the number shown in. Further, when a plurality of terminal pins are connected in parallel by branching the through hole 8 on the winding start side or winding end side so as to cope with a large current, the number of terminals increases.

[0059]

[Table 3]

Next, an example of a printed coil component for obtaining electrical connection between the printed coil board and the external conductor will be described.

FIG. 17 is an exploded perspective view showing an embodiment of the printed coil component. In FIG. 17, reference numeral 21 is a printed coil board. The printed coil board 21 has a rectangular thin plate shape in which coils are formed in a conductor pattern over the multi-layer surface including the inner layer surface, and since the shape can be maintained by itself, a support for supporting this is provided. No member is required. A rectangular hole 21a is formed in the center of the printed coil board 21. A plurality of (6 in the example of FIG. 17) through holes 23 connected from the pin pads 22 are formed at both ends in the longitudinal direction of the printed coil board 21 in a row at a predetermined equal pitch in the width direction of the printed coil board 21. Is formed. Further, 25 is a rectangular parallelepiped made of an insulating material.
On the upper surface of each base 25, a plurality of columnar terminal pins 24 (six in the example of FIG. 17) made of a conductive material are planted in a row at the same pitch as the through holes 23. It is set up.
On one side surface of each base 25, a plurality of (6 in the example of FIG. 17) conductor projections 26 connected to each terminal pin 24 are projected.
Each terminal pin 24 is longer than the through hole 23, and its length is approximately twice the length of the through hole 23.

Next, the process of assembling the print coil component will be described. 18 (a), (b), and (c) are a plan view, a front view, and a side view showing the printed coil component after assembly. First, a positioning jig is used to align the through holes 23 of the printed coil board 21 with the terminal pins 24 of the two bases 25, and then the printed coil board is positioned.
Insert each terminal pin 24 corresponding to this into each through hole 23 until the lower surface of 21 comes into contact with the upper surface of each base 25, and then,
Each corresponding through hole 23 and each terminal pin 24 are electrically connected by soldering. As shown in FIG. 18, the through holes 23 and the terminal pins 24 are soldered in a state in which approximately the upper half of each terminal pin 24 projects from the printed coil board 21. In addition, 27 of FIG. 18 shows a solder fillet after this soldering process.

By sandwiching the above-described printed coil component with an E-type ferrite core and an I-type ferrite core, a transformer for a switching power supply and a choke coil can be constructed. FIG. 19 is an exploded perspective view showing an embodiment of such a transformer, FIGS. 20 (a), 20 (b),
Similarly, (c) is a plan view showing the configuration after the assembly,
It is a front view and a side view. 19 and 20, in FIG.
The same parts as those in FIG. 18 are designated by the same reference numerals and the description thereof will be omitted. Reference numerals 28 and 29 in FIGS. 19 and 20 denote ferrite cores that sandwich the printed coil component from above and below, and specifically,
28 is an E-shaped core having convex portions at both ends and the center, and 29 is an I-shaped core having a flat rectangular parallelepiped shape. The central convex portion of the E-shaped core 28 is fitted into the hole 21a of the printed coil board 21, and the three convex portions are brought into contact with the upper surface of the I-shaped core 29 so that both cores 28, 29 and the printed coil component are integrated. To produce a transformer as shown in FIG.

An example of electrical connection between the transformer using the printed coil component and the mounting board is shown in FIGS. 21 (a) and 21 (b). In FIG. 21, the parts given the same numbers as in FIGS. 19 and 20 indicate the same parts. Each conductor protrusion 26 connected to each terminal pin 24 is connected to the mounting substrate 30 by a solder fillet 31, and the printed coil component and the mounting substrate 30 are electrically connected by soldering these. Figure 21
In the example shown in (a), the height of the base 25 is controlled so that the ferrite core (I-shaped core 29) is in contact with the mounting board 30, and the heat radiation of the ferrite core is performed via the mounting board 30. It is effective when doing. On the other hand, the example shown in FIG.
Ferrite core (I type core 29) by controlling the height of the base 25
The bottom surface of is mounted above the mounting substrate 30 and is effective in insulating the ferrite core from the mounting substrate 30.

According to the present embodiment, since the terminal pins 24 are mainly positioned by the through holes 23 of the printed coil board 21, it is possible to assemble using a simple positioning jig.
Assembling becomes easier as compared with the conventional method shown in FIG. 24 in which the terminal pins 43 are press-fitted to stand vertically. Also, the base
Only fixing the pitch of the terminal pins 24 implanted in 25, the number of the terminal pins 24, the terminal pins 2 facing each other.
There is no limit to the distance between 4 and 24. Therefore, not only the pitch of the terminal pins 65 to be implanted, but also the number of the terminal pins 65 and the terminal block 63 in which the distance between the facing terminal pins 65 and 65 are fixed are used in the conventional example shown in FIGS. In comparison, it can flexibly respond to various shapes of printed coil boards,
Greater freedom in designing printed coil components. As a result, the assembling cost and the member cost can be significantly reduced as compared with the conventional printed coil component.

Next, another embodiment of the printed coil component will be described. FIG. 22 is an exploded perspective view showing another embodiment. In the embodiment of FIG. 22, a plurality of printed coil boards 21 each having a coil formed of a conductor pattern on both sides of the board are laminated. Further, an insulating sheet 32 is interposed between the adjacent printed coil boards 21 and 21 in order to insulate the adjacent printed coil boards 21 from each other. In the embodiment shown in FIG. 22, four insulating sheets 32 and three printed coil boards 21 are alternately laminated one by one. A hole 32a having the same shape as the hole 21a of the printed coil board 21 is formed in the center of each insulating sheet 32, and a plurality of holes aligned with the plurality of through holes 23 of the printed coil board 21 are provided at both ends thereof. 33 are formed.
The electrical connection between the printed coil boards 21 is made by inserting the terminal pins 24 implanted in the base 25 into the through holes 23 and the holes 33 and soldering the same as in the above-described embodiment. . Generally, in a printed coil board, the manufacturing cost thereof increases exponentially as the number of layers of the conductor pattern increases.
Therefore, when a large number of conductor patterns are laminated, the conductor patterns to be formed are divided into a plurality of single-layer or multilayer printed coil boards, and each printed coil board is provided with an insulating sheet as shown in FIG. The total cost can be reduced by stacking the layers.

23 (a) and 23 (b) are a plan view and a front view showing a part of still another embodiment of the printed coil component. 23, the same parts as those in FIG. 17 are designated by the same reference numerals and the description thereof will be omitted. In the embodiment shown in FIG. 23, slits that lead from the end surface of the printed coil board 21 to the through holes 23 are formed.
34 are provided in the same number as the through holes 23. Therefore, when the through hole 23 and the terminal pin 24 are connected by soldering, it is possible to easily visually inspect the connection state between the two through the slit 34, which ensures reliable soldering connection and contributes to quality improvement. can do. Since the positioning of the terminal pin 24 is mainly performed by the through hole 23 of the printed coil board 21, the width of the slit 34 to be formed must be narrower than the diameter of the terminal pin 24 so that the positioning can be performed accurately. I have to.

In each of the embodiments relating to the printed coil parts, the shape and arrangement of the terminal pins 24, the shape of the through holes 23 of the printed coil board 21, the printed coil board.
It goes without saying that there is no restriction on the number of layers of the conductor pattern formed on 21, the number of printed coil boards to be laminated, the shape of the ferrite core to be sandwiched, and the like.

[0069]

As described above, according to the present invention, a plurality of printed coil boards having different coil patterns are prepared in advance, and an appropriate plurality of these are selected and laminated to form a printed coil. Like the conventional wound wire type magnetic product, the number of turns and the number of turns can be easily changed at the development / design stage, and high coupling between primary and secondary, reduction of copper loss due to skin effect, Planar type magnetic products, which have the excellent features of improved quality reliability and stability, can be manufactured easily and at low cost. As a result, the application range of planar type magnetic products can be greatly expanded.

Further, when a multilayer printed coil board having the same characteristics as the multilayer printed coil board as a prototype manufactured at the development / design stage is manufactured, the existing one used when the printed coil board used for the prototype is manufactured. Since the patterning film is used, a large amount of multilayer printed coil boards having the same characteristics as the prototype can be produced easily and at low cost.

Furthermore, the number of turns of the coil pattern formed on the printed coil board is not limited to an integer, but by adopting a small number of turns, the selectivity of the printed coil board can be improved and at the same time, in one printed coil board. With, the number of turns can be increased and the terminals facing each other can be electrically connected.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing the concept of a method for manufacturing a multilayer printed coil board according to the present invention.

FIG. 2 is a circuit diagram of a switching power supply using the multilayer printed coil board of the present invention.

FIG. 3 is an exploded perspective view of an embodiment of the planar magnetic product of the present invention.

FIG. 4 is an exploded perspective view of another embodiment of the planar magnetic product of the present invention.

FIG. 5 is a plan view showing an example of a printed coil board.

FIG. 6 is a plan view showing a large number of printed coil boards.

FIG. 7 is a plan view showing a large number of printed coil boards.

FIG. 8 is a plan view showing a large number of printed coil boards.

FIG. 9 is a plan view showing an example of a printed coil board.

FIG. 10 is an exploded perspective view of a planar transformer as a prototype.

FIG. 11 is a side view of a planar transformer as a prototype.

FIG. 12 is an exploded perspective view of a planar transformer as a product.

FIG. 13 is a side view of a planar transformer as a product.

FIG. 14 is a plan view showing an example of a printed coil board having a small number of turns.

FIG. 15 is a plan view showing a conventional example of electrical connection.

FIG. 16 is a plan view showing an example of the present invention for electrical connection.

FIG. 17 is an exploded perspective view of an embodiment of a printed coil component.

FIG. 18 is an assembly diagram of an embodiment of a printed coil component.

FIG. 19 is an exploded perspective view of a transformer using a printed coil component.

FIG. 20 is an assembly diagram of a transformer using a printed coil component.

FIG. 21 is a diagram showing an example of installation of a transformer using a printed coil component on a mounting board.

FIG. 22 is an exploded perspective view of another embodiment of a printed coil component using a plurality of printed coil boards.

23A and 23B are a partial plan view and a partial assembly view of still another embodiment of a printed coil component in which a slit is formed on a printed coil board.

FIG. 24 is a diagram showing an example of a conventional planar type magnetic product.

FIG. 25 is an exploded perspective view showing another example of a conventional planar type magnetic product.

FIG. 26 is an assembly view showing still another example of the conventional planar type magnetic product.

FIG. 27 is an exploded perspective view showing still another example of the conventional planar type magnetic product.

[Explanation of symbols]

 1, 1a, 1b, 1c, 1d, 1e Printed coil board 2 holes 3 Printed coil 4 Coil (conductor pattern) 5 Through hole 6 Clip lead terminal 7 Clip lead 8 Through hole 9 Terminal pin 10 Pin pad 11, 12 Core 13 Transformer 14 Choke 20 Solder fillet

Claims (18)

[Claims] 1. A method for producing a multilayer printed coil board, which comprises laminating a plurality of printed coil boards each having a coil formed of a conductor pattern of one layer or a plurality of layers, wherein a plurality of types of printed coil boards having different conductor patterns are provided. A step of preparing, a step of selecting a plurality of printed coil boards from the prepared plurality of printed coil boards,
Laminating a plurality of selected printed coil boards to produce a multilayer printed coil board. 2. The printed coil boards of the plurality of types,
The method for producing a multilayer printed coil board according to claim 1, wherein a coil is formed on both sides or one side of the conductor pattern by a conductor pattern. 3. The multi-layer printed coil board according to claim 1, wherein at least one of the number of windings, the winding shape, the width, and the thickness of the conductor pattern is different from each other. A method for manufacturing a printed coil board. 4. The printed coil boards of the plurality of types,
2. A through hole for forming electrical connection between the front and back of the printed coil board is formed.
A method for producing the multilayer printed coil board described. 5. The printed coil boards of the plurality of types,
The multilayer printed coil board according to claim 1, further comprising a connecting member for obtaining an electrical connection with another printed coil board when laminated, or an electrical connection with an external conductor. Of manufacturing. 6. The connecting member is a clip lead,
The method for producing a multilayer printed coil board according to claim 5, wherein the terminals for the clip leads are formed at the ends of each of the plurality of kinds of printed coil boards. 7. The connection member is a terminal pin, and a through hole for inserting the terminal pin is formed at an end of each of the plurality of types of printed coil boards. For manufacturing a multilayer printed coil board. 8. A method for producing a multilayer printed coil board, which comprises laminating a plurality of printed coil boards each having a coil formed of a conductor pattern of one layer or a plurality of layers, wherein plural kinds of printed coil boards having different conductor patterns are provided. A step of preparing, a step of selecting a plurality of printed coil boards from the prepared plurality of printed coil boards,
Stacking a plurality of selected printed coil boards to produce a multilayer printed coil board as a prototype,
Multi-layer printed coil board as a prototype, a step of creating a plurality of printed coil boards having the same characteristics as the plurality of printed coil boards used for the prototype printed coil board, and stacking the created multiple printed coil boards And a step of producing a multilayer printed coil substrate as a product having the same characteristics as the substrate. 9. A plurality of printed coil boards having the same characteristics as those of the plurality of printed coil boards, using the patterning film used when forming the plurality of printed coil boards used for the multilayer printed coil board as a prototype. 9. The method for producing a multilayer printed coil board according to claim 8, wherein: 10. A set of a plurality of printed coil boards, wherein a coil is formed of a conductor pattern of one layer or a plurality of layers, which is used when manufacturing a multilayer printed coil board, and the number and the shape of winding of the conductor pattern. A set of a plurality of printed coil boards having a plurality of types of printed coil boards having at least one of width and thickness different from each other. 11. A coil is formed by a conductor pattern on both sides or one side of the coil.
A set of printed coil boards as described above. 12. A set of a plurality of printed coil boards according to claim 10, wherein through holes for forming electrical connection on the front and back sides are formed. 13. A set of a plurality of printed coil boards according to claim 10, further comprising a connecting member for obtaining each electrical connection or an electrical connection with an external conductor. 14. The set of printed coil boards according to claim 13, wherein the connecting member is a clip lead, and a terminal for the clip lead is formed at an end portion thereof. 15. The set of printed coil boards according to claim 13, wherein the connecting member is a terminal pin, and a through hole for inserting the terminal pin is formed at an end portion of the connecting member. . 16. The set of printed coil boards according to claim 10, wherein the number of turns of the conductor pattern in all of the plurality of types of printed coil boards included is an integer. 17. A printed coil board having a small number of turns of the conductor pattern is included.
A set of a plurality of printed coil boards described in 0. 18. A multi-layered printed coil board comprising a plurality of printed coil boards, each of which has a coil formed of a conductor pattern of one layer or a plurality of layers, and a plurality of types of printed coil boards having different prepared conductor patterns. A multilayer printed coil board, wherein a plurality of printed coil boards selected from the above are laminated and integrally formed.