Inductor arrangement comprising an insert

Abstract

A inductor arrangement has a toroidal core with a central opening, a winding which is arranged around the core and has two winding ends, and an electrically insulating insert which is inserted into the central opening in a clamping manner. Here, the winding ends are inserted into the insert in a clamping manner.

Claims

1. An inductor arrangement, comprising: a toroidal core with a central opening, a winding arranged around the toroidal core and comprising two winding ends, and an electrically insulating insert which is inserted into the central opening in a clamping manner, wherein the electrically insulating insert has an outer surface that faces the toroidal core, and wherein a portion of the winding is disposed between the outer surface of the electrically insulating insert and the toroidal core, wherein the winding ends are inserted into the electrically insulating insert in a clamping manner, wherein the electrically insulating insert has a protrusion that protrudes outwardly from the outer surface of the electrically insulating insert toward an inner surface of the toroidal core, and wherein the protrusion separates the winding ends by a distance.

2. The inductor arrangement as claimed in claim 1, wherein a central axis extends through the central opening in a first direction and a second direction opposite the first direction, wherein the electrically insulating insert has a first side facing the first direction, and a second, opposite side facing the second direction, and wherein one of the winding ends is inserted into the electrically insulating insert from the first side and the other of the winding ends is inserted into the electrically insulating insert from the second side such that the two winding ends are inserted on mutually opposite sides of the electrically insulating insert.

3. The inductor arrangement as claimed in claim 1, wherein a central axis extends through the central opening in a first direction and a second direction opposite the first direction, wherein the electrically insulating insert has a first side facing the first direction, and a second, opposite side facing the second direction, and wherein both of the winding ends are inserted into the electrically insulating insert from one of the first or second sides of the electrically insulating insert such that the two winding ends are inserted on the same side of the electrically insulating insert.

4. The inductor arrangement as claimed in claim 1, wherein one connection wire is electrically connected to each of the two winding ends, respectively, in a section of the winding ends which is inserted into the electrically insulating insert.

5. The inductor arrangement as claimed in claim 1, wherein the winding ends each comprise a first portion and a second portion, wherein the second portion forms a non-zero angle with respect to the first portion, and wherein the second portion of each winding end is inserted into the electrically insulating insert, and the first portion of each winding end is not inserted into the electrically insulating insert.

6. The inductor arrangement as claimed in claim 1, wherein the electrically insulating insert comprises an integral injection-molded plastic part.

7. The inductor arrangement as claimed in claim 1, wherein the electrically insulating insert does not protrude out of the central opening beyond the winding.

8. The inductor arrangement as claimed in claim 1, wherein the outer surface of the electrically insulating insert faces the toroidal core and extends along the winding between the winding and a center of the central opening.

9. The inductor arrangement as claimed in claim 1, wherein the inner surface of the toroidal core faces the electrically insulating insert, and wherein the portion of the winding is disposed between the inner surface of the toroidal core and the outer surface of the electrically insulating insert.

10. The inductor arrangement as claimed in claim 9, wherein the portion of the winding separates the outer surface of the electrically insulating insert from the inner surface of the toroidal core.

11. An inductor arrangement, comprising: a toroidal core with a central opening, a winding arranged around the toroidal core and comprising two winding ends, and an electrically insulating insert which is inserted into the central opening in a clamping manner, wherein the electrically insulating insert has an outer surface that faces the toroidal core, and wherein a portion of the winding is disposed between the outer surface of the electrically insulating insert and the toroidal core, wherein the winding ends are inserted into the electrically insulating insert in a clamping manner, wherein the electrically insulating insert comprises an outer ring, a first pair of tabs, and a second pair of tabs, wherein the first pair of tabs extend in a first direction from the outer ring toward a center of the central opening, and wherein the second pair of tabs extend adjacent to the first pair of tabs in the first direction from the outer ring toward the center of the central opening.

12. The inductor arrangement as claimed in claim 11, wherein a first tab of the first pair of tabs is hook-shaped.

13. An inductor arrangement, comprising: a toroidal core with a central opening, a winding arranged around the toroidal core and comprising two winding ends, and an electrically insulating insert which is inserted into the central opening in a clamping manner, wherein the electrically insulating insert has an outer surface that faces the toroidal core, and wherein a portion of the winding is disposed between the outer surface of the electrically insulating insert and the toroidal core, wherein the winding ends are inserted into the electrically insulating insert in a clamping manner, wherein the electrically insulating insert comprises a pair of tabs and an outer ring with a gap therein, wherein the pair of tabs protrude from a section of the outer ring, which is opposite the gap in the outer ring, toward the gap in the outer ring.

Description

DESCRIPTION OF THE FIGURES

(1) The disclosure will be described below with reference to exemplary embodiments using drawings which, when considered together with the features of the claims, reveal further features, properties and advantages of the disclosure.

(2) In the drawings:

(3) FIG. 1 shows an example embodiment of a inductor arrangement according to the disclosure,

(4) FIG. 2 shows a sectional view of the example embodiment according to FIG. 1, and

(5) FIGS. 3a-3c show example embodiments of an insert according to the disclosure.

DETAILED DESCRIPTION

(6) FIG. 1 shows as example embodiment of a inductor arrangement 1 according to the disclosure comprising a toroidal core 2 and a central opening 3. The winding 4 has been wound onto the core 2 with a large number of turns. An insert 5 has been inserted into the central opening 3. In the relaxed state, not yet introduced, the spatial extent of the insert 5 is somewhat greater than the diameter of the central opening 3. When the insert 5 is inserted into the central opening 3, the insert 5 is compressed, so that it is then firmly held in the central opening 3 in a clamping manner. Connection wires 8, 9 protrude out of the housing 5, where they are connected to the winding ends 6, 7 (see FIG. 2). The slots of the insert 5 for receiving the connection wires 8, 9 and winding ends 6, 7 are spaced apart from one another in order to provide the creepage distances and clearance required for insulation.

(7) FIG. 2 shows how a winding end 6 has been electrically connected to a connection wire 8 in a section 12, for example by soldering or pressing with a common metal sleeve. This section is then held in a clamping manner by insertion into one of the tapering slots 14, 15 (see FIG. 3) of the insert 5. Insert 5 has approximately the same or a lower thickness than the core 2, so that it does not protrude out of the central opening 3 beyond the winding 4. Note that the winding ends each comprise a first portion and a second portion, wherein the second portion forms a non-zero angle (e.g., a right angle) with respect to the first portion, and wherein the second portion of each winding end is inserted into the insert, and the first portion of each winding end is not inserted into the insert.

(8) FIG. 3a shows an example embodiment of an insert 5 according to the disclosure. The insert 5 is manufactured from insulating material, for example in the form of an integral injection-molded part. The outer circumferential ring 20 of the insert 5 is not closed, so that the circumferential ring can be compressed and inserted into the central opening 3 of the inductor arrangement 1 according to the disclosure. After insertion into the central opening 3, the circumferential ring 20 expands again, so that the insert 5 is held in the central opening 3 in a clamping manner.

(9) The insert 5 has two slots 14, 15 which taper in one direction. The slots 14, 15 are delimited by tabs 16-19. The section 12, in which for example connection wire 8 and winding end 6 are connected to one another, can be inserted in the wider opened part of one slot 14. This section 12 is then pushed into the tapering region of the slot 14. Analogously, the connection wire 9 and the winding end 7 are connected to one another and pushed into the tapering region of the slot 15 (not shown). At least one of the tabs 16, 18 has sharp edges in the tapering region of one slot 14, so that the section 12 can be secured in a desired position. The section 12 is then held between the edges of the tabs 16, 18 in a clamping manner. The spacing of the tabs 16, 17 results in a minimum distance between the sections 12 of the two winding ends 6, 7 and therefore also between the two connection wires 8, 9, the creepage and clearance distances required for insulation being provided in this way.

(10) Furthermore, the insert 5 has at least one lug 10, in the example there are two. Said lugs, together with holding of the insert 5 in a clamping manner, have the effect that the first turn (for example that at winding end 6) and the last turn (at winding end 7) cannot move toward one another on the core 2, but rather maintain a minimum distance.

(11) FIG. 3b shows a further advantageous embodiment of an insert 25 according to the disclosure. The outer circumferential ring 20 is of similar design to that in FIG. 3a; the clamping structures are different. A rigid inner supporting ring 26 with a likewise rigid bar 29 has, in its interior, sharp edges 28 and elastic bars 27. Sharp edges can likewise be formed on this elastic bar 27, so that, between the sharp edges 28 and 27, the connection wires 8, 9 and, respectively, winding ends 6, 7 which are connected to one another can be secured in a desired position in their section 12, but at the same time can be separated from one another, and therefore insulated, by the rigid bar 29.

(12) FIG. 3c shows a further advantageous embodiment of an insert 35 according to the disclosure. In this case too, the outer circumferential ring 20 is of similar design to that in FIGS. 3a-3b. A rigid inner supporting ring 36 with a bar 39 is equipped with edges 38, 40 of elastic design. The edges 38, 40 are equipped with corrugations in order to improve the clamping effect. The connection wires 6, 7 and winding ends 8, 9 which are connected to one another can be easily inserted between these edges 38, 40 in one direction, for example, from front to rear in the left-hand side of the figure, and clamped there.