WO1990013135A1 - Improved surface-mountable air core inductor - Google Patents

Improved surface-mountable air core inductor Download PDF

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Publication number
WO1990013135A1
WO1990013135A1 PCT/US1990/001417 US9001417W WO9013135A1 WO 1990013135 A1 WO1990013135 A1 WO 1990013135A1 US 9001417 W US9001417 W US 9001417W WO 9013135 A1 WO9013135 A1 WO 9013135A1
Authority
WO
WIPO (PCT)
Prior art keywords
inductor
air core
core inductor
cylindrically
wire
Prior art date
Application number
PCT/US1990/001417
Other languages
French (fr)
Inventor
Leonard John Anderson
Original Assignee
Motorola, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Motorola, Inc. filed Critical Motorola, Inc.
Publication of WO1990013135A1 publication Critical patent/WO1990013135A1/en

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Classifications

    • 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
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10431—Details of mounted components
    • H05K2201/10568—Integral adaptations of a component or an auxiliary PCB for mounting, e.g. integral spacer element
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/01—Tools for processing; Objects used during processing
    • H05K2203/0195—Tool for a process not provided for in H05K3/00, e.g. tool for handling objects using suction, for deforming objects, for applying local pressure
    • 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
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/08—Treatments involving gases
    • H05K2203/082—Suction, e.g. for holding solder balls or components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • This invention relates generally to surface- mountable air core inductors used in communications equipment, and in particular to surface mountable air core inductors adaptable to automatic pick and place machines.
  • Chip-mountable inductors are well known in the art and consist primarily of two varieties.
  • the first is a so-called chip inductor, which is formed by winding a relatively small gauge wire around a rectangularly- shaped ceramic base. The ends of the wire are connected to metallized areas at the ends of the ceramic base, so that solder connection may be made to the PC board or ceramic substrate upon which this inductor is to be mounted.
  • Chip inductors are often coated on top with a plastic or epoxy material leaving the metallized areas on the bottom free of any coating to enhance solderability.
  • the small rectangular form factor, with the epoxy coating on the upper portion makes these chip inductors particularly suitable for handling by the vacuum pipette of automatic pick and place machines.
  • Another type of inductor is commonly known as an air wound coil.
  • This type of inductor is formed by winding several turns of a relatively larger gauge wire around a form to yield a component which looks much like a small spring.
  • These air wound inductors have several advantages. First, there is no dielectric material in the interior portion of the air wound coil which, as is known in the art, might cause the inductor to saturate prematurely or exhibit non-linear behavior. Secondly, since they are generally larger in cross-sectional area than the chip inductors previously noted, they generally have a higher inductance. Third, they can be formed from a larger gauge wire; the larger the wire gauge, the lower the equivalent series resistance of the coil.
  • air core inductors generally have a higher Q (the ratio of inductive reactance to equivalent series resistance) than chip inductors.
  • Q the ratio of inductive reactance to equivalent series resistance
  • a serious disadvantage of this type of coil is that it is not easily handled by automatic pick and place machines.
  • the cylindrical surface of the spring-like component is irregular in form, and no matter how closely wound the coil may be, there is still a finite space between each turn of wire, which makes it difficult for a vacuum system to grip the component. Accordingly, a need arises for a surface-mountable air core inductor that retains the desirable characteristics of an air wound coil and yet can be handled easily by the vacuum pipette of an automatic pick and place machine.
  • At least one substantially smooth and non-resilient surface is provided for a surface-mountable air core inductor, while ensuring that the dielectric material of the air core inductor remains essentially air.
  • a surface-mountable air core inductor is provided by winding one or more turns of wire to form a substantially cylindrically-shaped coil. The ends of the wire are then trimmed and bent outward so they lie in a mounting plane that does not intersect the cylindrically-shaped body of the coil. The coil thus formed is then inverted into a mold cavity to which a liquid, uncured plastic or epoxy material has been added. Only a relatively small amount of the plastic or epoxy material is added to the mold cavity prior to insertion of the coil, to ensure that it does not flow substantially into the interior portion of the coil. The plastic or epoxy material is then allowed to cure until it becomes hard and essentially non-resilient, and then the air core inductor is removed from the mold cavity.
  • the resultant device has at least one substantially smooth surface suitable for use with a vacuum pipette.
  • the surface-mountable air core inductor thus formed may then be placed into a tape and reel package.
  • This type of packaging is most convenient and economical for use with automatic pick and place machinery in high volume construction of printed circuit boards or hybrid substrates containing a large number of inductors.
  • Fig. 1 is a perspective view of a surface-mountable air core inductor
  • Fig. 2a is an end view of the improved surface- mountable air core inductor of the present invention
  • Fig. 2b is a top view of the inductor
  • Fig. 3 is an end view of a mold showing a mold cavity and the air core inductor properly positioned in the cavity;
  • Fig. 4 is a top plan view of tape and reel packaging for the inductor of the present invention.
  • FIG. 1 the surface-mountable air core inductor of the present invention can be seen as generally depicted by the number 100.
  • the inductor has an exterior portion (101) and an interior portion (102).
  • Fig. 2a shows an end view of the inductor.
  • a defined mounting plane (202) is the plane upon which the inductor rests when it is in mounting position on a printed circuit board or hybrid substrate (not shown).
  • the inductor has been provided with a substantially smooth surface (201) that makes the inductor particularly well adapted for use with automatic pick and place machines.
  • the substantially smooth surface has been created through a process, to be discussed below, that prevents material from substantially encroaching upon the interior portion (102) of the - inductor.
  • Fig. 2b shows the longitudinal axis (203) of the substantially cylindrically-shaped inductor.
  • the leads (204) are trimmed a relatively short distance from the cylindrically-shaped coil. Then the leads (204) are bent in such a way that they extend outwardly in opposite directions, parallel to each other, perpendicular to the longitudinal axis (203), and each lying in the mounting plane (202).
  • a mold (301) can be seen.
  • the mold contains a cavity (302) to which a plastic or epoxy material (303) has been added prior to insertion of the coil, but not in a quantity large enough to encroach upon the interior portion of the coil to any significant extent.
  • the inductor (100) is then inverted and placed in proper position within the mold cavity (302). After the plastic or epoxy material (303) has been allowed to cure, the inductor (100) is removed from the mold cavity (302).
  • the tape and reel strip (501) contains cavities (502) that are uniquely shaped to accommodate the improved air core inductor (100).
  • a plurality of inductors can be held in proper position on a mounting tape of this design, thus facilitating automatic pick and place applications.

Landscapes

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

Abstract

An improved surface mountable air core inductor (100) is described that has at least one smooth and substantially non-resilient surface (201) to facilitate handling by the vacuum pipette of an automatic pick and place machine.

Description

IMPROVED SURFACE-MOUNTABLE AIR CORE INDUCTOR
Technical Field
This invention relates generally to surface- mountable air core inductors used in communications equipment, and in particular to surface mountable air core inductors adaptable to automatic pick and place machines.
Background Art
Surface-mountable inductors are well known in the art and consist primarily of two varieties. The first is a so-called chip inductor, which is formed by winding a relatively small gauge wire around a rectangularly- shaped ceramic base. The ends of the wire are connected to metallized areas at the ends of the ceramic base, so that solder connection may be made to the PC board or ceramic substrate upon which this inductor is to be mounted. Chip inductors are often coated on top with a plastic or epoxy material leaving the metallized areas on the bottom free of any coating to enhance solderability. The small rectangular form factor, with the epoxy coating on the upper portion, makes these chip inductors particularly suitable for handling by the vacuum pipette of automatic pick and place machines.
Another type of inductor is commonly known as an air wound coil. This type of inductor is formed by winding several turns of a relatively larger gauge wire around a form to yield a component which looks much like a small spring. These air wound inductors have several advantages. First, there is no dielectric material in the interior portion of the air wound coil which, as is known in the art, might cause the inductor to saturate prematurely or exhibit non-linear behavior. Secondly, since they are generally larger in cross-sectional area than the chip inductors previously noted, they generally have a higher inductance. Third, they can be formed from a larger gauge wire; the larger the wire gauge, the lower the equivalent series resistance of the coil. Thus, as is well-known in the art, air core inductors generally have a higher Q (the ratio of inductive reactance to equivalent series resistance) than chip inductors. A serious disadvantage of this type of coil, however, is that it is not easily handled by automatic pick and place machines. The cylindrical surface of the spring-like component is irregular in form, and no matter how closely wound the coil may be, there is still a finite space between each turn of wire, which makes it difficult for a vacuum system to grip the component. Accordingly, a need arises for a surface-mountable air core inductor that retains the desirable characteristics of an air wound coil and yet can be handled easily by the vacuum pipette of an automatic pick and place machine. Summary of the Invention
According to the invention, at least one substantially smooth and non-resilient surface is provided for a surface-mountable air core inductor, while ensuring that the dielectric material of the air core inductor remains essentially air.
In one embodiment, a surface-mountable air core inductor is provided by winding one or more turns of wire to form a substantially cylindrically-shaped coil. The ends of the wire are then trimmed and bent outward so they lie in a mounting plane that does not intersect the cylindrically-shaped body of the coil. The coil thus formed is then inverted into a mold cavity to which a liquid, uncured plastic or epoxy material has been added. Only a relatively small amount of the plastic or epoxy material is added to the mold cavity prior to insertion of the coil, to ensure that it does not flow substantially into the interior portion of the coil. The plastic or epoxy material is then allowed to cure until it becomes hard and essentially non-resilient, and then the air core inductor is removed from the mold cavity. The resultant device has at least one substantially smooth surface suitable for use with a vacuum pipette. The surface-mountable air core inductor thus formed may then be placed into a tape and reel package. This type of packaging is most convenient and economical for use with automatic pick and place machinery in high volume construction of printed circuit boards or hybrid substrates containing a large number of inductors. Brief Description of the Drawings
Fig. 1 is a perspective view of a surface-mountable air core inductor; Fig. 2a is an end view of the improved surface- mountable air core inductor of the present invention;
Fig. 2b is a top view of the inductor;
Fig. 3 is an end view of a mold showing a mold cavity and the air core inductor properly positioned in the cavity;
Fig. 4 is a top plan view of tape and reel packaging for the inductor of the present invention.
Detailed Description of the Invention
Referring now to Fig. 1 , the surface-mountable air core inductor of the present invention can be seen as generally depicted by the number 100. The inductor has an exterior portion (101) and an interior portion (102). Fig. 2a shows an end view of the inductor. A defined mounting plane (202) is the plane upon which the inductor rests when it is in mounting position on a printed circuit board or hybrid substrate (not shown). The inductor has been provided with a substantially smooth surface (201) that makes the inductor particularly well adapted for use with automatic pick and place machines. The substantially smooth surface has been created through a process, to be discussed below, that prevents material from substantially encroaching upon the interior portion (102) of the - inductor. Thus, the material within the interior portion (102) remains primarily air (at least 50%). Fig. 2b shows the longitudinal axis (203) of the substantially cylindrically-shaped inductor. The leads (204) are trimmed a relatively short distance from the cylindrically-shaped coil. Then the leads (204) are bent in such a way that they extend outwardly in opposite directions, parallel to each other, perpendicular to the longitudinal axis (203), and each lying in the mounting plane (202).
Turning now to Fig. 3, a mold (301) can be seen. The mold contains a cavity (302) to which a plastic or epoxy material (303) has been added prior to insertion of the coil, but not in a quantity large enough to encroach upon the interior portion of the coil to any significant extent. The inductor (100) is then inverted and placed in proper position within the mold cavity (302). After the plastic or epoxy material (303) has been allowed to cure, the inductor (100) is removed from the mold cavity (302).
Turning now to Fig. 4, tape and reel packaging that is useful in automatic pick and place applications is depicted. The tape and reel strip (501) contains cavities (502) that are uniquely shaped to accommodate the improved air core inductor (100). A plurality of inductors can be held in proper position on a mounting tape of this design, thus facilitating automatic pick and place applications.
What is claimed is:

Claims

Claims:
1. An improved surface-mountable air core inductor having a substantially cylindrically-shaped body with an interior and an exterior region, wherein the improvement comprises: means for providing at least one substantially smooth and substantially non-resilient surface in the exterior region of said surface-mountable inductor while ensuring that the interior region of said surface- mountable inductor remains primarily air.
2. A method for providing a surface-mountable air core inductor comprising the steps of:
(a) forming a substantially cylindrically- shaped coil of wire, the coil having an interior and an exterior region;
(b) trimming the wire a relatively short distance away from the cylindrically-shaped coil to provide end portions of the wire;
(c) forming the end portions of the wire so that the end portions are substantially coplanar in a mounting plane to form an air core inductor; and
(d) providing a substantially smooth and substantially non-resilient surface in the exterior region of the air core inductor while ensuring that the interior region of the air core inductor remains primarily air.
3. The method of claim 2, wherein the substantially smooth and substantially non-resilient surface in the exterior region is provided through the steps of:
(a) providing a mold having a cavity;
(b) adding a liquid plastic or epoxy material to the cavity; (c) inverting the air core inductor and placing it into the mold cavity;
(d) allowing the plastic or epoxy material to cure; and
(e) removing the air core inductor from the mold.
4. The method of claim 2, including the additional step of:
(e) transferring said inductor to tape and reel packaging.
5. A method for providing a surface-mountable air core inductor comprising the steps of:
(a) forming a substantially cylindrically- shaped coil of wire having a longitudinal axis, an interior region, and an exterior region;
(b) trimming the ends of said wire a relatively short distance away from said cylindrically-shaped coil;
(c) forming said ends such that said ends extend outwardly from said cylindrically-shaped coil in opposite directions, each of said ends parallel to each other, perpendicular to said longitudinal axis, and each lying in a mounting plane, to form an air core inductor;
(d) providing at least one substantially smooth surface for said air core inductor by inverting said inductor into a mold cavity into which a liquid, uncured plastic or epoxy material has been added such that said cylindrically-shaped coil, with the exception of the mounting plane, is within the confines of said cavity, and said plastic or epoxy material does not extend substantially into said interior region of said coil, allowing said material to cure, then removing said inductor from said mold; and
(e) transferring said inductor to tape and reel packaging.
PCT/US1990/001417 1989-04-21 1990-03-20 Improved surface-mountable air core inductor WO1990013135A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US34161789A 1989-04-21 1989-04-21
US341,617 1989-04-21

Publications (1)

Publication Number Publication Date
WO1990013135A1 true WO1990013135A1 (en) 1990-11-01

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4029666A1 (en) * 1990-09-19 1992-03-26 Klaus Lorenzen Partly casing electrical component - by standing lower part of component, e.g. coil, vertically in trough, encapsulating in cast resin and cooling resin to set
WO1996019814A1 (en) * 1994-12-19 1996-06-27 Erwin Hagn Electric component, in particular a coil, preferably for an smd assembly technique
DE29617668U1 (en) * 1996-10-10 1996-12-05 Hagn, Erwin, 85368 Moosburg Device for producing a suction surface on an object and electrical component formed thereby
EP0845792A2 (en) * 1996-11-29 1998-06-03 Taiyo Yuden Co., Ltd. Wire wound electronic component and method of manufacturing the same
WO2000038493A1 (en) * 1998-12-21 2000-06-29 Koninklijke Philips Electronics N.V. Air-wound coil for vacuum pick-up, surface mounting, and adjusting
EP1026707A1 (en) * 1999-02-03 2000-08-09 Pace Micro Technology PLC Wire wound inductor
US6121866A (en) * 1997-03-14 2000-09-19 Murata Manufacturing Co., Ltd. Surface-mount air-core coil, electronic component having the same, and communication apparatus having the same
DE10322628A1 (en) * 2003-05-20 2005-01-05 Neosid Pemetzrieder Gmbh & Co Kg Producing suction surface on electrical surface mount component, especially coil, involves pressing component onto adhesion-compatible material on band while pre-hardening, releasing, final hardening

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DD21879A1 (en) * 1958-01-22 1961-09-22 Cylindrical field coil for electrical metering devices and method for producing the same
US3590329A (en) * 1969-05-05 1971-06-29 Sarkes Tarzian Coil assembly and method of making the same
US4193185A (en) * 1978-01-12 1980-03-18 Liautaud James P Method of making a high tolerance coil assembly
US4606117A (en) * 1983-05-13 1986-08-19 Tdk Corporation Apparatus for automatically mounting chip type circuit elements on printed circuit boards
DE3615307A1 (en) * 1986-05-06 1987-11-12 Johann Leonhard Huettlinger Air-cored coils for automatic SMD fitting

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DD21879A1 (en) * 1958-01-22 1961-09-22 Cylindrical field coil for electrical metering devices and method for producing the same
US3590329A (en) * 1969-05-05 1971-06-29 Sarkes Tarzian Coil assembly and method of making the same
US4193185A (en) * 1978-01-12 1980-03-18 Liautaud James P Method of making a high tolerance coil assembly
US4606117A (en) * 1983-05-13 1986-08-19 Tdk Corporation Apparatus for automatically mounting chip type circuit elements on printed circuit boards
DE3615307A1 (en) * 1986-05-06 1987-11-12 Johann Leonhard Huettlinger Air-cored coils for automatic SMD fitting

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4029666A1 (en) * 1990-09-19 1992-03-26 Klaus Lorenzen Partly casing electrical component - by standing lower part of component, e.g. coil, vertically in trough, encapsulating in cast resin and cooling resin to set
WO1996019814A1 (en) * 1994-12-19 1996-06-27 Erwin Hagn Electric component, in particular a coil, preferably for an smd assembly technique
EP0921538A3 (en) * 1994-12-19 2000-08-02 Erwin Hagn Electric component, in particular coil, preferably for SMD assembly technique
EP0921538A2 (en) * 1994-12-19 1999-06-09 Erwin Hagn Electric component, in particular coil, preferably for SMD assembly technique
US6042683A (en) * 1996-10-10 2000-03-28 Hagn; Erwin Method and device for producing an aspiration surface on an object, and electrical component obtained thereby
DE29617668U1 (en) * 1996-10-10 1996-12-05 Hagn, Erwin, 85368 Moosburg Device for producing a suction surface on an object and electrical component formed thereby
EP0836372A2 (en) * 1996-10-10 1998-04-15 Erwin Hagn Method and apparatus to create a sucking surface on an object and electrical component built this way
EP0836372A3 (en) * 1996-10-10 1998-07-01 Erwin Hagn Method and apparatus to create a sucking surface on an object and electrical component built this way
EP0845792A2 (en) * 1996-11-29 1998-06-03 Taiyo Yuden Co., Ltd. Wire wound electronic component and method of manufacturing the same
EP0845792A3 (en) * 1996-11-29 1999-02-10 Taiyo Yuden Co., Ltd. Wire wound electronic component and method of manufacturing the same
US6121866A (en) * 1997-03-14 2000-09-19 Murata Manufacturing Co., Ltd. Surface-mount air-core coil, electronic component having the same, and communication apparatus having the same
US6249207B1 (en) 1997-03-14 2001-06-19 Murata Manufacturing Co., Ltd. Surface-mount air-core coil, electronic component having the same, and communication apparatus having the same
US6404315B1 (en) * 1997-03-14 2002-06-11 Murata Manufacturing Co., Ltd. Surface-mount air-core coil, electronic component having the same, and communication apparatus having the same
US6531944B1 (en) 1997-03-14 2003-03-11 Murata Manufacturing Co., Ltd. Surface-mount air-core coil, electronic component having the same, and communication apparatus having the same
WO2000038493A1 (en) * 1998-12-21 2000-06-29 Koninklijke Philips Electronics N.V. Air-wound coil for vacuum pick-up, surface mounting, and adjusting
EP1026707A1 (en) * 1999-02-03 2000-08-09 Pace Micro Technology PLC Wire wound inductor
DE10322628A1 (en) * 2003-05-20 2005-01-05 Neosid Pemetzrieder Gmbh & Co Kg Producing suction surface on electrical surface mount component, especially coil, involves pressing component onto adhesion-compatible material on band while pre-hardening, releasing, final hardening
DE10322628B4 (en) * 2003-05-20 2006-12-07 Neosid Pemetzrieder Gmbh & Co Kg Method for producing a suction surface on an intended for the SMD mounting technology electrical component, in particular a coil, and apparatus for performing the method

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