Folded planar Litz wire and method of making same

• US 8,973,252 B2
• Filed: 09/27/2012
• Issued: 03/10/2015
• Est. Priority Date: 09/27/2012
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Nomura, Tsuyoshi, Guo, Yuanbo, Toshiyuki, Ken
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/628,635
• Publication Number:
  US 20140085031A1
• Time in Patent Office: 894 Days
• Field of Search: 336/200, 336/232, 297/29, 296/06
• US Class Current: 29/606
• CPC Class Codes: H01F 41/00 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
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers
• CPC Class Codes: H05K 1/0242 Structural details of individual signal conductors, e.g. related to the skin effect
• CPC Class Codes: H05K 1/028 Bending or folding regions of flexible printed circuits H05K1/0283 takes precedence
• 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 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

Several embodiments of a circuit device using principles of planar Litz wire construction are disclosed using flexible printed circuit boards on which a given set of conductors is located on one surface only. The FPCBs are folded at strategic locations to effectively cause conductors in adjacent parallel planes to effectively cross one another to realize the advantages of braided Litz wire conductors, but without the use of vias or circuit interconnections between opposite sides of any given FPCB or between different sections of a continuous FPCB wherein each section defines its own coil or coil set.

Claims

1. A method of constructing a planar litz wire comprising the steps of:

providing a flexible printed circuit board (FPCB) having one or more fold lines;

locating a plurality of conductors on a side of the FPCB, the plurality of conductors being configured to be electrically in parallel with one another and each conductor of the plurality of conductors having an initial lateral position on the side of the FPCB; and

folding the FPCB at least once along the one or more fold lines to produce a folded structure;

wherein folding causes a first conductor of the plurality of conductors to at least partially overlap a second conductor of the plurality of conductors.

2. The method as defined in claim 1 wherein folding causes each conductor of the plurality of conductors to at least partially overlap a counter conductor of the plurality of conductors, each conductor of the plurality of conductors and its at least partially overlapping counter conductor of the plurality of conductors being electrically in parallel with one another.

3. The method as defined in claim 2 wherein each conductor of the plurality of conductors and its overlapping counter conductor of the plurality of conductors has an inverse initial lateral position.

4. The method as defined in claim 1 wherein the folded structure has a ring-like shape suitable for use as at least one winding of a coil.

5. The method as defined in claim 1 where the folded structure has a multilayered, ring-like shape suitable for use as multiple windings of a coil.

6. The method as defined in claim 1 wherein the folded structure is substantially linear.

7. The method as defined in claim 1 wherein folding causes a first conductor of the plurality of conductors to at least partially overlap a second conductor of the plurality of conductors at least three times.

8. The method as defined in claim 1 wherein folding creates a multiplicity of overlaps between a first conductor of the plurality of conductors and a second conductor of the plurality of conductors, the multiplicity of overlaps occurring periodically over at least half the length of the first conductor of the plurality of conductors.

9. The method as defined in claim 1 wherein the folded structure is further characterized by an absence of vias.