Method for producing a winding for an inductive component, and inductive component

Abstract

The invention relates to a method for producing a winding for an inductive component, comprising the steps of: producing a planar, single-piece and electrically conductive blank, the blank comprising at least a first connection portion, a second connection portion and a strip-shaped winding portion having a constant width, and shaping the planar blank to form a winding by wrapping the winding portion around a bending die.

Description

[0001] Method for producing a winding for an inductive component and inductive component

[0002] The invention relates to a method for producing a winding for an inductive component. The invention also relates to an inductive component with a one-piece winding having a first terminal section and a second terminal section.

[0003] The invention is intended to improve a method for producing a winding for an inductive component and an inductive component with a one-piece winding.

[0004] According to the invention, a method for producing a winding for an inductive component comprises the following steps: producing a flat, one-piece and electrically conductive blank, wherein the winding blank is formed in one piece and has at least a first connection section, a second connection section and a strip-shaped winding section with a constant width, and deforming the flat blank to form a winding by wrapping a bending mold with the winding section.

[0005] In windings for inductive components, particularly windings designed for high currents, it is disadvantageous with regard to the electrical properties if the connection sections have to be connected to the winding wire, for example by soldering or welding. The connection point fundamentally has different electrical properties than the connection section and / or the winding wire. However, the mechanical and in particular fully automatic production of one-piece windings is problematic. In the method according to the invention, the winding is produced from a flat, one-piece and electrically conductive blank, wherein the blank has a first connection section and a second connection section. The connection sections serve to connect to other electrical components, for example a power supply or another electrical circuit.A strip-shaped winding section of constant width is integrally connected to the two terminal sections. This winding section has a constant width, so the finished winding has good electrical properties, since the strip-shaped winding section with constant width behaves comparable to a conventional winding wire. The strip-shaped winding section also has a constant thickness and thus a constant ohmic resistance over its entire length. The flat blank is then deformed to form a winding by wrapping the winding section around a bending die. Wrapping winding wire around a bending die is, of course, well known.Surprisingly, even with careful selection of the geometric shape of the flat blank, the strip-shaped winding section can be very easily wound around a bending die, while the terminal sections remain accessible in the finished winding. For example, the terminal sections are arranged so that they lie in a common plane and can then be soldered, for example, to solder pads on a circuit board. The method according to the invention very easily produces a winding for an inductive component, with the winding being formed as a single piece.

[0006] In a further development of the invention, in order to form a winding, the winding section is wound around a cylindrical bending form, whereby the winding section takes on the shape of a coil.

[0007] The usual form of a winding for an inductive component is a coil. Surprisingly, a coil can also be formed using a single, flat blank, if the geometric shape of the blank is appropriately designed.

[0008] In a further development of the invention, the bending form consists of magnetically conductive material and, after the winding has been formed, forms a core of the inductive component.

[0009] The core of the inductive component can thus simultaneously provide the bending shape. For example, the flat blank is coated before forming, thus providing an electrically non-conductive layer on its exterior.

[0010] In a further development of the invention, the flat, one-piece and electrically conductive blank is produced by punching out an electrically conductive sheet.

[0011] In this way, blanks can be produced in large quantities in a very simple and fully automated manner.

[0012] The problem underlying the invention is also solved by an inductive component with a one-piece winding, wherein the winding has a first terminal section, a second terminal section, and a strip-shaped winding section of constant width. The winding is produced from a flat blank by wrapping a bending die. In a further development of the invention, a core made of magnetic material is provided, which is wrapped with the winding section.

[0013] Further features and advantages of the invention will become apparent from the claims and the following description of a preferred embodiment in conjunction with the drawings. In the drawings:

[0014] Fig. 1 a flat blank for producing a winding from above,

[0015] Fig. 2 the flat cut of Fig. 1 from the side,

[0016] Fig. 3 the flat cut of Fig. 1 from above,

[0017] Fig. 4 shows a winding made from the blank of Fig. 1 from the side and

[0018] Fig. 5 shows the winding of Fig. 4 with a bending form used as the core of the inductive component.

[0019] Fig. 1 shows a flat blank 10 for producing a winding for an inductive component. The blank 10 has a first terminal section 12 and a second terminal section 14. The two terminal sections 12, 14, in the completed winding, are intended to be connected to an electrical circuit, for example, an electrical power supply or the like. Each of the terminal sections has a generally rectangular outline with a U-shaped cutout 16. The U-shaped cutout can be used, for example, to align the terminal sections 12, 14 on the completed winding with positioning pins on a printed circuit board.

[0020] Between the two connection sections 12, 14, a winding section 20 is provided, which is strip-shaped and has a constant width. Between the winding section 20 and the connection sections 12, a transition section 22, 24 is provided, wherein the side edges of the transition sections are each arranged at an angle of more than 90° to the side edges of the winding section 20. However, the side edges of the transition sections 22, 24 are arranged perpendicular to the side edges of the connection sections 12, 14, into which they merge. The transition sections 22, 24 are provided to ensure the transition from the then usually helical winding to the flat connection sections 12, 14 after deformation. The winding section 20 is arranged obliquely to the mutually facing side edges of the connection sections 12, 14. This results in an overall Z-shaped cut.The angle between the connecting sections and the length of the winding section 20 can then determine the pitch angle of the finished winding as well as the number of wraps. The terminal sections 12, 14 are wider than the winding section 20.

[0021] Fig. 2 shows a side view of the blank 20. The blank 20 has a constant thickness across its entire surface. The blank 20 is punched, for example, from a sheet of constant thickness.

[0022] Fig. 3 shows the blank 20 in a view from above.

[0023] Fig. 4 shows a winding 30 produced from the flat blank 20 by wrapping the winding section 20 around a bending form. The helical shape of the winding section 20 can be seen. It can also be seen that the connecting sections 12, 14 are arranged in the same plane and have not been deformed. The transition sections 22, 24 form the transition between the flat connecting sections 12, 14, which are arranged in a common plane, and the winding section 20, which has been deformed into a helix.

[0024] The winding 30 comprises a coil with a total of four wraps. The number of wraps can be varied by changing the length of the winding section 20 or by changing the diameter of a bending die used during the wrapping process.

[0025] Fig. 5 shows an inductive component 40 with the winding 30. A core 50 made of magnetically conductive material is arranged within the cavity formed by the winding. The core 50 is circularly cylindrical and simultaneously forms the bending shape during the production of the winding 30. For example, the terminal section 12 is held in place in a winding machine, and then the winding section 20 is wound around the core 50, which also forms the bending shape, resulting in the helical shape of the winding 30. The terminal section 14 is then arranged so that it is in a common plane with the terminal section 12.

[0026] The inductive component 40 can then be connected to solder pads on a circuit board via the connection sections 12, 14. The invention enables the fully automated production of inductive components with one-piece windings.

Claims

Claims: A method for manufacturing a winding (30) for an inductive component (40) comprising the steps of: manufacturing a planar, one-piece, and electrically conductive blank (10), wherein the blank (10) has at least a first connection section (12), a second connection section (14), and a strip-shaped winding section (20) of constant width, and deforming the planar blank (10) to form the winding (30) by wrapping a bending die with the winding section (20). A method according to claim 1, wherein, to form the winding (30), the winding section (20) is wound around a cylindrical bending die, thereby giving the winding section (20) the shape of a helix. A method according to claim 1 or 2, wherein the bending die is made of magnetically conductive material and, after forming the winding (30), forms a core (50) of an inductive component.A method according to any of the preceding claims, wherein the planar, one-piece, and electrically conductive blank (10) is produced by punching from an electrically conductive sheet. An inductive component (40) with a one-piece winding (30) comprising a first connection section (12), a second connection section (14), and a strip-shaped winding section (20) of constant width, wherein the winding (30) is produced from a planar blank (10) by wrapping it around a bending die. An inductive component according to claim 5, characterized in that a core (50) made of magnetic material is provided, which is wrapped with the winding section (20).

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