KR101123424B1 - Method for Fabricating Planar Transformer - Google Patents

Abstract

The present invention relates to a method for manufacturing a planar transformer by transferring a coiled coil pattern material by copper plating using a pole master and attaching it to a plastic film, and using an electro-formed master to input an outer portion. Transferring and adhering the coil pattern including the terminal and the output terminal to a plastic film to form a first inlay film having a winding coil for forming a primary coil; Transferring and adhering a coil pattern having an input terminal and an output terminal to the outside using a pole master with a plastic film to form a second inlay film having a winding coil for forming a secondary coil; Forming an insulation by pattern screen printing a portion of the winding coil of the inlay film with an insulation material; Transferring and bonding a jump line electrically connectable from an inner winding coil end to an outer output terminal using a pole master to the inlay film; And combining the first inlay film and the second inlay film by thermal compression.

Description

Method for manufacturing planar transformer {Method for Fabricating Planar Transformer}

The present invention relates to a planar transformer, and more particularly, to form a wound coil pattern using copper plating using an electro-formed master having a wound coil pattern, and then winding the wound coil pattern to a plastic. The present invention relates to a planar transformer that can be produced by transferring and attaching to a film to produce a wound inlay film and incorporating these films.

Planar transformers are electronic components used in power conversion devices of electronic devices such as televisions, communicators, computers, etc., and the basic configuration includes primary coils and secondary coils made by winding copper wire around a ferrite core.

The planar transformer may change the number of turns of the pair of primary and secondary coils to change the voltage applied to the primary and secondary coils.

Such transformers can be used for various purposes in electronic circuits. In other words, it is widely used as a transformer for increasing and decreasing voltage, a power transformer, a transformer for noise reduction, and the like, in particular, a transformer used in a switching mode power supply and a DC-DC converter, etc., to transmit a signal of a high voltage square wave to a low voltage square wave. Used.

Recently, due to the trend toward miniaturization and thinning of electronic devices, transformers entering the power supply unit of electronic devices also need to be miniaturized and low profile.

Conventional miniature transformers for electronic components have a problem in that they are structurally thin because they are formed of a primary coil and a secondary coil made of a wound copper wire.

In addition, in the case of the planar transformer which has improved this, a plurality of primary coils and secondary coils wound with copper wires have been stacked, and holes have been manufactured to process holes to electrically connect the stacked coils, and to be plated inside the holes.

However, the conventional planar transformer has a limitation in thinning because it is manufactured by winding a copper wire, and it is difficult to easily change the thickness, the cross-sectional area of the winding coil, the number of turns of the winding, and the terminal terminal.

In addition, the conventional planar transformer has a technical difficulty in that a plurality of coils are stacked and hole processing and secondary plating processes inside the holes are performed to electrically connect the stacked coils.

The present invention is to solve this problem, to manufacture a winding assembly of the shape wound around the ferrite core primary coil and the secondary coil wound while transferring the wound coil pattern to a flat plastic film. It is therefore an object of the present invention to provide a method of manufacturing a planar transformer that can be structurally thin.

In addition, an object of the present invention is to provide a planar manufacturing method excellent in dielectric breakdown voltage characteristics while reducing the volume of the transformer, miniaturization and thinning.

In addition, it is an object of the present invention to provide a planar manufacturing method that does not require hole processing for electrically connecting the terminals of the film when two or more coil films are laminated.

According to an embodiment of the present invention, a coil coil having an input part terminal and an output part terminal on the outside is transferred and bonded to a plastic film using an electro-formed master to form a winding coil for forming a primary coil. Forming an embedded first inlay film; Transferring and adhering a coil pattern having an input terminal and an output terminal to the outside using a pole master with a plastic film to form a second inlay film having a winding coil for forming a secondary coil; Forming an insulation by pattern screen printing a portion of the winding coil of the inlay film with an insulation material; Transferring and bonding a jump line electrically connectable from an inner winding coil end to an outer output terminal using a pole master to the inlay film; And combining the first inlay film and the second inlay film by thermal compression.

In this case, the method of manufacturing a planar string transformer according to the present invention transfers and bonds a coil pattern having an input terminal and an output terminal to the outside using a electro-formed master with a plastic film to form a primary coil. Forming a third inlay film having a winding coil embedded therein; Disposing the third inlay film opposite the first inlay film about the second inlay film and bonding by thermal compression; Preferably, the method further includes electrically connecting the output terminal of the first inlay film and the input terminal of the third inlay film by terminating the input terminal.

The method may further include applying a conductive paste to a surface in electrical contact with the first inlay film and the second inlay film when the jump line is formed before thermocompression bonding.

In addition, the bonded plurality of inlay film may further comprise the step of bonding to the E-shaped ferrite core.

In addition, the primary coil forming inlay film or the secondary coil forming inlay film with the winding coil is further formed, and the plurality of primary coil forming inlay films are electrically connected to each other and the plurality of second By further comprising electrically connecting the inlay films for forming the secondary coils to each other, it becomes possible to manufacture a planar transformer from a large number of inlay films.

According to the present invention, since the primary coil and the secondary coil pattern material can be easily implemented with the copper plating pattern having excellent electrical characteristics by using the pole master, the structure can be made thinner.

In addition, the copper plating pattern formed by the plating process can achieve the same characteristics as the conventional copper wire in terms of electrical characteristics and physical properties, and in the design of the pattern it is necessary to vary the cross-sectional area and the line width of the winding pattern It becomes possible.

In addition, when two or more coil films are laminated, cost reduction may be required because hole processing for electrically connecting terminals of the film is not necessary.

1 is an exploded view of a planar transformer according to an embodiment of the present invention.
2 is a configuration diagram of a first inlay film in which the wound coil for forming the primary coil is embedded;
3 is a cross-sectional view illustrating a jump line connection state of a first inlay film having a coiled coil for forming a primary coil;
4 is a configuration diagram of a second inlay film in which a wound coil for forming a secondary coil is embedded;
FIG. 5 is a cross-sectional view illustrating a jump line connection state of a second inlay film in which a wound coil for forming a secondary coil is embedded; FIG.
6 is a configuration diagram of a third inlay film in which the wound coil for forming the primary coil is embedded;
7 is a cross sectional view of the EF dashed portion of the completed planar transformer.
Figure 8 is a plan view and side view of the configuration of a flat transformer and a ferrite core made according to the present invention.
FIG. 9 illustrates a planar transformer including a first inlay film for forming a primary coil and a second inlay film for forming a secondary coil _.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In addition, the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the following examples may be modified in various other forms, the scope of the present invention Is not limited to the following examples.

FIG. 1 is an exploded view of a planar transformer showing the configuration of inlay films having a coil wound therein in a planar transformer according to an embodiment of the present invention.

As shown in FIG. 1, the number of windings is increased by using two inlay films 100 and 300 in which the wound coils 110 and 310 forming the primary coil are embedded. A planar transformer may be manufactured by inserting an inlay film 200 having a secondary coil forming winding coil embedded between the primary coil forming inlay films 100 and 300.

Such inlay films 100, 200, and 300 may first be selectively manufactured with a pattern plating material only on the pattern part, and the winding coil pattern material formed by the plating process may be formed by using an electro-formed master plastic film. Can be transferred and bonded together.

First, a wound coil embedded inlay film, which is formed by transferring a wound pattern coil using a pole master, is manufactured.

As used herein, the electric pole master refers to a thing such as a mold capable of plating and transferring a wound pattern coil, and having a mass productivity that can repeatedly use a desired pattern.

The inlay films 100 and 300 having the winding coils for forming the primary coil and the inlay film 200 having the winding coils for forming the secondary coil may be separately manufactured because the number of windings and the winding width are different. Can be.

In order to increase the number of windings of the primary coil, the inlay films 100 and 300 for forming the primary coil are formed in two sheets, and the number of turns of the primary coil can be doubled by connecting the contacts of the circuit with each other. Do.

2 is a configuration diagram of the first inlay film 100 in which the wound coil 110 for forming the primary coil is embedded.

As shown in FIG. 2, the input terminal 120 of the primary coil is connected to the wound coil wire 110 and ends at the winding end 140 of the inlay film 100. In addition, the winding end 140 is connected to the output terminal 130 of the inlay film 100 in the form of a jump line 150 for connection with an external electrical circuit.

The jump line 150 may be configured as a cross section of the dotted line A-B as shown in FIG. 3.

First, the insulating part 170 is formed by pattern screen printing a part of the winding coil of the inlay film with an insulating material. The jump line 150 may be formed with the winding coil 110 and the insulator 170 interposed therebetween. The jump line 150 may also be transferred and adhered to a separate plating pattern using a pole master. It is also possible to apply.

The winding coil 110 and the jump line 150 are electrically insulated from each other by the insulating unit 170.

In this case, the jump line 150 must maintain electrical contact with the winding end 140 and the output terminal 130.

The inlay films 100 and 300 for forming the primary coil are formed on the opposite side of the adhesive surface of the pattern plating material to be bonded to the inlay film during the transfer to the adhesive-coated plastic film through the pole master. By thermally compressing the inlay film 200 for forming the secondary coil, the jump line 150 can be secured in electrical contact with the winding end 140 and the output terminal 130. At this time, prior to thermocompression bonding the inlay films 100 and 300 for forming the primary coil and the inlay film 200 for forming the secondary coil, a conductive paste is applied to the surface of the electrical contact portion to further secure the electrical connection. It is also possible.

4 is a configuration diagram of the second inlay film 200 in which the wound coil 210 for forming the secondary coil is embedded. The manufacturing method of the second inlay film 200 is the same as the inlay film configured for the primary coil.

That is, as shown in FIG. 4, the input terminal 220 of the secondary coil extends into the wound coil wire 210 and ends at the winding end 240 of the inlay film 200.

In addition, the winding end 240 is connected to the output terminal 230 of the inlay film 200 in the form of a jump line 250 for the electrical circuit connection with the outside.

The jump line 250 may be configured as a cross section of the CD dotted line as shown in FIG. 5. The jump line 250 manufacturing method may also be transferred and adhered to a separate plating pattern using the pole master in the same manner as described above. Alternatively, the conductive paste may be applied by printing.

6 illustrates a configuration diagram of the third inlay film 300 in which the winding coil 310 for the primary coil is embedded.

As shown in FIG. 6, the input terminal 320 of the primary coil is connected to the wound coil wire 310 and ends at the winding end 340 of the inlay film 300. In addition, the winding end 340 is connected to the output terminal 330 of the inlay film 300 in the form of a jump line 350 for connection with an external electrical circuit.

As a result, the electrical flow is connected to the output terminal 130 through the winding coil wire 110 starting from the input terminal 120 of the first inlay film 100 as shown in FIG. 1. . It is connected to the input terminal 320 of the second inlay film 300 through the output terminal 130 and finally comes out to the output terminal 330 through the winding coil wire (310).

As such, the primary coil exhibits a winding effect wound eight times as a whole. At this time, the output terminal 130 of the inlay film 100 formed on the outside and the input terminal 320 of the inlay film 300 can be easily electrically connected to the termination (termination) processing method from the outside. The termination method may be composed of a conductive paste and a connection pin used in a general multilayer electronic component.

The planar transformer completed by doing so is shown in FIG. 7.

Referring to the cross-sectional view of the dotted line EF shown in FIG. 7, the first inlay v-fill 100 for forming the primary coil, the inlay film 200 for forming the secondary coil, and the third inlay film for forming the primary coil ( 300 and the like are shown in turn.

The film for inlay applied in the present invention is a polyester (PET) film or a polyimide (PI) film is applicable, and other plastic film can also be widely applied if the heat resistance.

In addition, the adhesive coated on the film to attach the coil pattern to the film as shown in Figure 3 may preferably use a liquid hot melt adhesive liquid. Parts 170 and 180 in FIG. 3 represent non-conductive adhesive layers coated on the base film.

FIG. 8 shows a plan view and a side view of the construction of a planar transformer manufactured by the present invention and a ferrite core.

In order to realize a more efficient magnetic effect, the winding assembly formed of the primary coil and the secondary coil may be assembled with the E-shaped ferrite core.

The E-shaped core may be composed of a central post 430 and a pair of outer posts 420, and a pair of channels 400 and an upper plate 410 are disposed.

The central post 430 may facilitate the winding assembly to rest inside the ferrite core. The central post 430 portion represents the through portion of the winding assembly of the planar transformer.

FIG. 9 illustrates an embodiment of another planar transformer configured by integrating one inlay film 100 for forming a primary coil and one inlay film 200 for forming a secondary coil.

As shown in FIG. 9, it is also possible to construct a planar transformer by pressing two inlay films to form a primary coil and a secondary coil. That is, by increasing or decreasing the number of turns of each inlay film, it is possible to manufacture a desired planar transformer.

As described above, the present invention can use only one inlay film for forming the primary coil, so that the process is simple, and when two or more primary coil inlay films are stacked, the terminals of the two inlay films are electrically connected. There is an advantage that the hole processing for the connection and the plating process of the secondary hole is not necessary.

While the above has been shown and described with respect to preferred embodiments of the invention, the invention is not limited to the specific embodiments described above, it is usually in the technical field to which the invention belongs without departing from the spirit of the invention claimed in the claims. Various modifications can be made by those skilled in the art, and these modifications should not be individually understood from the technical spirit or the prospect of the present invention.

100: first inlay film
200: second inlay film
300: third inlay film

Claims (5)

Transferring and bonding a coil pattern having an input terminal and an output terminal to the outside using a electro-formed master with a plastic film to form a first inlay film containing a winding coil for forming a primary coil step;
Transferring and adhering a coil pattern having an input terminal and an output terminal to the outside using a pole master with a plastic film to form a second inlay film having a winding coil for forming a secondary coil;
Forming an insulation by pattern screen printing a portion of the winding coils of each of the first inlay film and the second inlay film with an insulating material;
Transferring and bonding a jump line electrically connected to an output terminal terminal from an inner winding coil end to an outer output terminal terminal using a pole master to each of the first inlay film and the second inlay film;
Bonding the first inlay film and the second inlay film by thermal compression;
Method of producing a planar transformer, characterized in that it comprises a.
The method of claim 1,
Transferring and bonding a coil pattern having an input terminal and an output terminal to the outside using a electro-formed master with a plastic film to form a third inlay film containing a winding coil for forming a primary coil step;
Disposing the third inlay film opposite the first inlay film about the second inlay film and bonding by thermal compression;
And electrically connecting the output terminal of the first inlay film and the input terminal of the third inlay film by terminating the input terminal of the third inlay film.
The method according to claim 1 or 2,
The method of claim 1, further comprising applying a conductive paste to the surface of the electrical contact when the jump line is formed before thermal compression of the first inlay film and the second inlay film.
The method according to claim 1 or 2,
Bonding the plurality of bonded inlay films to an E-shaped ferrite core.
The method according to claim 1 or 2,
Further forming a primary coil forming inlay film or secondary coil forming inlay film with the winding coil is built in, and a plurality of primary coil forming inlay film electrically connected to each other and a plurality of secondary coils Method for producing a planar transformer, characterized in that it further comprises the step of electrically connecting the forming inlay film to each other.

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