US3736543A - Photoetched induction coil assembly - Google Patents

Photoetched induction coil assembly Download PDF

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Publication number
US3736543A
US3736543A US00240081A US3736543DA US3736543A US 3736543 A US3736543 A US 3736543A US 00240081 A US00240081 A US 00240081A US 3736543D A US3736543D A US 3736543DA US 3736543 A US3736543 A US 3736543A
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substrate
coil
coil assembly
pair
coils
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Expired - Lifetime
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US00240081A
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E Lademann
Connor J O
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Bendix Corp
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Bendix Corp
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    • 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
    • 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
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0393—Flexible materials
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/16—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
    • H05K1/165—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor incorporating printed inductors

Definitions

  • SHEET 2 (IF 2 etched on the metallic laminations.
  • the present invention contemplates an induction coil assembly having circuitry in the form of a geometric pattern of conductive metal photoetched in a planar arrangement on a flexible substrate.
  • the flexible sub-' strate is wound on an arbor, with locating tabs being provided on the substrate to insure predetermined spacing between windings.
  • a registration pin is inserted through the tabs to prevent the substrate from unwinding, after which the wound substrate is removed from the arbor, vacuum impregnated to fill the voids between and around the windings and machined as required.
  • One object of this invention is to provide an induction coil having photoetched circuitry.
  • Another object of this invention is to provide an induction coil of the type described whereby electrical characteristics can be predetermined with a high degree of repeatability.
  • Another object of this invention is to provide a method for manufacturing an induction coil of the type described which permits greater control of manufacturing tolerances than has heretofore been po ssible.
  • Another object of this invention is to manufacture an induction coil of the type described at a lower cost than has heretofore been possible.
  • FIG. 1 is a partially sectioned side view of a flexible substrate according to the invention and having metal.- lic laminations on either side thereof.
  • FIG. 2 is a partially sectioned side view showing the flexible laminated substrate of FIG. 1 with plated through holes for electrically connecting the metallic laminations.
  • FIG. 3 is a side view showing the flexible laminated substrate of FIGS. 1 and 2 having circuit patterns
  • FIG. 4 is a diagrammatic representation showing the geometric form of the etched circuit patterns, withsaid patterns being connected by the plated through holes.
  • FIG. 5 is a top view of the etched flexible laminated substrate.
  • FIGS. 6, 7 and 8 are pictorial representations showing the laminated substrate of FIGS. 1-5 wound on an arbor and machined to provide a final induction coil in accordance with the invention.
  • FIG. 1 shows a flexible, continuous substrate 4 having metallic laminations 6 and 8 on either side thereof.
  • Substrate 4 may be a suitable pclyimide plastic such as that carrying the trade name Kapton and marketed by Du Pont Company, and is approximately 0.002 inches thick.
  • Laminations 6 and 8 may be one ounce copper strips (0.0014 inches thick) suitably bonded to substrate 4 as is well known in the art.
  • Holes 10 are drilled through substrate 4 and metallic laminations 6 and 8 at predetermined locations along the length thereof as shown in FIG. 2. The holes are then conventionally plated through with a suitable conductive material such as copper, with plated through holes 10 thereby providing electrical connections between metallic laminations 6 and 8.
  • Laminations 6 and 8 are etched by conventional photochemical methods to provide circuit patterns designated by the numerals 14 and 15, respectively, as shown in FIG. 3. Plated through holes 10 connect circuit patterns 14 and 15 as shown in the figure.
  • circuit pattern 14 includes a single planar coil 16 and a pair of connected planar coils l7 and 18, with the pattern, Le. a single coil and a pair of connected coils, being repeated along the length of substrate 4.
  • Circuit pattern 15 includes a repeatable pattern of a pair of connected coils 19 and 20 and a single coil 21.
  • Single coil 16 in circuit 14 is connected by a plated through hole 10 to coil 19 in circuit 15.
  • Another plated through hole 10 connects coils 17 and 20 while still another plated through hole 10 connects coils 18 and 21. It will now be understood that in this manner a continuous electrical circuit is provided along the length of substrate 4.
  • the completed photoetched substrate has a configuration as shown in FIG. 5, wherein only circuit 14 is shown.
  • Substrate 4 further includes locating tabs 22 which are positioned to allow a spaceof approximately 0.002 inches between windings when the substrate is wound on an arbor and the tabs aligned aswill behereinafter explained.
  • Tabs 22 have'holes 24 therethrough to accommodate a registration pin 28 shown in FIG. 7.
  • photoetched substrate 4 is wound on an arbor 25.
  • Locating tabs 22 are positioned to allow the aforenoted 0.002 inch space between windings when the substrate iswound on the arbor and the tabs aligned as shown in FIG. 7, with the space between windings carrying the description A.
  • Registration pin 28 is inserted through holes 24 in tabs 22 to prevent the substrate from unwinding as will now be understood.
  • the photoetching process lends itself to greater control of manufacturing tolerances. Due to the good repeatability and dimensional control, gaps can be reduced with a subsequent increase in torque being thus provided when a torquer application is intended. Finally, a coil assembly manufactured according to the invention can be achieved at a cost greatly reduced from that required for coil assemblies manufactured as now known in the art.
  • a coil assembly comprising: a flexible, continuous substrate; conductive circuit patterns on both sides of the substrate; means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate; locating tabs at predetermined points along the length of the substrate; said substrate with the continuous circuit thereon wound with the locating tabs in alignment to provide predetermined spaces between windings; and an insulating material in and around said spaces.
  • the conductive circuit patterns are geometric patterns of conductive metal in a planar arrangement on both sides of the substrate.
  • the means connecting the circuit patterns. on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes through holes plated with a conductive metal.
  • a coil assembly as described by claim 4, wherein the means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes:

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Parts Printed On Printed Circuit Boards (AREA)

Abstract

An induction coil assembly includes circuits photoetched on metallic laminates bonded to a flexible substrate. The substrate is wound on an arbor and pinned, after which it is removed from the arbor, impregnated and machined to provide an induction coil having close mechanical and electrical tolerances.

Description

United States Patent n91 Lademann et al.
PHOTOETCHED INDUCTION COIL ASSEMBLY Inventors: Ernest E. Lademann, Park Ridge; James J. OConnor, Old Bridge,
both of NJ.
Assignee: The Bendix Corporation, Teterboro,
Filed: Mar. 31, 1972 Appl. No.: 240,081
US. Cl. ..336/200, 336/205, 336/232 Int. Cl ..H0lf 27/30 Field of Search ..336/96, 200, 205,
[ 1 3,736,543 51 May 29,1973
[56] References Cited UNITED STATES PATENTS 3,466,580 9/1969 Bull ..336/200 X 3,587,019 6/1971 Bull ..336/200 3,466,5 86 9/1969 Bullet al ..336/200 2,014,524 9/1935 Frans ..336/200 2,786,984 3/1957 Slate ..336/200 X Primary Examiner-Thomas J. Kozma Attorney- Anthony F. Cuoco and S. H. Hartz [57] ABSTRACT An induction coil assembly includes circuits photoetched on metallic laminates bonded to a flexible substrate. The substrate is wound on an arbor and pinned, after which it is removed from the arbor, impregnated and machined to provide an induction coil having close mechanical and electrical tolerances.
5 Claims, 8 Drawing Figures PATENIED W29 I975 3 736 543 SHEET 1. 0F 2 6 4 L; I\\\ \\\\\\\.l 1 L A I FIG. I
l0 l2 IO l2 I0 6 FIG. '2
fi h? PATENTEDMYZQ ms 3.736.543
SHEET 2 (IF 2 etched on the metallic laminations.
BACKGROUND OF THE INVENTION SUMMARY OF THE INVENTION The present invention contemplates an induction coil assembly having circuitry in the form of a geometric pattern of conductive metal photoetched in a planar arrangement on a flexible substrate. The flexible sub-' strate is wound on an arbor, with locating tabs being provided on the substrate to insure predetermined spacing between windings. A registration pin is inserted through the tabs to prevent the substrate from unwinding, after which the wound substrate is removed from the arbor, vacuum impregnated to fill the voids between and around the windings and machined as required.
One object of this invention is to provide an induction coil having photoetched circuitry.
Another object of this invention is to provide an induction coil of the type described whereby electrical characteristics can be predetermined with a high degree of repeatability.
Another object of this invention is to provide a method for manufacturing an induction coil of the type described which permits greater control of manufacturing tolerances than has heretofore been po ssible.
Another object of this invention is to manufacture an induction coil of the type described at a lower cost than has heretofore been possible.
The foregoing andother objects and advantages of the invention will appear more fully hereinafter from a consideration of the detailed description which follows, taken together with the accompanying drawings wherein one embodiment of the invention is illustrated by way of example.
It is to be expressly understood however, that the drawings are for illustration purposes only and are not to be construed as defining the limits of the invention.
DESCRIPTION OF THE DRAWINGS,
FIG. 1 is a partially sectioned side view of a flexible substrate according to the invention and having metal.- lic laminations on either side thereof.
FIG. 2 is a partially sectioned side view showing the flexible laminated substrate of FIG. 1 with plated through holes for electrically connecting the metallic laminations.
FIG. 3 is a side view showing the flexible laminated substrate of FIGS. 1 and 2 having circuit patterns FIG. 4 is a diagrammatic representation showing the geometric form of the etched circuit patterns, withsaid patterns being connected by the plated through holes.
FIG. 5 is a top view of the etched flexible laminated substrate.
FIGS. 6, 7 and 8 are pictorial representations showing the laminated substrate of FIGS. 1-5 wound on an arbor and machined to provide a final induction coil in accordance with the invention.
DESCRIPTION OF THE INVENTION FIG. 1 shows a flexible, continuous substrate 4 having metallic laminations 6 and 8 on either side thereof. Substrate 4 may be a suitable pclyimide plastic such as that carrying the trade name Kapton and marketed by Du Pont Company, and is approximately 0.002 inches thick. Laminations 6 and 8 may be one ounce copper strips (0.0014 inches thick) suitably bonded to substrate 4 as is well known in the art.
Holes 10 are drilled through substrate 4 and metallic laminations 6 and 8 at predetermined locations along the length thereof as shown in FIG. 2. The holes are then conventionally plated through with a suitable conductive material such as copper, with plated through holes 10 thereby providing electrical connections between metallic laminations 6 and 8.
Laminations 6 and 8 are etched by conventional photochemical methods to provide circuit patterns designated by the numerals 14 and 15, respectively, as shown in FIG. 3. Plated through holes 10 connect circuit patterns 14 and 15 as shown in the figure.
Thus, as seen in FIG. 4, circuit pattern 14 includes a single planar coil 16 and a pair of connected planar coils l7 and 18, with the pattern, Le. a single coil and a pair of connected coils, being repeated along the length of substrate 4. Circuit pattern 15 includes a repeatable pattern of a pair of connected coils 19 and 20 and a single coil 21. Single coil 16 in circuit 14 is connected by a plated through hole 10 to coil 19 in circuit 15. Another plated through hole 10 connects coils 17 and 20 while still another plated through hole 10 connects coils 18 and 21. It will now be understood that in this manner a continuous electrical circuit is provided along the length of substrate 4.
The completed photoetched substrate has a configuration as shown in FIG. 5, wherein only circuit 14 is shown. Substrate 4 further includes locating tabs 22 which are positioned to allow a spaceof approximately 0.002 inches between windings when the substrate is wound on an arbor and the tabs aligned aswill behereinafter explained. Tabs 22 have'holes 24 therethrough to accommodate a registration pin 28 shown in FIG. 7.
As shown in FIG. 6, photoetched substrate 4 is wound on an arbor 25. Locating tabs 22 are positioned to allow the aforenoted 0.002 inch space between windings when the substrate iswound on the arbor and the tabs aligned as shown in FIG. 7, with the space between windings carrying the description A. Registration pin 28 is inserted through holes 24 in tabs 22 to prevent the substrate from unwinding as will now be understood.
After substrate 4 has been wound and pinned, the assembly is removed from arbor 25 and vacuum impregnated so as to fill the voids between and around the layers with a suitable insulating material 30' such as an epoxy resin as shown in FIG. 8. After vacuum impregnation has been completed, locating tabs 20- and pin 28 are sheared off and the inner and outer diameters of the It will now be seen that an induction coil having the configuration shown in the drawings and manufactured by the method described has certain advantages. First, since circuits l4 and 15 are photographically produced, each and every coil 16-21 (FIG. 4) will be precisely the same. Thus, inductor widths and conductor spacing can be controlled to the extent that electrical characteristics such as impedance and capacitance can be predetermined with excellent repeatability. Also the photoetching process lends itself to greater control of manufacturing tolerances. Due to the good repeatability and dimensional control, gaps can be reduced with a subsequent increase in torque being thus provided when a torquer application is intended. Finally, a coil assembly manufactured according to the invention can be achieved at a cost greatly reduced from that required for coil assemblies manufactured as now known in the art.
Although but a single embodiment of the invention has been illustrated and described in detail, it is to be expressly understood that the invention is not limited thereto. Various changes may also be made in the design and arrangement of the parts without departing from the spirit and scope of the invention as the same will now be understood by those skilled in the art.
What is claimed is: 1. A coil assembly, comprising: a flexible, continuous substrate; conductive circuit patterns on both sides of the substrate; means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate; locating tabs at predetermined points along the length of the substrate; said substrate with the continuous circuit thereon wound with the locating tabs in alignment to provide predetermined spaces between windings; and an insulating material in and around said spaces.
2. A coil assembly as described by claim 1, wherein:
the conductive circuit patterns are geometric patterns of conductive metal in a planar arrangement on both sides of the substrate.
3. A coil assembly as described by claim 1, wherein:
the means connecting the circuit patterns. on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes through holes plated with a conductive metal.
4. A coil assembly as described by claim 1, wherein the conductive circuit patterns on both sides of the substrate include:
a repeatable pattern of a single planar coil and a pair of connected planar coils on one side of the substrate; and
a repeatable pattern of a pair of connected planar coils and a single planar coil on the other side of the substrate.
5. a coil assembly as described by claim 4, wherein the means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes:
a through hole plated with a conductive metal connecting the single planar coil on the one side of the substrate to one of the connected pair of planar coils on the other side;
another plated through hole connecting one of the connected pair of planar coils on the one side of the substrate with the other of the pair of coils on the other side; and
still another plated through hole connecting the other of the pair of coils on the one side of the substrate with the single planar coil on the other side.

Claims (4)

  1. 2. A coil assembly as described by claim 1, wherein: the conductive circuit patterns are geometric patterns of conductive metal in a planar arrangement on both sides of the substrate.
  2. 3. A coil assembly as described by claim 1, wherein: the means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes through holes plated with a conductive metal.
  3. 4. A coil assembly as described by claim 1, wherein the conductive circuit patterns on both sides of the substrate include: a repeatable pattern of a single planar coil and a pair of connected planar coils on one side of the substrate; and a repeatable pattern of a pair of connected planar coils and a single planar coil on the other side of the substrate.
  4. 5. a coil assembly as described by claim 4, wherein the means connecting the circuit patterns on one side of the substrate with those on the other side and providing a continuous circuit along the length of the substrate includes: a through hole plated with a conductive metal connecting the single planar coil on the one side of the substrate to one of the connected pair of planar coils on the other side; another plated through hole connecting one of the connected pair of planar coils on the one side of the substrate with the other of the pair of coils on the other side; and still another plated through hole connecting the other of the pair of coils on the one side of the substrate with the single planar coil on the other side.
US00240081A 1972-03-31 1972-03-31 Photoetched induction coil assembly Expired - Lifetime US3736543A (en)

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JPS5042373A (en) * 1973-08-18 1975-04-17
JPS5042372A (en) * 1973-08-18 1975-04-17
US4271370A (en) * 1979-09-21 1981-06-02 Litton Systems, Inc. Double air gap printed circuit rotor
US4421997A (en) * 1978-09-18 1983-12-20 Mcdonnell Douglas Corporation Multiple axis actuator
US4494100A (en) * 1982-07-12 1985-01-15 Motorola, Inc. Planar inductors
EP0153131A2 (en) * 1984-02-23 1985-08-28 Development Finance Corporation Of New Zealand Electric coil
WO1990001781A1 (en) * 1988-08-04 1990-02-22 Caterpillar Inc. Inductive coil structure
US4982157A (en) * 1988-09-22 1991-01-01 Siemens Aktiengesellschaft Superconducting gradiometer loop system of a multichannel measuring device
US5296831A (en) * 1989-10-02 1994-03-22 Deutsch Thomson Brandt Gmbh Coil arrangement for a focusing or track control circuit
US5369249A (en) * 1991-08-08 1994-11-29 Gold Star Co., Ltd. Inductor arrangement for an induction heating apparatus
US5565837A (en) * 1992-11-06 1996-10-15 Nidec America Corporation Low profile printed circuit board
US5714828A (en) * 1994-03-04 1998-02-03 U.S. Philips Corporation Electric motor having a stator and a rotor
US20030090171A1 (en) * 2001-11-14 2003-05-15 Sunonwealth Electric Machine Industry Co., Ltd. Direct current brushless motor
US20040145249A1 (en) * 2003-01-24 2004-07-29 Brown David C. Galvanometer motor with composite stator assembly
EP1998172A1 (en) * 2007-05-30 2008-12-03 Snecma Marking of points of interest on the surface of a workpiece and application to optimising the trajectory and angulation of eddy current probes
EP2043130A2 (en) 2007-09-25 2009-04-01 Ceos Corrected Electron Optical Systems GmbH Multipole coils
DE102007045946A1 (en) * 2007-09-25 2009-04-02 Stz Mechatronik Coil e.g. rectangular coil, producing method for generating spatially defined, controllable magnetic field, involves rolling flexible, electrical insulating substrate on which conductor is superimposed or in which conductor is placed
EP2056309A1 (en) 2007-09-25 2009-05-06 STZ Mechatronik Method for manufacturing a spool and a spool
US20110057629A1 (en) * 2009-09-04 2011-03-10 Apple Inc. Harnessing power through electromagnetic induction utilizing printed coils
JP2011149861A (en) * 2010-01-22 2011-08-04 Jtekt Corp Displacement sensor device and rolling bearing device
US20120013130A1 (en) * 2010-07-15 2012-01-19 Jung Sukho Electrical generator
US20130305520A1 (en) * 2012-05-20 2013-11-21 Trevor Graham Niblock Batch Manufacturing Meso Devices on flexible substrates
ITUB20161251A1 (en) * 2016-03-02 2017-09-02 Irca Spa Induction hob and method for making induction hobs
US20180330882A1 (en) * 2017-05-12 2018-11-15 Murata Manufacturing Co., Ltd. Taping electronic component array
CN109860146A (en) * 2019-02-18 2019-06-07 西安电子科技大学 A kind of density three-dimensional integrated spiral inductor device based on interconnecting silicon through holes
US10498183B2 (en) 2011-04-11 2019-12-03 Allied Motion Technologies Inc. Flexible winding for an electric motor and method of producing
US20220021262A1 (en) * 2020-07-17 2022-01-20 Ibiden Co., Ltd. Motor coil substrate and motor

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US4692705A (en) * 1983-12-23 1987-09-08 General Electric Company Radio frequency field coil for NMR
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Cited By (46)

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Publication number Priority date Publication date Assignee Title
JPS5042373A (en) * 1973-08-18 1975-04-17
JPS5042372A (en) * 1973-08-18 1975-04-17
US4421997A (en) * 1978-09-18 1983-12-20 Mcdonnell Douglas Corporation Multiple axis actuator
US4271370A (en) * 1979-09-21 1981-06-02 Litton Systems, Inc. Double air gap printed circuit rotor
US4494100A (en) * 1982-07-12 1985-01-15 Motorola, Inc. Planar inductors
EP0153131A2 (en) * 1984-02-23 1985-08-28 Development Finance Corporation Of New Zealand Electric coil
EP0153131A3 (en) * 1984-02-23 1985-09-25 Development Finance Corporation Of New Zealand Electric coil
US4639708A (en) * 1984-02-23 1987-01-27 Development Finance Corporation Of New Zealand Parallelogram electric coil helically wound
WO1990001781A1 (en) * 1988-08-04 1990-02-22 Caterpillar Inc. Inductive coil structure
US4982157A (en) * 1988-09-22 1991-01-01 Siemens Aktiengesellschaft Superconducting gradiometer loop system of a multichannel measuring device
US5296831A (en) * 1989-10-02 1994-03-22 Deutsch Thomson Brandt Gmbh Coil arrangement for a focusing or track control circuit
US5369249A (en) * 1991-08-08 1994-11-29 Gold Star Co., Ltd. Inductor arrangement for an induction heating apparatus
US5565837A (en) * 1992-11-06 1996-10-15 Nidec America Corporation Low profile printed circuit board
US5714828A (en) * 1994-03-04 1998-02-03 U.S. Philips Corporation Electric motor having a stator and a rotor
US20030090171A1 (en) * 2001-11-14 2003-05-15 Sunonwealth Electric Machine Industry Co., Ltd. Direct current brushless motor
US6608411B2 (en) * 2001-11-14 2003-08-19 Sunonwealth Electric Machine Industry Co., Ltd. Direct current brushless motor
US20040145249A1 (en) * 2003-01-24 2004-07-29 Brown David C. Galvanometer motor with composite stator assembly
WO2004068675A1 (en) * 2003-01-24 2004-08-12 Gsi Lumonics Corporation Galvanometer motor with composite stator assembly
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Also Published As

Publication number Publication date
FR2178954A1 (en) 1973-11-16
JPS4914970A (en) 1974-02-08
FR2178954B1 (en) 1976-05-21
CA993965A (en) 1976-07-27
DE2315498B2 (en) 1978-09-28
DE2315498A1 (en) 1973-10-04
JPS5522923B2 (en) 1980-06-19
GB1391038A (en) 1975-04-16
DE2315498C3 (en) 1979-05-23

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