US5852866A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing microcoils and microtransformers
Assignee: Robert Bosch GmbH
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Filing: 1997-04-02
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Granted: 1998-12-29
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Expires: 2017-04-02
Abstract
Abstract A process for producing single-layer or multi-layer microcoils or microcoil arrays that optionally have a magnetic core area to increase the coil inductance and to guide the magnetic flux. In this process, plastic films (e.g., made of polyimide or polyester), are applied using pressure and heat to serve as the insulation layers. This eliminates the need for curing the insulation and expensive leveling operations.
Inventors
- 👤 Klaus Kuettner
- 👤 Dietmar Hahn
- 👤 Gottfried Flik
- 👤 Markus Ohnmacht
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 10:05
CPC Classifications
H; H01; H01F; H01F17/00; H01F17/0006; H01F41/00; H01F41/02; H01F41/04; H01F41/041; H01F41/042; H01F41/046; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/4902; Y10T29/49075; Y10T29/49076; Y10T29/49117; Y10T29/49124; Y10T29/49126; Y10T29/49155; Y10T29/49158
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
88 words
A method for producing microcoils having at least one coil winding, comprising the steps of: (a) applying a conducting primer layer to one side of an insulating substrate; (b) applying a structurable layer to the conducting primer layer; (c) structuring the structurable layer to form a mold for a coil winding; (d) filling the mold with a material for the coil winding; (e) removing the structurable layer; and (f) applying, via a leveling process, an insulating layer of plastic film having an adhesive layer over the coil winding.
Claim 2
Independent Claim
88 words
A method for producing microcoils having at least one coil winding, comprising the steps of: (a) applying a conducting primer layer to one side of an insulating substrate; (b) applying a structurable layer to the conducting primer layer; (c) structuring the structurable layer to form a mold for a coil winding; (d) filling the mold with a material for the coil winding; (e) removing the structurable layer; and (f) applying, via a leveling process, an insulating layer of plastic film having an adhesive layer over the coil winding.
Claim 3
Dependent Claim
16 words
The method according to claim 1, wherein the plastic film includes one of polyimide and polyester.
Claim 4
Dependent Claim
20 words
. The method according to claim 1, wherein the insulating layer of plastic film is applied by pressure and heat.
Claim 5
Dependent Claim
17 words
The method according to claim 1, wherein the coil winding is designed as a double coil winding.
Claim 6
Dependent Claim
14 words
The method according to claim 1, wherein the structurable layer includes a positive lacquer.
Claim 7
Dependent Claim
20 words
The method according to claim 1, wherein a material for the coil winding includes one of Cu, Ag and Au.
Claim 8
Dependent Claim
31 words
The method according to claim 1, further comprising the step of: (g) repeating steps (a) through (f) for each additional coil winding, so that the coil windings have a stacked configuration.
Claim 9
Dependent Claim
57 words
The method according to claim 7, further comprising the step of, after applying the insulating layer of plastic film: introducing a plated-through hole in the layer of plastic film by forming a contacting hole in the insulating layer, the plated-through hole extending to the coil winding underneath and being filled with the material for the coil winding.
Claim 10
Dependent Claim
48 words
The method according to claim 1, wherein the layer of plastic film is provided with a metal layer, the metal layer functioning as one of a conducting primer layer and an etching mask on a side of the coil winding facing away from a surface to be leveled.
Claim 11
Independent Claim
233 words
A method for producing microcoils having at least one coil winding, comprising the steps of: (a) producing a magnetic core bottom part on one side of an insulating substrate; (b) covering the magnetic core bottom part with an insulation layer; (c) applying a conducting primer layer on the insulation layer; (d) applying a structurable layer to the conducting primer layer; (e) structuring the structurable layer to form a mold for a coil winding; (f) filling the mold with a material for the coil winding; (g) removing the structurable layer; (h) applying, via a leveling process, an insulating layer of plastic film having an adhesive layer over the coil winding; (i) repeating steps (c) through (g) for each additional coil winding, so that the coil windings have a stacked configuration; (j) forming a first recess in a core area surrounded by the coil windings and forming a second recess in a surrounding magnetic core area surrounding the coil windings, the first and second recesses extending through the insulating layer of plastic film of each coil winding and through the insulation layer of the magnetic core bottom part; (k) filling the first and second recesses with a magnetic material; and (l) forming a magnetic core top part connecting the core area and the surrounding magnetic core area, wherein the core area and the surrounding magnetic core area are connected to the magnetic core bottom part.
Claim 12
Independent Claim
233 words
A method for producing microcoils having at least one coil winding, comprising the steps of: (a) producing a magnetic core bottom part on one side of an insulating substrate; (b) covering the magnetic core bottom part with an insulation layer; (c) applying a conducting primer layer on the insulation layer; (d) applying a structurable layer to the conducting primer layer; (e) structuring the structurable layer to form a mold for a coil winding; (f) filling the mold with a material for the coil winding; (g) removing the structurable layer; (h) applying, via a leveling process, an insulating layer of plastic film having an adhesive layer over the coil winding; (i) repeating steps (c) through (g) for each additional coil winding, so that the coil windings have a stacked configuration; (j) forming a first recess in a core area surrounded by the coil windings and forming a second recess in a surrounding magnetic core area surrounding the coil windings, the first and second recesses extending through the insulating layer of plastic film of each coil winding and through the insulation layer of the magnetic core bottom part; (k) filling the first and second recesses with a magnetic material; and (l) forming a magnetic core top part connecting the core area and the surrounding magnetic core area, wherein the core area and the surrounding magnetic core area are connected to the magnetic core bottom part.
Claim 13
Dependent Claim
12 words
The method according to claim 10, wherein the magnetic material includes FeNi.
Claim 14
Dependent Claim
20 words
The method according to claim 10, wherein the magnetic material includes one of a ternary alloy and a quaternary alloy.
Claim 15
Dependent Claim
19 words
The method according to claim 10, wherein the magnetic material includes a hard magnetic powder dispersed in a polymer.
Claim 16
Dependent Claim
29 words
The method according to claim 10, wherein at least one of the first and second recesses is filled with a predetermined magnetic insulation material to create specific flux paths.
Claim 17
Dependent Claim
19 words
The method according to claim 10, wherein the coil windings are made of one of Cu, Ag and Au.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2001-12-28 | 2002-06-29 | 2002-12-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-12-28 | 2006-06-29 | 2006-12-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-12-28 | 2010-06-29 | 2010-12-29 | $7700.00 | Window Closed / Lapsed |