EP2395517B1 - Inductive component with magnetic core - Google Patents

Description

Field of the invention:

The invention relates to an inductive component with a magnetic core, in particular chokes, transformers, transformers, transducers, and similar inductive components.

State of the art:

State of the art is given for example by the EP 1 501 106 A1 same applicant. This application shows newer ferrite air gap technologies in the form of so-called sine-chokes, which have mainly established themselves in photovoltaics.

The bobbins of these inductive components are usually thin-walled cylinders, they carry one or more windings of a choke, a transformer or a transformer.

It is known that the bobbin or insulating cylinder are produced for example by injection molding or extrusion, wherein the bobbin is usually formed as a hollow cylinder, in which, for example, magnetic cores are used. But there are also known wound coil body, which are formed into insulating cylinders.

It is also known that magnetic cores for chokes are, for example, formed in a columnar shape and consist of one or more core parts and core disks glued together, which are separated by so-called "air gaps", e.g. B. in the form of spacers made of insulating material, are separated from each other. So far Kernartäulen z. B. core disks with intermediate air gaps, which are not known air gaps, but consist of Isolierzwischenlagen) constructed and glued at the same time to use them in bobbins or to wrap as a core column with insulating material. The purpose of these air gaps is to design and optimize the electromagnetic properties of the choke coils so that the highest possible amounts of magnetic energy are stored in the air gap spaces, but the stray fields outside the air gaps or the insides of the windings are still kept low. On the other hand, "air gap spaces" also serve to mechanically interconnect individual core parts or disks, in particular to bridge the so-called air gaps with adhesive coated disks.

This common method of making core magnetic columns from many disks or core parts is time consuming and costly. In addition, it is not easy to build aligned core columns and glue at the same time. These core column structures are hindered, at least made more difficult, by the tolerance of the disc diameters and thicknesses, the tolerances of the air-gap disks, the metering of the quantities of adhesive and layer thicknesses, which are actually not narrow enough, and also the different viscosity of the adhesive wg. Service life, different temperatures and humidities. All of these unstable factors and parameters are eliminated when using halftone half shell packages.

The next expensive operation in the conventional production of inductive components is to integrate the core columns in conventional tub housings and to produce mechanical supports of the core columns and yokes. Ultimately, external devices and aids usually have to be used for the adjustment of the inductance of inductive components, which slows down the cycle times and makes them more cost-intensive.

In this context, the EP 0 848 391 A1 a housing for the construction of separate by air gaps magnetic core columns for inductive components, which has an inner space bounding inner lateral surfaces on which a plurality of radially projecting into the interior ribs or fin projections are arranged. The interior is subdivided by the ribs or rib projections into several juxtaposed chambers for receiving core disks or core parts of the magnetic core column. The core disks or core parts are loose in the chambers and are not mechanically interconnected. This leads to non-optimal physical properties of the inductive components, such as greater electrical losses, greater electrical capacity to earth, leakage current problems and poorer heat dissipation.

Presentation of the invention:

The invention was based on the problem of designing an inductive component with magnetic cores in such a way that this component or inductor can be produced much more simply and cost-effectively, despite the multiple-part core division, than previous methods made possible.

The object is achieved by an inductive component having the features of claim 1 and by a method for producing such a component having the features of claim 8.

The central configuration for the construction of the inductive component is a housing with so-called grid half shells, or a grid bar, or grid grooves and a Rasterverguss. The housing forms chambers for receiving core disks or core parts, which together form the magnetic core. By combination z. B. with a corresponding outer housing or a novel tub housing, two or more of these housing can be assembled into a complex inductive component.

The chambers are either formed by the formed on the inner circumferential surfaces of the half-shells, radially projecting into the interior ribs or ribs approaches or nubs, or through in the inner wall of the half-shells trained grooves with intermediate layers. The ribs or rib projections or nubs or the intermediate layers at least partially define the required air gaps between the core disks or core parts.

Advantageous embodiments and further inventive features of the invention are described in the subclaims.

For the construction of the inductive component according to the invention new concepts and techniques are used. The preferred embodiments of the invention are carried out with so-called Innenstrukturverguss. This Innenstrukturverguss offers in many ways ways to break away from previously common coil inserts or partial-Einguss- method, with manufacturing advantages, including better physical properties of the chokes. Better properties such as, lower electrical losses, reduced electrical capacitance to earth, no leakage current issues, better heat dissipation from the windings. In addition, material and weight is saved.

In the mentioned Innenstrukturverguss the difference in volume between the chambers of the grid half shells and the core disks or core parts, and also the spaces between the outer core disks and outer housings, yokes with suitable potting compounds, e.g. thin-bodied resins but also standard Ausfüllmassen filled. It is used potting compounds with low thermal expansion coefficients. The penetration of the potting compounds in the cavities to be filled can be supported by evacuating the cavities.

The essence of innovation & a. is that the aforementioned minimum interior volumes are designed contiguous, are sealed to the outside, but are opened in the region of the entry of the potting compound to the atmosphere and designed with small-volume refill depots at the opening location.

The advantages are apparent. In addition to minimizing material quantities and manufacturing costs, and less resins or fillers, this technique allows not only physical advantages but also volume, weight and placement advantages for sine-wave reactors in inverters but also for all other applications.

In this way, the core columns and adhesive interstices between the outer casings and yokes are filled with potting adhesive resin, wherein the windings with their interconnections and beginnings, ends are previously pushed onto the housing. The Auffüllräume between the core discs or core parts are given taking into account the tolerances of the discs / split cores by the shape of the half shells and the outer shell.

By pouring the interiors with mostly low viscosity potting compounds, preferably in one operation, core disks and yokes are fixed and secured well. The previously complex bonding of the core parts and yokes with each other, is eliminated. Before encapsulation, the inductance value can be adjusted with adjusting screws on the outer or tub housings.

In contrast, the inner-structure potting can also be done in two operations by core pillars are first potted or molded and subsequently outer housing with yokes in a composite inner structure compound with resin or Auffüllmassen be attached. By this kind of internal structure casting technique with respect to the core disks or core parts, yokes and outer casings, low-noise inductive components or chokes with high stability, accuracy and quality are achieved.

The outflow of waste heat from the windings applied to the halves of the grid is versatile and effective. The air that absorbs the heat loss is usually connected to the internal air of the associated inverter or other electrical equipment. Most internal air circulations of inverters or electrical equipment absorb the low heat loss of the inductive component and transport it away.

According to the invention, the thicknesses of the ribs or rib projections or grid grooves in the grid half shells, grid bars or the grid shells are smaller than the thickness of the computed air gaps between the core disks or core parts. Therefore, the core disks or core parts lie on all sides with little play in the chambers of the half-shells. All tolerances of the discs or core parts and the half-shells are equalized before filling with low-viscosity resins without vacuum but also with higher viscosity casting compounds with vacuum with the constructive adjustment available.

Specifically, the thickness of the ribs may be different in this type halftone shells, grid bars or Rastervergüssen, depending on the design of the component.

Preferably, in the hollow bodies of the housing predominantly ribs or ribs projections or grooves are present, which separate the middle to outer chambers from each other, with some subsequent to the outside corrugated fins or bendable knobs for adjusting the core columns.

By axial pressure on the outer core disks or core parts, via the yokes correspondingly shaped corrugated ribs, rib projections, or knobs or intermediate layers in the grooves in the half-shell halves hollow body bent, axially displaced and sheared at larger tolerance compensations. This ensures large bandwidths in the adjustment of the total air gap dimensions z. B. an inductor or choke. The distances between the outer core disks or core parts can thus be adjusted in total and the inductance value of the component can thus be adjusted precisely.

Thus, the axial force stresses are controlled safely, the outer housing are preferably equipped with undercut Nutklemmungen and are thus fixed non-positively with the core disks or sub-cores filled half-shells. On the outer housings - as mentioned - adjustment provided to be able to exert axial forces on the arranged in the grid shells core disks so that the spaces between the outer core disks or core parts compressed, or can be reset, so that the adjusted sum of the air gaps between the core disks or core parts leads precisely to the nominal inductances.

After adjusting the distances (air gaps) between the core disks or core parts is shed with low-viscosity resin or a higher-viscosity potting compound and hardened by the core disks, permanently fixed within the half-shells and made immutable for the entire lifetime of the throttle.

It can disc and / or cuboid core parts are used, in the first case, the hollow body has a cylindrical shape, but also cuboid or cube-shaped, the hollow body then, for example, outside cylindrical and inside rectangular d. H. may have a substantially rectangular shape.

In an embodiment not claimed can be provided that the hollow body does not consist of half-shells, grid bars, but from an encapsulation housing. In this case, the casting material is poured or injected in a mold around the discs or partial cores, which are fixed at predetermined intervals with pins or holding nubs were. The potting compound forms in this way the housing and fills the air gaps between the core disks or core parts.

Furthermore, it can be provided that the outer housing are arranged separately on one piece sprayed grid columns. The outer housings can be clamped on the axially divided grid shell columns.

But it can also be made in a single operation, two halves halves with a horizontally split outer housing, d. H. sprayed, sintered, laser configured or poured.

According to the invention, the housing of the inductive component comprises so-called grid half shells, grid rails, grid casings which have at least one elongate hollow body, on the inner lateral surfaces of which a plurality of ribs, knobs or other configurations radially projecting into the interior are produced. Grooves are arranged, wherein the part-inner spaces are divided by ribs, corrugated surfaces, also axially bendable knobs, or rigid and flexible intermediate layers, quasi into several to many axially juxtaposed chambers for receiving core disks and core parts.

Preferably, the hollow body of the housing consists of two axially divided grid half-shells, each core part or core disc being characterized by at least one circularly arranged rib or knob arrangement or other configurations, e.g. Grooves, is separated from an adjacent core disk or a core part.

Preferably, the half-shells are constructed symmetrically, d. H. For example, semicylindrical, rectangular or other shaped cavities are formed in the interior of the two halves of the half-frame in which core disks or partial cores are accommodated in the manner necessary for the respective type of inductive component.

An attached hollow body of z. B. two half-shells forms several or many partial grid spaces, for example, cylindrical chambers but also other geometric, z. B. cuboidal and cube-shaped configurations that allow divisions between core disks or core parts.

The disks or core parts are inserted into the chambers of the first half-raster half-shell and closed by the second half-raster shell. This eliminates stacking, at which, for example, core disks, disk by disk core parts, piece by piece, had to be glued on each other.

After the core disks or partial cores have been enclosed by the half shells, the hollows can be filled with low-viscosity adhesive resin. But also standard resins are usable, if the Innenstrukturverguss after filling with cast resin or other filling material, e.g. Polyurethane resin is evacuated.

This to first versions of the novel grid half-throttle.

In addition, another throttle version or "throttle family" was developed with a similar to previous chokes housing technology.

Instead of the above-described two outer housing, a one-piece tub housing has been developed, the analogous as usual, z. B. receives two cores with windings and yokes and is completely or partially shed.

The tub housing, preferably made of plastic, but differs from previous tub housings in that it is not made of metal, but of thin-walled plastic configurations and cavities are closely formed on the windings and yokes.

Optionally, such housings also allow the incorporation of heat conductive metal or ceramic interfaces of a portion of the circumference of the windings to coolers or cooling surfaces of inverters.

With regard to material consumption, these new insulated bath versions are less suited to the grid-type chokes with two outer casings. Both versions - compared to previous Metallwannenlösungen- require significantly less potting compounds, because these new Isolierwannengehäuse are closely formed on windings and yokes, as is not possible with metal housings.

The invention will be explained in more detail below by means of examples. From the drawings and drawings and the following descriptions there are further features and advantages of the invention.

Brief description of the drawings:

Figur 1, 1a, 1b

Draufsicht und einen Schnitt durch eine Rasterhalbschale.

Figur 2, 2a

Schnitte durch die Rasterhalbschale mit geformten Rippen in der Gehäusehalbschale.

Figur 2b

Trapez -Nute- Zarge - Konfiguration

Figur 2c

umlaufende Nuten für Anschluss Außengehäuse

Figur 2d

Einfach- Nute- Zarge- Konfiguration

Figur 3, 3a

Ansicht, Schnitt einer mit Kernteilen bestückten Rasterhalbschale.

Figur 4

Draufsicht bestückte Kernsäule oder Rasterhalbschalenpaar.

Figur 4a

Schnitt einer Kernsäule gebildet aus Rasterhalbschalen.

Figur 5

Seitenansicht flexible (abscherbare Rippe) in Rasterhalbschale.

Figur 5a

Seitenansicht Luftspaltrippen groß starr.

Figur 5b

Seitenansicht Luftspalte mit Rippenansätzen klein starr

Figur 5c

isometrische Innenansicht Fig. 5b Rasterhalbschale

Figur 5d

Schnitt, Stellbereich R. Schale, Kernscheiben lose

Figur 5e

Schnitt, Stellbereich R. Schale Kernscheiben eingestellt

Figur 5f

Rasterhalbschalen große Starr und flexible Wellrippe

Figur 5g

komprimierbare Zwischenlage Kernscheiben

Figur 5h

Doppel-Rasterhalbschale mit flexiblem Biegescharnier

Figur 5i

Doppel-Rasterhalbschale mit flexiblem Biegescharnier

Figur 5j

Isometrisch Doppel-Rasterschale mit Biegescharnier

Figur 5k

Isometrisch Doppel-Rasterschale m. flex. Biegescharnier

Figur 6

Spulenseite und Seite eines Außengehäuses.

Figur 6a

Jochseite eines Außengehäuses.

Figur 6b

Draufsicht des Außengehäuses.

Figur 7

Seitenansicht Wickelung auf Spulenkörper.

Figur 7a

Draufsicht Wicklung auf Außengehäuse.

Figur 7b

Isometrie mit zwei bewickelten Spulenkörpern.

Figur 7c

Spulenseite eines Außengehäuses.

Figur 7d

Rückansicht des Außengehäuses.

Figur 7e

Draufsicht bewickelte Kernsäulen - Außengehäuse verbunden

Figur 8

Draufsicht auf Kernsäulen

Figur 8a

Kernsäulen, an einer Außenseite

Figur 9

eine Einzelwicklung

Figur 9a

Draufsicht einer Einzelwicklung

Figur 10

Kernsäulenstapel mit Rohrumhüllung ohne Rippen

Figur 11

Draufsicht von Figur 10

Figur 12

Gehäuse mit Kernscheiben-Kernsäule

Figur 13

Schnitt durch Figur 12

Figur 14

umspritzte Quadrat- und Rechteckkernteile

Figur 15

umspritzte Stapel-Kernsäulenversion

Figur 16

Draufsicht der Figur 14

Figur 17

Draufsicht der Figur 15

Figur 18

Kernsäulenschalen ohne Rippen Draufsicht

Figur 19

Seitenansicht einer Rasterhalbschale ohne Rippen

Figur 19a

Draufsicht auf eine Rasterhalbschale ohne Rippen

Figur 19b

isometrische Ansicht der Rasterhalbschale mit Nuten

Figur 19c

isometrische Ansicht des zusammengesetzten Gehäuses ohne Rippen.

Figur 19d

isometrische Ansicht des zusammengesetzten Gehäuses mit Zwischenlagen.

Figur 20

Rasterhalbschale mit Lochmuster

Figur 21

Kernsäulenleiste in Dreieck Anordnung 120°

Figur 22

Kernsäulenleiste gemäß Figur 21, Seitenansicht

Figur 23

Kernsäulenleiste als Distanzteil zu Wicklung

Figur 24

Einstellung Induktivität in Spritzmaschine

Figur 25

Zusammenstellung Drossel mit Rasterschale Standardjoche

Figur 26

Joche für Großserien Version

Figur 27

Außengehäuse Großserien Version

Figur 27a

Dichtung für Innenverguss Kernscheiben und Joche Version

Figur 28

Explosionszeichnung Drossel Auengehäuse Version

Figur 29

Zusammenstellung Drossel Außengehäuse Version

Figur 29a

Zusammenstellung Schnitt Innenstrukturverguss

Figur 29b

Zusammenstellung Stirnseite

Figur 29c

Drehstrom- Drosselstapel mit Außengehäuse

Figur 30

Rasterdrossel mit Wannengehäuse

Figur 30a, 30b

Rasterdrossel mit Wannengehäuse

Figur 31, 31a

Kernsäulen mit Wicklung, verschaltet

Figur 32

Wannengehäuse Seitenansicht

Figur 32 a

Wannengehäuse Draufsicht

Figur 32 b

Wannengehäuse Längsschnitt

Figur 32 c

Wannengehäuse Stirnseite

Figur 32 d

Wannengehäuse Kernsäulenaufständerung

Figur 32 e

Wannengehäuse Mitte, Schnitt

Show it:

Figure 1, 1a, 1b

Top view and a section through a grid half-shell.

Figure 2, 2a

Sections through the screen half shell with shaped ribs in the housing half shell.

FIG. 2b

Trapezoidal groove - configuration

Figure 2c

circumferential grooves for connection outer housing

Figure 2d

Single-groove frame configuration

Figure 3, 3a

View, section of a half-shell equipped with core parts.

FIG. 4

Top view equipped core column or grid half-shell pair.

FIG. 4a

Section of a core column formed from half-shells.

FIG. 5

Side view flexible (removable rib) in grid half shell.

FIG. 5a

Side view of air gap ribs big rigid.

FIG. 5b

Side view Air column with ribbed shoulders small rigid

FIG. 5c

isometric interior view Fig. 5b Grid half shell

FIG. 5d

Section, adjustment range R. Shell, core discs loose

FIG. 5e

Cut, adjustment range R. Shell core discs adjusted

FIG. 5f

Raster half shells large rigid and flexible corrugated fin

FIG. 5g

compressible liner core disks

FIG. 5h

Double screen half shell with flexible bending hinge

FIG. 5i

Double screen half shell with flexible bending hinge

FIG. 5j

Isometric double grid shell with bending hinge

FIG. 5k

Isometric double grid shell m. flex. bending hinge

FIG. 6

Coil side and side of an outer housing.

FIG. 6a

Yoke side of an outer casing.

FIG. 6b

Top view of the outer housing.

FIG. 7

Side view winding on bobbin.

Figure 7a

Top view winding on outer casing.

FIG. 7b

Isometry with two wound bobbins.

FIG. 7c

Coil side of an outer housing.

FIG. 7d

Rear view of the outer housing.

Figure 7e

Top view wound core columns - outer housing connected

FIG. 8

Top view on core columns

FIG. 8a

Core columns, on an outside

FIG. 9

a single winding

FIG. 9a

Top view of a single winding

FIG. 10

Core column stack with tube cladding without ribs

FIG. 11

Top view of FIG. 10

FIG. 12

Housing with core disk core column

FIG. 13

Cut through FIG. 12

FIG. 14

over-molded square and rectangular core parts

FIG. 15

overmoulded stack core column version

FIG. 16

Top view of FIG. 14

FIG. 17

Top view of FIG. 15

FIG. 18

Core column shells without ribs top view

FIG. 19

Side view of a grid half shell without ribs

FIG. 19a

Top view of a grid half shell without ribs

FIG. 19b

Isometric view of halftone screen with grooves

FIG. 19c

isometric view of composite housing without ribs.

Figure 19d

Isometric view of composite housing with liners.

FIG. 20

Raster half-shell with hole pattern

FIG. 21

Core column strip in triangle arrangement 120 °

FIG. 22

Core column strip according to FIG. 21 , Side view

FIG. 23

Core column strip as a spacer to winding

FIG. 24

Setting inductance in spraying machine

FIG. 25

Assortment of ballast with halftone shell. Standard yoke

FIG. 26

Joche for high volume version

FIG. 27

Outer housing large series version

Figure 27a

Gasket for Innenverguss core washers and yokes version

FIG. 28

Exploded view choke outer casing version

FIG. 29

Assembling throttle outer casing version

Figure 29a

Assortment cut interior structure casting

FIG. 29b

Compilation front page

Figure 29c

Three-phase choke stack with outer housing

FIG. 30

Grid choke with tub housing

Figure 30a, 30b

Grid choke with tub housing

Figure 31, 31a

Core columns with winding, interconnected

FIG. 32

Tub housing side view

Figure 32 a

Tub housing top view

FIG. 32b

Tub housing longitudinal section

FIG. 32c

Tub housing front side

Figure 32 d

Tub housing core column elevation

FIG. 32 e

Tub housing center, section

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

1. 1. Rasterhalbschalen-Kernsäulen mit Wicklung, spannbaren Jochen- auf die KernScheiben, Spannschrauben in den Brücken der Außengehäusen in einer Einfachstausführung für niedrige Stückzahlen und eine Serienausführung für hohe Stückzahlen beide Ausführungen mit Innenstruktur- Verguss für die Auffüllung der Luft-Spalte zwischen Kernscheiben oder Kernteilen und der Herstellung der Fixierung der Stabilität der gesamten Drossel
2. 2. Rasterhalbschalen-Kernsäulen mit Wicklung, spannbaren Jochen- auf die KernScheiben oder Kernteile, ebenfalls stirnseitigen Spannschrauben die in umhüllenden Wannengehäusen mit Standard- oder Magnetfluss- optimierten Jochen- in Spiegelverguss jedoch mit vermindertem Gussvolumen.

The following embodiments of the invention relate to novel housing for the construction of chokes whose magnetic circuits on the one hand of largely standardized soft magnetic materials or ferrite materials, such as core discs and yokes exist. On the other hand, the invention relates to the environment of the grid shell core columns, ie the connection of the grid shell core columns with the throttle or the transformer windings, or possible applications with different housings, substantially reduced to two construction lines:

1. 1. Center half-shell core columns with winding, tensionable yokes-on the core disks, clamping screws in the bridges of the outer casings in a simple, low-volume version, and a high-volume standard version, both versions with internal structure potting for filling the air gaps between core disks or core parts and the preparation of fixing the stability of the entire throttle
2. 2. Half-shell core columns with winding, tensionable yokes-on the core disks or core parts, also clamping screws on the front side-the Jochen mirror housings encased in enveloping shell housings with standard or magnetic flux-optimized but with reduced casting volume.

The core idea according to the invention: "half-shell core columns" was thus expanded and supplemented with magnetic flux-optimized yokes, plastic well casings, streamlined interconnections and power connections. The future series production processes are each attributed to only two integrating plastic parts. With this new, simplistic integration technique, the entire throttle structure is determined, which allows completely new manufacturing processes.

The Figures 1 and 1 a, 1 b show a plan view and a section through a housing 1 with so-called grid halves 1 a, 1 b. Each screen half shell 1 a, 1 b is formed in the form of a thin-walled half-cylinder and has, inter alia, a continuous axially-flat recess or channel 2, see. also FIG. 18 , Left and right of the recess / channel 2 are z. B. pairwise thin ribs or fin approaches 3 or (3a in Figures 5 ), which divide the interior of the screen half-shell 1a into individual chambers 76. The individual chambers 76 are in the longitudinal direction of the half-shells Fig. 1a, 1st b arranged one behind the other. Further, the ribs / lugs 3, 3a or air gap grooves on the inner circumference of the half-raster shell 1 a, 1 b placed, preferably in pairs in the form of, for example, circular segments.

For flanging of so-called outer housings 10 circumferential grooves 5 or segment grooves are respectively provided at the end of the half-shells 1a, 1b, the u. a. for fixing the outer housings 10, as described below:

The FIGS. 2 to 2c show cross sections through half-shells 1a, 1b and the joining examples show Fig. 2b and 2c , In FIG. 2 is the side view of the outside of a half-raster shell 1a, 1b mirrored. The ribs / lugs 3, 3a are preferably independent of their radial height as rigid ribs or rib projections 3a Fig. 5b , or grooves Fig. 19b formed, which are connected to the inner wall of the screen half-shell 1a, b.

FIG. 2a shows a section through the screen half-shell 1a in the region of the rigid ribs 3. The ribs 3, 4 are separated from each other by the recess or the channel 2 and preferably formed in pairs. The FIG. 5c shows an isometric view of a grid half-shell with rigid ribs 3 and until shearing bendable ribs 4 or nubs 4a in Fig. 5c , The axially slightly bendable ribs or nubs 4, 4a are preferably arranged in the respective outer parts of the half-shells 1 a, 1 b. The FIGS. 19b, 19d 5g and 5g show alternative embodiments of half-shells with grooves on the inner surfaces. The overall lengths of the half-shells 1a and 1b are smaller than the lengths of the sequentially arranged core disks 9 plus the sum of the air gaps. Ie. the frontal, outer core disks or core parts 9 protrude slightly up to a few millimeters projection 38, 39 from the closed half-shells 1a, 1b ( FIGS. 5d, 5e ). This is required to generate a force 53, 54 Fig. 5d, 5e ) to be able to exert on the outer core disks 9 or core parts, so that the core disk distance plus / minus adjusted and thus the length of the core column can be adjusted, but on the other hand, so that on the surfaces of the outermost core disks or core parts and the yokes 17 and 40 ( Fig. 28 ) can be placed without a column. Has in its axial sides each half raster 1a a continuous frame 6 in Fig. 2b and a continuous groove 7, with which it can be connected to another cylindrical half-shell 1b constructed identically to a cylindrical housing 1.

In the Figures 4 - 5e are the pimples in the loose state Fig. 5d , wherein the air gap 36 is large and in an untensioned state, and tensioned state Fig. 5e shown, in which the air gaps 37 are reduced. Easy and damage-free bendability of the nubs 4a ( Fig. 5e , 35) is possible because around the knob feet each inner recesses 34 in Fig. 5c are arranged, which prevents a nubble shearing when moving. The same applies to the halved halves with grid grooves, Fig. 19 , Pos. 89.

The difference between the diameter of the core disks 9 and the depth of the recesses over the inner diameter of the chamber Fig. 4a In addition, allows an axially elastic spring adjustment according to Fig. 5e each z. B. between one or more core disks 9 and their air gaps, Fig. 5e , which is no longer adjustable after encapsulation.

The FIG. 5g shows alternatively to the knob adjustment also elastic intermediate layers Fig. 5g , Pos. 78, 79, 80, in the form of a compressible but also retractable thin plate, which could be used instead of possibly in addition to bendable ribs 4 or nubs 4a, if much large adjustment strokes are to be realized, but this is not required for standard throttles is.

The FIGS. 3 and 3a show view or a section through a half-raster shell 1 a with inserted core disks 9 as a magnetic core column. The screen half-shell 1a comprises ribs 3, 4 or rib projections, nubs 4a, cf. Fig. 5 ff. In the cavities or raster chambers 3b between the ribs 3, 4 or nubs 4a core parts, z. B. in the form of core disks 9, inserted, wherein the plus-tolerance diameter of the core disks 9 are smaller than the inner diameter of two grid halves 1 a, 1 b or hinge closed half shells Fig. 5h to 5k , In each case at the ends of the half-shells, the inner diameter of the joined grid half shells is reduced Fig. 5c , 57, ie the two outermost core discs sit backlash-free or under slight compression in the unshifted half-shells 1 a, 1 b. Thus, when mounting the outer housing Fig. 6 . 7 . 25 and 28 pressed onto the non-cast core columns the end portions of the grid half-shell hollow chambers together without play, because the core disks 9 are rigid, in the open chambers Fig. 5c , 57 sitting, which leads to a good adhesion connection between core columns and outer housing. Fig. 6 . 7 . 25 . 28

Otherwise, the "thicknesses" or "heights" of the core disks 9 are slightly smaller than the minimum diameter and axial dimensions of the chambers 76, ie the distance between the ribs 3, rib projections 3a and nubs 4.

After inserting the core parts or core disks 9 into the chambers 76 (FIG. Fig. 1 , and Fig.) Between the positions 3-3, 3-4, 4-4 and 3a-3a and 3a-4a and 4a-4a, the half-raster shell 1 a with a second half-raster shell 1 b closed or analogous to Figures 5h or 5k folded by means of a bending hinge 52. This eliminates the need for conventional stacking operations where core disks / parts need to be stacked and glued together piece by piece. The technique described of inserting the core parts 9 into the half-shells 1a, b is more efficient and precise than stacking individual core disks or core parts, even if stacking techniques are automated or semi-automated.

According to the invention, the effort for merging the core parts 9 is reduced to simple and short-term insertion operations of the core parts 9 into the chambers ( Fig. 3a , 3b 4, 4a ) of the half-raster shell 1a and the adhesive bonding of the second half-raster shell 1 b, and Fig. 5d, 5e considerably. Apart from a possible gluing of the frames 6 and grooves 7 of the half-shells 1a, 1 b, no further manual or automated operations for assembling the grid shells with core parts are necessary.

The FIG. 4 shows z. B. the attached configuration 1 a, 1 b consisting of half-shells 1 a and 1 b. The FIG. 4a shows set core column 1 with inserted core parts. 9

The Figures 5 . 5a to 5g show in detail cross sections of the assembly of half-shells 1 a and 1 b ( Fig. 19 et seq.). Each grid half shell 1 a, 1 b comprises ribs 3 distributed on the inner circumference (FIG. Fig. 5a ) or rib projections 3a (FIG. Fig. 5b ), as well as bendable ribs 4 ( Fig. 5 ) or nubs 4a ( Fig. 5c ), which form the intermediate spaces, ie chambers 3b, for receiving the core parts 9.

Furthermore, there is also the possibility hinge half shells Fig. 5h to Fig. 5k manufacture. The two raster switching, quasi a lower and upper part, are connected to one of their longitudinal sides with a bending hinge 52 and can be folded together by means of this bending hinge 52. In this case, one side of the double screen half shell ( Fig. 5j ) fitted with core disks and the unfilled half-raster half-shell folded on the equipped half-raster.

The natural tightness of the jacket hinge connection is advantageous. Furthermore, no handling and Aufsetzjustierungen ( Fig. 5i ) with the second halftone half shell required because the integrated bending hinge 52 does not allow a shift of the halves of the grid with each other.

Which of the versions according to the invention are selected, individual halftone halves Fig. 1 or double grid shells, or grid half shells with grooves Fig. 5 The following halftone shell versions all versions can be connected to the so-called outer housings 10.

The FIGS. 6 to 6b and 27 and exploded view Fig. 28 For example, show outer housing 10, 43, which can be connected to grid half-shell core columns. These outer housing 10, 43 consist z. B. from a two-hole base plate, mounting bars and version Fig. 27 in addition from a Umrandungskragen, which for specially shaped yokes and the admission of casting resin Fig. 28 is designed.

The base plate of the outer housing Fig. 6 a, b , P10 includes holes 11 with undercuts 12 so that the core columns can be locked non-positively and shear-resistant on the outer housing 10, 43. The openings 11 with the undercuts 12 are reduced with clamping screws 13 in their diameters by the clamping screw 13 is tightened. The undercuts 12 of the holes 11 of the outer housing in Fig. 25 . 28 engage in the grooves 5 of the core columns 1 and are clamped by clamping screws 13 in the grooves 5.

The remaining gap Fig. 6a . 14 can with seals Fig. 6 . 15 be sealed so that the connections between the housing 1, the outer housings 10 and held on / in the outer housing yokes 17 is closed and interfere with the pouring of the cavities no leaks the potting process.

After z. B. the windings on the preassembled housing 1, no matter what version, are applied, the outer housing Fig. 6a, b . 10 moved over the undercuts 12 at the ends of the core columns. The tightening of the clamping screws 13 in the outer housings 10 ( Fig. 7c or Fig. 27 ), the outer housing 10 flanges frictionally on the core columns.

FIG. 9 shows a single winding 16, as it is applied to the housing 1.

FIG. 9a shows a plan view of a single winding. It forms between the housings 1 with core columns via the interface outer housing 10, a compound that z. B. by the automatic bonding with the structural cast, can be made even more stable. The equipped with yokes 17 outer housings 10 and associated housing 1 with core columns are filled after assembly with low-viscosity filling and / or adhesive resin. This is the difference volume Fig. 29a between the interior of the half-shells 1a, b minus the sum of the volumes of the core parts 9 plus Jochklebung filled.

The casting compound flows through the axially sealed half shells Fig. 29a and fills from the inner yoke 40, outer housing 10 via the individual core disks 9 to the filling space between the "upper" outer housing 43 and yoke 40, where no seal is placed on.

At the same time, the air displaced by the resin escapes from the cavities of the housings 1 with windings 16 and the adhesive and casting spaces between the outer housings 10 and yokes 17. As the casting compound, thin-bodied casting, polyester or PU resin etc. is generally used. but also standard resins.

The FIGS. 4, 4a 4b show how core disks 9 or core parts of a core column are inserted into the halftone half shell 1a. The core disks or core parts 9 usually have a slight axial play in their respective chambers, because the ribs 3 or ribs 4 are made thinner than the intended and calculated air gap between the disks or core parts 9.

Tolerances of the core parts 9 are easily compensated. The second half-raster 1 b is closed via the filled with core parts 9 housing half 1 a. Previously may - alternatively but not adhesive must be introduced into the groove 7 or the frame 6 of the half-shells.

With z. B. tapping screws Fig. 7d . 18 In the bridge connections 19, a connection with the outer housings 10, 51 is produced, wherein the yokes are pressed onto the core stacks in the housing 1. With the bridge connections 19, the outer core disks 9 can be stretched, causing z. B. several air gaps with bendable knobs 4, 4a (FIG. Fig. 5e ).

After biasing the yokes 17, 25, 28 and the adjustment of the distances of the core disks 9 or core parts in the core stack can use the curing of the potting compound, Fig. 29 , When adjusting the core stack z. B. also the "Shrinkage" of the potting compound are preceded by corrected, in that the difference, casting compound liquid - later hardened, is taken into account, FIGS. 5d , e.

The advantages of the half-shells 1 a, 1 b as a complete enclosure with flanged outer housings Fig. 25 . 28 Thus, in addition to the greatly simplified production, the limitation of assembly errors and the filling of the air gaps and the now possible plane-parallel bonding of the yokes.

The core idea of the simple assembly of core columns and their environment with core disks or core parts, yokes is also maintained with variable alternative and modified elements and manufacturing processes.

For example, when it comes to set core stack before encapsulation or potting with respect to their inductance, z. B. grid strips 69 also with frontally arranged brackets according to the Figures 21-24 get connected. The force stress of the construction of grid bars 69 and holders 70 with thin wall thicknesses, is sufficient for the adjustment of the inductance value.

In such a way that a spray or casting mold in the form of grid bars 69 is fitted with core disks 9 and the length of the core columns is determined by means of yokes 71 (FIG. Fig. 24 ) can be adjusted by compressing the core stacks until the nominal inductance is reached. Only then does the extrusion coating process follow, for example, according to the core column, Fig. 12 , A core column marking ensures that when the chokes are installed, the respectively adjusted core columns remain together until final assembly.

A similar approach is with so-called core column strips Fig. 22-24 possible. That is, the core disks 9 or parts with, for example, three or four grid strips 69 before insertion into an injection mold Fig. 21, 23 fixed by the brackets 70 and adjusted according to the described method, also encapsulated or cast around. FIG. 24 ,

The Figures 26-32 show tailored to mass production throttle design, substituted in previously customary single-part configurations and further developed.

In an explosion sketch Fig. 28 or or the Fig. 29a a choke is shown, which is designed for high volumes. In order to create compact designs, commercially available cuboid yokes are no longer used. Instead of standardized cuboid yokes, flow-specific shaped yokes were used " Fig. 26 designed, based different magnetic fluxes over the Jochlänge. This means that z. B. is the largest dimensioned cross section in the middle of a yoke 40, because only place is the full magnetic flux. All cross sections outside the center of the yoke can be reduced to half-left / right of the center or less large cross-sections. Ie. all cross sections going from the central area to the outside Fig. 26 , Numerals 65, 64, 63 are approximated to the actual magnetic fluxes. This creates space for the accommodation of terminals, contact fittings, winding bridges, and integrated foot structures of the chokes Fig. 27 . 28 ,

Furthermore, it is advantageous if the support side of these yokes offset surfaces Fig. 26 receives. The plane surface of the yoke for the passage of the magnetic flux is advantageously made only a little "wider" than the diameter of the core disks. In the paragraph Fig. 26 can connect bridges Fig. 31 , Stranded leads 84 can be accommodated, which advantageously allows for minimized overall volume and molded internal insulation to the yoke. Thus, up to 30% material is saved at the Jochen - at the same time better flow cross-sectional performance

Next are for the realization of a complete Innenvergusses a throttle Fig. 28 Thus, creating a tight connection between core disks / core parts, outer casings and yokes, separately cast-in starts, ends, connections of windings or contact pieces all the fixtures are combined and integrated.

The exploded drawing Fig. 28 shows this. The drawing in the compilation Fig. 29 also shows how the volume and weight reduction of a throttle is achieved.

With the half-shells according to the invention FIGS. 5 to 5k , the outer housings Fig. 27 . Fig. 29 For reasons of design, minimum capacities between the windings and against ground are achieved, which is advantageous for use in inverters because, as a rule, the minimized capacitances reduce the switching losses of the semiconductors in the inverters.

From the conception according to the invention, hitherto unachieved dielectric strengths, resistance to moisture result in greater creepage distances between windings and mechanical fastenings of the throttles, which results in safety, stability and very low-noise chokes Fig. 25-31 entails. Adhesive breaks between the core disks 9, Fig. 12 . 14 . 15 . 24 . 25-31 and core parts are virtually excluded. However, if an adhesive break between core disks 9 should occur, this has no consequences, because the halves halves keep the core columns stable without interruptions. The FIG. 13 shows an alternative to the previous embodiments, a complete manufacturing form, consisting of a lower part 25 and a top 26. With the help of this manufacturing form 25, 26 can be made completely one or more parts injection-molded or cast or pressure-gelled core columns. In the production form, two or more retaining pins 27 are arranged in the lower part 25 of the manufacturing mold per core part. The core parts 9 can thereby be fixed in the bottom part 25 exactly with a defined distance (air gap). The upper part 26 of the manufacturing form has per core disk or core part 9 a fixing pin 28. Three fixing pins 27, 28 for each core part 9 are sufficient to fix the entire arrangement of the core part 9 before the casting process exactly in the production form.

At the beginning or at the end of the stack of core disks or core parts 9, there are receptacles in the mold for enclosing the core disks or for sealing at the ends of the core pillars when core pillar single potting is practiced. This is not the case when the core columns are provided with outer or integral housings, as will be described below.

In a further embodiment of the invention according to FIG. 20 For example, the pin assemblies can be dispensed with in a mold or mold when, for example, halftone shells 72 are used with a thin, apertured sheath. The hole pattern in the shell of the half-raster shell 72 allow the unhindered entry of the spray or casting compound into the gaps between the core disks or core parts inserted in the half-rake shell, as well as the closure of the insulating cylinder part around the core disks or parts.

With little effort core columns with grid bars 69 according to the FIGS. 21 to 24 getting produced. Two or three grid strips 69 suffice to be molded in an injection mold, Fig. 24 9, core disks or core parts exactly bring in and overmold or encapsulate according to the above. Again, there are again two possibilities of realization. On the one hand, the grid strips 69 can be embedded in the holders 70, Fig. 23 ; On the other hand, with a final fixing, the grid strips 69 can also be converted into simple diameter half-shells, Fig. 21 , be inserted. In the former case according to Fig. 23 can the already conceptually low electrical capacitance to earth be further lowered because the winding at the inner diameter only a small contact surface on the grid bars 69 has. In the second case, the capacity of the winding to earth corresponds to the previous versions.

All stocked as above with core disks or core parts 9 manufacturing forms according to the Fig. 21-24 be like the Figures 12 or 13 filled with spray or potting compound. After solidification of the spray or potting compound to obtain a thin coated core column. The core disks 9 are separated from each other by tufts or disks and air gaps filled with injection molding compound. Provided at the ends, embossed mounting grooves are used for attachment to an outer housing 10th

It is also possible, two in a manufacturing mold 25, 26 manufactured core stack together with the configuration of an outer housing 10 together squirt or pour and mount after application of the windings for the inductive component element single outer housing.

As in the FIGS. 14 to 17 Shown in housings 1, consisting of upper part and lower part, not round core parts 30, 31 are added. For example, the show FIGS. 14-17 Housing 1, in which cuboid or cube-shaped core parts are included. In this configuration, clamping bolts 32, Fig. 14 , in the claddings of the core columns Fig. 14, 15th are introduced, which can serve for the attachment of outer housings, yokes or bearing plates or flanges.

The Figures 16,17 show configurations of such a molded or cast housing 1 in which rectangular core parts 30, 31 are arranged. The core parts have different dimensions and thicknesses to best fill the cross sections of the core columns. In this regard shows FIG. 16 a cross section of a core column, it can be seen that the total cross section of a square core member 30 and distributed on the sides, four rectangular side core parts 31 join.

Analog shows FIG. 17 shows a staggered core configuration. There are core parts 30, 31 are arranged, the differentiated in their dimensions -Folienbreite- different and thus use the round cross-section of the housing 1 and fill. The core columns of core parts 30, 31 are separated from each other by corresponding intermediate layers or rib projections, which then form the air gaps.

The Figures 19, 19a, 19b, 19c and 19d show half-shells 1 b in different views and the composite housing 1 according to FIGS. 19c and 19d , For filling the housing 1 with casting compound in turn recesses / channels 2 are arranged on the inner wall as in half-shells 1a, 1b.

This to the different embodiments of half-shell core columns with outer casing and Innenverguss.

Instead of the outer housing Fig. 28 but can also be used as "integrated molded plastic tub casing Fig. 30 be connected to previous throttle body - made of metal - but have more production or electrical functions as previous housing. The plastic tub housing Fig. 30-32 consist of quasi rectangular housing parts in the yoke area. The rectangular shapes go outside the yokes in semicircular-parallel tubs Fig. 32 e above. The adaptation of the plastic housing parts to the configuration of the throttle saves potting compound and causes more mechanical stability.

There are also small recesses in this type of integral plastic tub housing Fig.32a , 67 for the acceptance of welded or soldered joints between conductor profiles, strands Fig. 31 , 84 or interconnecting bridges Fig.31 , Pos. 85. In addition, there are spacers and insulating bars Fig. 32a , 68, 76 for the interconnecting bridges. This design allows no taping or hose insulation in the area of the conductor contacts required.

The core columns Fig. 31 can in the core shots Fig. 32a 67, with the yokes each "behind the recordings" Fig. 32e 76 are laid. Behind or in front of the brackets are insulating and spacer bars Fig. 32a placed, which distance the Verschaltungsbrücken the windings on the one hand to the winding, on the other hand to the yokes, without otherwise usual insulation measures. After in the tub housing Fig. 30 Following core columns with windings and yokes are inserted, the chokes can be adjusted with the adjusting screws before casting. These are in the front pages Fig. 30 , 81 small hubs with holes and subsequent pipe sockets 88, which cover the screw head, provided in which the screws are turned and the inductance can be accurately adjusted, the screw head pipe socket 88 covers the yoke potential.

Otherwise used external clamping devices for stacking, fixing and adjusting the cores or the cores with yokes can be omitted. Each individual throttle can be adjusted directly and very accurately to its L nominal values, including the pre-adjustments, which takes into account the minimum shrinkage of the complete casting.

When casting, it is such that the potting compound passes through the channels between grid half shells and core disks in the interior of the core columns and results in a compact potted throttle device.

With the encapsulation-embedding of the core disks in the half shells of the potting does not completely fill the air gap spaces - as in the outer housing version- fill. A grouting extending below to above the center line or for immersing the half-shell diameter is sufficient to produce the necessary compactness of the core columns, so that vibration and noise are excluded,

List of reference numbers

1

casing

1a, 1b

Grid half shell

2

Recess / channel

3

Rib, (rigid)

3a

Rib approach, (rigid)

4

Ribs bendable

4a

Knob is bendable

5

Groove for outer housing

6, 6 '

frame

7, 7 '

groove

9

Core disk or core part (core disk)

10

outer casing

11

Opening, bore

12

undercut

13

clamping screw

14

gap

15

poetry

16

winding

17

yoke

18

Scheid screw

19

bridge connection

20

Bridge fixation bar

21

Diameter fixing bar

22

Diameter groove fixing strip

23

Padding for injection molding or casting compound

24

Inductance adjusting yoke in injection or casting machine

25

Production form (lower part)

26

Production form (upper part)

27

Fixing pin (lower part)

28

Fixing pin (upper part

30

Core part for core columns

31

Core part for core columns

32

clamping screw

34

Recess, adjustment nubs

35

Noppe flexible

36

Air gap unclamped, large

37

Air gap set, reduced

38

Overhang core disk in grid shell, exterior

39

Supernatant core disc in rater cup, exterior, discontinued

40

yoke

43

outer casing

45

contact well

46

Contact trough with coil end and pigtail potted

47

Lug terminal winding end / beginning

48

Connection winding end-strand

49

Connection winding connection fitting

50

Power connection windings

51 52

bending hinge

53

P1-force core column unstrung

54

P2-force core column tensioned and adjusted

55

Double half shell hinged bracket large

56

Double half shell hinged angle small

57

Centering and retaining collar for outer core disks

58

Seal core pillar outer housing yoke, gap

59

resin potting

60

Resin filling core

61

Resin filling outer housing

62

Flow in yoke-optimized cross-sections

63

cross-section

64

cross-section

65

cross-section

67

Distance pouring troughs for connections

68

Distance channels for bridges

69

Sceenstrips

70

bracket

71

yoke

72

Raster half-shell (perforated)

73

Plastic tub housing

74

Yokes in the tub housing

75

Half shells in the tub housing

76

Kammer760 core column elevation in the tub housing

78

liner

780

Insulating bars in integral housing

79

liner

790

Set screw hub, reinforced on insulating housing

80

liner

800

Set screw hole in integral housings

81

screw

83

Screened channels for resin potting

84

Flexible wire

85

Connection bridge winding connections

86

Central axis throttle

88

Pipe socket, electrical cover of the clamping screws

89

groove

Claims (22)

1. Inductive component with at least one housing (1), in which one or more magnetic core columns are accommodated and on which at least one winding (16) is arranged, the housing (1) having inner lateral surfaces limiting the interior thereof, on which a plurality of ribs or rib lugs or burls (3; 3a; 4; 4a) projecting radially into the interior or grooves (89) with intermediate layers (78 to 80) are arranged, wherein the interior is divided by the ribs or rib lugs or burls (3; 3a; 4; 4a) or the grooves (89) with intermediate layers (78 to 80) into a plurality of chambers (76) arranged next to one another in a row to accommodate core discs or core parts (9; 30, 31) of the magnetic core column, characterised in that the core discs or core parts (9; 30, 31) are non-movably fixed by cast-in casting compound into the chambers (76), an internal structure casting being provided, in which the volume difference between the chambers and the volume of the core discs or core parts is filled with the casting compound.
2. Inductive component according to claim 1, characterised in that each core disc or core part (9; 30, 31) is separated by at least one rib or rib lug or burl (3; 3a; 4; 4a) or a groove (89) with an intermediate layer (78 to 80) from an adjacent core disc or core part, and this rib or rib lug (3; 3a; 4; 4a) or the intermediate layer produces or forms a part of a predetermined air gap between the adjacent core parts (9; 30, 31)
3. Inductive component according to either of claims 1 or 2, characterised in that the thickness of the ribs or the rib lugs or burls (3, 3a; 4, 4a) or intermediate layers (78 to 80) is preferably smaller than the thickness of the predetermined air gaps between the core discs or core parts (9, 30, 31).
4. Inductive component according to any one of claims 1 to 3, characterised in that both rigid ribs or rib lugs (3, 3a) and, in the axial direction, bendable, also axially flexible ribs or burls (4, 4a) are additionally present.
5. Inductive component according to any one of claims 1 to 4, characterised in that the individual chambers (76) are connected to one another by at least two recesses or channels (2) running in the wall of the housing (1) in the axial direction.
6. Inductive component according to any one of claims 1 to 5, characterised in that devices and grooves (5) for fastening external housings (10) are provided at the ends of the housing (1).
7. Inductive component according to any one of claims 1 to 6, characterised in that the external housings (10) have circular receivers and undercuts for the grooves (5) of the housing (1).
8. Method for producing an inductive component according to any one or more of claims 1 to 7, characterised in that continuously connected interiors of assembled components, which comprise a housing (1) assembled from grid half shells, a first external housing (10), yokes (17), core columns, and a second external housing, are cast with castings made of resin or casting compounds, whereby magnetic circuits consisting of the core discs or core parts (9, 30, 31), the yokes (17), the enveloping housing (1), the external housings (10) and tensioned bridge connections (19) are mechanically and electrically fixed and made non-adjustable for the service life of the inductive component.
9. Method according to claim 8, characterised in that filling resins or casting compounds for an internal structure casting are installed through separately distributed channels from respective tension fits of the core columns to the insides of the housing (1) and the external diameter of the core discs (9) throughflow resin passing points, wherein the internal casting takes place depending on the position from an external housing (10) by way of the core columns to the other external housing (10) and the yokes (17), as a restrictor internal structure casting.
10. Method according to either of claims 8 or 9, characterised in that the internal structure casting of the component is injected or cast into an internal structure casting or internal structure core columns or is divided in adaptive part castings of core columns individually or with yoke casting.
11. Method according to any one of claims 8 to 10, characterised in that the contact connections of the winding are also cast simultaneously with the internal structure casting in separate troughs of the external housing (10).
12. Method according to any one of claims 8 to 11, characterised in that casting-in points are present and gaps and configurations proceeding from the casting-in points exist between the yokes (17) and external housing (10), in which the casting compound can distribute while running and, after hardening, stably connects the core columns, the external housing (10) and yokes (17).
13. Method according to any one of claims 8 to 12, characterised in that casting-in faces are present on the external housings (10), and provided thereon are resin connecting configurations, such as, for example, fine burl faces produced by injection between the yokes (17) and the external housings (10), in which casting compound sets and, after hardening, connects core columns, external housings and yokes in a non-positive manner.
14. Method according to any one of claims 8 to 13, characterised in that transverse casting-in faces are present on the external housings (10), and provided thereon are resin connecting configurations interlocked by casting between the yokes (17) and external housings (10), which are located approximately in the centre between the core columns, external housings (10), yokes (17) and standing areas placed at the outer corners and their fastening bores.
15. Method according to claim 14, characterised in that bearing faces, which allow simple and multiple stacks of a plurality of inductive components one above the other, are additionally arranged next to the transverse casting-in faces of the external housings (10) with the resin connecting configurations interlocked by casting between the yokes and external housings.
16. Inductive component according to claims 1 to 4, characterised in that the individual chambers (76) are connected to one another by at least two semi-circular or approximately semi-circular or trapezoidal recesses or channels (2) running in the wall of the housing (1) in the axial direction, and these core columns with the winding, wiring and connections are arranged in a plastics material trough housing (73).
17. Inductive component according to claim 16, characterised in that the plastics material trough housing (73) is closely adapted to the external contours of the inductive components, contains hollowed-out areas and elevations, and the housing (1) with the core discs and winding is accommodated in integrated elevations.
18. Inductive component according to either of claims 16 or 17, characterised in that the plastics material trough housing (73) additionally contains open hollows and webs, which distance soldering or welding points and wiring bridges with respect to the winding and with respect to the yokes.
19. Inductive component according to any one of claims 16 to 18, characterised in that the plastics material trough housing (73), apart from the integrated elevations, contains open hollows and webs, which distance soldering or welding points and wiring bridges, on the one hand, with respect to the winding and, on the other hand, with respect to the yokes, and in addition contains hollowed-out areas, which otherwise accumulating resin volumes hollow out.
20. Inductive component according to any one of claims 16 to 19, characterised in that the plastics material trough housing (73), analogously to the external housings, has screw adjustments at the end faces, the screw adjustments being covered in terms of potential by pipe sockets, which adjoin the thread hubs.
21. Inductive component according to any one of claims 16 to 20, characterised in that the plastics material trough housing (73) is cast in with the inserted inductive components in such a way that the resin level can extend from slightly above the centre axis to immersion above the core columns and in the process only parts of the windings project from the casting.
22. Inductive component according to any one of claims 16 to 21, characterised in that yokes (40) are provided, which predominantly have, in the centre part between the core columns, the full arithmetical, also over-dimensioned cross section, and the width and thickness of the yoke cross section are reduced in steps or a trapezoidal structure, and recesses are present in the yoke in the region of bridges and connections.

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