Method for fabricating an inductive coil
View Patent ↗A method of fabricating an inductive coil having inner and outer winding portions formed from one or more metal sheets. The method includes wrapping a fiber strand around an outer surface of the inner winding portion, positioning the outer winding portion around the inner winding portion, and electrically coupling the inner winding portion to the outer winding portion to form an electric circuit.
1. A method of fabricating an inductive coil comprising:
wrapping a fiber strand around an outer surface of an inner sheet metal winding portion;
positioning an outer sheet metal winding portion around the inner sheet metal winding portion; and
electrically coupling the inner sheet metal winding portion to the outer sheet metal winding portion to form an electric circuit.
2. The method of claim 1 further comprising applying an encapsulation material to the inductive coil with the outer sheet metal winding portion positioned around the inner sheet metal winding portion, the encapsulation material impregnating a layer formed between the inner and outer sheet metal winding portions by the fiber strand.
3. The method of claim 2 wherein the encapsulation material comprises polyimide.
4. The method of claim 2 further comprising wrapping a second fiber strand around an outer sheet metal surface of the outer winding portion before applying the encapsulation material to the inductive coil, the encapsulation material impregnating a layer formed around the outer sheet metal winding portion by the second fiber strand.
5. The method of claim 1 further comprising wrapping a second fiber strand around an outer surface of the outer sheet metal winding portion.
6. The method of claim 1 further comprising forming the inner and outer sheet metal winding portions by cutting the one or more metal sheets.
7. The method of claim 6 wherein the one or more metal sheets are cut by etching.
8. The method of claim 7 wherein the one or more metal sheets are etched from both sides.
9. A method of fabricating an inductive coil comprising:
positioning an outer sheet metal winding portion around an inner sheet metal winding portion;
applying an encapsulation material to the inductive coil with the outer sheet metal winding portion positioned around the inner sheet metal winding portion, the encapsulation material being forced into a gap between the inner and outer sheet metal winding portions; and
electrically coupling the inner sheet metal winding portion to the outer sheet metal winding portion to form an electric circuit.
10. The method of claim 9 wherein the encapsulation material comprises polyimide.
11. The method of claim 9 further comprising wrapping a fiber strand around an outer surface of the inner sheet metal winding portion before applying the encapsulation material to the inductive coil, the encapsulation material impregnating a layer formed between the inner and outer sheet metal winding portions by the fiber strand.
12. The method of claim 11 further comprising wrapping a second fiber strand around an outer sheet metal surface of the outer winding portion before applying the encapsulation material to the inductive coil, the encapsulation material impregnating a layer formed around the outer sheet metal winding portion by the second fiber strand.
13. The method of claim 9 further comprising forming the inner sheet metal and outer sheet metal winding portions by cutting the one of more metal sheets.
14. The method of claim 13 wherein the one or more metal sheets are cut by etching.
15. The method of claim 14 wherein the one or more metal sheets are etched from both sides.
16. A method of fabricating an inductive coil comprising:
wrapping a fiber strand around an outer surface of an inner sheet metal winding portion;
positioning an outer sheet metal winding portion around the inner sheet metal winding portion;
applying an encapsulation material to the inductive coil with the outer sheet metal winding portion positioned around the inner sheet metal winding portion, the encapsulation material impregnating a layer formed between the inner and outer sheet metal winding portions by the fiber strand; and
electrically coupling the inner sheet metal winding portion to the outer sheet metal winding portion to form the inductive coil.
17. The method of claim 16 wherein the encapsulation material comprises polyimide.
18. The method of claim 16 further comprising wrapping a second fiber strand around an outer sheet metal surface of the outer winding portion before applying the encapsulation material to the inductive coil, the encapsulation material impregnating a layer formed around the outer sheet metal winding portion by the second fiber strand.
19. The method of claim 16 further comprising forming the inner and outer sheet metal winding portions by cutting the one or more metal sheets.
20. The method of claim 19 wherein the one or more metal sheets are cut by etching.
21. The method of claim 20 wherein the one or more metal sheets are etched from both sides.