EP3531433B1 - Inductive module and method for producing an inductive module - Google Patents

Description

The present invention relates to an inductive component and a method for producing an inductive component and, in particular, compliance with insulation requirements in the case of very compact inductive components.

Inductive components such as transformers and chokes are used in a large number of application areas. An application example for this is electronics in automobiles, in which inductive components are used, for example, as ignition transformers for gas discharge lamps or filter chokes. The extensive developments in the automotive sector with regard to automotive electronics led to a sharp increase in the number of electronic components, for example for use in vehicles as instrument clusters that are used to display data in the car, for controlling the engine management system by activating the ignition system or the injection system, in anti-lock braking and driving dynamics control systems, in the control of airbags, in body control units, in driver assistance systems, in car alarm systems and multimedia devices such as navigation systems, TV gymnasts, etc.

The number of electronic devices in automobiles, which is increasing with this development, necessitates, for example, further adjustments to the electronic components with regard to their structural size in order to adhere to the installation spaces specified in the automobile by the vehicle design despite the increasingly extensive and complex electronics in automobiles. In general, there are further requirements for the electronics in automobiles in terms of robustness, the temperature range (e.g. ensuring operability in a temperature range of -40 ° C to around 120 ° C), vibration and shock resistance (caused by vibrations in vehicle operation), etc., whereby the reliability of the electronics should be guaranteed over the longest possible period with regard to the most varied of conditions and states.

In addition to the application-related conditions with regard to a component size, which is particularly aimed at a more compact design of electronic components in order to meet specified installation spaces, for example as a specified maximum mounting area that an electronic component can be on a carrier, such as a printed circuit board the electronic component is to be attached, at most is allowed to take, it is essential to adhere to the generally prescribed safety standards without, in turn, reducing the performance and quality of electronic components. For example, insulation requirements are specified by safety standards for the implementation of uniform minimum safety standards that electronic components should meet, such as compliance with specified air and creepage distances and compliance with a specified dielectric strength.

Here, an air gap is generally understood to be the shortest distance between two conductive parts, especially the shortest possible connection via air, across recesses and gaps and across insulating attachments that are not connected to the substrate over the entire surface and without gaps. The clearance depends, among other things, on the voltages present, with electronic components being assigned to specified overvoltage categories. Both overvoltages that enter the electronic component from outside via connections (e.g. connection terminals of an electronic component) and are generated in the electronic component itself and occur at the connections must be taken into account. Predefined clearances are intended to rule out the possibility of a voltage breakdown through air via the shortest possible connections through air. In this sense, clearances limit the maximum possible electric fields in air so that no breakdown occurs.

In contrast, the creepage distance represents the shortest connection between two potentials over a surface of an insulating material which is arranged between the two potentials. The creepage distance is generally dependent on the effective operating voltage of an electronic component and is influenced, among other things, by the degree of contamination and / or the degree of moisture on a surface of an insulation material. For example, the creep resistance of an insulating material is determined by the insulation strength of a surface of the insulating material under the influence of moisture and / or contamination and can be understood as indicating the maximum creepage current that can be set under standardized test conditions in a defined test arrangement. The creepage resistance depends essentially on the water absorption capacity and the behavior of an insulating material under thermal stress.

Furthermore, the insulation distance is understood to mean the thickness of an insulation material, so that this variable is important for determining the dielectric strength of an insulation material.

By means of safety standards that place requirements on air, creepage and insulation distances, depending on the dimensioning of an electronic component, there are compulsory conditions for sufficient insulation in order to avoid voltage breakdowns (e.g. light bottom or sparking) and / or creepage currents as a potential safety risk. For example, voltage breakdowns as arcing or sparking are to be avoided in the context of explosion safety, while leakage currents represent a safety risk for a user in the event of contact with a leakage current source.

From document JP 2000-049020 A There is known an electromagnetic device having a transformer main body composed of the combination of coils with a core and a case in which the main body is housed. A transformer-side connection is provided on the main body and a housing-side connection is provided on a connection element of the housing. Both terminals are connected to one another, so that part of the terminal is brought into contact with the core-side surface of the terminal 6.

document US 2011/0187485 A1 shows a transformer with a coil, connection electrodes, a core, a primary winding, a secondary winding and an additional winding. The coil is made of an electrically insulating material and has a tubular section that defines an interior space. The tubular portion has an outer peripheral surface that provides first to third portions arranged side by side in the axial direction of the tubular portion. The connection electrodes are provided on the coil for electrical connection to the windings. The core is inserted into the interior. The primary winding has an insulating layer and is wound over the first section. The secondary winding has an insulating layer and is wound over the third section. The additional winding is wound over the second section and has an insulation layer whose insulation performance is greater than that of the insulation layer of the primary winding and the secondary winding.

In document DE 11 2013 005 380 T5 an SMD current sensor device is shown comprising a magnetic core, a first winding and a second winding, each around the first and second portions of the magnetic core are wound. Most of the first winding is surrounded by an electrically insulating material that defines a first shell that defines a through hole for inserting the first portion of the magnetic core. The device includes an electrically insulating support around which the second winding is wound and which defines a through hole for inserting the second portion of the magnetic core therein, both through holes being aligned with one another.

According to Scripture DE 10 2006 029 272 A1 a bobbin module with a winding space for applying a plurality of windings and for defining a longitudinal axis of the module is known. A fastening device is used to fasten the additional bobbin module along a longitudinal direction and along two axes perpendicular to the longitudinal axis. The fastening device consists of two contact units that are designed for contact in corresponding contact openings in the additional bobbin module.

In view of the above explanations, the object on which the invention is based is to provide inductive components with a compact design for assembly in small installation spaces while complying with specified safety standards, in particular without falling below specified air and / or creepage and / or insulation distances.

In one aspect, the present invention provides an inductive component comprising a magnetic core, an insulating body formed from an electrically insulating material in which the magnetic core is received, and a coil body wound with at least one winding. In this case, the insulation body has at least two insulation wall sections which are connected to one another and which are each directed at least partially towards a side surface section of the magnet core. The coil body comprises at least one contact element attached to a side surface section of the coil body for electrical connection to the at least one winding and a magnetic core receptacle in which the magnetic core received in the insulation body is partially received. In this case, a side surface section of the magnet core facing the at least one contact element is at least partially covered by an insulation wall section of the insulation body.

Since the insulation body is provided with at least two mechanically connected insulation wall sections, one of which is the insulation wall sections of the insulation body at least partially covers the side surface section of the magnetic core which is directed towards the contact elements in the inductive component, sufficient air and creepage distances are ensured in a safe and reliable manner regardless of the dimensions of the inductive component.

Furthermore, in this aspect, the insulation body further comprises at least one web portion which is formed on the insulation wall portion, which is directed towards the at least one contact element and which protrudes outwardly away from the insulation body along a normal direction of the insulation wall portion. On the one hand, the outwardly protruding web sections achieve a mechanical stability of the insulation body, and on the other hand, the web sections allow a lateral enlargement of the air and creepage distances.

In an advantageous embodiment of this aspect, the side surface section of the magnetic core that is directed towards the contact elements is completely covered by the insulation wall section. This allows leakage currents to be suppressed very efficiently.

In a further advantageous embodiment of this aspect, the insulation body and the coil body are mechanically connected by connecting means. This allows the insulation body and the coil body to be provided separately, as a result of which the inductive component can be modularized and the clearance and creepage distances can be retrofitted.

In a more advantageous refinement of this embodiment, the connection means can comprise at least one first connection element arranged on the insulation body and at least one second connection element arranged on the coil body, which mechanically engage with one another. This type of mechanical connection between the insulation body and the coil body also enables reliable assembly of the insulation body and coil body in a simple manner.

In a further, more advantageous embodiment of this embodiment, the connecting means can be designed to couple the insulation body and the coil body in a mechanically releasable manner. This allows creepage distance extensions in the inductive component to be achieved in a simple manner, with individual components being able to be exchanged and retrofitted if necessary.

In a further advantageous embodiment of this aspect, the insulation body is formed by at least three insulation wall sections which are mechanically connected to one another so that the insulation body has a pot-shaped or bowl-shaped shape with a recess in which the magnetic core is received. A correspondingly designed insulation body can easily be produced by injection molding techniques and can be produced inexpensively in large numbers. Furthermore, a pot-shaped or bowl-shaped insulation body enables a mechanically stable reception of the core by the insulation body.

In an advantageous refinement of this embodiment, a depth of the depression can be greater than or equal to a height dimension of the magnetic core that is defined with respect to the magnetic core along a direction along which the magnetic core is received in the depression. As a result, a clearance and creepage distance corresponding to a depth of the recess along the entire height dimension of the magnet core can be determined. As a result, very compact inductive components can be provided.

In an advantageous embodiment of this aspect, the at least one web section can have a protrusion section protruding towards the coil body, which is inserted into a positioning recess formed in the coil body, which is arranged on a side on which at least one contact is arranged. In this way, a mechanically reproducible positioning of the insulation body on the coil body can be achieved, which, for example, allows an advantage for a mechanical assembly of coil bodies with insulation bodies. Furthermore, an exact positioning of the magnetic core on the coil body and thus relative to the winding provided above the coil body can thereby be achieved.

In a further advantageous embodiment of this embodiment, the coil body can have at least two contact elements on a side surface section and two wire sections of the at least one winding can be guided along the at least one web section on opposite sides thereof to one of the contact elements. Thus, a mechanical separation of the wire sections can be achieved by means of the web section, so that an extension of the air and creepage distance between the two wire sections is provided by means of the web section.

In a further advantageous embodiment of this aspect, the inductive component further comprises at least one further contact element that is on a side surface section of the bobbin is attached, which is arranged on a side of the bobbin opposite the at least one contact element, a further magnetic core, and a further insulation body, the further insulation body having at least two interconnected insulation wall sections, each at least partially towards a side surface section of the further magnet core are directed, wherein the further insulation body is arranged on the coil body so that it is opposite the insulation body and the further magnetic core received in the further insulation body is partially received in the magnetic core receptacle, and wherein a side surface section of the further magnetic core directed towards the at least one further contact element through an insulation wall section of the further insulation body is at least partially covered. As a result, an advantageous core design formed from two individual magnetic cores can be provided while satisfying specified insulation distances, regardless of the dimensions of the inductive component. In an advantageous embodiment of this embodiment, the two magnetic cores are each designed according to an E core configuration.

In a further aspect of the present invention, a method for producing an inductive component according to the above aspect is provided. The method comprises winding the coil body with the at least one winding and receiving the magnetic core in the insulation body. The method further comprises attaching the insulation body with the magnetic core received therein to the wound coil body, the insulation body being partially received in the magnetic core receptacle of the coil body.

Fig. 1a

einen Isolationskörper gemäß erster Ausführungsformen der Erfindung in einer perspektivischen Ansicht schematisch darstellt,

Fig. 1b

den in Fig. 1a dargestellten Isolationskörper zusammen mit einem davon aufgenommenen Magnetkern in einer perspektivischen Ansicht schematisch darstellt,

Fig. 1c

einen bewickelten Spulenkörper gemäß den ersten Ausführungsformen der vorliegenden Erfindung in einer perspektivischen Ansicht schematisch darstellt,

Fig. 1d

ein induktives Bauelement gemäß den ersten Ausführungsformen der vorliegenden Erfindung in einer perspektivischen Ansicht schematisch darstellt,

Fig. 2a

einen Isolationskörper gemäß zweiter Ausführungsformen der Erfindung in einer perspektivischen Ansicht schematisch darstellt, und

Fig. 2b

ein induktives Bauelement mit dem in Fig. 2a dargestellten Isolationskörper in einer perspektivischen Ansicht schematisch darstellt.

Further advantages and features of the invention are described in more detail below in connection with the accompanying figures, wherein:

Fig. 1a

schematically represents an insulation body according to first embodiments of the invention in a perspective view,

Figure 1b

the in Fig. 1a shows the insulation body shown together with a magnetic core received therefrom in a perspective view,

Figure 1c

shows a wound bobbin according to the first embodiments of the present invention in a perspective view schematically,

Fig. 1d

schematically represents an inductive component according to the first embodiments of the present invention in a perspective view,

Fig. 2a

shows an insulation body according to second embodiments of the invention in a perspective view schematically, and

Figure 2b

an inductive component with the in Fig. 2a represents the insulation body shown schematically in a perspective view.

With reference to the Figures 1a to 1d inductive components according to the present invention according to various first embodiments of the present invention are clearly described below. It shows Fig. 1d an inductive component 100 according to the first embodiment. In Fig. 1a is an insulation body 20 of the inductive component 100 from Fig. 1d shown schematically in a perspective view. In Figure 1b the insulation body 20 with a magnetic core 10 is shown schematically in a perspective view, the magnetic core 10 being received in the insulation body 20. In Figure 1c is a coil body 30 of the inductive component 100 from Fig. 1d shown schematically in a perspective view with at least one winding W1 provided above.

As shown in Fig. 1a the insulation body 20 is formed from insulation wall sections 22, 24 and 26, the insulation wall sections 22, 24 and 26 being mechanically connected to one another and defining a receptacle 25 which is suitably designed and dimensioned to accommodate the magnetic core 10 (cf. Figure 1b ). Furthermore, the insulation body 20 has U-shaped insulation wall sections 27, which are arranged on the floor-side insulation wall section 22 in accordance with the shape of the magnet core 10. These U-shaped insulation wall sections 27 are optional and can also not be present. By means of the U-shaped insulation wall sections 27, which alternatively can also be only L-shaped or in each case by only one insulation wall section, a stable mechanical accommodation of the magnet core 10 in the insulation body 20 can be provided, as with reference to FIG Figure 1b is described in more detail below.

The bottom-side insulation wall section 22 can have a shape adapted to the magnetic core 10, for example recesses can be provided in the bottom-side insulation wall section 22, which are surrounded by the U-shaped insulation wall sections 27 (in the illustration of FIG Fig. 1a these recesses are not visible, but there is a recess in Fig. 1a indicated by dashed lines with respect to one of the U-shaped insulation wall sections 27). However, this does not represent a restriction of the bottom-side insulation wall section 22 and this can be designed as a plate-shaped body without recesses.

The insulation wall sections 24, 26 protrude from the floor-side insulation wall section 22 along a normal direction of the floor-side insulation wall section 22, so that the receptacle 25 is fixed by the floor-side insulation wall section 22 and the insulation wall sections 24, 26 protruding therefrom. The insulation body 20 is open with respect to a side of the floor-side insulation wall section 22 opposite the floor-side insulation wall section 22 and a side of the floor-side insulation wall section 22 opposite the insulation wall section 24.

This does not represent a limitation of the present invention and a side of the insulation body 20 opposite the bottom insulation wall section 22 can be partially covered by an insulation wall section (not shown) provided there. For example, an insulation wall section (not shown) can be covered over the U-shaped insulation wall sections 24 with a smaller area than the bottom area of the bottom insulation wall section 22, for example an area smaller by at most half. This optional insulation wall section (not shown) can be provided as a "pick & place cap" in order, for example, to be graspable for a suction nozzle on a transport device (not shown) in an automated production process.

The floor-side insulation wall section 22 is mechanically connected to the insulation wall sections 26 and the insulation wall section 24, the insulation wall section 24 being arranged at an edge of the floor-side insulation wall section 22 and extending away from the floor-side insulation wall section in the normal direction, so that the insulation wall section 22 extends transversely extends to directions of extent of the insulation wall sections 26 and is mechanically connected to the insulation wall sections 26.

As shown in Fig. 1a the insulation wall sections 24 have a height H24 and the insulation wall sections 26 each have a height H26. Although this is not shown, the U-shaped insulation wall sections 27 can have the height H24 or the height H26. At least the height H24 defines a depth of the receptacle 25 in accordance with the height dimension of the insulation wall section 24 (in relation to the normal direction to the bottom insulation wall section 22).

Although the insulation wall sections 24, 26 in the illustration of Fig. 1a are shown as being of the same height, this does not constitute a limitation of the invention and the insulation wall sections 24, 26 and 27 can have different height dimensions, the height dimension H26 of the insulation wall sections 26 being smaller than the height dimension H24 of the insulation wall 24.

The insulation body 20 further comprises two web sections 28 which are formed on the insulation wall section 24. The two web sections 28 shown do not represent a limitation of the invention and any number of web sections 28 can be formed along the insulation wall section 24, for example only one web section (cf. Fig. 1d , the insulation body shown there having only one web section 28) or more than two web sections.

The web sections 28 have a protrusion section 28a which extends in the normal direction of the insulation wall section 24 and thus protrudes from this in the normal direction to the insulation wall section 24. In addition, the web sections 28 can furthermore have a protrusion section 28b which extends along the normal direction of the bottom-side insulation wall section 22 and which protrudes downwards from the insulation body 20 along an underside of the bottom-side insulation wall section 22.

Referring now to Figure 1b shows a state in which the magnetic core 10 is received in the insulating body 20. The magnetic core 10 is shown in FIG Figure 1b formed in the form of an E-shaped magnet core 10, which has two side legs Sa, Sb and a central leg Sc lying between them, which are connected by a transverse yoke Sd oriented transversely to the side legs Sa, Sb and the central leg Sc. According to the illustration, the magnetic core 10 has a height H10 that extends along a direction perpendicular to an extension direction of the transverse yoke Sd and perpendicular to the extension directions of the Side legs Sa, Sb and the middle leg Sc is set. This does not constitute a limitation of the invention and the magnetic core 10 can alternatively be provided as a C or I-shaped magnetic core (not shown), the bottom-side insulation wall section of the insulation body 20 being adapted to this core shape and the U-shaped insulation wall sections 27 not being provided.

As from the Fig. 1a and 1b is apparent and is described above, the insulating body 20 is designed in accordance with the magnetic core 10, so that the magnetic core 10 is received in the receptacle 25 of the insulating body 20. In particular, the height dimensions (corresponds to the depth of the receptacle 25) H24, H26 are matched to the height dimension H10 of the magnetic core 10, so that H10 H24 and H10 H26. In accordance with specific illustrative embodiments, the following examples are provided herein, (a) H10 = H24 = H26, (b) H10 = H26 <H24, (c) H10 <H26 = H24, and (d) H10 <H26 <H24.

According to the above-described height dimensions of the magnetic core 10 and the above-described depth of the receptacle 25, it is ensured that a side surface 14 of the transverse yoke Sd of the magnetic core 10, which is shown in FIG Figure 1b The illustrated state of the magnetic core 10, in which the magnetic core 10 is received in the insulating body 20, faces the insulating wall section 24, the side surface section 14 of the magnetic core 10 being covered by the insulating wall section 24 along the height dimension H10 of the magnetic core 10 (H10 H24). This should not rule out that the side surface section 14 of the magnetic core 10 is only partially covered by the insulation wall section 24 if recesses (not shown) are formed in the insulation wall section 24, which partially expose the side surface section 14 of the magnetic core 10, for example in the event that the Isolation wall section 24 is formed by several subsections which protrude from the bottom-side isolation wall section 22 along its normal direction.

With further reference to Figure 1b Embodiments of the web portions 28 will now be described in more detail. The protrusion section 28a of one of the web sections 28 protruding along the normal direction of the insulation wall section 24 protrudes from the insulation wall section 24 by a protrusion height HT. Furthermore, at least one of the web sections 28 can extend around the protrusion section 28b with a protrusion height HS from the bottom-side insulation wall section 22 along the normal direction of the bottom-side insulation wall section 22 on the underside of the insulation body 20 downwards. As a result, at least one of the web sections 28 can be one on the insulation wall sections 22, 24 form L-shaped web configuration. As an alternative to the representation in the Fig. 1a and 1b For example, at least one web section of the web sections 28 can only be formed by a web protruding from the insulating wall section 24 (in this case HS = 0). A function of the web portions 28 is described below with regard to Figure 1c and 1d described in more detail at the appropriate point.

Regarding Figure 1c the bobbin 30 is shown, which is wound with at least one winding W1. For example, in the case of a transformer, at least one primary winding and one secondary winding are provided (primary and secondary windings are shown in the schematic representations of FIG Figure 1c and 1d not specifically shown). Alternatively, for example, only one winding can be provided.

The one in the Figure 1c and 1d The bobbin 30 shown can represent a bobbin which can be wound easily and in particular automatically and is designed for SMD assembly, as in FIG Fig. 1d and 1c is illustrated schematically by contact elements in the form of U-shaped contact pins 50a and 50b. However, this does not constitute a limitation of the invention, since instead of the SMD design of the coil body 30, it can alternatively be designed as a THT coil body for push-through assembly, the contact elements instead of the contact pins 50a, 50b shown as U-shaped contact elements in L-shape can be provided.

As shown in Figure 1c the bobbin 30 has a core receptacle 32, above which at least one winding chamber 34 is provided for receiving the at least one winding W1, with contact strips 36a and 36b extending transversely to a longitudinal direction of the magnetic core receptacle 32 being arranged at opposite ends of the magnetic core receptacle 32 of the bobbin 30 . Contact elements corresponding to contact pins 50a, 50b are received in contact strips 36a, 36b, so that a row of contact pins 52a, 52b protrude from end faces 37a, 37b of contact strips 36a, 36b along a direction of extent of magnetic core receptacle 32. In this case, winding connections are attached to the contact pins 52a, 52b, as shown by some connections Aa, Ab of wire end sections Wa, Wb of the winding W1 in FIG Figure 1c is illustrated schematically. The wire end sections Wa, Wb can be led to the contact pins 52b under the contact strip 36b of the bobbin 30 and electrically connected to the contact pins 52b in order to electrically connect the winding W1 to the contact pins 52b, for example by means of a contact pin or contact pins Pb in Figure 1c is illustrated, the connection Ab des Wire end portion Wb is mechanically and electrically connected to the contact pin Pb, for example (without limitation) by wrapping the contact pin Pb with the wire end portion Wb or soldering the wire end portion Wb to the contact pin Pb or the like, whereby the terminal Ab is formed. In illustrative embodiments, at least one contact element, which is represented by at least one contact pin 50a, is attached to the further side surface section 37a of the coil former 30, which is opposite to at least one other contact element, which is represented by at least one of the contact pins 50b. The side surface portions 37a and 37b are formed on opposite sides of the spool 30.

The winding chamber 34 of the bobbin 30 can, as shown in FIG Figure 1c are formed by wall sections 34a and 34c which protrude from a connecting section 36c along a normal direction with respect to the connecting section 36c, the connecting section 36c mechanically connecting the contact strips 36a and 36b to one another. The contact strips 36a, 36b and the connecting section 36c can be formed integrally. According to the embodiment shown, the contact strips 36a, 36b and the connecting section 36c are formed in the shape of the letter H.

Furthermore, a wall section 34b is formed opposite the connecting section 36c and connects the winding chamber sections 34a and 34c to one another. As a result, the magnetic core receptacle 32 is enclosed by the winding chamber sections 34a, 34c, the connecting sections 36c and the wall section 34b opposite thereto.

According to some illustrative embodiments herein, as in FIG Figure 1c As is explicitly shown, flange-like projections Fa, Fb can be formed on opposite end sections of the magnetic core seat 32, which projections delimit the winding chamber along the magnetic core seat 32. As a result, the coil body 30 provides a coil between the contact strips 36a, 36b through the winding with at least the winding W1 in the winding chamber 34. Additionally or alternatively, partition walls (not shown) can be provided in the winding chamber 34 in order to separate individual winding sections of the at least one turn W1 from one another.

Regarding Figure 1c is also formed in the contact strip 36a at least one recess 38a, for. B. in the form of a slot. The at least one recess 38a can partially penetrate the contact strip 36a along a direction parallel to the contact pins 52a. Furthermore, the at least one recess 38a can support the contact strip 36a along its entire thickness (cf. thickness d of the contact strips in the illustration of FIG Fig. 1d ) at least partially enforce.

Additionally or alternatively, at least one recess 38b can furthermore be formed in the contact strip 36b (for example two, as in FIG Figure 1c is illustrated), e.g. B. in the form of a slot. The recess 38b can partially penetrate the contact strip 36b along a direction parallel to the contact pins 52b. Furthermore, the at least one recess 38b can support the contact strip 36b along its entire thickness (cf. thickness d of the contact strips in the illustration of FIG Fig. 1d ) at least partially enforce.

According to some illustrative embodiments, the recesses 38a and 38b can be formed in the respective contact strips 36a and 36b between adjacent contact elements, for example the contact pins 50a and 50b (alternatively, at least one recess can also be formed only in one contact strip). For example, the contact elements, for example the contact pins 50a and 50b in the respective strips 36a and 36b, can be subdivided into subsets of contact elements by respective recesses 38a and 38b, the degree of subdivision depending on the application. The number of cutouts that are formed in one of the contact strips 36a, 36b can differ from or be the same as the number of cutouts that are formed in the other of the contact strips 36a, 36b. In any case, the number of recesses corresponds to the number of projection sections 28b which are located on the insulation body 20 (cf. Fig. 1a and 1b ) are formed in relationship.

In an illustrative example of the first embodiment, a height HS of a projection section 28b is less than or equal to the thickness (cf. d in Fig. 1d ) a contact strip. Positioning and stabilization of the insulating body 20 on the coil body 30 can thereby be achieved. For example, permanent and fixed mounting of the insulation body 20 on the coil body 30 can be achieved by means of gluing by introducing an adhesive into at least one recess. Alternatively, the insulation body 20 can be detachably or permanently connected to the coil body 30 by means of a latching mechanism (not shown), with latching lugs or latching hooks (not shown), which are formed on at least one web section 28 of the insulation body 20, in corresponding depressions (not shown). , which are provided in at least one recess 38, engage or vice versa (latching lugs / hooks that are provided in at least one recess and engage in a recess that are provided in at least one web section). This allows the insulation body 20 to be positioned in a fixed position on the coil body 30 and thus the magnetic core 10 with respect to the at least one winding W1 above the coil former 30.

According to a specific illustrative configuration of the first embodiment, the height HS of at least one protrusion section 28b is greater than a thickness (cf.d in Fig. 1d ) the contact strips 36a, 36b. In this case, the at least one protrusion section 28b protrudes from the underside of the associated contact strip 36a, 36b and thus allows a labyrinth to be formed on the underside for lengthening the creepage and clearance between the contact pins 50a, 50b on the underside of the relevant contact strip 36a, 36b. This labyrinth structure (not shown) can interact with a labyrinth structure (not shown) additionally provided on the underside of at least one of the contact strips 36a, 36b. For example, guide grooves (not shown) can be formed on the underside of at least one of the contact strips 36a, 36b in order to guide the wire sections Wa, Wb of the winding W1 to corresponding contact pins 52b on the underside. The same can apply to the contact strip 36a.

Regarding Fig. 1d the inductive component 100 will now be described in greater detail. According to the embodiment shown, the inductive component 100 further comprises a further magnetic core 10a and a further insulation body 20a, the insulation body 20a having an insulation wall section 24a and one in the illustration of FIG Fig. 1d Has not visible insulation wall section, which is formed corresponding to the insulation wall section 22 of the insulation body 20 and is arranged to the coil body 30 and connected to the insulation wall portion 24a. Furthermore, the insulation body 20a can have at least one further insulation wall section 26a, which is connected to the insulation wall sections 24a and the insulation wall section (not shown) (which is provided in the insulation body 20a in a manner similar to the insulation wall section 22 of the insulation body 20). Regardless of their number and configuration, the insulation wall sections are each at least partially facing a side face section of the magnetic core 10a (for example, the insulation wall section 24a is facing a side face section 14a of the magnetic core 10a and the insulation wall section 26a is facing a side face section 16a of the magnetic core).

According to illustrative embodiments, the insulating body 20a is arranged on the coil body 30, so that the insulating body 20a is opposite the insulating body 20 and the magnetic core 10a received in the insulating body 20a in the magnetic core receptacle 32 of the bobbin 30 is partially added. A side surface section 14a of the magnet core 10a facing the at least one further contact element 50a is at least partially covered by the insulation wall section 24a of the insulation body 20a.

In an alternative perspective, the inductive component 100 can be viewed as having a modular magnetic core 10 ′. This modular magnetic core 10 'may be formed from the E-shaped magnetic cores 10, 10a according to a double E core configuration as shown. This is not a restriction and instead of two E cores, two C cores, an E core and a C core, an E core and an I core and a C core and an I core in the inductive component 100 can be combined.

In the perspective of a modular magnetic core 10 ', the individual magnetic cores 10, 10a represent individual core segments of the modular magnetic core 10'.

According to the representation in Fig. 1d the magnetic cores 10, 10a (or core segments 10, 10a in the modular magnetic core 10 ') are received in the corresponding E-shaped insulation bodies 20, 20a. The representation in Fig. 1d with regard to the separate insulation bodies 20, 20a is not to be interpreted as restrictive here. For example, the insulation bodies 20, 20a can be designed as connected by at least one insulation wall section, for example the insulation bodies 20, 20a can be connected to one another by a common insulation wall section corresponding to the insulation wall section 26 or a connected bottom-side insulation wall section (in the form of an "H") or as a integral insulation body 20 'be formed.

As shown in Fig. 1d each of the insulating bodies 20, 20a is connected to a corresponding one of the contact strips 36a, 36b, as in FIG Fig. 1d is shown. In particular for the case that recesses are provided in the bottom insulation wall section 22, which are formed by the (optional) U-shaped insulation wall sections 27 (cf. Fig. 1a ) are provided, each of the insulation bodies 20, 20a is on one side of the magnetic core receptacle (cf. 32 in Figure 1c ) of the bobbin 30 is inserted. As a result, a center leg of each of the E-shaped magnetic cores 10, 10a is inserted into the magnetic core receptacle 32 of the bobbin 30, which is shown in FIG Figure 1c is shown, inserted.

Although in Fig. 1d If only one web section 28 is shown, this does not represent a restriction and, alternatively, more than one web section 28, for example two web sections 28, as in FIG Fig. 1a and 1b is shown, be provided.

Although the modular or integral insulation body 20 'is shown in FIG Fig. 1d as is shown formed by two individual insulating bodies 20, 20a, which are arranged on corresponding contact strips 36a, 36b of the coil body 30, this does not represent a limitation of the invention and instead only a single insulating body 20 or 20a can be attached to a corresponding one of the contact strips 36a, 36b of the bobbin 30 in Fig. 1d to be available.

Regarding Figure 1b A function of the web portions 28 will now be further described. As with reference to Figure 1b As described above, in some illustrative embodiments herein, the web sections 28 can protrude by the height HT from the insulation wall section 24 of the body element 20 along a normal direction of the floor-side insulation wall section. As a result, an extension of the creepage distance between two of the contact pins 50b, between which the web section 28 is arranged, can be provided as a function of the height HT. If, for example, the height HT of the web section, which is arranged between two contact pins 50b, is greater than an extension length of the contact pins 50b by which the contact pins 50b protrude from the end face 37b of the contact strip 36b, an extension of the air gap between these contact elements can be provided.

With further reference to Fig. 1d the insulation wall portion 24 covers a side surface portion of the magnetic core 10 which is facing the contact pins 50b and in connection with Figure 1b is described as side surface portion 14. As a result, the side surface section 14 of the magnetic core 10 that is trimmed to the contact pins 50b is covered by the insulation wall section 24 and the distance between the contact pins 50b and the magnetic core 10 is lengthened according to a height of the insulation wall 24, as described above with reference to the heights H24 and H26 is. The same applies to an insulation wall section 24a of the insulation body 20a on the side of the opposite contact strip 36a, the side surface section 14a of the magnetic core 10a facing the contact pins 50a being covered by the insulation wall section 24a and thus an extension of the distance between the contact pins 50a and the magnetic core 10a corresponding to a height the isolation wall 24a takes place.

Accordingly, the required air and creepage distances between the contact pins 50a, 50b of the inductive component 100 and the magnetic cores 10, 10a are each determined on the basis of the height of the insulation bodies 20, 20a. The creepage distance is advantageously extended independently of a base area of the inductive component 100, in particular an underside Area of the coil former 30. This in turn means that the inductive component 100 can be provided in a very compact manner while at the same time maintaining the necessary air and creepage distances.

The inductive component 100 according to the first embodiment can be produced in accordance with the following method steps. The magnetic cores 10 and 10a (or magnetic core segments of the modular magnetic core 10 ') are received in the corresponding insulation bodies 20, 20a. Optionally, each of the magnetic cores 10, 10a can be glued or otherwise glued into the corresponding insulation body 20, 20a, for example by structures in accordance with latching lugs or hooks (not shown) provided on the corresponding insulation body 20, 20a, or an insulation cover can be attached on the top the corresponding insulation bodies 20, 20a after receiving the magnetic cores 10, 10a are mounted in the corresponding insulation bodies 20 and 20a. As a result, the individual magnetic cores 10, 10a are each received in the individual insulation bodies 20, 20a and can be provided separately at this point in time.

Independently of the provision of the magnetic cores 10, 10a in the insulation bodies 20, 20a, the coil body 30 is wound with at least one winding W1, for example in an automatic winding process.

Subsequently, each of the insulation bodies 20, 20a with the corresponding magnetic cores 10, 10a is attached to a corresponding one of the contact strips 36a, 36b in accordance with the manner described above. For this purpose, the middle legs (cf. Sc in Figure 1b ) the magnetic cores 10, 10a are pushed into the core receptacle 32 of the bobbin 30 from opposite sides of the core receptacle 32.

If necessary, the individual magnetic cores 10, 10a can be fixed to one another by gluing them to contacting end faces of the magnetic cores 10, 10a, the magnetic core 10 'being provided as a unit. Additionally or alternatively, the individual insulation bodies 20, 20a can be attached to the coil body 30 by means of gluing and the like.

This in Fig. 1d The inductive component 100 shown here can be produced by a method that involves winding the coil body 30 with the at least one winding W1, receiving at least one of the magnetic cores 10, 10a in the associated insulation body 20, 20a (e.g. only the magnetic core 10 can be in Figure 1b in the ones shown there Insulating body 20 can be used, the other magnetic core 10a can be attached to the coil body without the insulating body 10a, so that the insulating body 20a is dispensed with in the inductive component 100) and the insulating body (s) 20, 20a with the magnetic core 10, 10a received therein can be attached on the wound bobbin 30, the magnetic cores 10, 10a being partially received in the magnetic core receptacle 32 of the bobbin 30. The winding of the coil body 30 can take place independently of the inclusion of the magnetic cores 10, 10a in the insulation body (s) 20, 20a, for example at a separate time or at the same time. The magnetic cores 10, 10a can also be received in the insulation bodies 20, 20a in that the magnetic core 10 is received in the insulation body 20 and the magnetic core 10a is received in the insulation body 20a. As noted, however, alternatively only one magnetic core (e.g. the magnetic core 10 or the magnetic core 10a) can be accommodated in one of the insulating bodies 20, 20a before this insulating body is attached to the coil body 30 and the other of the magnetic cores 10, 10a directly onto it the bobbin 30 is attached. As a result, an automated production method for producing the inductive component 100 can be provided.

In summary, with reference to the Figures 1a to 1d First embodiments of the inductive component 100 described, wherein the inductive component 100 includes the magnetic core 10, the insulation body 20 formed from an electrically insulating material, in which the magnetic core 10 is received, the insulation body 20 at least the two connected insulation wall sections 22, 24 (optionally with at least one of the insulation wall sections 26), each of which is at least partially aligned with a corresponding one of the side surface sections 14, 16 of the magnetic core 10, the at least one winding W1 and the bobbin 30 wound with the at least one winding W1, which comprises at least that on the Contact element attached to the side surface section 37b of the coil body 30, for example at least one contact pin 50b, for electrical connection to the at least one winding W1 and the magnetic core receptacle 32, in which the magnetic core 10 received in the insulating body 20 is partially received, wherein the side surface section 14 of the magnetic core 10 that is aligned with the at least one contact element is at least partially covered by the insulation wall section 24 of the insulation body 20.

The side surface section 14 of the magnetic core 10, which is aligned with the at least one contact element 50b, can be completely covered by the insulation wall section 24.

Furthermore, the insulating body 20 and the coil body 30 can be mechanically connected by the connecting means 240. In this case, the connecting means 28, 38 can comprise at least one first connecting element 28 arranged on the insulation body 20 and at least one second connecting element 38 arranged on the coil former 20, which mechanically engage with one another. Additionally or alternatively, the connecting means 28, 38 can be designed to couple the insulating body 20 and the coil body 30 in a mechanically releasable manner.

Furthermore, the insulation body 20 can be formed by at least the three insulation wall sections 22, 24, 26, which are connected to one another, so that the insulation body 20 has a pot-shaped or bowl-shaped shape with the recess 25 in which the magnetic core 10 is received. In this case, a depth of the recess 25 can be greater than or equal to the height dimension H10 of the magnetic core 10, which is defined with respect to the magnetic core 10 along a direction along which the magnetic core 10 is received in the recess 25.

Furthermore, the insulation body 20 can further comprise at least one of the web sections 28 which is formed on the insulation wall section 24, which is aligned with the at least one contact element 50b and which protrudes outwardly away from the insulation body 20 along a normal direction of the insulation wall section 24. This at least one web portion 28 can have the protrusion portion 28b protruding towards the coil body 30, which is inserted into the positioning recess 38 formed in the coil body 30, which is arranged on the side of the coil body 30 on which the at least one contact element 50b is arranged . Furthermore, the contact elements 50b can be provided in the number of two contact pins on the side surface portion 37b of the coil former 30 and at least the two wire end portions Wa and Wb of the at least one winding W1 can be provided along the at least one web portion 28 on opposite sides thereof to one of the contact elements 50b be performed.

Furthermore, the inductive component 100 can further comprise at least one of the contact elements 50a, which is attached to the side surface section 37a of the coil body 30, which is arranged on the side of the coil body 30 opposite the contact element 50b, the further magnetic core 10a and the further insulation body 20a, wherein the further insulation body 20a have at least the insulation wall section 24a, which is at least partially aligned with the side surface section 14a of the further magnetic core 10a, and a further insulation wall section connected thereto, which is a further Side surface section (side surface section connected to the side surface section 14a) of the further magnetic core 10a is at least partially trimmed, the further insulation body 20a being arranged on the coil body 30 so that it is opposite the insulation body 20 and the further magnetic core 10a received in the further insulation body 20 is inserted into the Magnetic core holder 32 is partially added. In this case, the side surface section 14a of the further magnet core 10a that is aligned with the at least one further contact element 50a can be at least partially covered by the insulation wall section 24a of the further insulation body 20a, and the magnet cores 10, 10an can each be designed according to an E core configuration.

With reference to the Fig. 2a and 2 B an inductive component 200 (cf. Figure 2b ) described according to a second embodiment. The inductive component 200 according to the second embodiment differs from the inductive component 100 according to the first embodiment, which with reference to FIG Figures 1a to 1d is described above, by an alternative embodiment of the insulation body, as shown on the basis of an insulation body 220 in FIG Fig. 2a and 2 B and is described below. A bobbin 230 of the inductive component 200, as in FIG Figure 2b is shown differs from the bobbin 30 according to the illustrations in FIG Figure 1c and 1d in that a connection mechanism is implemented between the insulation body 220 and the coil body 230 by means of a latching mechanism 240, a latching hook 242 formed on the insulation body 220 engaging a recess 244 in the coil body 230 when the insulation body 220 is mounted on the coil body 230 . The recess 244 is formed on a contact strip 236b of the coil former 230. Although in Fig. 2a Only one latching hook 242 is shown, a further latching hook (not shown) can be provided on the same side of the insulation body 220 opposite the latching hook 244. A recess (not shown) would accordingly be formed in the contact strip 236b opposite the recess 244.

Apart from this, the coil body 230 is designed in accordance with the coil body 30 and in particular has contact strips 236a, 236b which are connected by a connection region (not shown) corresponding to the connection section 360. Furthermore, contact pins 25a, 25b are formed in the corresponding end faces 237a, 237b of the corresponding contact strips 236a, 236b.

The insulation body 220 has a floor-side insulation wall section 222 and insulation wall sections 224 and 226 extending therefrom along a direction normal to the floor-side insulation wall section 222. Furthermore, U-shaped insulation wall sections 227 corresponding to the U-shaped insulation wall sections 27 in the illustration of FIG Fig. 1a educated. Over the insulation wall sections 227, as in Fig. 2a is shown, an optional "Pick &Place" surface "229 can be designed, which extends as a planar cap over the U-shaped insulation wall sections 227 and can serve as a starting point for a suction nozzle (not shown) in an automatic production and assembly process.

A receptacle 225 is formed in the insulation body 220 and is laterally surrounded by the insulation wall sections 224 and 226. A depth of the recess 225 is determined by a height of the insulation wall sections H220, as in FIG Fig. 1a is designed according to the heights H24 and H26. In particular, the insulation wall sections 226 and 224 can have different heights, although these are shown in FIG Fig. 2a are shown as being of the same height.

Into the recess 225 in Fig. 2a a magnetic core 210 is used, for example by inserting a core segment 210a of an E core and then inserting a core segment 210b from the outside into the insulation body 220 (cf. magnetic core 210 in Figure 2b ). A height H210 of the magnetic core 210 can be essentially less than or equal to a depth of the recess: H220 H210. The magnetic core 210 has side surface sections 214, 216.

According to some illustrative embodiments, the magnetic core 210 can be a modular magnetic core 210 composed of individual magnetic cores 210a, 210b, wherein the magnetic cores 210a, 210b can be glued to one another in order to provide the magnetic core 210 in integral form after the inductive component 200 has been provided.

The insulation body 220 can be used when the inductive component 200 only provides contact elements 250a on one contact strip (236a) for applying a high voltage (high-voltage connections should be provided on one contact strip), while contact elements 250b are provided on the other contact strip 236b a low-voltage potential are provided. Accordingly, by means of the insulation body 220 on the high-voltage side of the inductive Component 200, in particular on the contact strip 236a of the high-voltage contact elements 250a, provided by the insulation wall section 224, which is prepared for the high-voltage connections, an advantageous air and creepage distance extension to the magnetic core 210 and the winding W2 above the coil body 230.

The assembly of the insulation body 220 on the coil body 230 as shown in FIG Fig. 2a and 2 B is only illustrative and not restrictive, since instead of the connecting means 240 and / or in addition to this, web sections (not shown) corresponding to the web sections 28 according to the first embodiment with corresponding slots can be provided in the coil body.

This in Figure 2b The illustrated inductive component 200 can be produced by a method that involves winding the coil former 230 with the at least one winding W2, accommodating the magnetic core 210 in the insulating body 220 and attaching the insulating body 220 with the magnetic core 210 accommodated therein to the wound coil former 230 comprises, wherein the magnetic core 210 is partially received in the magnetic core receptacle 232 of the bobbin 230. The winding of the coil body 230 can take place independently of the reception of the magnetic core 210 in the insulation body 220, for example at different times or at the same time. The magnetic core 210 can also be received in the insulation body 220 in that the core segment 210a is received in the insulation body 220 and the core segment 210b is then pushed into the insulation body 220. As a result, an automated production method for producing the inductive component 100 can be provided.

In summary, the Fig. 2a and 2 B the inductive component 200 ready, which, according to the described second embodiments, the magnetic core 210, the insulating body 220 formed from an electrically insulating material, in which the magnetic core 210 is accommodated, the insulating body 220 having at least the two connected insulating wall sections 222, 224, each of which one of the side surface section 214, 216 of the magnetic core 210 are each at least partially trimmed, which comprises at least one winding W2 and the coil former wound with the at least one winding W2, the at least one contact element attached to the side surface section 237a of the coil former 230 in the form of one of the contact pins 250a for the electrical connection to the at least one winding W2 and the magnetic core receptacle 232, in which the magnetic core 210 received in the insulation body 220 is partially received, the side surface section facing the at least one contact element 250a 214 des Magnet core 210 is at least partially covered by one of the insulation wall sections 224 of the insulation body 220.

Furthermore, the side surface section 214 of the magnetic core 210, which is aligned with the at least one contact element 250a, can be completely covered by the insulation wall section 224.

Furthermore, the insulation body 220 and the coil body 230 can be mechanically connected by the connecting means 240. In this case, the connecting means 240 can comprise at least the first connecting element 242 arranged on the insulation body 220 and at least the second connecting element 244 arranged on the coil former 230, which mechanically engage with one another. The connecting means 240 can be designed to couple the insulating body 220 and the coil body 230 in a mechanically releasable manner.

Furthermore, the insulation body 220 can be formed by at least three insulation wall sections that are connected to one another, so that the insulation body 220 has a pot-shaped or bowl-shaped shape with the recess 225 in which the magnetic core 210 is received.

Furthermore, the depth of the recess 225 may be greater than or equal to the height dimension H210 of the magnetic core 210, which is defined with respect to the magnetic core 210 along the direction along which the magnetic core 210 is received in the recess 225.

Claims (12)

1. An inductive component (100; 200) comprising:

   a magnetic core (10; 210),

   an insulation body (20; 220) formed from an electrically insulating material, in which the magnetic core (10; 210) is housed, the insulation body (20; 220) having at least two interconnected insulation wall portions (22, 24; 222, 224), each of which is at least partially facing a side surface portion (14, 16; 214) of the magnetic core (10; 210),

   at least one winding (W1; W2), and

   a bobbin (30; 230) on which the at least one winding (W1; W2) is wound, comprising

   at least one contact element (50b; 250a) attached to a side surface portion (37b; 237a) of the bobbin (30; 230) for electrical connection to the at least one winding (W1; W2), and

   a magnetic core receptacle (32; 232) in which the magnetic core (10; 210) housed in the insulation body (20; 220) is partially accommodated,

   wherein a side surface portion (14; 214) of the magnetic core (10; 210) facing the at least one contact element (50b; 250a) is at least partially covered by one of the insulation wall portions (24; 224) of the insulation body (20; 220),

   characterized in that the insulation body (20) further comprises at least one rib portion (28) formed on the insulation wall portion (24) facing the at least one contact member (50b) and protruding to the outside away from the insulation body (20) along a normal direction of the insulation wall portion (24).
2. The inductive component (100; 200) according to claim 1, wherein the side surface portion (14; 214) of the magnetic core (10; 210) facing the at least one contact element (50b; 250a) is completely covered by the insulation wall portion (24; 224).
3. The Inductive component (100; 200) according to claim 1 or 2, wherein the insulation body (20; 220) and the bobbin (30; 230) are mechanically connected via connecting means (240).
4. The inductive component (100; 200) according to claim 3, wherein said connecting means (28, 38; 240) comprise at least one first connecting element (28; 242) disposed on said insulation body (20, 220) and at least one second connecting element (38; 244) disposed on said bobbin (30, 230) which mechanically engage with each other.
5. The inductive component (100; 200) according to claim 3 or 4, wherein said connecting means (28, 38; 240) are adapted to provide releasable mechanical coupling between said insulation body (20; 220) and said bobbin (30; 230).
6. The inductive component (100; 200) according to any one of claims 1 to 5, wherein the insulation body (20; 220) is formed by at least three insulation wall sections connected to each other so that the insulation body (20; 220) has a pot- or bowl-shaped configuration with a recess (25; 225) in which the magnetic core (10; 210) is housed.
7. The inductive component (100; 200) according to claim 6, wherein a depth of the recess (25; 225) is greater than or equal to a height dimension (H10; H210) of the magnetic core (10; 210) defined with respect to the magnetic core (10; 210) along a direction in which the magnetic core (10; 210) is received in the recess (25; 225).
8. The inductive component (100) according to any one of claims 1 to 7, wherein the at least one rib portion (28) comprises a projection portion (28b) protruding toward the bobbin (30) and being respectively inserted into a positioning recess (38) formed in the bobbin (30) and arranged on a side where the at least one contact element (50b) is arranged.
9. The inductive component (100) according to any one of claims 1 to 8, wherein at least two contact elements (50b) are formed on the side surface portion (37b) of the bobbin (30), and wherein at least two wire end portions (Wa, Wb) of the at least one winding (W1) are guided along the at least one rib portion (28) on opposite sides thereof to one of the contact elements (50b), respectively.
10. The inductive component (100) according to any one of claims 1 to 9, further comprising at least one further contact element (50a) attached to a side surface portion (37a) of the bobbin (30) arranged on a side of the bobbin (30) opposite to the at least one contact element (50b),
    a further magnetic core (10a), and
    a further insulation body (20a), the further insulation body (20a) having at least two interconnected insulation wall portions (24a) each at least partially facing a side surface portion (14a) of the further magnetic core (10a),
    wherein said further insulation body (20a) is arranged on said bobbin (30) opposite to said insulation body (20) and said further magnetic core (10a) housed in said further insulation body (20; 220) is partially accommodated in said magnetic core receptacle (32), and
    wherein a side surface portion (14a) of the further magnetic core (10a) facing the at least one further contact element (50a) is at least partially covered by an insulation wall portion (24a) of the further insulation body (20a).
11. The inductive component (100) according to claim 10, wherein the magnetic cores (10, 10a) are each formed in an E-core configuration.
12. A method of manufacturing the inductive component (100, 200) according to any one of claims 1 to 11, the method comprising:

    winding the at least one winding (W1; W2) on the bobbin (30; 230),

    housing the magnetic core (10; 210) in the insulation body (20; 220), and

    attaching the insulation body (20; 220) with the magnetic core (10; 210) housed therein to the bobbin (30; 230) with the winding thereon, wherein the magnetic core (10; 210) is partially received in the magnetic core receptacle (32; 232) of the bobbin (30; 230).

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