Multi-turn coil device

• US 8,387,234 B2
• Filed: 11/05/2010
• Issued: 03/05/2013
• 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:
  US12/940,701
• Publication Number:
  US 20110050381A1
• Time in Patent Office: 851 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: 29/729
• 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 multi-turn coil device comprising:

a. 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. a plurality of serially electrically coupled coils coupled to the flexible circuit board, each coil having a coil direction, and 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. one or more conductive paths formed 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 device 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.

3. The device of claim 1, wherein the flexible circuit board is a multilayer flexible circuit board.

4. The device of claim 1, further comprising an insulator configured to prevent the shorting of the plurality of serially electrically coupled coils when the flexible circuit board is folded.

5. The device of claim 4, wherein the insulator is an insulating membrane coupled to the first side and the second side.

6. The device of claim 4, wherein the insulator includes individual membranes coupled to the plurality of serially electrically coupled coils.

7. The device of claim 4, further comprising coupling material between the plurality of serially electrically coupled coils and the insulator to hold the device in a folded aligned configuration.

8. The device of claim 1, further comprising one or more alignment means.

9. The device of claim 8, wherein the alignment means is a folding line.

10. The device of claim 1, wherein the flexible circuit board if folded a pattern formed in the flexible circuit board, therein forming a multi-turn coil.

11. The device of claim 10, wherein the pattern is an accordion folding pattern, a fold over pattern, a double fold pattern, or a rolling fold pattern.

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