Methods of forming coils for inductive components

Patent metadata

Field	Value
Publication number	US-10418172-B2
Application number	US-201615371832-A
Country	US
Kind code	B2
Filing date	Dec 7, 2016
Priority date	Dec 7, 2016
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

A method of forming a coil for an inductive component includes bending a conductor into a figure 8 configuration. The figure 8 configuration has opposite first and second ends, a first substantially rounded portion, and a second substantially rounded portion. Each of the first and second substantially rounded portions terminates at one of the first and second ends. The method further includes folding the figure 8 configuration so the first substantially rounded portion overlies the second substantially rounded portion. Other example methods of forming coils for inductive components and other example coils are also disclosed.

First claim

The invention claimed is:

1. A method of forming a coil for an inductive component, the method comprising:
providing a substantially flat, elongated and straight conductor;
bending the substantially flat, elongated and straight conductor into a figure 8 configuration without stamping or photochemical etching the conductor, the figure 8 configuration having opposite first and second ends, a first substantially rounded portion, and a second substantially rounded portion, each of the first and second substantially rounded portions terminating at one of the first and second ends; and
folding the figure 8 configuration so the first substantially rounded portion overlies the second substantially rounded portion.

2. The method of claim 1 wherein folding includes folding the figure 8 configuration so that the first and second ends are located on opposite sides of the coil.

3. The method of claim 1 wherein the conductor is continuous.

4. The method of claim 1 further comprising bending at least one of the first and second ends.

5. The method of claim 4 wherein bending the at least one of the first and second ends includes bending the at least one of the first and second ends before bending the conductor into the figure 8 configuration.

6. The method of claim 1 further comprising substantially covering the conductor with an insulative material.

7. The method of claim 6 wherein substantially covering the conductor includes substantially covering the conductor with the insulative material before bending the conductor into the figure 8 configuration.

8. The method of claim 1 wherein the bending step and the folding step are automated.

9. The method of claim 1 wherein folding the figure 8 configuration includes folding the figure 8 configuration so the first and second ends of the figure 8 configuration extend in substantially parallel planes.

10. The method of claim 1 wherein the bending step and the folding step forms a coil having at least two turns.

11. The method of claim 1 wherein folding includes folding the figure 8 configuration to create a gap between the first substantially rounded portion and the second substantially rounded portion for receiving another coil.

12. The method of claim 1 wherein the inductive component includes an interleaved transformer and the coil includes at least one coil of the interleaved transformer.

13. The method of claim 12 wherein the coil includes a secondary winding of the interleaved transformer.

14. The method of claim 1 wherein bending the conductor into the figure 8 configuration includes bending the conductor into the figure 8 configuration so that the conductor forms a portion extending diagonally between the first substantially rounded portion and the second substantially rounded portion.

Assignees

• Astec Int Ltd

Inventors

• Grueso Alfredo
• Abella Joven
• Mendoza Roger

Classifications

• H01F2027/2861

  Coil formed by folding a blank · CPC title

• H01F41/061 Primary

  Winding flat conductive wires or sheets · CPC title

• H01F27/2866

  Combination of wires and sheets · CPC title

• H01F27/2847

  Sheets; Strips (H01F27/2866 takes precedence) · CPC title

• H01F41/04 Primary

  for manufacturing coils {(coils for transformer or inductances H01F27/28)} · CPC title