JPS598054B2 - Method of manufacturing an integrated matrix containing a large number of electrical components - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to electrical components, and more particularly to composite electrical components assembled together into an integrated matrix.

It is well known that inductors, capacitors, and resistors are used in electronic circuits.

The use of these components in small electronics and other hybrid industries has traditionally been limited by the size of the components, the cost involved in assembling them into circuit form, and the conductors used to interconnect these components. have been limited due to undesirable electrical circuit characteristics caused by changes in inductance and capacitance due to the effects of Based on this basic concept,
The present invention provides multiple electrical components assembled into a single integrated matrix by forming multiple layers of electrically conductive elements having desired morphology and electrical properties and separated by membranes of insulating material. The terminals of these conductors can be selectively connected to form a variety of single series and parallel component circuit arrangements.

The main object of the present invention is to build on the above-mentioned basic concept and to overcome the above-mentioned controls and disadvantages traditionally associated with the use of individual electrical components. Another important object of the present invention is to form a composite electrical component in an integrated form having a simple structure that is inexpensive to manufacture, with the component elements being arranged in a wide variety of ways relative to one another. These and other objects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings of the preferred embodiment.

A composite electrical component constructed in an integrated form as described above is arranged in accordance with the invention and comprises interconnecting a number of laminated films of electrical conductors having defined electrical properties separated by layers of electrical material. Electrical terminals are selectively connected to provide circuit configurations of various series and parallel components, and wires are extended from certain ones of the conductors through layers of insulating material.

According to Figures 1 and 2 of the accompanying drawings, an electrical conductor 10 consisting of a number of interconnected windings of electrically conductive conductor is shown.
is shown, and this winding is separated from the others by an intervening layer of insulation 14.

The opposing end winding portions 16 and 18 each have an insulating film 20.
and 22. Electrical terminals 24 and 26 extend laterally from end turns 16 and 18, respectively, through an insulating membrane.

The multiple layers of conductor and insulating material are joined together as an integrated matrix. A central opening 28 is provided through the matrix and a pair of inductors are connected by a magnetic metal loop to function as a transformer. The layer forming the winding portion of the coil is, for example, a thick film formed by stamping metal.

These layers can also be thin films formed by conventional printed circuit techniques, for example. The layers of insulating material are bonded to preformed sheets by adhesive or heat sealing to form a reduced-laminar assembly. However, the inductor was
U.S. Patent No. 17,1, currently under examination, filed on March 6, 2017
It is formed by vapor deposition of an electrically conductive material and an insulating material using the method described in No. 57. According to the invention, one or both of the end turns 16 and 18 of the inductor coil are formed to have a predetermined electrical resistance that is greater than the resistance of the remaining turns. The combination of the windings thus forms a series RL circuit. Furthermore, one or both of the end turns 16 and 18 of the inductor may act as one of the plates of the capacitor, thereby forming a series RL circuit. Form an LC circuit.

To this end, a layer 30 of conductor material is superimposed on the corresponding end of the coil in order to form a second capacitor plate cooperating with one of the capacitor plates mentioned above. The second plate 30 is electrically isolated from the first plate 16 or 18 by an intervening insulating film 20 or 22, respectively. One or more electrical terminals, preferably a pair of terminals 32 and 34, extend from the second capacitor lamina 30.

The insulating film 36 is placed over the assembly joined to the second electrode plate 30 as an integrated matrix. When the end windings 16 and 18 of the inductor are not used as capacitor plates, the insulating film 36
A pair of laminar plates 30 separated by the above are placed over one or both ends of the inductor 10. This arrangement allows the inductor and capacitor to be used as separate components,
Appropriate connections between terminals 24, 26, 32, and 34 make it possible to connect these components in series or in parallel. The electrically conductive layer 30 has a predetermined electrical resistance and is connected to the inductor 10 so that the inductor and resistor can be used separately or connected in series or in parallel as shown in FIG.

Thus, a predetermined number of electrically conductive membranes 30 are incorporated into an integral matrix of laminates to form the desired number of capacitor plates or resistors.

Various combinations of these elements are illustrated in FIGS. 3-10. Figure 3 shows the assembled state of Figure 1, and Figure 3a
The figure shows the various circuit arrangements this results in.

The topmost circuit arrangement is thus a series LC circuit formed using the inductor end turns 18 as a capacitor plate associated with the second plate 30. The next stage circuit arrangement is an RLC circuit formed using the windings 18 at the opposite ends as capacitor plates and the windings 16 at the inductor ends as resistors. The following two figures illustrate the use of a layer 30 as a resistor in conjunction with an inductor 10.

These elements may be used separately or connected in series or parallel as indicated by one or both of the dashed lines indicating connected terminals. When an end turn 16 or 18 of the inductor 10 is used as a capacitor plate or resistor, the connection of conductors between it and the adjacent turns of the inductor coil is eliminated, but this is a separate It should be noted that this is done to avoid adverse effects commonly caused by conductive wires used to connect the components.

Furthermore, when the conductor layer 30 is used as an electrical resistor and its terminal 32 is connected to the terminal 26 of the inductor 10,
The adverse effects resulting from these very short conductor connections are suppressed to an absolute minimum. FIG. 4 shows a single inductor 10 within which an end turn 18 (or an opposing end turn 16, if desired) has a resistance greater than the resistance of the remaining turns. It is formed with an electrical resistance of This arrangement is the fourth
Form the series RL circuit shown in Figure a. In FIG. 5, two inductors 10 and 10' are shown joined as an integrated matrix. These two inductors can be used separately as separate inductors or as a series LC circuit as shown in FIG. 5a. Thus, by arranging one of the end turns 16 or 18' as an electrical resistor as described above, a series resistor is included in the circuit of FIG. 5a. FIG. 6 shows an inductor 10 and a pair of conductor films 30 and 30.
' is assembled. As shown in Figure 6a, this arrangement is used to place an inductor and another capacitor. These elements may be used separately or connected in series or parallel. Figure 6a shows one arrangement.
The assembly of FIG. 6 consists of L in series with separate resistor 3'.
Let's form a C circuit.

These elements may be used separately or connected in series or parallel. The arrangement of FIG. 6 is connected to form a series RL circuit or a separate capacitor, forming the first turn 16 of the inductor as a resistor. The series RLC circuit and the separately sold resistor are provided as shown in FIG. 6 in order to use the first winding part 16 as a resistor, and the winding part 18 at the opposite end is a second condescender monopolar plate. 30 is utilized as a capacitor plate in conjunction with membrane 30' to provide a separate resistor. In FIG. 7, the conductor layer 30 is placed close to the end turns of the inductor 10, and the second conductor film 30' is placed close to the opposing end turns 18.

As shown in Figure 7a, this arrangement places a series CLC circuit and separate resistors 30 and 31' across the inductor 10 for use in series, in parallel, or separately. An LC circuit is formed with another resistor 3' as an element in a series or parallel arrangement. The arrangement of FIG. 7 also forms a series RL circuit and a separate resistor or a series RLC circuit.
form a circuit. The arrangement shown in FIG. 8 forms a pair of series LC circuits by utilizing the windings 16 as electrical resistors, as shown in FIG. 8a.

This arrangement also provides a pair of series RLC circuits. In either case, separate circuits are used separately or connected in series or parallel.

Furthermore, if the conductor films 30 and 30' are arranged as electrical resistors, they can be used as a pair of resistors and a pair of inductors, which can be used separately as in the arrangement of FIG. 8 or connected in various series and parallel configurations. can be formed. The arrangement of FIG. 9 shows a rearrangement of the elements of FIG. 8 to provide a pair of separate inductors 10 and 10' and a separate capacitor, as shown in FIG. 9a. These components may be used separately or connected in various series or parallel configurations. Further, as shown in FIG. 9a, the end winding part of the inductor 10 can be used as a resistor, the end winding part 18 on the opposite side can be formed as a capacitor plate, and the conductor film 3' can be used as an electrical resistor. The arrangement of FIG. 9 thus forms a series RL circuit and a separate series RLC circuit. These elements can be used separately or connected in series or parallel. Furthermore, by utilizing the conductive films 30 and 3' as electrical resistors, the arrangement of FIG. Form a vessel.

FIG. 10 shows the assembly of a conductor membrane in which the layers 30 and 3' form a capacitor plate and the layer 3' is formed as an electrical resistor.

As shown in Figure 10a, these components may be used separately or in series and parallel connections. In view of the foregoing, the present invention provides a simplified and inexpensive means of forming a variety of composite electrical components in the form of an integrated matrix that has a very wide range of applications and can be used separately or in series or parallel configurations. It will be understood that we can provide.

All or most of the conductors connecting the components are eliminated, depending on whether the adverse effects previously experienced in connecting separate electrical components are to be eliminated or reduced.

The physical dimensions of the integrated matrix have become much smaller than those of the prior art components. In fact, by utilizing the manufacturing method disclosed in our patent application under examination, the integrated matrix of the present invention can be made extremely compact.

It will be apparent to those skilled in the art that various changes may be made in the size, form, type, quantity and arrangement of the parts described above without departing from the spirit of the invention.
Embodiment 1 A predetermined number of said multiple layers of electrical conductors are interconnected to form multiple turns of an inductor, the turns being separated from each other by said layers of insulating material. one of the plurality of layers of electrical conductor is placed over one of the end turns of the inductor separated from it by the membrane of insulating material to form the plate of the capacitor; , the end turns of the inductor adjacent to the capacitor plates are used to form the second plate of the capacitor, and one of the pair of electrical terminals extends from the first plate of the capacitor. the other extending from the end turn of the inductor opposite the end turn forming the second plate of the capacitor, thereby forming a series LC circuit between the pair of terminals; A method of manufacturing an integrated matrix as claimed in the claims, including a capacitor and a capacitor.

Embodiment 2 A predetermined number of said multiple layers of electrical conductors are interconnected to form multiple turns of an inductor, said turns being separated from each other by said membrane of insulating material. A number of membranes of the paired electrical conductors are placed over one end turn of the inductor separated from each other by the membrane of insulating material to form the plates of the capacitor, and the electrical terminals are Claims that include the above inductor and capacitor, which are disposed so as to extend from both ends of the inductor and the plates of the capacitor, and which are used as separate components or selectively in series or parallel circuits. A method for producing an integrated matrix as described in .

Embodiment 3 A predetermined number of said multiple layers of electrical conductors are interconnected to form multiple turns of an inductor, said turns being separated from each other by said membrane of insulating material, At least one end-turn circuit of the electrical conductor is formed to have a predetermined electrical resistance greater than the remaining turns, and an electrical terminal extends from the end-turn circuit to form a series RC circuit between these turns. A method of manufacturing an integrated matrix as claimed in the claims, comprising the inductor and resistor forming the inductor and resistor.

Embodiment 4 A predetermined number of said multiple layers of electrical conductors are connected to form multiple turns of an inductor, said turns being separated from each other by said membrane of insulating material, said electrical conductor one of the plurality of films consisting of a plurality of films is placed over one end turn of the inductor separated from it by the film of insulating material; electrical terminals extending from both ends of the inductor and from the single membrane, the inductor and resistor being selectively utilized as separate components or in series or parallel circuits. A method of manufacturing an integrated matrix according to the claims, which includes the above-mentioned inductor and resistor.

Embodiment 5 Said multiple pairs of films of electrical conductors are separated from each other by said films of insulating material and are used to form the plates of a capacitor, the third film of electrical conductors being separated from each other by said films of insulating material. one of the above capacitor plates separated from this by a membrane;
The third membrane is formed so as to provide a predetermined electrical resistance greater than the capacitor plates, thereby forming an electrical resistor, and electrical terminals extending from both sides of the capacitor plates to form the third membrane, thereby forming a capacitor. 2. A method of manufacturing an integrated matrix as claimed in claim 1, wherein said capacitor and resistor are selectively utilized as separate components or as a series or parallel circuit.

Embodiment 6 A first predetermined number of said multiple layers of electrical conductors are connected together to form multiple turns of a first inductor, said turns being interconnected by said membrane of insulating material. Separated from each other, a second predetermined number of said plurality of layers of electrical conductor are connected to one of the first inductor to form a plurality of turns of the second inductor.
the turns are separated from each other by the membrane of insulating material, electrical terminals extend from opposite ends of the first and second inductors, and the pair of inductors are separate. A method of manufacturing an integrated matrix as claimed in the claims, comprising a pair of electrical conductors such as those used selectively as a component or in a series or parallel circuit.

[Brief explanation of the drawing]

FIG. 1 is an enlarged perspective exploded view illustrating the assembly of multiple electrical component elements to provide an integrated matrix containing multiple electrical components in accordance with the present invention; FIG. 3 through 10 are cross-sectional views illustrating preferred constructions of assembled electrical inductor components.
Exploded views from the side showing various arrangements of electrical component elements according to the invention, FIGS. 3a to 10a respectively a single series and parallel arrangement resulting from the corresponding assembly shown in FIGS. 3 to 10. 1 is a schematic electrical circuit diagram showing the component arrangement of the circuit; FIG. 16... End winding part, 18... End winding part, 20... Insulating film, 22... Insulating film,
28... Central opening, 30... Conductor film, 32... Electric terminal, 34... Electric terminal, 36... Insulating film .

Claims (1)

[Claims] 1. A large number of thin films of electrically conductive material having predetermined electrical properties are separated one by one by a thin film of insulating material, and an electrically conductive terminal is connected to a predetermined thin film of the electrically conductive thin films. extending outwardly from the electrically conductive film through the thin film of insulating material, thereby forming electrical components of a type that can be coupled together in a variety of ways to form various forms of circuitry. A method for manufacturing an integrated matrix containing multiple electrical components.