Method of producing a multi-turn coil from folded flexible circuitry

• US 8,191,241 B2
• Filed: 03/28/2008
• Issued: 06/05/2012
• Est. Priority Date: 03/29/2007
• Status: Active Grant

• Current Assignee: MyPAQ Holdings Ltd. (Transpacific IP Group Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Olson, Bruce D.
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US12/079,777
• Publication Number:
  US 20080238600A1
• Time in Patent Office: 1,530 Days
• Field of Search: 295/921, 296/021, 296/032.3, 296/06, 298/31, 298/32, 298/37, 336/65, 336/83, 336 90- 96, 336/200, 336206-208, 336/323
• US Class Current: 29/606
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 2017/006 flexible printed inductors
• CPC Class Codes: H01F 2027/2861 Coil formed by folding a blank
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/055 Folded back on itself
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/4906 Providing winding
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49139 by inserting component lead or terminal into base aperture
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/5313 Means to assemble electrical device

Abstract

A multi-turn coil device comprising a flexible circuit board and a plurality of serially electrically coupled coils coupled to both sides of the flexible circuit board. The coils are formed such that when the circuit board is folded in an accordion manner, the coils are substantially aligned and have the same direction of current flow. The coils are serially coupled sequentially from front to back and back to front wherein the coupling of the coils is through a plated through hole in the flexible circuit board.

Claims

1. A method of manufacturing a multi-turn coil device comprising the steps of:

a. forming a flexible circuit board having a first side, and a second side on the opposite side of the flexible circuit board as the first side when the flexible circuit board is unfolded;

b. forming a plurality of serially electrically coupled coils coupled to the flexible circuit board, each coil having a coil direction, wherein the coils are positioned such that each coil substantially overlaps each of the other coils when the flexible circuit board is folded; and

c. forming one or more conductive paths from the first side to the second side of the flexible circuit board, wherein one or more coils of the plurality of serially electrically coupled coils are coupled to the second side, and wherein at least one coil of the plurality of serially electrically coupled coils on the first side is electrically coupled to an opposing coil of the plurality of serially electrically coupled coils on the second side through the one or more conductive paths when the flexible circuit board is unfolded.

2. The method of claim 1, wherein the plurality of serially electrically coupled coils is formed such that when the flexible circuit board is folded, the coil direction of the plurality of serially electrically coupled coils is substantially the same and thereby forming a multi-turn coil.

3. The method of claim 2, further comprising the step of forming an alignment structure.

4. The method of claim 3, wherein the alignment structure is a folding line.

6. The method of claim 2, further comprising the step applying an insulation material configured to prevent shorting between the plurality of serially electrically coupled coils when the flexible circuit board is folded.

7. The method of claim 6, wherein the insulation material is an insulating membrane coupled to the first side and the second side.

8. The method of claim 6, wherein the flexible circuit board is folded according to a pattern formed in the flexible circuit board and thereby forming the multi-turn coil.

9. The method of claim 8, wherein the pattern is an accordion folding pattern, a fold over pattern, a double fold pattern, or a rolling fold pattern.

10. The method of claim 1, wherein the one or more conductive paths are plated through holes.

5. The method of 2, wherein the plurality of serially electrically coupled coils are formed by printing with electrically conductive ink, etching, or adhesively applied.