Process for producing microcoils and microtransformers
AssigneeRobert Bosch GmbH
InventorsKlaus Kuettner, Dietmar Hahn, Gottfried Flik, Markus Ohnmacht
Life of this patent
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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.
Claims15
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.
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.
Dependencies are inferred from the claim text.