Method for manufacturing an electrical component and electrical component

Abstract

A method of manufacturing an electrical component, comprising: forming an armature (1) from a polymeric plastic material and an organic metal additive, the armature comprising a support arm (4), a winding (2) of which is formed directly on a surface of the support arm (4) from a conductor track (10) forming a turn. According to the invention, in order to obtain a winding with a high density of turns, with a precise arrangement that varies little over time, while at the same time making it possible to design a winding with any desired geometry, the manufacturing method comprises laser engraving the support arm (4) for engraving an initiation track forming a turn of the winding (2), in which the organic metal additive is locally activated. The method then comprises metallizing the initiation track with a conductive metal so as to form the conductor track (10) from the turn formed by the initiation track.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing an electrical component and to an electrical component obtainable by the method. BACKGROUND

[0002] Current sensors are used to measure the value of the current flowing through a power line. This measurement can be used to quantify the power and / or the energy consumed by an electrical receiver, or to detect a fault in the receiver. It is known how to use a Rogowski sensor as a current sensor, which uses one or more wire windings around a non-magnetic core, this type of sensor is usually associated with signal processing circuits comprising integration circuits.

[0003] For example, the sensor can take the form of a conductor winding extending along a circular or rectangular trajectory. This results in a toroidal coil, which forms a loop. In use, the power line, the current of which is to be measured, is positioned to pass through the loop formed by the winding in the center of the trajectory. The power line is thus radially surrounded by the winding. In order to reduce interference with the measurement, the winding can be made to comprise outgoing turns which cross the return turns, or the return turns are wound inside the outgoing turns or are parallel below the outgoing turns, or the unwound part of the conductor from one end of the winding of outgoing turns passes through the inside of the winding in the opposite direction along the trajectory of the winding. EP 3 171 182 A1 gives some examples on this subject.

[0004] In order to construct this type of winding, the copper wire is conventionally sometimes wound around a core made of toroidal polymer plastic, sometimes on a multilayer printed circuit board, as described in FR 3 075 387 A1.

[0005] In order to make the current sensor more compact, FR 3 053 795 A1 provides to form a hybrid sensor by associating the winding with a ferromagnetic rod, the arrangement forming an opening intended to be crossed by the conductor measuring the current.

[0006] The accuracy of the measurement depends in particular on the precision of the geometry of the turns and on the regularity of their spatial arrangement. Furthermore, in order to obtain a significant gain, a high number of turns is required. It is therefore necessary to provide complex and expensive machines for winding the wire. Furthermore, the coiling of the coil limits the density of the turns, the wound conductor being likely to deform during use, for example under the effect of thermal stresses. Finally, the coiling method used and the type of support, in particular for a printed circuit board, impose strong geometric constraints on the shape of the winding and of the sensor. SUMMARY

[0007] The present invention therefore aims to solve the above-mentioned drawbacks of the prior art by proposing a new manufacturing method, which makes it possible to obtain an electrical component comprising a winding with a high density of turns, the precise arrangement of which varies little over time, which makes it possible to design a winding with any desired geometry.

[0008] The subject of the present invention is a manufacturing method of an electrical component, which preferably constitutes a current sensor. The electrical component comprises an armature composed of a material comprising a polymeric plastic material and an organic metal additive, said armature comprising a support arm extending along a guide trajectory. The electrical component also comprises a winding formed directly on the surface of the support arm by conductor tracks forming turns of the winding, which are distributed along the guide trajectory and encircle the guide trajectory. The manufacturing process comprises successively: providing or manufacturing the armature; laser engraving said support arm to engrave an initiator track forming the turns of said winding and locally activating said organic metal additive; and metallizing the initiator track with an electrically conductive metal, thereby forming conductor tracks directly on the surface of the support arm according to the turns formed by the initiator track.

[0009] The basic idea of the present invention is to form the winding by means of conductor tracks traced on the support arm of the armature, rather than forming the winding in the form of wires as provided in the prior art. By laser engraving and activating the additive, then by metallization, the initiator track is formed, which is used to form conductor tracks with a high resolution according to any desired geometry. The thickness of the conductor tracks can be, for example, less than 15 pm, formed mainly by the copper deposit resulting from the metallization, advantageously coated with a nickel barrier layer and a gold polishing layer, of the order of 5 pm. It is thus possible to obtain a particularly high density of turns for the winding, which leads to a high compactness and / or a high gain of the winding if the winding of the component is used as a sensor. The turns are characterized by a pitch of less than 400 pm, for example of the order of 200 pm. The layout of the conductor tracks is very precise, since it is essentially determined by the precision of the laser engraving and the quality of the metallization. The desired winding shape is easily obtained, since it depends on the layout of the laser engraving and the shape of the outer surface of the armature, which can be easily shaped by molding during the manufacturing process. Since the support arm of the armature is a bulky part, the surface area of each turn is easily relatively high, essentially relatively not very thick, which often leads to turns of the design having a flattened shape, in particular compared to the windings of the prior art, which are formed by winding wires on a printed circuit board.

[0010] Since the conductor tracks are intimately associated with the support arm of the armature, they retain their initial shape over time and are not very sensitive to deformation under the influence of heat, unlike windings composed of wound wires.

[0011] Thanks to this high-quality winding, the electrical component obtained by the manufacturing process is particularly suitable for forming a current sensor, in particular a Rogowski sensor, the armature being advantageously suitable for forming a non-magnetic core.

[0012] Other optional and advantageous features of the application are described below.

[0013] The support arm preferably comprises a first side and a second side, the first side and the second side being opposite and adjacent on both sides of the guide trajectory, the laser engraving comprising: laser engraving a first portion of the initiation track on the first side, the first portion of the initiation track forming only a first portion of the initiation track for each turn; and laser engraving a second portion of the initiation track on the second side, the second portion of the initiation track forming a second portion of the turn completing the first portion of the turn for each turn.

[0014] Preferably, the laser engraving comprises: positioning the armature so that the first side is oriented facing the laser engraver, so as to perform the laser engraving of the first portion of the initiation track by the laser engraver; and repositioning the armature so that the second side is oriented facing the laser engraver, so as to perform the laser engraving of the second portion of the initiation track by the laser engraver.

[0015] Preferably, the manufacturing of the armature comprises molding the armature by injecting the material into a mold.

[0016] The mold preferably comprises: a molding cavity for molding the support arm; a first opening for injecting a first portion of the material; a second opening for injecting a second portion of the material; and a connection chamber into which the second opening enters and which communicates with the first opening via the molding cavity of the support arm. Preferably, the injection molding comprises: injecting the first portion of the material into the mold through the first opening, so that the first portion of the material: enters the molding cavity of the support arm, the support arm being subsequently entirely formed from the first portion of the material; extends into the connection chamber. The injection molding further comprises injecting the second portion of the material into the mold through the second opening, so that the second portion of the material meets the first portion of the material in the connection chamber, the armature being formed by the combination of the first portion of the material and the second portion of the material.

[0017] Preferably, the first opening and the second opening are disposed on the same plane and in the same direction, so that: by injecting the first portion of the material, the first opening molds a first stud of the armature; by injecting the second portion of the material, the second opening molds a second stud of the armature, the first stud and the second stud being configured for positioning the electrical component on a printed circuit board.

[0018] Preferably, the manufacturing process comprises manufacturing or providing a rod of ferromagnetic material and attaching the rod to an attachment arm belonging to the armature, after the armature is provided or manufactured. Preferably, the shaping comprises forming the support arm and the attachment arm in a mold, so that the support arm and the attachment arm are formed as a single piece.

[0019] Preferably, the attachment of the rod comprises snapping the rod to the attachment arm using complementary snap means belonging to the rod and to the attachment arm.

[0020] Preferably, the rod attachment comprises positioning the rod piece on the attachment arm and screwing a snap-riveting pin belonging to the attachment arm through a snap-riveting hole of the rod; and attaching the rod thus positioned on the attachment arm by melting the snap-riveting pin.

[0021] The present application also relates to an electrical component, which can be obtained by the manufacturing method defined above, comprising an armature formed of a material comprising a polymer plastic and an organic metal additive, the armature comprising a support arm extending along a guide trajectory. The electrical component further comprises a winding directly formed on a surface of the support arm by a conductor track forming turns of the winding, the turns of the winding being distributed along and encircling the guide trajectory.

[0022] Preferably, the electrical component according to the present application is obtained by using the manufacturing method described above.

[0023] As a variant, the electrical component manufactured with the method described above is an antenna, instead of a current sensor. For this variant, the winding is configured to be apt to radiate and / or capture electromagnetic waves. In this case, the electrical component can be integrated into a radio system. BRIEF DESCRIPTION OF DRAWINGS

[0024] The application will be better understood by reading the following description of embodiments thereof, given only by way of example and without limitation with reference to the appended drawings.

[0025] Figure 1 is an exploded perspective view of an electrical component according to a first embodiment of the application.

[0026] Figure 2 is a perspective view of the electrical component shown from another angle. Figure 1

[0027] Figure 3 schematically shows Figure 1 and Figure 2 different steps of the manufacturing process of the electrical component.

[0028] Figure 4 ​This is a perspective view of electrical components according to a second embodiment of the present invention.

[0029] Figure 5 This is an exploded perspective view of electrical components according to a third embodiment of the present invention.

[0030] Figure 6 This is an exploded perspective view of electrical components according to a fourth embodiment of the present invention.

[0031] Figure 7 This is a perspective view of an electrical component according to a fifth embodiment of the present invention. Detailed Implementation

[0032] according to Figures 1 to 3 In the illustrated embodiment, the electrical components include an armature 1, two windings 2, and two rods 3. Using reference numerals, these include a longitudinal direction X1, a transverse direction Y1, and a height direction Z1, which are mutually perpendicular and fixed relative to the armature 1.

[0033] like Figures 1-3 The component shown preferably constitutes a current sensor. The value of the current flowing through the conductor 6 (essentially parallel to direction Z1) via the guide trajectory L7 (in the form of a closed loop, inscribed in a plane parallel to directions X1 and Y1) defined by the component can be determined by the component, and the voltage induced at the terminals of the component is a function of the magnetic flux along the opening 7 in direction Z1. In practice, the armature 1 defines the opening 7 of the component in the same plane as the guide trajectory L7, which is surrounded by the guide trajectory L7 through which the conductor 6 can pass. Preferably, the component is a Rogowski sensor, and the induced voltage depends on the change in current flowing through the opening 7.

[0034] This component is preferably mounted on a printed circuit board (not shown) using an armature 1, the printed circuit board extending below the component parallel to directions X1 and Y1. This component is used to connect to electronic systems for sensors, including conditioning electronics, for example, in the form of an integrating circuit.

[0035] This component, particularly armature 1, measures, for example, about 25 mm in the Y1 direction and about 15 mm in the X1 direction. More generally, the length of the component described herein is advantageously less than 50 mm and the width is less than 40 mm.

[0036] The armature 1 is preferably formed by forming a single component consisting of a single part made of exactly the same material (i.e., integrally).

[0037] The material comprises a polymeric plastic material, which is preferably a thermoplastic resin, such as polycarbonate (PC), which is relatively easy to injection mold, or a liquid crystal polymer (LCP), which is particularly resistant to heat, which is recommended when soldering on printed circuit boards is contemplated. The material further comprises an organic metal additive, which is integrated into the polymeric plastic material, which is at least distributed over the skin of the armature, even at the core. The organic metal additive, in a non-activated state, is electrically conductive. Thus, the armature 1 is electrically non-conductive and magnetically non-active, except for any activated portion of the organic metal additive, as described below.

[0038] As shown in Figure 1 and Figure 2 structurally, the armature 1 extends along a guide trajectory L7, advantageously having the overall shape of a closed loop, or more generally having a toroidal shape, which defines an opening 7 therethrough at its center. The armature 1 comprises two support arms 4 and two attachment arms 5. In the present example, the two support arms 4 are arranged opposite each other on either side of the opening 7 so as to delimit the opening. Each support arm 4 extends herein parallel to a direction X1. The two attachment arms 5 are arranged opposite each other in front of the opening 7 so as to delimit the opening. Each attachment arm 5 extends parallel to a direction Y1. Each attachment arm 5 extends herein parallel to the direction Y1. Each attachment arm 5 connects, by its end, one end of an arm 4 to the other end of the arm 4. In other words, along the trajectory L7, around the conductor 6, the arms 4 and the arms 5 alternate. For the example shown in Figure 1 and Figure 2 each arm 4 and arm 5 has a rectilinear shape or a curvilinear shape for rotation around the conductor 6.

[0039] Each support arm 4 is designed to receive one of the windings 2, while each attachment arm 5 is designed to receive one of the bars 3. In Figure 1 , one bar 3 is shown detached from the armature 1, while the other bar is shown in assembly.

[0040] Each winding 2 is formed directly on a surface of the relevant support arm 4.

[0041] In particular, along the trajectory L7, each support arm 4 has a radially outer surface 12, i.e. a surface in the form of a handle around the trajectory L7. At each axial end of said radially surface 12, i.e. at each axial end of said arm 4, said arm 4 comprises a respective axial surface 13, i.e. an end face. In this regard, the winding 2 is formed only on the radially surface 12, while the two axial surfaces 13 are free of winding.

[0042] Each winding 2 is composed of a respective conductor track 10, i.e. electrically conductive with respect to the material forming the armature 1, which is electrically insulating. Thus, Figure 1 and Figure 2The illustrated component comprises two distinct tracks 10, each track forming a separate coil 2. Each conductor track 10 is formed on a surface of the support arm 4 that carries the conductor track, here on a radial surface 12. Due to the very thinness of each conductor track 10, a portion of one of the conductor tracks is in the radial direction X1, as shown in the detail view D. Figure 1 is shown on a larger scale in the detail view D.

[0043] Due to the electrical component comprising one or more conductor tracks 10 formed on an armature 1 made of a polymer plastic, the electrical component can be considered a molded interconnect device component, or a molded interconnect device sensor.

[0044] In terms of structure, the conductor tracks 10 form a continuous flat wire, preferably without branches, laid flat on the outer surface of the arm 4. The conductor tracks 10 are wound helically on the arm 4, forming a series of turns, forming a winding 2. The turns are distributed in succession along a trajectory L7, preferably in a regular manner. Each turn encircles a portion of the trajectory L7. In other words, the turns here are distributed parallel to the direction X1, while each turn is preferably approximately inscribed in a plane parallel to the directions Y1 and Z1. Since the tracks 10 are formed directly on the surface of the arm 4, the shape of the radial surface 12 determines the cross-sectional geometry of each turn, and thus the envelope of the winding 2. In particular, for each turn, the cross section of the turn corresponds to the outer profile of the cross section of the arm 4. Here, each arm 4 advantageously has a tubular shape, or more generally a block shape, encircling the trajectory L7. Thus, the winding 2 is a block in the directions Y1 and Z1, making it possible to easily form turns with a large cross-sectional area and an arbitrary shape. Turns with a circular or elliptical cross section can advantageously be formed, as is the case in the example shown. Alternatively, it is also possible to form turns with a square or rectangular cross section, or any other shape of cross section desired, by modifying the shape of the arm 4, in particular the radial surface 12 of the arm.

[0045] By the manufacturing method described below, the track width L10 of the tracks 10 can advantageously be less than 400 pm (micrometers), even less than 200 pm. The pitch P10 of the winding 2, i.e. the distance connecting one turn to another, is advantageously less than 400 pm, even less than 200 pm. Thus, it is possible to obtain a very high density of turns along the trajectory L7, for example several turns per millimeter, as well as a very precise layout of the conductor tracks 10. By contrast, by providing a support arm with an arbitrary shape, it is possible to make the cross section of the winding 2 very large. In particular, the diameter or other characteristic dimension (such as the diagonal) of the cross section of the winding 2 can be greater than 3 mm (millimeters), for example 5 millimeters, even greater than 5 millimeters, for example the circumference of each turn can be about 20 millimeters. The length of each winding 2, measured along the trajectory L7, can be comprised between, for example, 5 and 15 millimeters.

[0046] Preferably, the support arms 4 form a non-magnetic core for the windings 2. If the support arms 4 have a tubular shape, as shown in Figure 1 and Figure 2 the amount of air contained in the tube further has the function of non-magnetic core.

[0047] Preferably, in order to form the magnetic circuit along the guiding trajectory L7, the turns of the two windings 2 are oriented in the same direction along and around the trajectory L7, i.e. in the positive direction, i.e. in the direction of rotation. As a result of the above, for example, a turn of one of the windings 2 is oriented in the positive direction with respect to the direction X1, while a turn of the other winding 2 is oriented in the positive direction with respect to the direction opposite to the direction X1.

[0048] Each rod 3 is made of ferromagnetic material, for example soft iron. Each rod 3 forms a piece fitted on the armature 1, unlike the windings 2 integrated in the armature.

[0049] Each rod 3 is advantageously in the form of a blade, extending parallel to the direction Y1. The rod 3 comprises two axial ends 14 and a central portion 15 connecting the two axial ends 14. At its two ends 14, the rod 3 is in mechanical contact with one axial surface 13 of one of the arms 4, parallel to the direction X1, i.e. locally perpendicular to the trajectory L7. Thus, each rod 3 connects an axial end of a first winding 2 with an end of the other winding, without electrical contact with the tracks 10 forming the windings 2 respectively, but as close as possible to reduce the air gap. In this way, along the trajectory L7, a toroidal magnetic circuit is obtained, formed alternately by the windings 2 and the rods 3. In operation, the magnetic field lines extend along the trajectory L7.

[0050] Each attachment arm 5 can serve both to support a support arm 4 and to support one of the rods 3.

[0051] In order to support the support arms 4 in a fixed manner with respect to each other, each attachment arm 5 comprises a yoke 11 structurally connecting an end of one of the arms 4 to an end of the other support arm 4. With the arms 4, the yoke 11 delimits an opening of the electrical component. Each yoke 11 advantageously extends parallel to the directions Y1 and Z1. Each yoke is mechanically attached to two support arms. For each arm 4, the yoke 11 is attached to an axial end of the arm 4, or more generally to a region of the arm 4 not comprising a winding 2. Preferably, as shown in Figure 1 and Figure 2 the position occupied by the axial end of the arm 4 to the yoke 11 is as small as possible, so as to leave as large as possible the axial surface 13 in contact with the rod 3.

[0052] Each attachment arm 5 advantageously comprises a base 20 extending parallel to the directions X1 and Y1, so that the bases 20 of the two arms belong to the same plane. Each base 20 is connected to the yoke 11 by a longitudinal edge of said yoke 11, which extends parallel to the direction Y1. The yoke 11 and the arm 4 are both arranged in the same plane comprising the trajectory L7, the base 20 being arranged in a parallel plane, offset with respect to the plane of the trajectory L7.

[0053] To position the rod 3 along the direction X1 on the armature 1, it is advantageous to rest the end portions 14 against the surfaces 13 of the support arm 4 and / or to rest the central portion 15 of the rod 3 against the yoke 11. The rod 3 is spaced apart from the opening 7 by the yoke 11.

[0054] To position the rod 3 along the direction Z1 on the armature 1, it is advantageous to rest the longitudinal edges 17 of the rod 3 against the bases 20 of the arms 5 that receive the rod 3.

[0055] To position the rod 3 along the direction Y1 on the armature 1, the attachment arms 5 and the rod 3 advantageously form a stop comprising a pin 16 formed by the yoke 11 here outside the opening 7 at the intersection between the base 20 and the yoke 11, and a notch 19 formed here by the longitudinal edges 17 of the rod 3. The positioning of the rod is provided by the reception of the pin 16 within the notch 19.

[0056] Optionally, the positioning of the rod 3 parallel to the direction Y1 is provided at least partially by a shape match between the rod 3 and the yoke 11 of the arm 5. As Figure 1 and Figure 2 indicated, the rod 3 advantageously has an arched shape, with the central portion 15 extending in a first plane parallel to the directions Y1 and Z1, the end portions 14 each extending in a same second plane parallel to the directions Y1 and Z1, the planes of the end portions 14 being offset with respect to the plane of the central portion. The yoke 11 cooperates with this particular shape to position the rod 3 parallel to the direction Y1.

[0057] To attach the rod 3 to the armature 1, said arms 5 comprise a snap lug 18, for example two lugs 18. Here, the snap lugs 18 are each matched with one of the end portions 14 of the rod 3. To this end, the lugs 18 are carried at the longitudinal ends of the base 20, each lug 18 extending along the direction Z1 so as to be opposite one of the surfaces 13. The pin 16 is thus arranged between the two lugs 18. Each end portion 14 advantageously comprises a recess 21 for receiving a protrusion forming a hook, carried by the end of the lug 18. Once snapped, the rod 3 is captured parallel to the direction Z1 between the base 20 and the hooks of the lugs 18, the hooks of the lugs being received in the recesses 21. The lugs 18 and the recesses 21 are an example of snap match formed by the rod 3 and the arm 5.

[0058] Therefore, attaching the rod 3 to the armature is particularly easy, because the rod 3 can be moved relative to the armature 1 in the opposite direction to the direction Z1 and slide along the arm 5 onto the rod 3 until the pin 16 is received by the notch 19 and the lug 18 is engaged in the groove 21.

[0059] Figure 1 and Figure 2 The arrangement of the means for positioning and attaching rod 3 in the example shown advantageously allows the arms to have multiple symmetries, which makes them interchangeable if desired, particularly beneficial for the manufacture of electrical components. For example, rod 3 is symmetrical with respect to a plane parallel to directions X1 and Y1, so each rod 3 includes two symmetrical longitudinal edges 17, each longitudinal edge 17 having a symmetrical notch 19. For example, rod 3 is symmetrical with respect to a plane parallel to directions X1 and Z1, so the ends 14 are interchangeable.

[0060] Preferably, the armature 1 further includes a foot 23, in Figure 2 This can be seen more clearly in the image. Preferably, four feet 23 are provided. Here, each foot 23 is formed to protrude from one of the attachment arms 5, particularly from the base 20, while being oriented in a direction opposite to direction Z1. Each foot 23 is advantageously attached individually to the arm 5 supporting it. Each arm 5 includes, for example, two feet 23 at its longitudinal end. Advantageously, for the same arm 5, the feet are distributed parallel to direction Y1. For two opposing arms 5, advantageously, the feet are distributed in pairs, each pair of feet 23 parallel to direction X1. Preferably, each pair of feet 23 is aligned with one of the windings 2.

[0061] The electrical component is advantageously designed to be placed on a printed circuit board by means of the attachment arm 5, and more precisely, the base 20, by resting on the four feet 23.

[0062] Preferably, each winding 2 is electrically connected to the circuit of the printed circuit board via the two legs 23. More precisely, each winding 2 has two ends, forming two terminals of the winding 2. For each end of the winding 2, a corresponding auxiliary conductor track 24 advantageously connects one end of the winding 2 to the leg 23. Preferably, on the surface of the armature 1, said tracks 24 have the same properties as said conductor tracks 10 of said windings 2 and are obtained and manufactured in the same way, simultaneously. Electrically, the two windings are advantageously connected in series to each other and to the circuit for processing the signals emitted thereby. This connection is preferably made through the electronic circuit board. Advantageously, the connections of the coils 2 and of any return tracks can be foreseen to be made directly on the electronic circuit board. In particular, for each winding 2, a corresponding return track is provided, which extends in the plane of the printed circuit board following the guiding trajectory L7 below the winding 2 concerned. Here, at least a portion of each return track is rectilinear and parallel to the direction X1, extending from one axial end to the other axial end of the winding 2 below the winding 2 concerned. Thus, the first winding 2, the first return track, the second return track and the second winding 2 are connected in series to each other.

[0063] Preferably, the armature 1 further comprises studs 22, which can be seen more clearly in Figure 2 . Here, each stud 22 projects integrally from one of the attachment arms 5, in particular from the base 20 opposite the yoke 11. Each stud 22 projects in a direction opposite to the direction Z1. Each stud 22 can advantageously be used to position and / or attach electrical components on the printed circuit board, in particular along the directions X1 and Y1, which comprises for example a corresponding hole for receiving the stud 22. To this end, the studs 22 are advantageously arranged on the same plane parallel to the directions X1 and Y1 and oriented in the same direction, here in the direction opposite to the direction Z1.

[0064] Figure 1 and Figure 2 the manufacturing method defined below and Figure 3 the manufacturing method defined below.

[0065] In essence, the manufacturing process successively comprises Figure 3 the supply or manufacture of the armature 1, as illustrated in block A, followed by Figure 3 the laser engraving of the armature 1, as illustrated in blocks B and C, followed by the chemical treatment of the armature 1, including metallization (not shown), followed by Figure 3 the assembly of the rod 3 on the armature 1, as illustrated in block D.

[0066] The manufacture of the armature 1 preferably comprises the molding of the armature 1 by injection of a material into a mold, while this material is in a viscous state. One of the mold cavities 30 is as illustrated in Figure 3Frame A schematically shows that, while knowing that the mold advantageously comprises another mold cavity and preferably a core, in particular for producing the tubular shape of the support arms 4. The mold is configured to shape all the parts of the armature 1, i.e. in particular the arms 4 and 5, the feet 23 and the studs 22, in one molding operation.

[0067] As Figure 3 shown, for the mold cavity 30, the mold preferably comprises a chamber 31, a chamber 32, a chamber 33 and a chamber 34, the chamber 31 and the chamber 32 being designed to shape each of the support arms 4, the chamber 33 and the chamber 34 being designed to shape one of the attachment arms 5, respectively. As for the armature 1, the mold has an annular shape around an axis parallel to the direction Z1. Thus, the chamber 31 connects the chambers 33 and 34, the chamber 32 connects the chambers 33 and 34, the chamber 33 connects the chambers 31 and 32, the chamber 34 connects the chambers 31 and 32.

[0068] In the present case, the mold cavities comprising the mold cavity 30 are closed parallel to the direction Z1. Thus, the mold cavity 30 forms the bottom side of the armature 1, here comprising the studs 22, the feet 23 and the base 20, while another mold cavity (not shown) forms the top of the armature 1.

[0069] The mold also comprises two openings 35 and 36 for injecting material into the mold, which are provided in the present case in the mold cavity 30. In the present case, the opening 35 directly accesses the chamber 33, the opening 36 directly accesses the chamber 34. More generally, it is preferable that each opening of the mold accesses a chamber forming one of the attachment arms 5, or at least a chamber not forming one of the support arms 4, the radial surface 12 of which must have a perfect state, the structure of which must withstand laser engraving. Advantageously, said openings 35 and 36 form said studs 22 of said armature 1. Indeed, the studs 22 are a part of the armature 1 for which the requirements in terms of production precision and mechanical properties are less demanding, the quality of which is less critical, in particular with respect to the support arms 4.

[0070] In order to make the obtained studs 22 easy to use as a means of positioning components on a printed circuit board, advantageously, the openings 35 and 36 are arranged on a same plane parallel to the directions X1 and Y1, and in a same orientation, here parallel to the direction Z1, while being carried by the same mold cavity 30.

[0071] From the annular arrangement of the chambers 31 to 34, it results that the chamber 33 communicates with the opening 36 along a first direction only through the chamber 31 and the chamber 34. Along a second direction, said chamber 33 communicates with said opening 36 only through said chamber 32 and said chamber 34. The opening 35 directly accesses the chamber 33. Similarly, said chamber 34 communicates along a first direction with said opening 35 only through said chamber 32 and said chamber 33. Along a second direction, said chamber 34 communicates with said opening 35 only through said chamber 31 and said chamber 33. The opening 36 directly accesses the chamber 34.

[0072] At the time of molding, since the mold is of annular shape, it is provided to inject the material through two openings 35 and 36, which are opposite to each other, to obtain a correct distribution of the material in the mold. A first portion 37 of the material is injected through the opening 35, while a second portion 38 of the material is injected through the opening 36, simultaneously with the injection of the first portion 37.

[0073] As shown in Figure 3 As shown in block A, the injection of the portion 37 of material causes the partial intrusion of the portion 37 into the cavity 33, the complete intrusion of the portion 37 into the cavity 31, and the partial intrusion of the portion 37 into the cavity 34. One of the two support arms 4 is completely formed by the portion 37 of material in the cavity 31. The injection of the portion 38 of material causes the partial intrusion of the portion 38 into the cavity 34, the complete intrusion of the portion 38 into the cavity 32, and the partial intrusion of the portion 38 into the cavity 33. The other support arm 4 is completely formed by the portion 38 of material in the cavity 32. One of the studs 22 is shaped by the opening 35 and is completely formed by the portion 37 of material. The other stud 22 is shaped by the opening 36 and is completely formed by the portion 38 of material.

[0074] Each portion 37 and 38 of material extends into the cavities 33 and 34, where the portions 37 and 38 meet. Therefore, each cavity 33 and 34 acts as a joining cavity between the portions 37 and 38 of material. In the cavity 33, the joining between the portions 37 and 38 of material occurs at a welding plane 39. In the cavity 34, the joining between the portions 37 and 38 of material occurs at a welding plane 40. Therefore, each arm is formed by the combination of the two portions 37 and 38 of injected material. The armature 1, and in particular the arms 4 and 5, is integrally formed with the same material injected at the same time in the same mold, although in two portions 37 and 38.

[0075] More generally, the mold is advantageously configured so that the possible welding planes 39 and / or 40 are formed outside the cavities 31 and 32, for example inside the cavities 33 and / or 34. Therefore, in the finished armature 1, the possible welding planes are located outside the support arms 4, which offers the same production resistance and precision for the subsequent operations aimed at forming the tracks 10. In the present case, the possible sealing surface is formed at the attachment arm 5, the quality of which is less critical than that of the support arms 4.

[0076] Once the armature 1 has been manufactured according to the method described above, the armature 1 is engraved with a laser, as shown in Figure 3 blocks B and C. In particular, for each support arm 4, a corresponding priming track is engraved with the laser, which subsequently serves as a basis for forming the conductor track 10 of the support arm 4. If it is desired to produce the auxiliary conductor track 24 described above, a corresponding auxiliary priming track is also formed at this step, in the same way as the priming track for forming the conductor track 10.

[0077] The material of the armature 1 is specifically designed for forming the priming tracks 50 by laser engraving, for example using any appropriate laser engraving machine 51. The term "laser engraving machine" refers to a device comprising a light source of a laser beam, means for directing the laser beam, for example a set of directable mirrors, and means for focusing the laser beam, for example a set of lenses.

[0078] The local use of the laser on the surface of the material results in the formation of the priming tracks 50, which can be drawn in any desired layout using the laser. The priming tracks 50 differ from the rest of the surface of the armature 1 in that they consist of activated parts of the organometallic additive, whereas the organometallic additive is in a non-activated state for the rest of the armature 1. In addition, the priming tracks differ from the rest of the surface of the armature 1 in that they form grooves, or at least in that they have a more abrasive surface condition.

[0079] Preferably, the organometallic additive is formed from a metal complex comprising a metal core, for example a copper core, which is covalently bound to the polymeric plastic material in the non-activated state. This organometallic additive is susceptible to selective activation on the surface of the armature by the local and selective application of appropriate laser radiation, for example pulsed infrared laser radiation. To activate the organometallic additive, the laser radiation breaks the complex, releasing the metal core only where it is irradiated. More precisely, the laser causes reduction of the metal in the complex, and then the core becomes in metallic form, here metallic copper. In addition, the laser radiation locally heats the surface of the material and causes a local increase in surface roughness by partial ablation of the polymeric plastic material.

[0080] For each arm 4, the laser engraving aims to form priming tracks 50 on the arm 4 so that the priming tracks 50 have exactly the same layout as the conductor tracks 10 to be formed. Thus, for each arm 4, the priming tracks 50 are provided on the outer surface of the arm 4, in particular only on the radial surface 12. The priming tracks 50 are helically wound around the arm 4 so as to form successive turns which will form the winding 2 in a subsequent step of the process.

[0081] To carry out the laser engraving, two successive sub-steps are preferentially performed, respectively as shown in blocks B and C.

[0082] Each support arm 4 is divided into a side 52 and a side 53, which are opposite and adjacent on either side of the guide trajectory L7, respectively. The side 52 forms a part of the surface 12, for example half, while the other side 53 forms another part of the surface 12. The combination of the side 52 and the side 53 forms the entire surface 12. For example, the two sides are separated by a median plane 4 of the arm (parallel to the directions X1 and Y1).

[0083] First, as shown in block B, the armature 1 is positioned so that the side 52 is oriented facing the laser engraver 51. In other words, the armature 1 is arranged so that the side 52 can be engraved by the laser engraver 51. In this orientation, the laser engraving of the first portion 54 of the priming track 50 is performed only on the first side 52. The portion 54 thus engraved begins to form all the turns of the priming track 50 by forming only the first portion of each turn, while the second portion of the turn remains to be engraved. The half-turn is engraved on the side 52 of the arm 4, as shown in block B. Once the side 52 is engraved, the armature 1 is repositioned so that the side 53 is oriented facing the laser engraver 51. The second portion 55 of the priming track 50 can then be engraved on the side 53, thus completing the first portion 54, as shown in block C. The second portion 55 occupies the side 53 and consists in forming, for each turn, a portion that matches the portion formed by the first portion 54. The combination of the two portions 54 and 55 thus forms the entire priming track 50.

[0084] The auxiliary priming track is also formed in one of the steps, for example when the armature is in the position shown in block C.

[0085] To change from the side 52 to the side 53, it is preferable to turn the armature 1 over, for example by a human or robotic arm, while the position of the laser engraver 51 is not changed, except for a simple orientation of the laser beam used to draw the guide track 50.

[0086] Preferentially, once the laser engraving is performed, the armature 1 is cleaned to remove any debris resulting from this operation.

[0087] The engraved priming track 50 and any possible auxiliary priming track are not sufficiently conductive to make the electrical components work. The armature 1 is thus subjected to a chemical treatment in order to grow the conductor tracks.

[0088] Said chemical treatment first comprises a metallization of the priming track 50 to form the conductor tracks 10 and any auxiliary conductor tracks 24 directly on the surface of the armature 1. The metallization causes the growth of the priming track, while the rest of the surface of the armature 1 remains electrically insulating.

[0089] The term "metallization" refers to a catalytic metallization for example. The armature carrying the initiation track is immersed in a solution containing metal ions of a metal, which is intended to form the conductor track, for example copper. The solution comprises a metal salt containing metal ions, here copper ions, and a reducing agent for reducing the metal ions. By means of an oxidation-reduction reaction, the metal of the metal ions is deposited only on the initiation track, which is a catalyst for the oxidation-reduction reaction, and not on the rest of the surface of the armature 1. The metal layer deposited by this process is a catalyst for depositing more metal by means of an oxidation-reduction reaction. In this way, the conductor track grows by metallization. Mechanically, the conductor track thus formed is firmly attached to the polymer plastic material by mechanical anchoring to the protrusions formed by the abrasive properties of the surface of the armature 1 (as a result of the laser engraving).

[0090] Preferably, once the conductor track has been formed by metallization, the chemical treatment comprises depositing a finishing layer for protecting the conductor track. For this purpose, the ENIG (electroless nickel immersion gold) process is used for example. For this purpose, a nickel-phosphorus layer is first applied on the free face of the conductor track (i.e. the face opposite the surface of the armature 1) by means of a catalytic metallization. This catalytic metallization is advantageously performed after the copper conductor track has been activated with palladium. Then, an external gold layer is applied, for example by chemical transfer. The gold layer prevents oxidation of the coated conductor track, while the phosphorus-nickel layer prevents migration of the gold to the copper.

[0091] At the end of the chemical treatment forming the conductor track, the rod 3 is attached to the armature 1, i.e. the attachment arm 5, as shown in Figure 3 Once the armature 1 has been molded and coated with the conductor track, the rod is attached here by snap-on using the snap-on lug 18. In the present example, in order to perform this attachment, the rod 3 is slid onto the arm 5 by moving it relative to the armature 1 in a direction opposite to the direction Z1, until the pin 16 is received by the notch 19 and the lug 18 snaps into the groove 21.

[0092] Advantageously, the part is then polished.

[0093] In a variant, it is possible to provide a single support arm 4 which can carry the winding 2, without any additional arm 5, and therefore without any rod, the support arm 4 and its winding 2 extending over the whole or most of the guiding trajectory L7. In this case, the single support arm 4 and its winding will have the shape of a ring, or at least the shape of a "C". As a variant, the single support arm 4 carries a single winding 2, the single additional arm 5 carries a single rod 3, the additional arm 5 being connected between the two ends of the support arm 4. As a variant, it is possible to provide more than two support arms 4, carrying as many windings 2, and if appropriate, more than two additional arms 5, carrying as many rods 3. Advantageously, along the guiding trajectory L7, two successive support arms 4 are separated by an additional arm 5 carrying a rod 3, each support arm carrying a respective winding 2. However, it is possible to provide two immediately successive support arms 4, each carrying a respective winding 2.

[0094] Figure 4 The electrical components of the embodiments shown and the method of manufacturing them are identical to those of the Figures 1 to 3 embodiments shown, except for the differences described below. In particular, Figure 4 The electrical component of the embodiments shown comprises an armature 1, two windings 2, carried respectively by two support arms 4 of the armature 1, and two rods 3, carried by two additional arms of the armature 1. Figures 1 to 3 The electrical components of the embodiments shown and the method of manufacturing them are identical to those of the Figure 4 embodiments shown, except for the differences described below. In particular,

[0095] The electrical components of the embodiments shown and the method of manufacturing them are identical to those of the Figures 1 to 3 embodiments shown, except for the differences described below. In particular, Figure 4 The embodiments shown provide that each arm 5 comprises a snap lug 118 having a dual function, ensuring snap fitting and positioning of the associated rod 3 parallel to the direction Y1. Here, each snap lug 118 cooperates with a recess 121 provided for example in a corner of one end 14 of the rod 3, for snap fitting and positioning parallel to the direction Y1. There is no need to provide a groove. Each arm 5 comprises two lugs 118, carried at the longitudinal ends of the base 20, each lug 118 extending along the direction Z1. Each rod 3 has two recesses 121 corresponding to the two lugs 118. Each recess has a face parallel to the directions Z1 and X1, resting on the lug 118, so as to provide positioning parallel to the direction Y1. Each recess 121 has a face parallel to the directions X1 and Y1, which allows the rod 3 to be clamped parallel to the direction Z1 between a hook formed at the end of the lug 118 and the base 20, thus achieving snap fitting of the rod 3.

[0096] In such embodiments, the pin 16 and the recess 19 are not necessary.

[0097] To reinforce the positioning of the bar 3, the attachment arm 5 advantageously comprises a stabilizing blade 116 attached to the base 20 by protruding in the direction Z1. The blade 116 is disposed between two lugs 118 so as to come into contact with the central portion 15 of the bar 3. In this way, the central portion 15 of the bar is slipped between the blade 116 and the yoke 11 of the arm 5 so as to be captured parallel to the direction X. Preferentially, the central portion 15 of the bar 3 is clamped between the yoke 11 and the blade 116. The blade 116 takes up part of the force exerted on the bar 3 parallel to this direction, which reduces the risk of breakage of the lugs 118.

[0098] Figure 5 The electrical component of the embodiment shown and the method of manufacturing it are identical to those of the Figures 1 to 3 embodiment shown, except for the differences described below. In particular, Figure 5 The electrical component of the embodiment shown comprises an armature 1, two windings 2 carried respectively by two support arms 4 of the armature 1, and two bars 3 carried by two attachment arms of the armature 1. Figures 1 to 3 The embodiment shown is identical to that of the Figure 5 embodiment shown, except for the differences described below. In particular,

[0099] The electrical component of the embodiment shown is identical to that of the Figures 1 to 3 embodiment shown, except for the differences described below. In particular, Figure 5 The embodiment shown provides that each arm 5 comprises a retaining lug 218 instead of a snap lug 18. Each arm 5 comprises, for example, two retaining lugs 218 protruding from the base 20 in the direction Z1 at the longitudinal end of the base 20. Each end 14 of the bar 3 is positioned parallel to the direction X1 between one lug 218 and the axial surface 13 of the support arm 4, the bar 3 being slipped between the lug 218 and the axial surface 13, preferably without snapping. It is thus not necessary to provide the recess 21 or the notch 121.

[0100] In the Figure 5 embodiment shown, the bar 3 has no notch 19 and the arm 5 has no pin 16. On the contrary, said arm 5 advantageously comprises a snap lug 216 cooperating with a snap opening 219 passing through the central portion 15 of the bar 3. The snap lug 216 is advantageously disposed between the lugs 218. To have good mechanical resistance, for example, the snap lug 216 is attached to the base 20, for example, by a gate 225, but also in a similar manner to the Figure 1 and Figure 2The lugs 18, as shown, protrude directly from the base 20. A door 225, arranged between the lugs 218, further provides a similar function to the lugs 218, as the central portion 15 slides between the door 225 and the yoke 11, positioning the rod 3 parallel to direction X1. The combination of the lugs 218, the door 225, and the arched rod 3, conforming to the shape of the yoke 11, provides positioning of the rod parallel to direction Y1. A snap-fit ​​lug 216 of the arm 5 is received in the opening 219 of the rod 3, which attaches the rod 3 to the arm 5 via a snap-fit.

[0101] Figure 6 The electrical components and manufacturing method of the embodiments shown are similar to those described. Figures 1 to 3 The electrical components of the illustrated embodiment are the same, except for the differences described below. Specifically, Figure 6 The electrical components include an armature 1, two windings 2, each supported by two support arms 4 of the armature 1, and two rods 3, each supported by two attachment arms of the armature 1. Figures 1 to 3 The illustrated embodiments and Figure 6 Similar elements in the illustrated embodiments use the same reference numerals.

[0102] and Figures 1 to 3 The embodiments shown are different. Figure 6 The illustrated embodiment does not provide any snap-fit ​​for rod 3, but rather provides attachment to the rod via a rivet, as described below. This simplifies the design of rod 3 and arm 5. On the other hand, the material of armature 1 must be compatible with the rivet, i.e., it must be remeltable. It should be specified, for example, that the polymeric plastic material of armature 1 or at least arm 5 is thermoplastic.

[0103] like Figure 6 As shown, rod 3 does not have groove 21 and notch 19. Rod 3 preferably has a rivet hole 319 passing through its central portion 15, which passes through rod 3 parallel to direction X1.

[0104] like Figure 6 As shown, arm 5 does not have lug 18 and pin 16. Arm 5 preferentially protrudes from yoke 11 parallel to direction X1, and rivet 316 matches the hole 319. In addition to positioning rod 3 using base 20 and yoke 11, rod 3 is positioned on rivet 316 parallel to direction X1 using rivet hole 319.

[0105] In order to assemble rod 3 onto armature 1, for Figure 6 In the embodiment shown, the rod 3 slides onto the pin 316, which is received in the hole 319 of the rod 3, and at the same time positions the rod 3 on the arm 5 of the armature 1. For example, the edge 17 of the rod is guided by the base 20, and the rod 3 rests against the yoke 11.

[0106] The thus positioned bar 3 is then attached to the attachment arm 5 by swage, which involves heating the pin 316, causing a local melting of the armature material, so as to form a neck at the end of the pin 316. Once the pin 316 has solidified with its neck, the bar 3 is clamped between the neck and the yoke 11 parallel to the direction X1. The bar 3 is then permanently attached to the armature 1.

[0107] The advantage of this method of attaching the bar 3 is that the connection between the bar 3 and the armature 1 is very resistant and irreversible, and the bar 3 can have the same symmetry as the Figures 1 to 3 embodiment shown, so that, during the manufacturing process of the component, the bar can be mounted indifferently on one side or the other of the armature 1.

[0108] The manufacturing method described for the Figures 1 to 6 embodiment shown can be applied to an electrical component of the Figure 7 embodiment shown. This electrical component comprises two windings 402 and an armature (not shown).

[0109] The reference signs comprise a longitudinal direction X401, a transverse direction Y401 and a height direction Z401, which are perpendicular to each other and relative to the Figure 7 armature of the electrical component.

[0110] Figure 7 The component shown is preferentially a current sensor. The value of the current of a conductor 406 can be determined using the electrical component when the conductor passes through a guide trajectory L407 defined by the component, this trajectory having the shape of a closed loop, here a circle, centered on an axis Z406 parallel to the direction Z401. In practice, the armature of the component defines an opening 407 of the component in the same plane as the guide trajectory L407 and surrounded by the guide trajectory L407, through which the conductor 406 can be fitted, parallel to the directions X401 and Y401. Preferentially, this component is a Rogowski sensor, the induced voltage depending on the varying value of the current passing through the opening 407.

[0111] The component is intended to be connected to an electronic system for the sensor, including conditioning electronics, for example in the form of an integrating circuit.

[0112] The armature is a single-piece ring, following the trajectory L407 around the axis Z406, forming a circular crown, of exactly the same material as the armature 1 described above.

[0113] The component has a symmetrical structure relative to a plane P406 comprising the axis Z406 and parallel to the direction Y401.

[0114] The armature comprises two support arms. The armature has no attachment arms, and the component does not comprise any bar.

[0115] For the Figure 7In the illustrated embodiment, the first support arm forms a first portion, here half of the armature, which extends along a trajectory L407 on a first side of the plane P406. The other support arm extends symmetrically on the other side of the plane P406. Thus, each support arm has the shape of a portion of a crown. In the present case, each support arm has a square cross-section, but any desired cross-sectional shape can be provided. The support arms are connected to each other by their two ends, so that the armature has a closed loop shape around the axis Z406.

[0116] Each support arm receives one of the windings 402, which is formed directly on the surface of the corresponding support arm by a corresponding conductor track 410. Thus, the component comprises two different tracks 410, each of which forms a winding 402 separate from the other winding 402. The production method for each conductor track 410 is identical to that of the conductor tracks 10 in the component illustrated. In particular, for each winding 402, laser engraving of initiation tracks is carried out on the relevant support arm to map out the layout of the future conductor track 410. The armature is then metallized so as to form the two conductor tracks only at the locations of the two initiation tracks engraved on the support arm. Figures 1 to 6

[0117] Each conductor track 410 is wound helically around its corresponding support arm, so as to form successive turns, which form the relevant winding 402. The turns are distributed in succession along the trajectory L407, preferably in a regular manner. Each turn encircles a portion of the trajectory L407, so that each turn 402 extends over the entire portion of the trajectory which extends on the same side of the plane P406. Since each track 410 is formed directly on the surface of the corresponding support arm, it is profiled to the cross-section of the support arm, here square, which determines the geometry of the cross-section of each turn, and thus of the envelope of the winding 402.

[0118] In the present case, the turns of the two windings 402 are oriented in opposite directions. The turns of one of the windings 402 are oriented, for example, in the positive direction along the trajectory L407, while the turns of the other winding are oriented in the indirect direction. Preferably, each support arm forms a non-magnetic core for its winding 402.

[0119] The component also comprises means for electrically connecting the windings 402. The first winding 402 has a terminal 491 and a terminal 492, located at the two ends of the winding 402, on the plane P406. The second winding 402 has a terminal 493 and a terminal 494 at the plane P406. These different terminals 491 to 494 are preferably intended for connection and wiring by means of tracks of a printed circuit board, on which the component is designed to be positioned.

[0120] ​A terminal 491 is provided, for example, for forming a first terminal of a component connected to a signal processing circuit. Said terminal 492 is connected to a first return track formed on said printed circuit board, said first return track following the guide track L407 under the winding 402 carrying the terminal 492 in the opposite direction to the winding, until reaching a terminal 493, so that the first return loop connects the first winding 402 in series to the second winding 402. A terminal 494 is connected to a second return track formed on the printed circuit board, the second return track following the guide track L407 under the winding 402 carrying the terminal 494 in the opposite direction to the winding 402, symmetrically to the first return track with respect to the plane P406. The other end of the second return track forms a second terminal of said component. The first winding 402, the first return track, the second winding 102 and the second return track are thus connected in series with each other.

[0121] A manufacturing method for manufacturing Figure 7 The component shown, comprising the supply or manufacture of the armature, preferably by molding, then laser engraving of the support arms of the armature in order to form the initiation tracks according to the layout of the future windings 402, and finally a chemical treatment comprising the metallization of the initiation tracks in order to grow the conductor tracks 410 forming the windings 402. In particular, as in the case shown in boxes B and C, by inverting the component, the laser engraving Figure 3 Figure 7 The armature of the embodiment shown can be carried out in two steps.

[0122] Any of the features described above for one embodiment or variant can be implemented for other embodiments and variants described above.​

Claims

1. A method of manufacturing an electrical component, the electrical component comprising: • an armature (1) composed of a material comprising a polymeric plastic material and an organic metal additive, the armature (1) comprising a support arm (4) extending along a guide trajectory (L7; L407); • a winding (2; 402) directly formed on a surface of the support arm (4) by conductor tracks (10; 410) forming turns of the winding (2; 402), the turns of the winding being distributed along and encircling the guide trajectory (L7; L407); the manufacturing process comprising in sequence: • providing or manufacturing the armature (1); • laser engraving the support arm (4) for engraving initiation tracks (50) forming the turns of the winding (2; 402), at which the organic metal additive is locally activated; • metallizing the initiation tracks (50) with an electrically conductive metal to directly form the conductor tracks (10; 410) on the surface of the support arm (4) from the turns formed by the initiation tracks (50).

2. The manufacturing method according to claim 1, wherein: • the support arm (4) comprises a first side (52) and a second side (53) opposite and adjacent on both sides of the guide trajectory (L7; L407); • the laser engraving comprises: • laser engraving a first portion (54) of the initiation tracks (50) on the first side (52), the first portion (54) of the initiation tracks (50) forming only a first portion of the initiation tracks for each turn, and • laser engraving a second portion of the initiation tracks (50) only after the first portion (54) of the initiation tracks (50) has been engraved on the second side (53), the second portion (55) of the initiation tracks (50) forming a second portion of the turn completing the first portion of the turn for each turn.

3. The manufacturing method according to claim 2, wherein the laser engraving comprises: • positioning the armature (1) so that the first side (52) is oriented facing a laser engraving machine (51) so as to perform the laser engraving of the first portion (54) of the initiation tracks (50) by the laser engraving machine; • repositioning the armature (1) so that the second side (53) is oriented facing the laser engraving machine (51) so as to perform the laser engraving of the second portion (55) of the initiation tracks (50) by the laser engraving machine (51).

4. The manufacturing method according to any one of claims 1 to 3, wherein manufacturing the armature (1) comprises molding the armature (1) by injecting the material into a mold.

5. The manufacturing method according to claim 4, wherein: • the mold comprises: • a molding cavity (31, 32) for molding the support arm (4); • a first opening (35) for injecting a first portion (37) of the material; • a second opening (36) for injecting a second portion (38) of the material; • a connection cavity (34, 33) into which the second opening (36) opens and which communicates with the first opening (35) via the molding cavity (31, 32) of the support arm (4); • the injection molding comprises: • injecting the first portion (37) of the material through the first opening (35) into the mold so that the first portion (37) of the material: • fills the molding cavity (31, 32) of the support arm (4) and forms the first portion (54) of the initiation tracks (50) on the first side (52) of the support arm (4); and • fills the connection cavity (34, 33) and forms the second portion (38) of the material in the connection cavity (34, 33) and in the molding cavity (31, 32) of the support arm (4) via the first opening (35) and the second opening (36). a forming cavity of the support arm (4) is introduced, which is then entirely formed by the first portion of material (37); extends into the connection cavity (34, 33); a second portion of material (38) is injected into the mould through a second opening (36), so that the second portion of material (38) meets the first portion of material (37) in the connection cavity (34, 33), the armature (1) being formed by the combination of the first portion of material (37) and the second portion of material (38).

6. The manufacturing method according to claim 5, wherein the first opening (35) and the second opening (36) are arranged on the same plane and along the same orientation, so that: • the first opening (35) shapes the first stud (22) of the armature (1) by injecting the first portion of material (37); • the second opening (36) shapes the second stud (22) of the armature (1) by injecting the second portion of material (38), the first stud (22) and the second stud (22) being configured to enable the positioning of the electrical component on a printed circuit board.

7. The manufacturing method according to claim 4, wherein: • the manufacturing method comprises: manufacturing or providing a rod (3) of ferromagnetic material, and attaching the rod (3) on an attachment arm (5) belonging to the armature (1) after the armature (1) is provided or manufactured; • the moulding comprises forming the support arm (4) and the attachment arm (5) in the mould, so that the support arm (4) and the attachment arm (5) are formed integrally.

8. The manufacturing method according to claim 7, wherein the attachment of the rod (3) comprises snap-fitting the rod on the attachment arm (5) using matching snap means (18, 21; 118, 121; 216, 219) belonging to the rod (3) and the attachment arm (5).

9. The manufacturing method according to claim 7, wherein the attachment of the rod (3) comprises: • positioning the rod (3) on the attachment arm (5) by sliding a swage pin (316) belonging to the attachment arm (5) on a swage hole (319) passing through the rod (3); • attaching the thus positioned rod (3) to the attachment arm (5) by swaging by performing a melting of the swage pin (316).

10. The manufacturing method according to any one of claims 1 to 3, wherein the electrical component forms a current sensor.

11. An electrical component produced according to the manufacturing method of any one of claims 1 to 3, comprising: • an armature (1) composed of a material comprising a polymeric plastic material and an organic metal additive, the armature (1) comprising a support arm (4) extending along a guide trajectory (L7; L407); • a winding (2; 402) formed directly on a surface of the support arm (4) by a conductor track (10; 410) forming turns of the winding (2; 402), the turns of the winding being distributed along and encircling the guide trajectory (L7; L407).

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