WO2019001814A1 - Process for manufacturing a coil - Google Patents

Process for manufacturing a coil Download PDF

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Publication number
WO2019001814A1
WO2019001814A1 PCT/EP2018/061785 EP2018061785W WO2019001814A1 WO 2019001814 A1 WO2019001814 A1 WO 2019001814A1 EP 2018061785 W EP2018061785 W EP 2018061785W WO 2019001814 A1 WO2019001814 A1 WO 2019001814A1
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WO
WIPO (PCT)
Prior art keywords
coil
electrical
electrical conductors
conductors
conductor
Prior art date
Application number
PCT/EP2018/061785
Other languages
German (de)
French (fr)
Inventor
Ulrich Brenner
Original Assignee
Robert Bosch Gmbh
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 Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2019001814A1 publication Critical patent/WO2019001814A1/en

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Classifications

    • 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
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2804—Printed windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/14—Inductive couplings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/02—Coils wound on non-magnetic supports, e.g. formers

Definitions

  • the present invention relates to a method of manufacturing a coil suitable for an inductive charging system.
  • Inductive charging systems transfer electrical energy from a transmitting coil in one device to a receiving coil in another device.
  • a magnetic field is generated in the transmitting coil by an alternating current, which induces an electric current in the receiving coil. This one in the
  • Reception coil induced current may be used to charge an electrical energy store in the receiving device, operate the receiving device, and / or transmit information between the sending device and the receiving device. For example in the Scriptures
  • Inductive charging systems include a charging device that transmits power and / or signals to an electronic device by inductive coupling between the transmitting coil and the receiving coil in the electronic device. Since inductive charging systems, for example, for electric vehicles transmitted electric power of several kilowatts over periods of several hours, the highest possible efficiency is of great importance. If the coils are driven at high frequencies in order to transmit the powers, current displacements occur in the electrical conductor of the coil due to the skin and proximity effect. This increases the electrical
  • Coil resistance and thus the power dissipation in the coil are used for the electrical conductors in the coil lines of RF strand (high-frequency stranded wire).
  • RF strand high-frequency stranded wire
  • These cables are stranded conductors, in which the individual strands are insulated from each other in the conductor. The individual strands are stranded over a certain length so that each strand runs on the outside of the surface and then again inside the conductor. Thus, the skin and proximity effects are reduced to a minimum. This reduces the electrical resistance and thus the power loss and heating in the transmission coil and in the supply lines.
  • stranded conductors are used, in which several hundred or a thousand insulated individual strands are stranded into a stranded cable. The diameter of the individual strands is often 0.2 or 0.1 mm.
  • Support structure may be present, which allows threading of the coil wire, taking into account the above-mentioned mechanical processing conditions.
  • the inventive method with the characterizing part of claim 1 has the advantage that it is cost-effective, simplified and robust feasible.
  • a method for producing a coil which is suitable for inductive transmission of electrical energy, is provided for this purpose.
  • the coil has at least one first electrically non-conductive coil carrier, which comprises at least one coil winding.
  • the at least one electrical conductor of the coil winding is completely enclosed by the carrier structure of the coil carrier and is produced by means of a 3 D printing method.
  • the coil carrier and the conductor of the coil winding are produced in a common 3D printing process.
  • the support structure of the bobbin and the electrical conductors of the coil winding are made so that the electrical conductors are completely enclosed by the support structure of the bobbin and occur in an advantageous robust manner no mechanical stresses in the conductors and in the support structure of the bobbin.
  • the complete enclosure of the electrical conductors through the support structure ensures uninterrupted electrical insulation of the electrical conductors
  • the support structure of the electrically non-conductive coil support holds the electrical conductor in the predetermined position. Due to the complete embedding of the electrical conductors in the support structure of the bobbin mechanical displacements of the conductors or the entire coil by vibrations, temperature changes, electrical and / or magnetic forces are prevented.
  • the coil consists of several by the non-conductive coil carrier against each other insulated electrical conductors. The use of multiple mutually insulated conductors allows the use of higher currents and thus the generation of a larger magnetic flux and thus the transmission of a higher power compared to single conductor coils. Also damage to the insulation by rubbing or hitting the individual conductors together are avoided.
  • the electrical conductors are arranged relative to one another such that a stranded structure results. Due to the stranded arrangement of the carrier structure of the bobbin against each other electrically insulated conductor each conductor extends a piece outside on the surface and then again inside the stranded structure. Thus, the skin and proximity effects are reduced to a minimum and reduce the electrical resistance and thus the
  • the electrical conductors are arranged in any spatial structure to each other.
  • 3D printing arrangements can be realized with further optimized skin and Proximity binen the electrical conductor, which can not be produced with the conventional stranding.
  • FIG. 1 shows a schematic representation of a coil according to the invention.
  • FIG. 1 is merely a schematic representation of the device according to the invention or its components according to embodiments of the invention. In particular distances and size relations are not in the figure
  • Figure 1 shows a schematic representation of a coil 1 according to the invention consisting of a coil carrier 2 with coil windings 3. For better illustration, the coil 1 is shown cut.
  • the coil 1 is shown cut.
  • Cut surfaces are the better view also cut electrical conductor 4 and the support structure 5 can be seen.
  • the illustrated coil 1 is designed as a flat coil, which was created by an SD printing process.
  • the 3-D printing process allows the production of the coil 1 without the use of prefabricated electrical conductors.
  • Support structure 5 of the bobbin 2 are the electrical conductors 4 so that they have no contact with each other and through the electrically non-conductive
  • Carrier structure 5 are electrically isolated.
  • the electrically non-conductive support structure 5 carries the electrical conductors 4 so that they always exactly in their
  • the conductors 4 are printed so that a predetermined stranded structure of the electrical conductors 4 results in order to minimize the skin and Proximity bine. Furthermore, the 3D printing process offers the possibility of arranging the electrical conductors 4 in any desired spatial structure. This arrangement can be realized with further optimized Skin- and Proximity binen the electrical conductor 4, which can not be produced with conventional stranding. These arrangements of the electrical conductors 4, for example, by computer-aided calculation methods be optimized and lead to a further reduction of the electrical
  • the electrical conductors 4 of the coil winding 3 can be arranged directly in a transparent coil carrier 2 with the 3 D printing method.
  • crystal clear bobbins 2 can be made as table tops, the use of very thin electrical conductor 4 almost invisible coil windings 3 for charging mobile phones, portable
  • Heat loss from the electrical conductors 4 of the coil winding 3 can be improved.
  • coils with higher power density are possible, which can be flexibly adapted to the installation situation and use.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)

Abstract

The invention relates to a process for manufacturing a coil suitable for the inductive transmission of electricity. The coil includes at least one first electrically non-conductive coil support that comprises at least one coil winding. According to the invention, the at least one electric conductor of the coil winding is entirely surrounded by the support structure of the coil support and is made using a 3D printing process.

Description

Beschreibung Titel Verfahren zur Herstellung einer Spule  Description Title Method of making a coil
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung einer Spule geeignet für ein induktives Ladesystem. The present invention relates to a method of manufacturing a coil suitable for an inductive charging system.
Stand der Technik State of the art
Induktive Ladesysteme übertragen elektrische Energie von einer Sendespule in einer Vorrichtung zu einer Empfangsspule in einer anderen Vorrichtung. Dazu wird in der Sendespule durch einen Wechselstrom ein Magnetfeld erzeugt, welches in der Empfangsspule einen elektrischen Strom induziert. Dieser in der Inductive charging systems transfer electrical energy from a transmitting coil in one device to a receiving coil in another device. For this purpose, a magnetic field is generated in the transmitting coil by an alternating current, which induces an electric current in the receiving coil. This one in the
Empfangsspule induzierte Strom kann verwendet werden, um einen elektrischen Energiespeicher in der Empfangsvorrichtung zu laden, die Empfangsvorrichtung zu betreiben und/oder Informationen zwischen der Sendevorrichtung und der Empfangsvorrichtung zu übertragen. Wie beispielsweise in der Schrift Reception coil induced current may be used to charge an electrical energy store in the receiving device, operate the receiving device, and / or transmit information between the sending device and the receiving device. For example in the Scriptures
DE 21 3025 000 119 beschrieben sind induktive Ladesysteme Stand der Technik. Induktive Ladesysteme umfassen eine Ladevorrichtung, die Leistung und/oder Signale an eine elektronische Vorrichtung überträgt, und zwar durch induktive Kopplung zwischen der Sendespule und der Empfangsspule in der elektronischen Vorrichtung. Da bei induktiven Ladesystemen beispielsweise für elektrisch angetriebene Fahrzeuge elektrische Leistungen von mehreren Kilowatt über Zeiträume von mehreren Stunden übertragen werden, ist ein möglichst hoher Wirkungsgrad von großer Bedeutung. Werden zum Übertragen der Leistungen die Spulen mit hohen Frequenzen angesteuert, treten durch den Skin- und Proximityeffekt Stromverdrängungen im elektrischen Leiter der Spule auf. Hierdurch erhöht sich der elektrische DE 21 3025 000 119 describes inductive charging systems prior art. Inductive charging systems include a charging device that transmits power and / or signals to an electronic device by inductive coupling between the transmitting coil and the receiving coil in the electronic device. Since inductive charging systems, for example, for electric vehicles transmitted electric power of several kilowatts over periods of several hours, the highest possible efficiency is of great importance. If the coils are driven at high frequencies in order to transmit the powers, current displacements occur in the electrical conductor of the coil due to the skin and proximity effect. This increases the electrical
Spulenwiderstand und somit die Verlustleistung in der Spule. Um dem entgegen zu wirken, werden für die elektrischen Leiter in der Spule Leitungen aus HF-Litze (Hochfrequenzlitze) verwendet. Diese Leitungen sind Litzenleiter, bei denen die einzelnen Litzen im Leiter zueinander isoliert sind. Die einzelnen Litzen sind über eine gewisse Länge so verseilt, dass jede Litze mal außen an der Oberfläche und dann wieder im Inneren des Leiters verläuft. Somit reduzieren sich die Skin- und Proximityeffekte auf ein Minimum. Dies verringert den elektrischen Widerstand und somit die Verlustleistung und Erwärmung in der Übertragungsspule und in den Zuleitungen. Je nach Stromstärke kommen Litzenleiter zum Einsatz, bei denen mehrere hundert oder tausend isolierte Einzellitzen zu einem Litzenkabel verseilt werden. Der Durchmesser der einzelnen Litzen liegt hierbei oft bei 0,2 oder 0,1 mm. Coil resistance and thus the power dissipation in the coil. To counter that To act, are used for the electrical conductors in the coil lines of RF strand (high-frequency stranded wire). These cables are stranded conductors, in which the individual strands are insulated from each other in the conductor. The individual strands are stranded over a certain length so that each strand runs on the outside of the surface and then again inside the conductor. Thus, the skin and proximity effects are reduced to a minimum. This reduces the electrical resistance and thus the power loss and heating in the transmission coil and in the supply lines. Depending on the current strength, stranded conductors are used, in which several hundred or a thousand insulated individual strands are stranded into a stranded cable. The diameter of the individual strands is often 0.2 or 0.1 mm.
Nachteilig an der Herstellung dieser HF- Litzenleiter sind der Aufwand und die Kosten. Bei der Verarbeitung dürfen zusätzlich nachteilig Mindestbiegeradien und maximale Zugkräfte nicht überschritten werden. Zusätzlich darf bei der A disadvantage of the production of these RF stranded conductors are the effort and the cost. In addition, minimum bending radii and maximum tensile forces must not be exceeded during processing. Additionally may at the
Verarbeitung die oft dünne Leiterisolation nicht beschädigt werden. Um die  Processing the often thin conductor insulation will not be damaged. To the
Spulendrähte in der vorbestimmten Position zu halten, muss eine To hold coil wires in the predetermined position, one must
Trägerkonstruktion vorhanden sein, die ein Einfädeln des Spulendrahtes unter Berücksichtigung der oben genannten mechanischen Verarbeitungsbedingungen ermöglicht. Support structure may be present, which allows threading of the coil wire, taking into account the above-mentioned mechanical processing conditions.
Es besteht daher der Bedarf nach einem kostengünstigen, vereinfachten und robusten Herstellungsverfahren. There is therefore a need for a low cost, simplified and robust manufacturing process.
Offenbarung der Erfindung Disclosure of the invention
Das erfindungsgemäße Verfahren mit dem Kennzeichen des Anspruchs 1 hat den Vorteil, dass es kostengünstig, vereinfacht und robust durchführbar ist. The inventive method with the characterizing part of claim 1 has the advantage that it is cost-effective, simplified and robust feasible.
Erfindungsgemäß ist dazu ein Verfahren zur Herstellung einer Spule, die zur induktiven Übertragung elektrischer Energie geeignet ist, vorgesehen. Die Spule weist mindestens einen ersten elektrisch nicht leitenden Spulenträger auf, welcher mindestens eine Spulenwicklung umfasst. Der mindestens eine elektrische Leiter der Spulenwicklung ist von der Trägerstruktur des Spulenträgers vollständig umschlossen und wird mittels eines 3 D- Druckverfahrens erzeugt. According to the invention, a method for producing a coil, which is suitable for inductive transmission of electrical energy, is provided for this purpose. The coil has at least one first electrically non-conductive coil carrier, which comprises at least one coil winding. The at least one electrical conductor of the coil winding is completely enclosed by the carrier structure of the coil carrier and is produced by means of a 3 D printing method.
Vorteilhafterweise ist das erfindungsgemäße Verfahren gegenüber der Advantageously, the inventive method over the
Verwendung von HF- Litzenleitern vereinfacht und billiger. Zusätzlich entfällt der Biegeprozess, der bei der üblichen Verarbeitung die Einhaltung von Using HF stranded conductors simplified and cheaper. In addition, the bending process, which in the usual processing, the compliance of
Mindestbiegeradien und die NichtÜberschreitung maximaler Zugkräfte fordert. Durch die Einbettung der elektrischen Leiter in die Trägerstruktur durch 3D-Druck, werden die elektrischen Leiter automatisch vorteilhaft in der vorbestimmten Position gehalten. Minimum bending radii and not exceeding maximum tensile forces calls. By embedding the electrical conductors in the support structure by 3D printing, the electrical conductors are automatically held advantageously in the predetermined position.
Durch die in den abhängigen Ansprüchen genannten Maßnahmen sind vorteilhafte Weiterbildungen des in dem unabhängigen Anspruch angegebenen Verfahrens möglich. The measures mentioned in the dependent claims advantageous refinements of the method specified in the independent claim are possible.
Vorteilhafterweise werden der Spulenträger und die Leiter der Spulenwicklung in einem gemeinsamen 3D-Druckprozess erzeugt. Durch die gemeinsame Advantageously, the coil carrier and the conductor of the coil winding are produced in a common 3D printing process. By the common
drucktechnische Erzeugung werden die Trägerstruktur des Spulenträgers und die elektrischen Leiter der Spulenwicklung so gefertigt, dass die elektrischen Leiter vollständig durch die Trägerstruktur des Spulenkörpers umschlossen sind und in vorteilhafter robuster Weise keine mechanischen Spannungen in den Leitern und in der Trägerstruktur des Spulenträgers auftreten. In vorteilhafter Weise sorgt die vollständige Umschließung der elektrischen Leiter durch die Trägerstruktur für eine unterbrechungsfreie elektrische Isolierung der elektrischen Leiter printing technology production, the support structure of the bobbin and the electrical conductors of the coil winding are made so that the electrical conductors are completely enclosed by the support structure of the bobbin and occur in an advantageous robust manner no mechanical stresses in the conductors and in the support structure of the bobbin. Advantageously, the complete enclosure of the electrical conductors through the support structure ensures uninterrupted electrical insulation of the electrical conductors
gegeneinander und nach außen. against each other and out.
Weiterhin ist vorteilhaft, dass die Trägerstruktur des elektrisch nicht leitenden Spulenträgers den elektrischen Leiter in der vorbestimmten Position hält. Durch die vollständige Einbettung der elektrischen Leiter in die Trägerstruktur des Spulenträgers werden mechanische Verlagerungen der Leiter bzw. der ganzen Spulen durch Vibrationen, Temperaturwechsel, elektrische und/oder magnetische Kräfte verhindert. Vorteilhafterweise besteht die Spule aus mehreren durch den nicht leitenden Spulenträger gegeneinander isolierten elektrischen Leitern. Die Verwendung von mehreren gegeneinander isolierten Leitern erlaubt den Einsatz von höheren Strömen und somit die Erzeugung eines größeren magnetischen Flusses und damit verbunden die Übertragung einer höheren Leistung im Vergleich zu Spulen mit Einzelleitern. Ebenfalls werden Beschädigungen der Isolation durch Reiben oder Aneinanderschlagen der einzelnen Leiter aneinander vermieden. Furthermore, it is advantageous that the support structure of the electrically non-conductive coil support holds the electrical conductor in the predetermined position. Due to the complete embedding of the electrical conductors in the support structure of the bobbin mechanical displacements of the conductors or the entire coil by vibrations, temperature changes, electrical and / or magnetic forces are prevented. Advantageously, the coil consists of several by the non-conductive coil carrier against each other insulated electrical conductors. The use of multiple mutually insulated conductors allows the use of higher currents and thus the generation of a larger magnetic flux and thus the transmission of a higher power compared to single conductor coils. Also damage to the insulation by rubbing or hitting the individual conductors together are avoided.
Vorteilhafterweise sind die elektrischen Leiter so zueinander angeordnet, dass sich eine verseilte Struktur ergibt. Durch die verseilte Anordnung der durch die Trägerstruktur des Spulenträgers gegeneinander elektrisch isolierten Leiter verläuft jeder Leiter ein Stück außen an der Oberfläche und dann wieder im Innern der verseilten Struktur. Damit reduzieren sich die Skin- und Proximityeffekte auf ein Minimum und verringern den elektrischen Widerstand und somit die Advantageously, the electrical conductors are arranged relative to one another such that a stranded structure results. Due to the stranded arrangement of the carrier structure of the bobbin against each other electrically insulated conductor each conductor extends a piece outside on the surface and then again inside the stranded structure. Thus, the skin and proximity effects are reduced to a minimum and reduce the electrical resistance and thus the
Verlustleistung und die Erwärmung in der Übertragungsspule und in den Power loss and heating in the transmission coil and in the
Zuleitungen. Leads.
Weiterhin ist vorteilhaft, dass die elektrischen Leiter in einer beliebigen räumlichen Struktur zueinander angeordnet sind. Durch den 3D-Druck können Anordnungen mit weiter optimierten Skin- und Proximityeffekten der elektrischen Leiter verwirklicht werden, die mit den herkömmlichen Verseilungsmethoden nicht herstellbar sind. Furthermore, it is advantageous that the electrical conductors are arranged in any spatial structure to each other. By 3D printing arrangements can be realized with further optimized skin and Proximityeffekten the electrical conductor, which can not be produced with the conventional stranding.
Weitere Merkmale und Vorteile der vorliegenden Erfindung werden dem Other features and advantages of the present invention will become
Fachmann aus der nachfolgenden Beschreibung beispielhafter Expert from the following description of exemplary
Ausführungsformen, die jedoch nicht als die Erfindung beschränkend auszu sind, unter Bezugnahme auf die beigelegte Zeichnung ersichtlich. Kurze Beschreibung der Zeichnung Es zeigt: Fig. 1: eine schematische Darstellung einer erfindungsgemäßen Spule. Embodiments, which should not be construed as limiting the invention, with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 shows a schematic representation of a coil according to the invention.
Die Figur ist lediglich eine schematische Darstellung der erfindungsgemäßen Vorrichtung bzw. ihrer Bestandteile gemäß Ausführungsbeispielen der Erfindung. Insbesondere Abstände und Größenrelationen sind in der Figur nicht The figure is merely a schematic representation of the device according to the invention or its components according to embodiments of the invention. In particular distances and size relations are not in the figure
maßstabsgetreu wiedergegeben. reproduced to scale.
Figur 1 zeigt eine schematische Darstellung einer erfindungsgemäßen Spule 1 bestehend aus einem Spulenträger 2 mit Spulenwicklungen 3. Zur besseren Veranschaulichung ist die Spule 1 aufgeschnitten dargestellt. In den Figure 1 shows a schematic representation of a coil 1 according to the invention consisting of a coil carrier 2 with coil windings 3. For better illustration, the coil 1 is shown cut. In the
Schnittflächen sind die zur besseren Darstellung ebenfalls geschnittenen elektrischen Leiter 4 und die Trägerstruktur 5 zu erkennen. Cut surfaces are the better view also cut electrical conductor 4 and the support structure 5 can be seen.
Die dargestellte Spule 1 ist als Flachspule ausgeführt, die durch ein SD- Druckverfahren erstellt wurde. Das 3 D- Druckverfahren ermöglicht die Anfertigung der Spule 1 ohne Verwendung von vorgefertigten elektrischen Leitern. In derThe illustrated coil 1 is designed as a flat coil, which was created by an SD printing process. The 3-D printing process allows the production of the coil 1 without the use of prefabricated electrical conductors. In the
Trägerstruktur 5 des Spulenträgers 2 liegen die elektrischen Leiter 4 so, dass sie keinen Kontakt zueinander haben und durch die elektrisch nicht leitende Support structure 5 of the bobbin 2 are the electrical conductors 4 so that they have no contact with each other and through the electrically non-conductive
Trägerstruktur 5 elektrisch isoliert sind. Die elektrisch nicht leitende Trägerstruktur 5 trägt die elektrischen Leiter 4 so, dass diese immer genau in ihrer Carrier structure 5 are electrically isolated. The electrically non-conductive support structure 5 carries the electrical conductors 4 so that they always exactly in their
vorbestimmten Position gehalten werden. In dem 3D-Druckprozess werden die Leiter 4 so gedruckt, dass sich eine vorbestimmte verseilte Struktur der elektrischen Leiter 4 ergibt, um die Skin- und Proximityeffekte auf ein Minimum zu beschränken. Weiterhin bietet der 3D-Druckprozess die Möglichkeit, die elektrischen Leiter 4 in einer beliebigen räumlichen Struktur zueinander anzuordnen. Damit lassen sich Anordnungen mit weiter optimierten Skin- und Proximityeffekten der elektrischen Leiter 4 verwirklichen, die mit herkömmlichen Verseilungsmethoden nicht herstellbar sind. Diese Anordnungen der elektrischen Leiter 4 können beispielsweise durch computergestützte Berechnungsmethoden optimiert werden und führen zu einer weiteren Reduktion des elektrischen be held predetermined position. In the 3D printing process, the conductors 4 are printed so that a predetermined stranded structure of the electrical conductors 4 results in order to minimize the skin and Proximityeffekte. Furthermore, the 3D printing process offers the possibility of arranging the electrical conductors 4 in any desired spatial structure. This arrangement can be realized with further optimized Skin- and Proximityeffekten the electrical conductor 4, which can not be produced with conventional stranding. These arrangements of the electrical conductors 4, for example, by computer-aided calculation methods be optimized and lead to a further reduction of the electrical
Widerstands der Spulenwicklung 3 und senken damit weiterhin die Verlustleistung. Resistance of the coil winding 3 and thus continue to reduce the power loss.
Die ebenfalls zu beachtenden Einschränkungen bei der bekannten Anfertigung von Spulenwicklungen 3 mittels verseilten Litzenleitern wie beispielsweise The likewise to be considered limitations in the known production of coil windings 3 by means of stranded stranded conductors such as
Zugkraftgrenzen und Mindestbiegeradien spielen bei der Herstellung mittels SD- Druckverfahren keine Rolle und schränken die Designfreiheit für die Anordnung der Spulenwicklung 3 und der einzelnen elektrischen Leiter 4 nicht ein. Bei Verwendung von transparenten Werkstoffen für die Trägerstruktur 5 des Tensile force limits and minimum bending radii play no role in the production by means of SD printing process and do not limit the freedom of design for the arrangement of the coil winding 3 and the individual electrical conductors 4. When using transparent materials for the support structure 5 of
Spulenträgers 2 können mit dem 3 D- Druckverfahren die elektrischen Leiter 4 der Spulenwicklung 3 direkt in einen durchsichtigen Spulenträger 2 angeordnet werden. Damit können beispielsweise glasklare Spulenträger 2 als Tischplatten angefertigt werden, die bei Verwendung sehr dünner elektrischer Leiter 4 nahezu unsichtbare Spulenwicklungen 3 zum Laden von Mobiltelefonen, tragbaren Spool carrier 2, the electrical conductors 4 of the coil winding 3 can be arranged directly in a transparent coil carrier 2 with the 3 D printing method. Thus, for example, crystal clear bobbins 2 can be made as table tops, the use of very thin electrical conductor 4 almost invisible coil windings 3 for charging mobile phones, portable
Computern und anderen Verbrauchern enthalten. Computers and other consumers included.
Weitere Anwendungsmöglichkeiten bieten sich bei Verwendung von transparenten Werkstoffen für die Trägerstruktur 5 des Spulenträgers 2 beispielsweise durch die Möglichkeit, nahezu unsichtbare Hochleistungsantennen oder Heizelemente in Fensterscheiben anzufertigen. Further applications are possible when using transparent materials for the support structure 5 of the bobbin 2, for example, by the ability to make almost invisible high-performance antennas or heating elements in windows.
Bei Spulen 1, die zur induktiven Übertragung elektrischer Energie vorgesehen sind, bietet sich die Verwendung von Werkstoffen für die Trägerstruktur 5 des Spulenträgers 2 an, deren Wärmeleitung durch Zusätze gegenüber den In coils 1, which are provided for the inductive transmission of electrical energy, the use of materials for the support structure 5 of the bobbin 2 offers, the heat conduction through additives to the
Standardwerkstoffen gesteigert ist. Damit kann die Abfuhr der anfallenden Standard materials is increased. Thus, the removal of accumulating
Verlustwärme aus den elektrischen Leitern 4 der Spulenwicklung 3 verbessert werden. In Verbindung mit der optimierten Anordnung der elektrischen Leiter 4 der Spulenwicklung 3 sind somit Spulen mit höherer Leistungsdichte möglich, die flexibel an die Einbausituation und die Verwendung angepasst werden können. Heat loss from the electrical conductors 4 of the coil winding 3 can be improved. In connection with the optimized arrangement of the electrical conductors 4 of the coil winding 3 thus coils with higher power density are possible, which can be flexibly adapted to the installation situation and use.

Claims

Ansprüche claims
1. Verfahren zur Herstellung einer Spule (1) die zur induktiven 1. A method for producing a coil (1) for inductive
Übertragung elektrischer Energie geeignet ist, mit mindestens einem ersten elektrisch nicht leitenden Spulenträger (2) welcher mindestens eine Spulenwicklung (3) umfasst, dadurch gekennzeichnet, dass mindestens ein elektrischer Leiter (4) der Spulenwicklung (3) von einer Trägerstruktur (5) des Spulenträgers vollständig umschlossen ist und mittels eines 3 D- Druckverfahrens erzeugt wird.  Transmission of electrical energy is suitable, with at least one first electrically non-conductive bobbin (2) which at least one coil winding (3), characterized in that at least one electrical conductor (4) of the coil winding (3) of a support structure (5) of the bobbin is completely enclosed and generated by a 3-D printing process.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der 2. The method according to claim 1, characterized in that the
Spulenträger (2) und die Leiter (4) der Spulenwicklung (3) in einem gemeinsamen 3D-Druckprozess erzeugt werden.  Coil carrier (2) and the conductor (4) of the coil winding (3) are generated in a common 3D printing process.
3. Verfahren nach einem der vorhergehenden Ansprüche, dadurch 3. The method according to any one of the preceding claims, characterized
gekennzeichnet, dass die Trägerstruktur (5) des elektrisch nicht leitenden Spulenträgers (2) den elektrischen Leiter (4) in der vorbestimmten Position hält.  characterized in that the support structure (5) of the electrically non-conductive coil support (2) holds the electrical conductor (4) in the predetermined position.
4. Verfahren nach einem der vorhergehenden Ansprüche, dadurch 4. The method according to any one of the preceding claims, characterized
gekennzeichnet, dass die Spule aus mehreren durch den nicht leitenden Spulenträger (2) gegeneinander isolierten elektrischen Leitern (4) besteht.  characterized in that the coil consists of several by the non-conductive coil support (2) against each other insulated electrical conductors (4).
5. Verfahren nach einem der vorhergehenden Ansprüche, dadurch 5. The method according to any one of the preceding claims, characterized
gekennzeichnet, dass die elektrischen Leiter (4) so zueinander angeordnet sind, dass sich eine verseilte Struktur ergibt.  in that the electrical conductors (4) are arranged relative to one another such that a stranded structure results.
6. Verfahren nach einem der vorhergehenden Ansprüche, dadurch 6. The method according to any one of the preceding claims, characterized
gekennzeichnet, dass die elektrischen Leiter (4) in einer beliebigen räumlichen Struktur zueinander angeordnet sind.  characterized in that the electrical conductors (4) are arranged in any spatial structure to each other.
PCT/EP2018/061785 2017-06-28 2018-05-08 Process for manufacturing a coil WO2019001814A1 (en)

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DE102018118551A1 (en) * 2018-07-31 2020-02-06 Tdk Electronics Ag Method for producing an inductive component and inductive component

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013010228A1 (en) * 2013-06-18 2014-03-27 Daimler Ag Inductor used in e.g. pressing tool for inductive heating of sheet metal semi-finished product, has induction coil that is made of conductive material, and is completely integrated in supporting element made of non-conductive material
DE102014220978A1 (en) * 2014-10-16 2016-04-21 Robert Bosch Gmbh Coil arrangement for inductive energy transmission, inductive energy transmission device and method for producing a coil arrangement for inductive energy transmission
DE212015000119U1 (en) 2014-04-28 2016-12-21 Apple Inc. Inductive charging system with encapsulated charging coil

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013010228A1 (en) * 2013-06-18 2014-03-27 Daimler Ag Inductor used in e.g. pressing tool for inductive heating of sheet metal semi-finished product, has induction coil that is made of conductive material, and is completely integrated in supporting element made of non-conductive material
DE212015000119U1 (en) 2014-04-28 2016-12-21 Apple Inc. Inductive charging system with encapsulated charging coil
DE102014220978A1 (en) * 2014-10-16 2016-04-21 Robert Bosch Gmbh Coil arrangement for inductive energy transmission, inductive energy transmission device and method for producing a coil arrangement for inductive energy transmission

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