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] The invention relates to a method for manufacturing a winding for an inductive component. The invention also relates to an inductive component with a one-piece winding comprising a first connection section and a second connection section.

[0002] Chinese patent application CN 110060851 A discloses the process of punching out a blank and forming the punched-out blank into a coil.

[0003] The manufacture of a winding from strip-shaped wire with a rectangular cross-section is known from US Publication US 2018 / 366301 A1.

[0004] The manufacture of a winding from strip-shaped wire with a rectangular cross-section is known from US Publication US 2019 / 148057 A1. A longer transverse dimension of the rectangular cross-section of the winding wire lies perpendicular to the central longitudinal axis of the winding.

[0005] The invention aims to improve a method for manufacturing a winding for an inductive component and an inductive component with a one-piece winding.

[0006] According to the invention, a method with the features of claim 1 is provided for this purpose. In a method for producing a winding for an inductive component, the following steps are provided: 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 constant width, and deforming the flat blank to form a winding by wrapping a bending shape with the winding section.

[0007] In windings for inductive components, especially those designed for high currents, it is disadvantageous with regard to electrical properties if the connection sections have to be joined to the winding wire, for example, by soldering or welding. The connection point generally exhibits different electrical properties than the connection section and / or the winding wire. However, the automated and, in particular, fully automated 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 other electrical circuits.A strip-shaped winding section of constant width is integrally connected to the two connecting sections. This winding section has a constant width, resulting in good electrical properties for the finished winding, as the strip-shaped winding section behaves similarly to a conventional winding wire. The strip-shaped winding section also has a constant thickness and therefore a constant ohmic resistance along its entire length. The forming of the flat blank to create a winding is achieved by wrapping a bending shape with the winding section. Wrapping a bending shape with winding wire is, of course, a well-known technique.Surprisingly, even with careful selection of the geometric shape of the flat blank, the strip-shaped winding section can be wound around a bending die in a very simple manner, while the connection sections remain accessible in the finished winding. For example, the connection sections are arranged so that they lie in a common plane and can then be soldered to pads on a printed circuit board. The inventive method thus creates a winding for an inductive component in a very simple way, with the winding being formed in one piece.

[0008] In a further development of the invention, to form a winding, the winding section is wound around a cylindrical bending shape, whereby the winding section takes on the shape of a helix.

[0009] The usual form of a winding for an inductive component is a helix. Surprisingly, a helix can also be formed with a single-piece flat blank if the geometric shape of the blank is appropriately designed.

[0010] According to the invention, the bending shape consists of magnetically conductive material and, after the winding has been formed, forms a core of the inductive component.

[0011] The core of the inductive component can thus simultaneously provide the bending shape. For example, the flat cutout is painted before forming, thereby acquiring an electrically non-conductive layer on its outer surface.

[0012] In a further development of the invention, the flat, one-piece and electrically conductive blank is produced by punching it out of an electrically conductive sheet.

[0013] In this way, cut-out pieces can be produced in a very simple and fully automated manner in large quantities.

[0014] According to the invention, an inductive component with the features of claim 4 is also provided. In an inductive component with a one-piece winding, the winding has a first connection section, a second connection section and a strip-shaped winding section of constant width, wherein the winding is produced from a flat blank.

[0015] According to the invention, a core made of magnetic material is provided as a bending shape, which is wrapped with the winding section.

[0016] 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. The drawings show: Fig. 1 a flat cut for producing a winding from obliquely above, Fig. 2 the flat cut of the Fig. 1 from the side, Fig. 3 the flat cut of the Fig. 1 from above, Fig. 4, one from the cut of the Fig. 1 manufactured winding from the side and Fig. 5 the winding of the Fig. 4 with a bending shape used as the core of the inductive component.

[0017] Fig. 1 Figure 10 shows a planar blank 10 for producing a winding for an inductive component. The blank 10 has a first connection section 12 and a second connection section 14. The two connection sections 12 and 14 are intended to be connected to an electrical circuit, such as a power supply or the like, in the completed winding. Each connection section has a generally rectangular outline with a U-shaped cutout 16. The U-shaped cutout can be used, for example, to align the connection sections 12 and 14 on the completed winding with positioning pins on a printed circuit board.

[0018] A winding section 20, which is strip-shaped and has a constant width, is provided between the two connection sections 12 and 14. A transition section 22 and 24 is provided between the winding section 20 and each of the connection sections 12, with the side edges of the transition sections arranged at an angle of more than 90° to the side edges of the winding section 20. The side edges of the transition sections 22 and 24 are perpendicular to the side edges of the connection sections 12 and 14 into which they transition. The transition sections 22 and 24 are designed to ensure the transition from the typically helical winding to the flat connection sections 12 and 14 after deformation.

[0019] The winding section 20 is arranged at an angle to the opposing side edges of the connection sections 12 and 14. This results in an overall Z-shaped cut. The angle between the connection sections and the length of the winding section 20 then determine the pitch angle of the completed winding as well as the number of turns of the winding. The end sections 12 and 14 are wider than the winding section 20.

[0020] Fig. 2 Figure 20 shows a side view of blank 20. Blank 20 has a constant thickness across its entire surface. Blank 20 is, for example, punched out of a sheet of constant thickness.

[0021] Fig. 3 shows section 20 in a top view.

[0022] Fig. 4 Figure 1 shows a winding 30, which was produced from the flat blank 20 by wrapping a bending die with the winding section 20. The helical shape of the winding section 20 is visible. 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 is deformed into a helix.

[0023] The winding 30 has a helix with a total of four wraps. The number of wraps can be changed by altering the length of the winding section 20 or by the diameter of a bending die used during the winding process.

[0024] Fig. 5Figure 1 shows an inductive component 40 with a winding 30. A core 50 made of magnetically conductive material is arranged within the cavity formed by the winding. The core 50 is cylindrical and simultaneously forms the bending shape during the production of the winding 30. For example, the terminal section 12 is held 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 positioned so that it lies in the same plane as the terminal section 12.

[0025] The inductive component 40 can then be connected to solder pads on a circuit board via connection sections 12, 14.

[0026] The invention enables the fully automated production of inductive components with one-piece windings.

Claims

1. Method for producing a winding (30) for an inductive component (40) with the steps of: producing a sheet-like, one-piece and electrically conductive blank (10), the blank (10) having at least a first connecting portion (12), a second connecting portion (14) and a strip-shaped winding portion (20) of a constant width, wherein, during producing the sheet-like blank (10) the connecting portions (12, 14) are formed so that each of the connecting portions (12, 14) has a generally rectangular outline with a U-shaped cut-out (16), and deforming the sheet-like blank (10) to form a winding (30) by means of wrapping the winding portion (20) around a bending form, wherein the bending form consists of magnetically conductive material and after forming the winding (30) forms a core (50) of an inductive component and wherein the connecting portions (12, 14) are arranged in such a way so that they lie in a common plane.

2. Method according to Claim 1, wherein, to form the winding (30), the winding portion (20) is wrapped around a cylindrical bending form, whereby the winding portion (20) is given the form of a helix.

3. Method according to one of the preceding claims, wherein the sheet-like, one-piece and electrically conductive blank (10) is produced by means of stamping out from an electrically conductive metal sheet.

4. Inductive component (40) with a one-piece winding (30), which has a first connecting portion (12), a second connecting portion (14) and a strip-shaped winding portion (20) of a constant width, the winding (30) being produced from a sheet-like blank (10) by means of wrapping around a bending form, wherein each of the connecting portions (12, 14) has a generally rectangular outline with a U-shaped cut-out (16) and wherein the connecting portions (12, 14) are arranged in such a way that they lie in a common plane, and wherein a core (50) of magnetic material is provided, the winding portion (20) being wrapped around the core.

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