Method for producing a coil

• US 9,087,636 B2
• Filed: 11/01/2013
• Issued: 07/21/2015
• Est. Priority Date: 11/02/2012
• Status: Expired due to Fees

• Current Assignee: Wurth Elektronik GMBH & Company KG (Adolf Wã¼Rth GmbH & Company KG), Hahn-Schickard-Gesellschaft Fur
• Original Assignee: Wurth Electronik GmbH & Company
• Inventors: Kostelnik, Jan, Schreivogel, Alina, Wolf, Jrgen, Keck, Jrgen, Giousouf, Metin, Kiessling, Albert, Reininger, Thomas
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US14/069,413
• Publication Number:
  US 20140132386A1
• Time in Patent Office: 627 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: 1/1
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 2017/0066 with a magnetic layer
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/303 Clamping coils, windings or parts thereof together
• CPC Class Codes: H01F 27/402 Association of measuring or protective means
• CPC Class Codes: H01F 41/042 by thin film techniques
• CPC Class Codes: H01F 41/043 by thick film techniques
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: H03K 17/9505 Constructional details
• CPC Class Codes: H03K 2017/9527 Details of coils in the emitter or receiver; Magnetic detector comprising emitting and receiving coils
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/086 for inductive purposes, e.g. printed inductor with ferrite core
• CPC Class Codes: H05K 2201/09036 Recesses or grooves in insulating substrate recess in metallic substrate H05K2201/09745
• CPC Class Codes: H05K 2203/1344 Spraying small metal particles or droplets of molten metal
• CPC Class Codes: H05K 3/125 by ink-jet printing
• CPC Class Codes: H05K 3/1258 by using a substrate provided with a shape pattern, e.g. grooves, banks, resist pattern
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

The invention relates to a method for producing a coil (140) integrated in a substrate (100) or applied to a substrate, wherein the coil has first winding portions (136), which each have first ends (141) and second ends (147), and wherein the coil has second winding portions (138) and third winding portions (139), wherein each two of the first ends are electrically interconnected by the second winding portions and two corresponding second ends of the first winding portions are electrically interconnected by the third winding portions, such that coil windings of the coil are formed hereby, wherein at least the first winding portions are applied by means of a 3D printing method, wherein this is aerosol jet or inkjet printing, for example.

Claims

1. A method comprising:

producing a coil integrated in a substrate or applied to the substrate, wherein the coil has first winding portions, which each of the first winding portions has a first end and a second end, and wherein the coil has second winding portions and third winding portions, wherein each of the first winding portions has a first end and a second end by the second winding portions and two corresponding second ends of the first winding portions are electrically interconnected by the third winding portions, such that coil windings of the coil are thus formed, wherein at least the first winding portions are applied by a 3D printing process comprising at least one of an aerosol jet printing process and an inkjet printing process; and

producing a cavity in the substrate, wherein the first winding portions are applied to flanks of the cavity and the second winding portions are applied to a base of the cavity by the 3D printing process, wherein, after applying the first and second winding portions, the method comprises;

introducing a core material into the cavity; and

applying the third winding portions to the core material.

2. The method according to claim 1, further comprising applying the first winding portions and the second winding portions in a single printing process of the 3D printing method.

3. The method according to claim 1, wherein the substrate includes glass fibers and the cavity is produced in the substrate by means of a machining process, such that the glass fibers in the substrate located in an edge region of the cavity are severed by the machining process when producing the cavity, the method further comprising:

introducing a material into the cavity, wherein the material extends at least over the base and the flanks of the cavity;

partially removing the material from the cavity apart from a layer of the material extending over the base and the flanks of the cavity, wherein the first winding portions and the second winding portions are applied to the layer of material.

4. The method according to claim 3, wherein the material comprises at least one of a resin and a plastic.

5. The method according to claim 1, wherein the core material is introduced in the form of one of a paste and a solid into the cavity or is applied to the substrate in the form of the paste or the solid.

6. The method according to claim 1, wherein the substrate is a printed circuit board material of an electronic printed circuit board, in particular fiber-reinforced plastic.

7. The method according to claim 1, wherein the flanks of the cavity enclose one of a right angle and an acute angle with the base of the cavity.

8. The method according to claim 7, wherein the angle is between 30°

and 60°

, preferably 45°

.

9. The method according to claim 1, wherein the core material includes ferromagnetic particles, in particular particles formed from at least one of a soft magnetic amorphous, a nanocrystalline alloy, and a ferrite.

10. The method according to claim 1, wherein the core material is pressed into the cavity in the form of a paste or is applied using a dispenser.

11. The method according to claim 1, wherein the second winding portions are applied by means of a structuring technique, in particular by etching.

12. The method according to claim 1, wherein a plurality of coils are produced in or on the substrate, and the coils are connected to form a sensor array.

13. The method according to claim 1, wherein the core material comprises a paste and the cavity is filled completely with the paste.

14. The method according to claim 13, wherein the paste is mixed during a drying process of the paste in order to cure the paste, in particular by means of shaking or by application of ultrasound.

15. A method comprising:

producing a coil integrated in a substrate or applied to the substrate, wherein the coil has first winding portions, which each of the first winding portions has a first end and a second end, and wherein the coil has second winding portions and third winding portions, wherein each of the first winding portions has a first end and a second end by the second winding portions and two corresponding second ends of the first winding portions are electrically interconnected by the third winding portions, such that coil windings of the coil are thus formed, wherein at least the first winding portions are applied by a 3D printing process comprising at least one of an aerosol jet printing process and an inkjet printing process; and

producing a cavity in the substrate, wherein the first winding portions are applied to flanks of the cavity and the second winding portions are applied to a base of the cavity by the 3D printing process, wherein the substrate includes glass fibers and the cavity is produced in the substrate by means of a machining process, such that the glass fibers in the substrate located in an edge region of the cavity are severed by the machining process when producing the cavity, the method further comprising;

introducing a material into the cavity, wherein the material extends at least over the base and the flanks of the cavity; and

partially removing the material from the cavity apart from a layer of the material extending over the base and the flanks of the cavity, wherein the first winding portions and the second winding portions are applied to the layer of material.

16. The method according to claim 15, further comprising applying the first winding portions and the second winding portions in a single printing process of the 3D printing method.

17. The method according to claim 15, wherein, after applying the first and second winding portions, the method comprises:

introducing a core material in the form of one of a paste and a solid into the cavity; and

applying the third winding portions to the core material; and

wherein the core material includes ferromagnetic particles, in particular particles formed from at least one of a soft magnetic amorphous, a nanocrystalline alloy, and a ferrite.

18. The method according to claim 17, wherein the paste is mixed during a drying process of the paste in order to cure the paste, in particular by means of shaking or by application of ultrasound.

19. The method according to claim 15, wherein the material comprises at least one of a resin and a plastic.

20. The method according to claim 15, wherein the flanks of the cavity enclose one of a right angle and an acute angle with the base of the cavity.

21. The method according to claim 15, wherein the second winding portions are applied by means of a structuring technique, in particular by etching.

22. The method according to claim 15, wherein a plurality of coils are produced in or on the substrate, and the coils are connected to form a sensor array.