Inductor devices – Coil or coil turn supports or spacers – Printed circuit-type coil
Reexamination Certificate
2000-01-28
2004-02-03
Vo, Peter (Department: 2832)
Inductor devices
Coil or coil turn supports or spacers
Printed circuit-type coil
C029S846000, C029S830000, C029S605000, C029S606000, C029S602100, C029S601000, C336S223000, C336S232000
Reexamination Certificate
active
06686824
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a toroidal printed coil manufacturing method as well as to a toroidal printed coil manufactured by the manufacturing method. The toroidal printed coil manufacturing method according to the present invention is suited for manufacturing a plurality of toroidal printed coils simultaneously, and a printed coil sheet to be used in the processes of the manufacturing method can also be used as a printed wiring board having a plurality of toroidal printed coils. Toroidal printed coils obtained by the present invention are used as inductance devices, antennas, solenoid coils, motor coils and the like.
BACKGROUND OF THE INVENTION
A printed coil manufacturing method according to the prior art is described with reference to FIG.
8
.
There has been known a coil manufacturing method comprising the following steps. That is, as shown in
FIG. 8
, long, narrow and linear through slits
11
, at least two in number, are formed in an insulating substrate
10
so as to be opposite to one another with a specified spacing. Metal layers are formed at front and rear surfaces of the insulating substrate
10
as well as inner surfaces of the through slits
11
. The metal layers of the front and rear surfaces of the insulating substrate
10
except portions
16
forming a plurality of coil wires are removed, and the insulating substrate
10
is cut at cutting lines A, B, C, and D along the through slits
11
. Then, in the cutting sections, except connection-use metal layers for individually interconnecting the metal layers of coil-wire forming portions of the front and rear surfaces of the insulating substrate
10
, the metal layers of the inner surfaces of the through slits are removed. Therefore, the metal layers of the front and rear surfaces of the insulating substrate
10
are connected spirally to one another, by which coils are manufactured (Japanese Laid-Open Patent Publication No. 59-103321).
However, this m method has a large number of manufacturing steps and is complex, due to the steps of forming metal layers forming a plurality of coil wires at the front and rear surfaces of the insulating substrate as well as the inner surfaces of the through slits, then cutting the insulating substrate along the through slits, and thereafter further connecting the metal layers of the front and rear surfaces of the insulating substrate to one another spirally.
Accordingly, an object of the present invention is to solve the aforementioned issues and to provide a toroidal printed coil manufacturing method which allows toroidal printed coils to be manufactured with great simplicity without requiring much time and labor, and to provide a toroidal printed coil manufactured by this manufacturing method.
SUMMARY OF THE INVENTION
In order to achieve the above object, the present invention has the following constitutions.
According to a first aspect of the present invention, there is provided a toroidal printed coil manufacturing method for simultaneously manufacturing a plurality of toroidal printed coils including a plurality of annular holes, a plurality of center holes, and annular juts formed on an insulating substrate. The annular juts are formed of a plurality of annular portions surrounded by the plurality of annular holes and the plurality of center holes surrounded by these annular holes. Each annular portion is taken as an axis, forming a conductor film at front-and-rear surfaces and inner-and-outer side surfaces of the annular portion simultaneously and spirally.
According to a second aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to the first aspect, wherein the plurality of annular holes and the plurality of center holes surrounded by these annular holes are formed in the insulating substrate prior to forming the conductor film.
According to a third aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to the first or second aspect, wherein for the formation of the conductor film, after a plating resist layer is formed and patterned at portions of the front-and-rear surfaces and the inner-and-outer side surfaces other than portions to be left as the conductor film, plating process is performed so that the conductor film is formed at the portions to be left as the conductor film.
According to a fourth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to the first or second aspect, wherein for the formation of the conductor film, after the conductor film is formed generally entirely at the front-and-rear surfaces and inner-and-outer side surfaces of the annular jut, unnecessary portions of the generally entirely formed conductor film are removed by irradiation of a laser beam or the like so that the conductor film is formed at only necessary portions.
According to a fifth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to the first or second aspect, wherein for the formation of the conductor film, after the conductor film is formed generally entirely at the front-and-rear surfaces and inner-and-outer side surfaces of the annular jut, an etching resist layer is formed and patterned at portions to be left as the conductor film, unnecessary portions of the generally entirely formed conductor film are removed by etching so that the conductor film is formed at only necessary portions.
According to a sixth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to any one of the first, second, and fifth aspects, further comprising preparing a copper-clad laminate in which a copper foil is cladded on front and rear surfaces of the insulating substrate. The center holes are formed through the insulating substrate and the annular holes are formed so that the annular portion of each annularjut has a specified width and so that a portion for connecting with the other portion of the insulating substrate is left, by which the plurality of annular juts are formed. Copper plating is generally formed entirely at the front-and-rear surfaces and inner-and-outer side surfaces of the annular portion of each annular jut. Etching resist is formed congruous with the spiral conductor film with the annular portion of the annular jut taken as an axis. Unnecessary portions of the generally entirely formed conductor film are then removed, by etching, where the etching resist has not been formed. The etching resist is thereafter flaked off from the insulating substrate, by which the conductor film is obtained.
According to a seventh aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to any one of the first to sixth aspects, further comprising forming terminals of start and end portions of the spiral conductor film at the connecting portion and in the same plane by etching. Portions of the coil terminal portions other than copper-foil portions are coated, with solder resist, to thereby insulate those portions, and then the connecting portion is cut, by which the plurality of toroidal printed coils are obtained.
According to an eighth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to any one of the first to seventh aspects, wherein each of the center holes is circular shaped and a perimeter of the annular portion of the annular jut has a circular shape concentric with the center hole.
According to a ninth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to any one of the first to eighth aspects, wherein each of the center holes is polygonal-shaped and a perimeter of the annular portion of the annular jut has a polygonal shape similar to the center hole.
According to a tenth aspect of the present invention, there is provided the toroidal printed coil manufacturing method according to any one of the first to ninth aspects, whe
Nissha Printing Co. Ltd.
Trinh Minh
Vo Peter
Wenderoth , Lind & Ponack, L.L.P.
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