COMPONENT WITH A WINDING CARRIER AND CORE AND METHOD FOR PRODUCING A COMPONENT

Abstract

A component having a winding carrier, at least one winding, a magnetic core and first and second connections. The winding carrier surrounds at least regions of the core in such a way that an insulation section between the connections along an underside of the component cannot be bypassed via the core. In particular, an underside of the winding carrier is designed to be closed.

Claims

1. A device comprising a winding carrier and at least one winding of a wire arranged around the winding carrier a magnetic core and at least one first electrical terminal and at least one second electrical terminal wherein the winding carrier encloses the core at least in regions such that an insulation path between the terminals along a lower side of the device does not comprises a bridging by the core.

2. The device according to claim 1, wherein the core is encased by the winding carrier such that the sum of the insulation path between the first terminal and the core and the insulation path between the second terminal and the core is at least as large as the geometric distance between the first terminal and the second terminal.

3. The device according to claim 1, which is designed as a transformer, wherein the first terminal is at the primary side and the second terminal is at the secondary side.

4. The device according to claim 1, wherein the lower side of the winding carrier lacks a cutout through which the core is exposed.

5. The device according to claim 1, wherein the winding carrier comprises at least one opening through which the core can be inserted into the winding carrier, wherein the lower side of the winding carrier lacks such opening.

6. The device according to claim 5, wherein the opening is arranged on a side face of the winding carrier.

7. The device according to claim 5, wherein the opening is arranged at the upper side of the winding carrier and the side faces lack any openings.

8. The device according to claim 1, wherein the core comprises at least two core parts, wherein the winding carrier comprises an opening at an upper side, wherein both core parts are inserted into the winding carrier through the opening at the upper side.

9. The device according to claim 1, wherein the core comprises a first core part and a second core part, wherein one of the core parts is I-shaped and one of the core parts is U-shaped.

10. The device according to claim 1, wherein the first terminal is arranged at a first side face of the winding carrier and the second terminal is arranged at a second side face of the winding carrier, wherein the core is completely or in a predominant part encased by the winding carrier at least at one of these side surfaces.

11. The device according to claim 1, wherein the winding carrier comprises a lead-through along a winding axis, the core being arranged in the lead-through.

12. The device according to claim 1, wherein at least one of the terminals is arranged set back in the lateral direction.

13. The device according to claim 1, wherein the winding carrier comprises at least one opening for insertion of the core on that side face on which at least one of the terminals is arranged.

14. A method for manufacturing a device, comprising the steps of: A) providing a winding carrier comprising one or more openings on a side face or on an upper side of the winding carrier, B) inserting a first core part into one of the openings, C) inserting a second core part into the same or into another of said openings.

15. The method according to claim 14, wherein after insertion of the first core part a winding is applied to the winding carrier and thereafter the second core part is inserted.

16. The method according to claim 14, wherein the first and second core parts are inserted into the same opening.

17. The method according to claim 14, wherein one of the core parts is inserted through an opening on the side face and one of the core parts is inserted through an opening on the upper side.

18. A device comprising: a winding carrier and at least one winding of a wire arranged around the winding carrier, a magnetic core and at least one first electrical terminal and at least one second electrical terminal, wherein the winding carrier comprises a lower side, wherein the terminals are arranged opposite to each other with respect to the lower side, wherein the winding carrier lacks a cutout through which the core is exposed at least in a region of the lower side which is laterally bounded by the first and second terminals.

19. The device of claim 1, wherein the winding carrier is formed as a single piece, wherein the core comprises a first core part and a second core part, wherein the winding carrier comprises two opposite side faces and an upper side, wherein a first opening for inserting the first core part in the winding carrier is arranged at one of the side faces, wherein the core is completely or in a predominant part encased by the winding carrier at the other one of the side faces and a second opening for inserting the second core part in the winding carrier is arranged at the upper side.

20. The device of claim 1, wherein the winding carrier is formed as a single piece, wherein the winding carrier comprises a lead-through, the core being arranged in the lead-through, wherein the winding carrier comprises a first opening at a side face for inserting a first core part and a second opening at an upper side for inserting a second core part, wherein the lead through is accessible from the outside only through the first opening and the second opening.

Description

[0035] In the following, the subject matters described herein will be explained in more detail by means of schematic embodiments.

[0036] They show:

[0037] FIG. 1A an embodiment of a device in sectional view,

[0038] FIG. 1B the device from FIG. 1A in a view diagonally from top,

[0039] FIG. 1C the device of FIG. 1A in a view diagonally from bottom,

[0040] FIG. 2 a further embodiment of a device in a view diagonally from top,

[0041] FIG. 3A an embodiment of a winding carrier in a view diagonally from top,

[0042] FIG. 3B the winding carrier from FIG. 3A in longitudinal sectional view,

[0043] FIG. 4A a further embodiment of a device in a lateral view from diagonally above,

[0044] FIG. 4B the device of FIG. 4A in another lateral view diagonally from top,

[0045] FIG. 4C the device of FIG. 4A in a view diagonally from bottom,

[0046] FIG. 4D the device of FIG. 4A in a view from the top,

[0047] FIG. 5 a further embodiment of a device in a lateral view diagonally from top,

[0048] FIGS. 6A to 6E method steps for producing the component of the device of FIG. 5,

[0049] FIG. 7 a further embodiment of a device in a lateral view diagonally from top.

[0050] Preferably, in the following figures, the same reference signs refer to functionally or structurally corresponding parts of the various embodiments.

[0051] FIG. 1A shows an embodiment of a device 1 in a longitudinal section. FIG. 1B shows the device 1 in a view diagonally from top, FIG. 1C shows the device 1 in a view diagonally from bottom.

[0052] The device 1 is configured, for example, as a transformer. The device 1 may also be configured as a device with a different functionality, in particular a device in which the maintenance of insulation paths between electrical terminals is of particular importance.

[0053] The device 1 comprises a winding carrier 2 around which at least one winding 3 of a wire 4 is wound. The winding 3 is arranged here in upright form, i.e., the winding axis is arranged perpendicular to a lower side 14 of the device 1. The lower side 14 corresponds to a mounting side of the device 1, for example in the case of fixation to a printed circuit board. The winding carrier 2 is formed of an electrically insulating material. The winding carrier 2 is also formed, for example, in a non-magnetic manner. The winding carrier 2 may be formed of a plastic material. For example, the winding carrier 2 is produced by an injection molding process.

[0054] A plurality of windings may be applied around the winding carrier 2, in particular one or more primary-side windings and one or more secondary-side windings of a transformer. Where reference is made here to one winding, this also applies accordingly to several windings. The winding carrier 2 comprises flange-shaped boundaries 10, 11 on both sides, between which the winding 3 is arranged.

[0055] The wire 4 comprises a metallic material, for example copper. The wire 4 is sheathed with an insulation, for example a triple insulation (TIW—“triple insulated wire”). Thus, the wire 4 or the winding 3 do not have to be separately covered or additionally insulated.

[0056] The device 1 comprises at least a first terminal 5 and a second terminal 6. The terminals 5, 6 are attached directly to the winding carrier 2, for example co-injection molded when manufacturing the winding carrier 2 in an injection molding process. The wire ends of the windings 3 are connected with the terminals 5, 6. Presently, a plurality of first terminals 5 are arranged in a row and a plurality of second terminals 6 are arranged in a row. The first terminals 5 and the second terminals 6 are arranged on opposite side faces 16, 24 of the device 1.

[0057] In this regard, all of the first terminals 5 may be primary-side terminals, i.e., power-supply-side terminals, and all of the second terminals 6 may be secondary-side terminals, i.e., consumer-side terminals. For example, the first terminals 5 are for connection to a supply network and the second terminals 6 are for connection to a consumer, e.g., a refrigerator. For example, each of two of the first terminals 5 are connected to a first, primary-side winding and two of the second terminals 6 are connected to a secondary-side winding.

[0058] The device 1 comprises a magnetic core 7. The core 7 comprises, for example, a ferrite material or another magnetic material. The core 7 is not itself formed as a winding carrier, but is a separate element attached to the winding carrier 2. The core 7 also differs in its material from the winding carrier 2. In particular, the core 7 comprises a greater electrical conductivity than the winding carrier 2.

[0059] In the present case, the core 7 is made of several parts. A first core part 8 comprises an I-shape. A second core part 9 comprises a U-shape. The core parts 8, 9 can also comprise another shape, for example both core parts 8, 9 can be U-shaped. The core parts 8, 9 together form a closed magnetic circuit. The core parts 8, 9 are glued to each other, for example.

[0060] A magnetic core 7 usually comprises a higher electrical conductivity than the winding carrier 2 and can lead to electrical bridging of insulation paths between the first and second terminals 5, 6. Thus, the core 7 does not contribute to an insulation path between the first and second terminals 5, 6, so that insulation clearances must be observed separately from the core 7.

[0061] An insulation path 28 between the first and second terminals 5, 6 is here in particular the shortest creepage distance between the terminals 5, 6 along a surface of the component 1 and/or the shortest clearance distance between the terminals 5, 6. For such insulation paths a minimum length, for example according to IEC standard, must be observed. In the case of a plurality of first terminals 5 and a plurality of second terminals 6, the insulation path is the shortest of the insulation paths between all first terminals 5 and all second terminals 6. In other words, the conditions for spacing and insulation paths mentioned herein may apply to any pair of first terminals 5 and second terminals 6.

[0062] In FIG. 1B, a first insulation path 12 is illustrated between the core 7 and the first terminals 5. In addition, a second insulation path 13, in particular a shortest air gap, is depicted between the core 7 and the second terminals 6.

[0063] The insulation path between the first and second terminals 5, 6 along the upper side 15 of the device is herein the sum of the first and second insulation paths 12, 13.

[0064] In FIG. 1C, the device 1 is illustrated with a view on its lower side 14. The winding carrier 2 is closed at the bottom. In particular, there are no cutouts on the lower side 14 through which the core 7 protrudes out of the winding carrier 2 or through which the core 7 can be pushed into the winding carrier 2. The core 7 is thus insulated on the lower side 14 in the region between the first and second terminals 5, 6 by the winding carrier 2. The arrangement of the core 7 inside the winding carrier 2 ensures space-saving insulation. The core 7 protrudes only laterally out of the winding carrier 2. At least in a region of the lower side 14 which is laterally bounded by the first and second terminals 5, 6, the winding carrier 2 does not comprise a cutout through which the core 7 is exposed.

[0065] In this way, an insulation path 28 between the second terminals 6 along the lower side 14 is not bridged by the core 7. As can be seen, an insulation path 29 from the second terminals 6 to the core 7 is increased by the encasing by the insulating winding carrier 2. Thus, the core 7 is partially insulated from the outside by the winding carrier 2 such that the minimum creepage or clearance distance between the first and second terminals 5, 6 along the lower side 14 of the device 1 does not comprise a bridging by the core. Thus, the core 7 does not bridge and shorten the insulation paths between the terminals 5, 6.

[0066] Thus, at the lower side 14, the core 7 does not influence the insulation path 28 between the terminals 5, 6, so that the size of the device 1 can be reduced. In particular, at the lower side 14 the distance d of the first terminals 5 from the second terminals 6 can be minimized to the minimum insulation distance. It is only necessary to ensure that along the upper side 15 the required minimum insulation distance is maintained even in a bridging by the core 7.

[0067] In particular, the core 7 is encased by the winding carrier 2 in such a way that the sum of the insulation path 12 between the first terminals 5 and the core 7 and the insulation path 13 between the second terminals 6 and the core 7 is at least as large as the geometric distance between the first terminal 5 and the second terminal 6.

[0068] On the lower side, the winding carrier also comprises recesses 23 through which the insulation paths 29 between the second terminals 6 and the core 7 can be prolonged.

[0069] The core 7 protrudes out of the winding carrier 2 only at a side face 16 of the winding carrier 2. In particular, the winding carrier 2 comprises at a side face 16 a first opening 17 (see FIGS. 3A, 3B) through which the core 7 protrudes out of the winding carrier 2. In addition, the winding carrier 2 comprises at its upper side 15 a second opening 18 (see FIGS. 3A, 3b) through which the core 7 protrudes out of the winding carrier 2.

[0070] The core 7 protrudes into the first opening 17, leads through the winding carrier 2 through a lead-through 19 and leads out of the winding carrier 2 through the second opening 18. The lead-through 19 (see FIGS. 3A, 3B) extends in a first region 30 along the winding axis and in a second region 31 parallel to the lower side 14. Inside the lead-through 19, i.e. from the first opening 17 to the second opening 18, the core 7 is enclosed by the winding carrier 2 without interruption.

[0071] In the embodiment of FIGS. 1A, 1B, 1C, the core 7 is arranged and insulated asymmetrically with respect to the winding carrier 2 and the terminals 5, 6. Thus, the insulation path 12 between the core 7 and the first terminals 5 is small, but the insulation path 13 between the core 7 and the second terminals 6 is considerably larger.

[0072] The first core part 8 is I-shaped, and the second core part 9 is U-shaped. The I-shaped first core part 8 is arranged parallel to the lower side 14. The U-shaped, second core part 8 is arranged with a leg along the winding axis. In other embodiments, an I-shaped, first core part may be arranged along the winding axis and a U-shaped, second core part may be arranged with its legs parallel to the lower side. It is also possible for both core parts 8, 9 to be U-shaped, for example.

[0073] In the following, a method for producing the device 1 is described.

[0074] Therein, the winding carrier 2 is provided and a winding 3 is applied to the winding carrier 2. For this purpose, for example, a winding mandrel (not shown here) is inserted into the first opening 17 (see FIGS. 3A, 3B). After applying the winding 3, the winding mandrel is removed and the I-shaped first core part 8 is inserted laterally into the first opening 17. Subsequently, the U-shaped second core part 9 is inserted from the upper side 15 into the second opening 18 (see FIGS. 3A, 3B). The first and second core parts 8, 9 can be glued together.

[0075] FIG. 2 shows a further embodiment of a device 1. In contrast to the embodiment described above, the device 1 comprises two first terminals 5 on a first side face 15 and four second terminals 6 on a second side face 24.

[0076] The first terminals 5 are configured, for example, for connection to a supply network and the second terminals 6 are configured for connection to a consumer. The first terminals 5 are connected, for example, to a first winding 3 and the second terminals 6 are connected in pairs to two further windings 20. The first winding 3 is arranged, for example, above the second windings 20 in the direction of the winding axis. The second windings 20 are located, for example, at the same position one above the other relative to the winding axis. Since the winding wires are insulated from the outside, the windings 3, 20 can also be arranged differently, for example all at the same position relative to the winding axis.

[0077] The invention is not limited to the shown number and arrangement of first and second terminals and windings. For example, there may also be only two first terminals and two second terminals and two windings.

[0078] Also in the embodiment shown, the lower side 14 of the winding carrier 2 is completely closed, so that in order to maintain the minimum insulation path at the lower side 14 of the device 1, it is sufficient to select the distance between opposite terminals 5, 6 equal to the minimum insulation path.

[0079] In addition, the winding carrier 2 comprises protrusions on its upper side 15 by which creepage and clearance distances between core 7 and second terminals 6 along the upper side 15 are increased. A first protrusion 21 extends a region of the winding carrier 2 upwardly. A second protrusion 22 extends the winding carrier 2 towards one side. Both protrusions 21, 22 are selected in such a way that they do not increase the outer dimensions of the device 1.

[0080] FIG. 3A shows an embodiment of a winding carrier 2 diagonally from a top. FIG. 3B shows the winding carrier 2 in longitudinal section. The winding carrier 2 is essentially configured as the winding carrier 2 of FIG. 2, except that it does not comprise the additional projections 21, 22.

[0081] The winding carrier 2 comprises a first opening 17 on a side face 16 and a second opening 18 on its upper side 15. In the sectional view of FIG. 3B, the lead-through 19 can be seen. The lead-through 19 comprises a first region 30 running parallel to the winding axis (vertical in this case) and a second region 31 running perpendicular to the winding axis. The second region 31 runs parallel to the lower side 14. The lead-through 19 is configured overall L-shaped. The lead-through 19 is completely encased by the winding carrier 2 and is thus only accessible from the outside at the openings 17, 18.

[0082] FIG. 4A shows an embodiment of a device 1 in a side view diagonally from the top. FIG. 4B shows the device from another side view diagonally from the top. FIG. 4C shows the device in a view diagonally from the bottom. FIG. 4D shows the device in a top view.

[0083] For reasons of clearness, the device 1 is shown without winding. The winding is applied directly around the winding carrier 2 in the finished device 1. In contrast to the preceding embodiments, the winding axis runs parallel to the lower side 14 of the device 1. The winding carrier 2 comprises two flange-shaped boundaries 10, 11, which bound the winding on both sides.

[0084] First and second terminals 5, 6 are provided directly on the winding carrier 2. In the present case, there are only two first terminals 5 and two second terminals 6.

[0085] Also here, the core 7 comprises a first core part 8 in I-shape and a second core part 9 in U-shape (see FIG. 4B). The first core part 8 is arranged in the winding carrier 2 along the horizontal winding axis.

[0086] The winding carrier 2 completely encases the core 7 at the lower side 14. The lower region of the core 7, in this case formed by the I-shaped core part 8, is encased by the winding carrier 2 almost from all sides. Only the region of the I-shaped core part 8 directed towards a further side face 24 lies open. Towards the first side face 16, the core 7 is completely insulated from the winding carrier 2 towards the outside. Thus, no core area is visible from a view on the lower side 14 and in a view on the side surface 16. Overall, large regions of the core 7 are built into the winding carrier 2 and thus are arranged to be hidden and insulated from the terminals 5, 6.

[0087] Thus, also here, the insulation path between the first and second terminals 5, 6 along the lower side 14 of the device 1 is not bridged by the core 7. Depending on the geometry of the device 1, the insulation path, i.e., the minimum creepage or clearance distance, between the first and second terminals 5, 6 runs along the lower side 14 of the device 1 or along the side faces 16, 24. Here, too, the sum of the insulation path between the first terminals 5 and the core 7 and the insulation path between the second terminals 6 and the core 7 is at least as great as the geometric distance d between the first and second terminals 5, 6.

[0088] The distance d between the first terminals 5 and the second terminals 6 can thus be selected to be equal to the minimum insulation distance. As can be easily seen in FIG. 4D, the first and second terminals 5, 6 are offset inwardly. In particular, the regions of the winding carrier 2 in which the terminals 5, 6 are anchored are further inward than the regions which laterally encase the core 7. Thus, the winding carrier 2 is configured stepped at the side faces 16, 24.

[0089] This allows a further reduction in size of the component 1 without violating the required minimum insulation distance. This reduction in size is made possible by the insulation of the core 7 with respect to the terminals 5, 6 by the winding carrier 2.

[0090] In the following, a method for producing the device 1 is described.

[0091] Therein, the winding carrier 2 is provided and a winding is applied to the winding carrier 2 (not shown here). For this purpose, for example, a winding mandrel (not shown here) is inserted into a first opening 17 (FIG. 4B). After applying the winding, the winding mandrel is removed and the I-shaped first core part 8 is inserted into the first opening 17. Then, the U-shaped second core part 9 is inserted into the second opening 18 from the upper side 15. The first and second core parts 8, 9 may be glued to each other.

[0092] In another embodiment, for example, the I-shaped core part may also be inserted into an opening at the left end of the upper side and the U-shaped core part may be inserted laterally. The invention is also not limited to I-shaped and U-shaped core parts.

[0093] FIG. 5 shows a further embodiment of a device 1. FIGS. 6A to 6E show a method for producing the device, thereby also illustrating the internal structure of the device 1 of FIG. 5.

[0094] As in the embodiments described above, the winding carrier 2 also forms a housing for the core 7 in order to insulate the core 7 from first and/or second terminals 5, 6. The winding carrier 2 encases the core 7 from the lower side 14 such that no region of the core 7 is exposed between the terminals 5, 6. As in the embodiment according to FIGS. 4A to 4D, the core 7 is fully encased at the lower side 14 so that no region of the core 7 is exposed.

[0095] The core 7 also here comprises a first core part 8 (FIG. 5) and a second core part 9 (FIG. 6A). The first core part 8 is U-shaped, the second core part 9 is I-shaped.

[0096] In contrast to the preceding embodiments, the core 7 is completely, i.e. both core parts 8, 9 (core part 8 see FIG. 6A), inserted into the winding carrier 2 from an upper side 15. In particular, the winding carrier 2 comprises an opening 18 only on the upper side 15 for insertion of both core parts 8, 9. At the side faces 16, 24, the core 7 is completely encased by the housing 2. The housing 2 also extends partially over the two further side faces 25, 26. The lower core part 8 is not visible from the outside. The upper core part 9 is only visible from the top.

[0097] Thus, the core 7 is similarly insulated from the first and second terminals 5, 6. In particular, the insulation path between the first terminals 5 and the core 7 is of the same length as the insulation path between the second terminals 6 and the core 7. Overall, there is a symmetrical apportionment of the insulation paths between the core 7 and the first terminals 5 and between the core 7 and the second terminals 6.

[0098] As shown in FIG. 6A, the winding carrier 2 is provided during the manufacturing of the device 1. Terminals 5, 6 are attached to the winding carrier 2. No winding is yet attached to the winding carrier 2. The U-shaped first core part 8 is inserted into the winding carrier 2 through an opening 18 at the upper side 15. In particular, the first core part 8 is inserted into the open winding axis in the winding carrier 2.

[0099] FIG. 6B shows the winding carrier 2 with the inserted U-shaped first core part 8. The winding carrier 2 encases the first core part 8 at the lower side 14 and from all side faces 16, 24, 25, 26. Only at the upper side 15 the first core part 8 is exposed. A wire 4 is then wound around the winding carrier 2 and, thus, a winding 3 is applied.

[0100] FIG. 6C shows the winding carrier 2 with the winding 3. The winding 3 is arranged horizontally so that the winding axis runs parallel to the lower side 14 of the device 1. Wire ends of the winding 3 are guided through guide grooves in the winding carrier 2 to the terminals 5, 6 and electrically connected with the terminals 5, 6. At the terminals 5, 6, the insulating layer is removed from the wire and the wire is soldered or laser-welded to the respective terminal 5, 6, for example.

[0101] As shown in FIG. 6D, a second core part 9 is then inserted into the winding carrier 2 through the opening 18 from the upper side 15. The second core part 9 is I-shaped in the present case. However, it is also possible to use differently shaped core parts 8, 9, for example both core parts 8, 9 as U-cores.

[0102] FIG. 6E shows the finished device 1. The first core part 8 forms a closed magnetic circuit with the second core part 9.

[0103] The first core part 8 is glued to the second core part 9, for example. The second core part 9 is completely encased by the winding carrier 2 at two side faces 16, 24. The winding carrier 2 fits tightly against the core parts 8, 9 and thus defines the position of the core parts 8, 9. Thus, an automatic and well controllable arrangement and gluing of the core parts 8, 9 is possible.

[0104] FIG. 7 shows a variant of the device 1 of FIGS. 5 to 6E. Here, the winding carrier 2 comprises lateral retaining devices 27 for securing the winding carrier 2 in a winding machine. The retaining devices 27 comprise webs between which, for example, a two-part spindle can be attached to the winding carrier 2.

[0105] In contrast to the embodiments of FIGS. 1A to 4D, in the embodiments of FIGS. 5 to 7 the winding carrier 2 does not comprise an opening through which a spindle can be inserted into the winding axis during the production of the winding. By placing the first core part 8 in the winding carrier 2 before applying the winding, the space is already occupied by the first core part 8.

LIST OF REFERENCE SIGNS

[0106] 1 device [0107] 2 winding carrier [0108] 3 winding [0109] 4 wire [0110] 5 first terminal [0111] 6 second terminal [0112] 7 core [0113] 8 first core part [0114] 9 second core part [0115] 10 boundary [0116] 11 boundary [0117] 12 insulation path between first terminal and core [0118] 13 insulation path between second terminal and core along side face [0119] 14 lower side [0120] 15 upper side [0121] 16 side face [0122] 17 opening on side face [0123] 18 opening on upper side [0124] 19 lead-through [0125] 20 further winding [0126] 21 first protrusion [0127] 22 second protrusion [0128] 23 recess [0129] 24 further side face [0130] 25 further lateral face [0131] 26 further side face [0132] 27 retaining device [0133] 28 insulation path between first and second terminal [0134] 29 insulation path between second terminal and core along lower side [0135] 30 first region of lead-through [0136] 31 second region of lead-through [0137] d distance