Coil and method for manufacturing a coil

Abstract

A coil (1) having a tube (2) with a tube wall (6) composed of an electrically conductive material, wherein the tube (2) has an inductance section (7) in which a gap (4) is provided in the tube wall (6), which shapes the tube wall (6) in the inductance section (7) as a spiral, and wherein the tube (2) has two contact sections (8) with a connection region (10) and at least one terminal region (11), wherein the connection region (10) has the same profile as the adjoining section of the spiral, and wherein the terminal region (11) forms an electrical terminal of the coil (1), and wherein the connection region (10) electrically connects the terminal region (11) with the inductance section (7). Other aspects relate to a module having a plurality of coils (1), a method for manufacturing a coil (1) and a method for manufacturing a module.

Description

Technical Field

[0001] The present invention relates to a coil having a tube made of a conductive material, and to a method for manufacturing the coil. Background Technology

[0002] In the process of miniaturizing circuits, it is of great interest to provide small inductor devices with low power loss, high current carrying capacity and reliable durability.

[0003] Especially in wire coils, the weakest point can be the connection between the wire and the contact element, which requires external contact. Connections achieved by fusion welding or brazing typically have at least slightly increased resistance due to the alloys containing copper, tin, or nickel, or due to oxygen impurities. Furthermore, when the contact is poorly constructed, the resistance increases significantly. This results in high contact resistance, leading to high power loss. Consequently, an increased heat load also occurs at this point, which can cause coil failure in harmless cases or, in severe cases, fire.

[0004] Especially with small coils, the design of the coil contacts and feeder has a significant impact on the coil's electrical characteristics. The ratio of the feeder size to the coil size has a substantial influence on the characteristics of the coil as an electronic device. Summary of the Invention

[0005] The object of this invention is to provide a coil with improved properties. Furthermore, the object of this invention is to provide a method for manufacturing a coil.

[0006] The objective is achieved by a coil according to the invention. Other embodiments of the coil and methods for manufacturing the coil will be obtained from the following description.

[0007] A coil is proposed having a tube having a wall made of a conductive material, wherein the tube has an inductive section, in which a gap is provided in the tube wall, the gap forming a helical element within the inductive section, and wherein the tube has at least one contact section having a connecting region and at least one terminal region, wherein the connecting region has the same profile as an adjacent section of the helical element, and the terminal region forming an electrical terminal of the coil, wherein the connecting region electrically connects the terminal region to the inductive section.

[0008] An elongated hollow body, referred to as a tube, has an opening extending from a first end of the body through the entire body to a second end opposite the first end. The tube may be symmetrical about its longitudinal axis, which extends from the midpoint of the bottom surface at the first end to the midpoint of the bottom surface at the second end. In one embodiment, the tube has a circular, oval, or rectangular cross-section. However, other cross-sections are also possible.

[0009] A spiral structure can be called a spiral component. Spiral components are especially useful for forming the turns of a coil.

[0010] The tube, in particular, can have helical gaps within its wall, thereby forming the turns of a coil. The tube is constructed of a conductive material. It will have a conductivity higher than 10... 4 Materials with an electrical conductivity of S / m, especially those with a conductivity higher than 10. 5 S / m or higher than 10 6 Materials with an electrical conductivity of S / m are considered conductive materials. Materials with very high electrical conductivity, such as metals like copper, aluminum, silver, or gold, can be suitable for this purpose. Industrial steels, such as carbon steel, stainless steel, alloy steel, or tool steel, are also suitable as raw materials for pipes.

[0011] The tube has an inductor section and at least one contact section. The inductor section can be formed by a helical element with a gap-formed structure. The inductor section and the contact section are integrally constructed from the tube wall material. Therefore, no connecting mating parts, such as solder, are required to connect the inductor section and the contact section. More precisely, the inductor section and the contact section can be formed by a corresponding structure of the tube wall and are thus held together by the tube material.

[0012] The coil has the advantage that it eliminates the need for internal connection portions to connect the inductor to the terminals. More precisely, the inductor region and the contact region can be integrally formed. The coil has a smaller total resistance than a coil that requires internal connection portions to connect the inductor to the terminals. Furthermore, by eliminating internal contacts, thermal and mechanical loads that would otherwise occur at possible internal contacts are also eliminated, thereby reducing the coil's susceptibility to error.

[0013] The tube does not necessarily need to be rounded in cross-section; instead, it can be, for example, oval, square, rectangular, polygonal, square with rounded corners, rectangle with rounded corners, or polygonal with rounded corners. A square cross-section, with its height or width preset, offers the advantage of optimal utilization of the available structural space.

[0014] Depending on the application for the coil, the bottom surface of the tube can be planar, meaning the expansion of the unfolded bottom surface is large relative to the expansion in height, and the height is small. Alternatively, the tube can have a small bottom surface while having a very large height. If the coil is mounted, for example, on a circuit board housed in a narrow housing, then a planar and flat shape would be advantageous. However, if limited space is available on the circuit board itself, then a tube shape with a small bottom surface, but for this purpose, a significant height, might be advantageous.

[0015] The connecting region has the same profile as the adjacent region of the helical component. Therefore, deformation of the connecting region, which would otherwise be transmitted to the directly connected helical component, can be avoided. This deformation specifically refers to bending and compression. This force acting on the connecting region acts directly as a bending moment on the inductor section and causes deformation of the helical component. The division of the helical component indicates the regularity of the turns and gaps within the helical component, and this regularity can worsen even with small forces acting on the connecting region. For example, the helical component may thus have a smaller gap width on one side and a larger gap width on the opposite side. Stronger forces acting on the connecting region can also easily cause short circuits in the helical component because the turns of the helical component, especially those closest to the connecting region, can bend together and subsequently touch.

[0016] The profile can be understood as the external shape of a region or segment of the helical component when viewed along a direction parallel to the longitudinal axis of the tube. If the tube is, for example, quadrilateral and the connecting region lies on the straight side of the quadrilateral, then the connecting region is also straight. If adjacent segments of the helical component have corners, then the profile of the corners is also present in the connecting segment. In a circular tube, the connecting segment correspondingly has an arc-shaped profile. Adjacent segments and connecting regions of helical components with the same profile can be arranged parallel to each other.

[0017] The transition from the connection area to the inductor section can be straight along the longitudinal axis of the tube. By eliminating bends or angles between the connection area and the inductor section, weak points in the material at this location can be avoided, thus preventing breakage. Furthermore, a straight transition avoids changes or bends in the path of the flowing current, thereby preventing unintended inductance in the coil.

[0018] Preferably, the inductor region is free from deformation. Because the connecting region has the same profile as the adjacent segment of the screw, deformation of the connecting region can be avoided, thus eliminating the force exerted on the connecting region. Force exerted on the connecting region that would cause deformation would easily lead to deformation within the screw. Even small deformations in the inductor region can cause changes in the spacing, thereby characterizing the ratio of the screw to the gap and the regularity of the screw's turns, and altering the electrical characteristics of the coil, thus no longer meeting the design requirements. Stronger deformation can press the individual turns of the screw together, even causing a short circuit in the coil. A short circuit between two turns does not necessarily cause the coil to malfunction; however, a short-circuited turn without current flow does not contribute to the coil's inductance.

[0019] Furthermore, the terminal area can be formed by deforming the tube wall. In this way, the coil can be constructed as a whole from the terminal area to the inductor section (including the inductor section) while maintaining a small series resistance of the coil.

[0020] The terminal area and the connection area can be in a plane perpendicular to the longitudinal axis of the tube. This arrangement of the terminal area does not extend the overall coil dimension because the terminal area is not connected to the connection area along the longitudinal axis of the tube. Therefore, the overall coil length can be kept short relative to the screw, and a form factor beneficial to the coil can be achieved.

[0021] Furthermore, the terminal area can have a flat surface that forms a solderable terminal. Accordingly, the coil can be designed, in particular, for soldering to, for example, printed conductors on a circuit board.

[0022] The inductor section can be spaced apart from the support surface by a portion of the terminal area. This has the advantage of providing mechanical and thermal isolation between the inductor area and the support surface on which the coil is mounted. Therefore, it prevents vibration or heat from the coil from being transferred to the mounting surface, such as the mounting surface of a circuit board. The magnetic field of the coil is also less strongly affected by the spaced-apart mounting surface, thereby allowing the coil to have the desired electrical characteristics. In one embodiment where the coil can be surrounded or embedded in a magnetic material, sufficient magnetic material can also be provided between the coil and the support surface by ensuring that the coil is spaced apart from the support surface. In this way, the coil can be uniformly covered with magnetic material, thereby generating a uniform magnetic field around the coil and additionally protecting the coil from all sides.

[0023] The spacing of the inductor segments can be achieved, for example, through L-shaped terminal areas. The vertical portion of the L-shaped terminal area serves as a spacing element, and the horizontal portion can be a flat surface for electrical contact. The vertical portion of the terminal area spaces the inductor segments of the coil from a mounting surface, such as a circuit board, and the coil can be electrically connected to the mounting surface via the horizontal portion.

[0024] Furthermore, the coil can have a magnetic core. For example, the use of a ferromagnetic core ensures a higher magnetic flux density and increased inductance in the coil. Suitable materials for the core include metallic nickel-zinc, manganese-zinc, and cobalt, as well as other alloys. Here, the core is not limited to the core disposed within the coil, but also includes cores integrally formed as part of a modular coil housing. Implementing a coil with a modular coil housing can improve the coil's electromagnetic compatibility (EMC). By using an EP core, for example, as the housing, electromagnetic shielding through the housing can be improved, particularly in high-frequency applications, thereby enhancing EMC.

[0025] Furthermore, the tube can be embedded in plastic to protect it, particularly from mechanical influences, but also from the effects of temperature and chemicals. Suitable plastics include epoxy resin, phenolic resin, and silicone resin. By embedding the tube in plastic, coil devices are more suitable for assembly using automated machines, such as in pick-and-place methods.

[0026] Powders with magnetic properties, such as iron powder or magnetic nanoparticles, can be incorporated into plastics. Adding magnetic particles to the plastic increases the inductance of the coil and improves its electrical characteristics. The inductance can be adjusted by the proportion of magnetic particles in the plastic. The coil can also have a magnetic core, regardless of whether the plastic contains a proportion of magnetic powder, when embedded in plastic, in order to increase the coil's inductance. Embedding the coil in plastic, especially in plastic with a proportion of powder possessing magnetic properties, can also improve the electromagnetic shielding of the device and enhance electromagnetic compatibility, particularly in high-frequency applications.

[0027] Furthermore, the coil can have an outer diameter ranging from 0.2 mm to 50 mm. Preferably, the outer diameter of the coil can be in the range of 0.5 mm to 20 mm. This size is particularly suitable for providing coils suitable for applications on circuit boards. The outer diameter should not be less than 0.2 mm, preferably not less than 0.5 mm, because otherwise small coils will be produced, making automated component handling associated with significant technical difficulties. The outer diameter should not be greater than 50 mm, preferably not greater than 20 mm, because otherwise the manufacturing of the coil from the tube becomes uneconomical.

[0028] Another aspect of this application relates to a module having at least two coils. The coils may, in particular, be the coils described above. The at least two coils are disposed within a common housing. The housing may be formed of plastic, and the two coils are embedded in the plastic. The two coils may here be arranged spatially parallel to each other.

[0029] Preferably, the coils are configured such that they can be electrically contacted individually and are not connected to each other within the module. In an alternative embodiment, the coils can be electrically connected to each other in parallel or in series to give the entire module the desired inductance. It is feasible in this way to assemble the module from multiple coils such that the entire module has a higher or lower inductance than the individual coils.

[0030] The use of modules can shorten the cycle time in the manufacturing process by reducing the number of coils required to assemble a circuit board. Instead of mounting multiple individual coils, by installing modules, only one module needs to be positioned on the circuit board when mounting coils, for example using an automated pick-and-place machine. Modules thus simplify subsequent processes in which they are incorporated.

[0031] Furthermore, by housing multiple coils within a module, space is saved compared to arranging multiple individual coils side-by-side. This space saving can be particularly advantageous in applications where available space is very limited, such as in circuit boards for mobile devices like smartphones. Additionally, housing material can be saved when using modules instead of individual embedded coils.

[0032] Another aspect of this application relates to a method for manufacturing a coil. The coil may in particular be the aforementioned coil.

[0033] The method includes the following steps:

[0034] a. Providing a tube having a wall made of a conductive material;

[0035] b. A gap is created in the inductive section of the tube, wherein the gap forms a spiral in the tube wall and forms at least two sections of the tube as contact sections.

[0036] c. The first portion of the contact segment is formed into at least one terminal region, wherein the second portion of the contact segment retains the shape of the tube wall and forms a connection region, wherein the connection region electrically connects the terminal region to the inductor segment.

[0037] The inductance of the inductor section can be created first by generating a gap. This gap can be a cut gap, generated using a laser. The shape of the contact section can also be generated using a laser, especially in conjunction with the gap generation process.

[0038] Laser processing is suitable for creating gaps in inductor sections, and also for creating recesses in contact sections of tubes. Laser processing offers the advantages of flexibility and speed. Furthermore, it eliminates mechanical stress because it operates non-contactly and leaves minimal residue. Alternatives for creating gaps include milling, sawing, or waterjet cutting.

[0039] Step b. above may have additional sub-steps, wherein a recess is formed in the contact section of the tube by removing a region of the tube wall. The recess in the contact section of the tube and the gap in the inductive region can be created together in a single method step. Correspondingly, the entire step b. can be created in a single process step, for example by means of laser cutting.

[0040] Furthermore, in step c., a terminal region can be formed by deforming the first portion of the contact section in a direction perpendicular to the longitudinal axis of the tube. Because the terminal region is not deformed in a direction perpendicular to the longitudinal axis of the tube, the deformation of the terminal region in a direction perpendicular to the longitudinal axis does not lengthen the coil. By extending the terminal region primarily in a direction perpendicular to the longitudinal axis of the tube, the overall length of the coil can be prevented from increasing excessively relative to the length of the inductor section or the screw.

[0041] Furthermore, in step c., the first portion of the contact segment can be formed into a terminal area using a stamping process. The shaping achieved through stamping, such as bending or pressing, is effective, reliable, and reproducible.

[0042] The second part of the connecting area, which can be formed by the stamping process, can be supported during the stamping process by opposing punches or support surfaces, so that no bending force is applied to the second part during the stamping process. The opposing punch can be shaped to match the profile or external shape of the tube. Because no bending moment is applied to the connecting section, the connecting area retains the profile of the tube wall that forms it, and thus the same as the profile of the adjacent inductor section. Forces that would cause undesirable deformation of the inductor section are also avoided. Even slight deformation of the inductor section will result in a change in the electrical characteristics of the coil. Larger forces applied to the connecting area can even cause a short circuit in the inductor area, in which two adjacent turns of the screw contact each other as a result of the force. By eliminating bending moments in the connecting area, the electrical characteristics of the coil manufactured by the aforementioned process become more reproducible and more predictable.

[0043] Additionally, in step b., the coil bundle can first be generated by generating multiple inductor segments along the tube, creating gaps in each of the inductor segments, the gaps forming a spiral shape in the tube wall within the respective inductor segments, and forming contact segments between each pair of inductor segments. In step c., the first portion of each contact segment can be formed into at least one terminal region, and the second portion of the contact segment can maintain the shape of the tube wall and form a connection region, wherein the connection region electrically connects the terminal region to the inductor segment.

[0044] This coil bundle design optimizes coil handling during production. Therefore, multiple coils can be processed simultaneously, resulting in shorter production cycle times. Furthermore, material can be saved by incorporating multiple inductor segments within the tube.

[0045] Additionally, the terminal area can be formed by deforming the tube wall in a direction perpendicular to the tube's longitudinal axis. Deformation of the tube wall in a direction perpendicular to the tube's longitudinal axis allows for the formation of the terminal area without causing a change in the length of the coil bundle, which could be due to stretching or compression. Deformation in a direction parallel to the longitudinal axis inevitably causes a change in the length of the coil bundle. Therefore, the coil bundle formed in this way retains its defined total length, despite the molding process for the terminal area. The handling of the coil bundle is improved because the same dimensions can be assumed in different manufacturing steps on the production line, thus framing the conditions. Especially in the manufacturing process, it is advantageous that the length of the coil bundle remains constant throughout production because additional measurements or re-entry of framing conditions are not required in different production steps, such as when the coil bundle is cut.

[0046] Additionally, in the continuing step d, the coil bundle can be divided perpendicular to the longitudinal axis of the tube between the two inductor segments. Thus, the coil bundle can then be divided into multiple coils. The coils can be divided individually, resulting in only one inductor segment along with two adjacent contact segments. However, it is also possible to separate the multiple inductor segments, held together by the contact segments, from the coil bundle into a matched overall coil composed of multiple individual coils.

[0047] Multiple coils or coil bundles can be embedded in plastic to form a package. The coils or coil bundles may already have a magnetic core at this point. Advantageously, the coil bundles are arranged parallel to each other before embedding. By embedding multiple coil bundles simultaneously, rather than individually, the manufacturing process can be accelerated. The plastic protects the coils from mechanical influences as well as the effects of temperature and chemicals. Powders or magnetic nanoparticles with magnetic properties can also be incorporated into the plastic. By adding magnetic particles to the plastic, the inductance of the coil can be increased and can also be adjusted via the proportion of magnetic particles in the plastic.

[0048] Advantageously, a magnetic core can be incorporated into the coil bundle or coil itself. This can increase the inductance of the coil or coil bundle. Furthermore, incorporating the core into the coil bundle before embedding it in the plastic allows for the manufacture of coils with magnetic cores, which can also be embedded in plastic with a magnetic component. This can improve the inductance and electromagnetic compatibility of the coil.

[0049] After embedding multiple parallel coil bundles into the package, the coils can be divided laterally and parallel to the longitudinal axis of the coil bundles. It is advantageous to guide the separation line through the contact section of the coil. This divides the package into individual coils. It is feasible to first divide the package laterally and then parallel, or to first divide the package parallel and then laterally.

[0050] On the other hand, a method for manufacturing modules is involved. Here, a package having multiple parallel coil bundles can be divided transversely to the longitudinal axis of the bundles. It is also advantageous in this option to guide a separation line through the contact section of the coils. The division to individual coils is not parallel to the axis.

[0051] The module has at least two coils in a common housing, wherein the tube has a contact section divided into a connection area and a terminal area. A method for manufacturing the module includes the following steps:

[0052] - At least two coil bundles are generated by generating a plurality of inductor segments along each tube, creating gaps in each of the inductor segments, the gaps forming a helical shape in the tube wall of the respective inductor segment, and wherein contact segments are formed between each of the two inductor segments, wherein a first portion of each contact segment is formed as at least one terminal region, and wherein a second portion of the contact segment retains the shape of the tube wall and forms a connection region, wherein the connection region electrically connects the terminal region to the inductor segment.

[0053] - Position the coil bundles in parallel;

[0054] - Embedding the coil bundle in plastic, the plastic forming a housing; and

[0055] - The coil bundle, connected by plastic, is divided into modules along a separation line that extends transversely to the longitudinal axis of the coil bundle. Attached Figure Description

[0056] The present invention will now be described in detail with reference to the schematic diagrams of the embodiments.

[0057] Figure 1a A spatial diagram showing one possible implementation of the tube is provided.

[0058] Figure 1b A spatial diagram showing a feasible second embodiment of the tube is provided.

[0059] Figure 2 A spatial diagram of the coil bundle is shown.

[0060] Figure 3 This shows a spatial diagram of the intermediate products produced when manufacturing coils from coil bundles.

[0061] Figure 4 A spatial diagram of a coil according to an embodiment of the present invention is shown.

[0062] Figure 5 A spatial diagram of multiple coil bundles embedded in a plastic encapsulation is shown.

[0063] Figure 6 A spatial diagram of a coil embedded in plastic and which is a single, readily available device is shown.

[0064] Identical, similar, or obviously identical elements are given the same reference numerals in the accompanying drawings. The sizes in the drawings and the relationships between them are not necessarily proportional. Detailed Implementation

[0065] exist Figure 1a and 1b The diagram shows a tube 2 having both circular and rounded square cross-sections. The tube 2 is an elongated hollow body with an opening extending from a first end of the body through the entire body to a second end opposite the first end. The tube 2 may be symmetrical about its longitudinal axis 3, which extends from the midpoint of the bottom surface at the first end to the midpoint of the bottom surface at the second end. In one embodiment, the tube 2 may have a circular, oval, rectangular, or polygonal cross-section. Other cross-sections are also possible.

[0066] The tube 2 can have an outer diameter ranging from 0.2 mm to 50 mm. Preferably, the outer diameter of the tube 2 can be in the range of 0.5 mm to 20 mm. This size is particularly suitable for manufacturing coils 1, which are suitable for application on circuit boards. The thickness of the tube wall 6, determined by the distance between the inner and outer radii of the tube 2, can vary considerably depending on the tube 2 used, wherein a thickness of less than 1 mm can be advantageous for processing. The side surface 5 of the tube 2 extends along the longitudinal axis 3 along the outer radius. The tube 2 is primarily composed of a conductive material.

[0067] Tube 2 is a raw material used in the manufacture of coil 1. During the manufacturing process, in... Figure 1a The tube 2 shown can first be structured as a coil bundle. Figure 2 The coil bundle is shown. Here, tube 2 can be structured, in particular, by laser processing, wherein an inductor segment 7 and a contact segment 8 are formed within tube 2. The inductor segment 7 and the contact segment 8 alternate along tube 2.

[0068] A gap 4 is created in the inductor section 7, the gap penetrating the tube wall 6 and shaping the tube wall 6 into a spiral. This constitutes the inductance of the inductor section 7. During the manufacturing process, the contact section 8 is partially shaped into a terminal region 11, with another portion of the contact section becoming a connection region 10. In the contact section 8, a recess is formed during the structuring of the tube 2, in which a portion of the tube wall 6 is removed.

[0069] The operation of coil 1 in production is optimized by using coil bundles. This allows multiple coils 1 to be processed simultaneously, resulting in a shorter cycle time in production. Furthermore, materials can be saved by creating multiple inductor segments 7 in tube 2.

[0070] The inductor sections 7 are interconnected by the contact sections 8 and there is no unnecessary contact resistance between them.

[0071] Different inductive sections 7 of the coil bundle can have different or the same inductance. This allows for the generation of different coils 1 from the tube 2, each with varying inductance, thus suited to entirely different applications. The inductance can be varied, for example, by the number of turns formed by the gap 4, or by the spacing of the gap 4 along the longitudinal axis 3 after one revolution around the tube 2, corresponding to the width of the turns. Figure 2 In the embodiments shown, the gaps 4 are the same, and therefore the inductance of each inductor segment 7 is also the same.

[0072] exist Figure 3 The diagram shows a spatial representation of the intermediate product during the manufacture of coil 1 from the coil bundle. The coil bundle has been divided along a separation line 12 extending transversely to the longitudinal axis 3 of the coil bundle.

[0073] The coil 1 has a tube 2 made of conductive material, in which a gap 4 extending along the side surface 5 and around the longitudinal axis 3 of the tube 2 is formed, thus constituting an inductor segment 7. In an alternative embodiment, the entire tube 2 can be structured such that only one unique inductor segment 7 and two contact segments 8 adjacent to said inductor segment are obtained. Accordingly, the tube 2 can be structured such that... Figure 3 The intermediate product shown in the figure involves cutting tube 2 to an appropriate length. Contact segment 8 and inductor segment 7 are directly connected to each other. Contact segment 8 and inductor segment 7 are integrally and one-piece formed from the structured tube wall 6.

[0074] Figure 4The diagram shows a coil 1 after the first portion of the contact segment has been bent into two terminal regions 11 by means of a stamping process, wherein the undeformed second portion of the contact segment forms a connecting region 10. For this purpose, the second portion of the contact segment is supported during the stamping process by opposing punches or a support surface so that bending forces or moments cannot be applied to the second portion during the stamping process. Preferably, the opposing punch shape matches the profile or shape of the tube 2. Due to the lack of bending moments on the connecting region 10, the connecting region 10 remains unchanged and has the same tube wall 6 profile as the adjacent inductor segment.

[0075] Because the force of the stamping process in the connecting region 10 is neutralized when the first part of the contact section is shaped into the terminal region 11 by means of the opposing punch, no bending moment is applied to the adjacent spiral member. As a result, the spiral member maintains its shape and division and also eliminates the possibility of short circuits between adjacent turns.

[0076] exist Figure 4 In the embodiment shown, the connecting region 10 has an arcuate shape because the tube 2 used to manufacture the coil 1 is circular. Therefore, in embodiments where the tube 2 has a basic quadrilateral shape, the connecting region 10 may therefore have, for example, a straight profile. The shape of the connecting region 10, however, is not limited to this. More precisely, the connecting region 10 can have any shape and profile equivalent to the shape and profile of the tube 2 in adjacent segments.

[0077] Figure 4 The terminal region 11 is formed by deformation of the tube wall 6 in a direction perpendicular to the longitudinal axis 3 of the tube 2. Deformation in a direction perpendicular to the longitudinal axis 3 of the tube 2 to form the terminal region 11 is permissible, forming the terminal region 11 without causing a change in the length of the coil bundle; this could be stretching or compression. Deformation in a direction parallel to the longitudinal axis 3 inevitably causes a change in the length of the coil bundle. If the terminal region 11 is, for example, along the longitudinal axis 3 of the tube 2 (in... Figure 4 If the coil bundle is formed as shown in the diagram, then a coil bundle with multiple such segments will shorten due to deformation. Conversely, if the terminal region 11 is bent perpendicular to the longitudinal axis 3 of the tube 2, then the coil bundle thus formed retains its defined total length, despite the molding process for the terminal region 11. In this regard, the handling of the coil bundle is particularly improved in the manufacturing process because the same dimensions and accompanying frame conditions, such as the frame conditions for the position of the inductor segments, can be assumed in different manufacturing steps on the production line. Therefore, when dividing the coil bundle, for example, the intermediate cut between two inductor segments can be performed automatically and without other measurements.

[0078] Another advantage is that the terminal area 11 is set perpendicular to the longitudinal axis 3 of the tube 2, so that the overall length of the coil, especially compared with the length of the screw, can be kept short in order to achieve an improved forming factor for the coil 1.

[0079] In addition, Figure 4 In the embodiment shown, the L-shaped inductor segment is spaced apart from the support surface by a portion of the terminal region 11. In this way, the inductor segment is mechanically and thermally isolated from the support surface. This prevents vibration or heat from the coil 1 from being transferred to the support surface, which may be, for example, a circuit board. Additionally, the spacing between the inductor segment 7 and the support surface ensures sufficient space for fully embedding the inductor segment into the plastic 9. The magnetic field of the coil 1, and the associated inductance, is less affected by the spaced-apart support surface.

[0080] exist Figure 4 The horizontal portion of the L-shaped terminal region 11 shown forms a flat surface, which forms a solderable terminal. Correspondingly, it is feasible to solder the coil 1 to, for example, printed conductors on a circuit board. The coil 1 is achieved through the integral construction of the tube 2, eliminating the need for additional connection techniques. For this reason, the coil 1 has a smaller total resistance, which in turn results in lower power loss. Furthermore, thermal stress is reduced, especially at possible contact points, thereby reducing the susceptibility of the coil 1.

[0081] exist Figure 5 In this assembly, four coil bundles are embedded in plastic 9, with the longitudinal axes 3 of coil 1 arranged parallel to each other. This arrangement is also called a package. Each of the four coil bundles here has four inductive sections 7 and four contact sections 8. Figure 5 The package shown is merely one example and multiple coil bundles, particularly more than 20, can be used, having any other number of inductor segments 7 and contact segments 8. In this embodiment, the contact segments 8 are opened by recesses and subsequently stamped into a non-deformable connection region 10 and two terminal regions 11. The dashed lines represent multiple possible dividing lines 12 for segmentation, which are transverse to or parallel to the longitudinal axis 3 of the coil 1 and extend through the contact segments 8. Alternative embodiments are also conceivable, where segmentation occurs along any other number of dividing lines 12. If the coil 1 is segmented parallel to the longitudinal axis 3 of the tube 2, then the inductor segments 7 are connected in series with each other. By embedding multiple coil bundles simultaneously and not individually, the manufacturing process can be accelerated.

[0082] The plastic 9 serves as a housing for protection against potential risks from the surrounding environment. The protective function of the plastic can be expanded as needed by adding particles with desired magnetic properties. The inductance can also be adjusted via the amount or concentration of magnetic particles in the plastic. In an alternative embodiment, the coil 1 can be connected to an EP core, which also integrally forms the housing. The EP core can consist of two halves that can then be bonded together. The EP core provides electromagnetic shielding for the coil 1, particularly in high-frequency applications, thereby improving the device's electromagnetic compatibility.

[0083] It is equally simple and feasible to produce a module with multiple coils 1 within a housing using a package. Here, the package, as in... Figure 5 As shown in the diagram, the tube 2 is divided as needed, parallel to and / or perpendicular to the longitudinal axis 3. Figure 5 The package shown is merely an example, and significantly longer coil bundles and a greater number of coil bundles with multiple coils 1 can be arranged within the package. The module itself has contact surfaces that are accessible from below and, if necessary, from the sides, and can be contacted via pads or printed wires through soldering or bonding processes. The use of modules results in a reduction in cycle time when mounting the coils 1. By loading modules instead of individual coils 1, for example, automated pick-and-place machines must position the device on the circuit board only once, rather than multiple times. Furthermore, by arranging multiple coils 1 within a module, space is saved compared to arranging multiple individual coils 1 side-by-side.

[0084] The coils 1 in the module can be configured to be connected in parallel, in series, or not connected at all. In an embodiment where multiple coils 1 are arranged side by side, each coil 1 can be individually contacted. If such a module is contacted by two printed conductors extending perpendicular to the longitudinal axis 3, then the inductor segments 7 are electrically connected in parallel. If the printed conductors are arranged in a meandering manner under the module, then the inductor segments 7 can be connected in series. Thus, the coils 1 themselves can be connected to each other in completely different ways within the module, yet still within the electronic device.

[0085] Figure 6 A single coil 1 is shown embedded in plastic 9. A contact segment is provided at the end side of the embedded coil 1, the contact segment having an arc-shaped connection area 10 and two L-shaped terminal areas 11. The coil 1 can be manufactured by dividing the coil 1 in a package, or by embedding a single coil 1 into plastic 9, as shown. Figure 4 Like in the middle.

[0086] List of reference numerals

[0087] 1 coil

[0088] 2 tubes

[0089] 3. Longitudinal axis

[0090] 4 gaps

[0091] 5 side surfaces

[0092] 6 Pipe wall

[0093] 7. Inductor Section

[0094] 8 contact section

[0095] 9. Plastic

[0096] 10 Connecting Areas

[0097] 11 Terminal Area

[0098] 12 Separation Line

Claims

1. A coil (1), having a tube (2) with a tube wall (6) composed of an electrically conductive material, wherein the tube (2) has an inductance section (7) in which a gap (4) is provided in the tube wall (6), which shapes the tube wall (6) in the inductance section (7) as a spiral, and wherein the tube (2) has two contact sections (8) at opposite ends of the spiral, which have a connection region (10) and two terminal regions (11) respectively, wherein the connection region (10) has the same profile as the adjoining section of the spiral, wherein the terminal regions (11) form electrical terminals of the coil (1), wherein the connection region (10) electrically connects the two terminal regions (11) with the inductance section (7), and wherein each terminal region (11) is composed L-shaped, wherein the horizontal part of the terminal region (11) is composed of a flat face, which forms a solderable terminal, and wherein the vertical part of the terminal region spaces the inductance section (7) of the coil (1) from a mounting surface.

2. The coil (1) according to claim 1, wherein the transition from the connection region (10) to the inductance section (7) is straight in the direction of the longitudinal axis (3) of the tube (2).

3. The coil (1) according to claim 1 or 2, wherein the inductance section has no deformation.

4. The coil (1) according to claim 1 or 2, wherein the terminal regions (11) are formed by a deformation of the tube wall (6).

5. The coil (1) according to claim 1 or 2, wherein the terminal regions (11) and the connection region (10) are in a plane perpendicular to the longitudinal axis of the tube (2).

6. The coil (1) according to claim 1 or 2, wherein the terminal regions (11) have a flat face, which forms a solderable terminal.

7. The coil (1) according to claim 1 or 2, wherein the inductance section is spaced from a support surface by a part of the terminal region (11).

8. The coil (1) according to claim 7, wherein the coil (1) has a core.

9. The coil (1) according to claim 8, wherein the core is an EP core.

10. The coil (1) according to claim 1 or 2, wherein the tube (2) is embedded in plastic (9).

11. The coil (1) according to claim 10, wherein the plastic (9) is mixed with a magnetic powder, magnetic particles or other magnetic material.

12. A module with at least two coils (1) according to claim 1 or 2, which are arranged in a common housing.

13. A method for manufacturing a coil (1), comprising the following steps: a. providing a tube (2) with a tube wall (6) composed of an electrically conductive material, ​ ​ b. producing a gap (4) in an inductive section (7) of the tube (2), wherein the gap (4) forms the tube wall (6) as a spiral in the inductive section (7) and at least two sections of the tube (2) are shaped as contact sections (8) at opposite ends of the spiral, c. shaping a first portion of the contact sections (8) as two terminal areas (11) each, wherein a second portion of the contact sections (8) maintains the shape of the tube wall (6) and forms a connection area (10), wherein the connection area (10) electrically connects the two terminal areas (11) with the inductive section (7), wherein each terminal area (11) is L-shaped, wherein the horizontal portion of the L-shaped terminal area (11) constitutes a flat face, which forms a solderable terminal, and wherein the vertical portion of the terminal area spaces the inductive section (7) of the coil (1) from a mounting surface.

14. The method according to claim 13, wherein a laser process is used for producing the gap (4) and for shaping the contact sections (8).

15. The method according to claim 13 or 14, wherein in a sub-step of step b. a recess is formed in the contact sections (8) of the tube (2) by removing areas of the tube wall (6).

16. The method according to claim 15, wherein the recess in the contact sections (8) of the tube (2) and the gap (4) in the inductive section (7) are produced jointly in a single method step.

17. The method according to claim 13 or 14, wherein in step c. the terminal areas (11) are formed by a deformation of the first portion of the contact sections (8) in a direction perpendicular to the longitudinal axis (3) of the tube (2) each.

18. The method according to claim 13 or 14, wherein in step c. the first portion of the contact sections (8) is shaped as a terminal area (11) by a stamping process with a counter punch.

19. The method according to claim 18, wherein a second portion of the contact sections (8), which becomes the connection area (10) by the stamping process, is supported by the counter punch in the stamping process, so that no bending forces act on the second portion in the stamping process.

20. The method according to claim 13 or 14, wherein in step b. a coil bundle is first produced by producing a plurality of inductive sections (7) along the tube (2), in which inductive sections (7) a gap (4) is produced each, which forms the tube wall (6) as a spiral in the respective inductive section (7), and wherein a contact section (8) is shaped between two inductive sections (7) each, and wherein the contact sections (8) are shaped in a single method step. wherein a first part of the contact section (8) is shaped to at least one terminal area (11) in step c., and wherein a second part of the contact section (8) retains the shape of the tube wall (6) and forms a connection area (10), wherein the connection area (10) electrically connects the terminal area (11) with the inductance section (7).

21. The method according to claim 20, wherein the terminal area (11) is formed by a deformation of the tube wall (6) in a direction perpendicular to the longitudinal axis (3) of the tube (2).

22. The method according to claim 20, The method has additionally the following steps: d) The coil bundle is split between two inductance sections (7) perpendicular to the longitudinal axis (3) of the tube (2).

23. The method according to claim 20, The method has additionally the following steps: A plurality of coil bundles is produced and embedded in plastic (9), wherein the coil bundles are arranged parallel to each other.

24. The method according to claim 23, The method has additionally the following steps: The coil bundle is split transversely and / or parallel to the longitudinal axis (3) of the coil bundle.

25. A method for producing modules, which each have at least two coils (1) in a common housing, the method having the following steps: - providing a tube (2) which each has a tube wall (6) composed of an electrically conductive material, - producing at least two coil bundles by producing a plurality of inductance sections (7) along each of the tubes (2), in which inductance sections a gap (4) is produced which forms the tube wall (6) as a spiral in the respective inductance section (7), and wherein a contact section (8) is shaped between two inductance sections (7), and wherein a first part of the contact section (8) is shaped to two terminal areas (11) each, wherein a second part of the contact section (8) retains the shape of the tube wall (6) and forms a connection area (10), wherein the connection area (10) electrically connects the two terminal areas (11) with the inductance section (7), - arranging the coil bundles parallel to each other; - embedding the coil bundles in plastic (9), which forms the housing; - splitting the coil bundles connected by the plastic (9) into the modules along a separation line (12) which runs perpendicular to the longitudinal axis (3) of the coil bundle and between inductance sections (7), wherein each terminal area (11) is composed L-shaped, wherein the horizontal part of the terminal area (11) which is L-shaped constitutes a flat face, which forms a solderable terminal, and wherein the vertical part of the terminal area spaces the inductance section (7) of the coil (1) from a mounting surface.

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