U.S. patent number 3,736,543 [Application Number 05/240,081] was granted by the patent office on 1973-05-29 for photoetched induction coil assembly.
This patent grant is currently assigned to The Bendix Corporation. Invention is credited to Ernest E. Lademann, James J. O'Connor.
United States Patent |
3,736,543 |
Lademann , et al. |
May 29, 1973 |
PHOTOETCHED INDUCTION COIL ASSEMBLY
Abstract
An induction coil assembly includes circuits photoetched on
metallic laminates bonded to a flexible substrate. The substrate is
wound on an arbor and pinned, after which it is removed from the
arbor, impregnated and machined to provide an induction coil having
close mechanical and electrical tolerances.
Inventors: |
Lademann; Ernest E. (Park
Ridge, NJ), O'Connor; James J. (Old Bridge, NJ) |
Assignee: |
The Bendix Corporation
(Teterboro, NJ)
|
Family
ID: |
22905037 |
Appl.
No.: |
05/240,081 |
Filed: |
March 31, 1972 |
Current U.S.
Class: |
336/200; 336/205;
336/232 |
Current CPC
Class: |
H01F
41/041 (20130101); H01F 5/003 (20130101); H05K
1/0393 (20130101); H05K 1/165 (20130101) |
Current International
Class: |
H01F
41/04 (20060101); H01F 5/00 (20060101); H05K
1/16 (20060101); H05K 1/00 (20060101); H01f
027/30 () |
Field of
Search: |
;336/96,200,205,232 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Kozma; Thomas J.
Claims
What is claimed is:
1. A coil assembly, comprising:
a flexible, continuous substrate;
conductive circuit patterns on both sides of the substrate;
means connecting the circuit patterns on one side of the substrate
with those on the other side and providing a continuous circuit
along the length of the substrate;
locating tabs at predetermined points along the length of the
substrate;
said substrate with the continuous circuit thereon wound with the
locating tabs in alignment to provide predetermined spaces between
windings; and
an insulating material in and around said spaces.
2. A coil assembly as described by claim 1, wherein:
the conductive circuit patterns are geometric patterns of
conductive metal in a planar arrangement on both sides of the
substrate.
3. A coil assembly as described by claim 1, wherein:
the means connecting the circuit patterns on one side of the
substrate with those on the other side and providing a continuous
circuit along the length of the substrate includes through holes
plated with a conductive metal.
4. A coil assembly as described by claim 1, wherein the conductive
circuit patterns on both sides of the substrate include:
a repeatable pattern of a single planar coil and a pair of
connected planar coils on one side of the substrate; and
a repeatable pattern of a pair of connected planar coils and a
single planar coil on the other side of the substrate.
5. a coil assembly as described by claim 4, wherein the means
connecting the circuit patterns on one side of the substrate with
those on the other side and providing a continuous circuit along
the length of the substrate includes:
a through hole plated with a conductive metal connecting the single
planar coil on the one side of the substrate to one of the
connected pair of planar coils on the other side;
another plated through hole connecting one of the connected pair of
planar coils on the one side of the substrate with the other of the
pair of coils on the other side; and
still another plated through hole connecting the other of the pair
of coils on the one side of the substrate with the single planar
coil on the other side.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to induction coils of the type used in gyro
torquer assemblies and, more particularly, to induction coils of
the type described having photoetched circuitry.
2. Description of the Prior Art
Prior to the present invention, induction coils were hand wound.
The coil so provided was then encapsulated and machined as
required. It is difficult and costly to control mechanical and
electrical tolerances within limits required for modern
applications when providing induction coils in this manner.
SUMMARY OF THE INVENTION
The present invention contemplates an induction coil assembly
having circuitry in the form of a geometric pattern of conductive
metal photoetched in a planar arrangement on a flexible substrate.
The flexible substrate is wound on an arbor, with locating tabs
being provided on the substrate to insure predetermined spacing
between windings. A registration pin is inserted through the tabs
to prevent the substrate from unwinding, after which the wound
substrate is removed from the arbor, vacuum impregnated to fill the
voids between and around the windings and machined as required.
One object of this invention is to provide an induction coil having
photoetched circuitry.
Another object of this invention is to provide an induction coil of
the type described whereby electrical characteristics can be
predetermined with a high degree of repeatability.
Another object of this invention is to provide a method for
manufacturing an induction coil of the type described which permits
greater control of manufacturing tolerances than has heretofore
been possible.
Another object of this invention is to manufacture an induction
coil of the type described at a lower cost than has heretofore been
possible.
The foregoing and other objects and advantages of the invention
will appear more fully hereinafter from a consideration of the
detailed description which follows, taken together with the
accompanying drawings wherein one embodiment of the invention is
illustrated by way of example.
It is to be expressly understood however, that the drawings are for
illustration purposes only and are not to be construed as defining
the limits of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectioned side view of a flexible substrate
according to the invention and having metallic laminations on
either side thereof.
FIG. 2 is a partially sectioned side view showing the flexible
laminated substrate of FIG. 1 with plated through holes for
electrically connecting the metallic laminations.
FIG. 3 is a side view showing the flexible laminated substrate of
FIGS. 1 and 2 having circuit patterns etched on the metallic
laminations.
FIG. 4 is a diagrammatic representation showing the geometric form
of the etched circuit patterns, with said patterns being connected
by the plated through holes.
FIG. 5 is a top view of the etched flexible laminated
substrate.
FIGS. 6, 7 and 8 are pictorial representations showing the
laminated substrate of FIGS. 1-5 wound on an arbor and machined to
provide a final induction coil in accordance with the
invention.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a flexible, continuous substrate 4 having metallic
laminations 6 and 8 on either side thereof. Substrate 4 may be a
suitable polyimide plastic such as that carrying the trade name
Kapton and marketed by Du Pont Company, and is approximately 0.002
inches thick. Laminations 6 and 8 may be one ounce copper strips
(0.0014 inches thick) suitably bonded to substrate 4 as is well
known in the art.
Holes 10 are drilled through substrate 4 and metallic laminations 6
and 8 at predetermined locations along the length thereof as shown
in FIG. 2. The holes are then conventionally plated through with a
suitable conductive material such as copper, with plated through
holes 10 thereby providing electrical connections between metallic
laminations 6 and 8.
Laminations 6 and 8 are etched by conventional photochemical
methods to provide circuit patterns designated by the numerals 14
and 15, respectively, as shown in FIG. 3. Plated through holes 10
connect circuit patterns 14 and 15 as shown in the figure.
Thus, as seen in FIG. 4, circuit pattern 14 includes a single
planar coil 16 and a pair of connected planar coils 17 and 18, with
the pattern, i.e. a single coil and a pair of connected coils,
being repeated along the length of substrate 4. Circuit pattern 15
includes a repeatable pattern of a pair of connected coils 19 and
20 and a single coil 21. Single coil 16 in circuit 14 is connected
by a plated through hole 10 to coil 19 in circuit 15. Another
plated through hole 10 connects coils 17 and 20 while still another
plated through hole 10 connects coils 18 and 21. It will now be
understood that in this manner a continuous electrical circuit is
provided along the length of substrate 4.
The completed photoetched substrate has a configuration as shown in
FIG. 5, wherein only circuit 14 is shown. Substrate 4 further
includes locating tabs 22 which are positioned to allow a space of
approximately 0.002 inches between windings when the substrate is
wound on an arbor and the tabs aligned as will be hereinafter
explained. Tabs 22 have holes 24 therethrough to accommodate a
registration pin 28 shown in FIG. 7.
As shown in FIG. 6, photoetched substrate 4 is wound on an arbor
25. Locating tabs 22 are positioned to allow the aforenoted 0.002
inch space between windings when the substrate is wound on the
arbor and the tabs aligned as shown in FIG. 7, with the space
between windings carrying the description A. Registration pin 28 is
inserted through holes 24 in tabs 22 to prevent the substrate from
unwinding as will now be understood.
After substrate 4 has been wound and pinned, the assembly is
removed from arbor 25 and vacuum impregnated so as to fill the
voids between and around the layers with a suitable insulating
material 30 such as an epoxy resin as shown in FIG. 8. After vacuum
impregnation has been completed, locating tabs 20 and pin 28 are
sheared off and the inner and outer diameters of the assembly are
machined as required to provide a finished coil assembly as showin
in FIG. 8.
It will now be seen that an induction coil having the configuration
shown in the drawings and manufactured by the method described has
certain advantages. First, since circuits 14 and 15 are
photographically produced, each and every coil 16-21 (FIG. 4) will
be precisely the same. Thus, inductor widths and conductor spacing
can be controlled to the extent that electrical characteristics
such as impedance and capacitance can be predetermined with
excellent repeatability. Also the photoetching process lends itself
to greater control of manufacturing tolerances. Due to the good
repeatability and dimensional control, gaps can be reduced with a
subsequent increase in torque being thus provided when a torquer
application is intended. Finally, a coil assembly manufactured
according to the invention can be achieved at a cost greatly
reduced from that required for coil assemblies manufactured as now
known in the art.
Although but a single embodiment of the invention has been
illustrated and described in detail, it is to be expressly
understood that the invention is not limited thereto. Various
changes may also be made in the design and arrangement of the parts
without departing from the spirit and scope of the invention as the
same will now be understood by those skilled in the art.
* * * * *