Inductor device, method of manufacturing same and antenna

Abstract

The present invention relates to an inductor device, a method of manufacturing same and antenna. The proposed inductor device comprising a magnetic core (1), an electrically insulating support (10) with a cavity (11) arranged around said magnetic core (1), and three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wherein said electrically insulating support (10) is made of a single part and completely houses the magnetic core (1) which is accessible through an opening, the three windings (DX, DY, DZ) being supported on winding supporting faces (12X, 12Y and 12Z) of the electrically insulating support, confined between winding limiting edges (22) defined by lower corner protuberances (20) and centered with respect to the three orthogonal axes (X, Y, Z) such that said electrically insulating support (10) assures symmetry and orthogonality of said electromagnetic field vectors generated by the mentioned inductor device.

Claims

1. An inductor device comprising: a rectangular prismatic magnetic core with eight vertexes and three pairs of opposite faces facing and parallel to one another defining an axis X, an axis Y, and an axis Z orthogonal to one another each perpendicular to one of said pairs of opposite faces and passing through the geometric center of the opposite faces; an electrically insulating support surrounding all but one of the opposite faces of the magnetic core and made of a single part with a rectangular prismatic cavity arranged around said magnetic core, said cavity completely housing the rectangular prismatic magnetic core and being accessible through an opening surrounded by a frame having four sides arranged opposite one another in pairs, said electrically insulating support being provided with: two orthogonal winding up channels dimensioned to delimit respective two orthogonal windings (DX, DY) of conductive wire, said winding up channels being defined by winding supporting outer faces (12X, 12Y) each perpendicular to one of said axis X, Y, winding limiting edges perpendicular to the winding supporting outer faces (12X, 12Y), four additional winding supporting outer faces (12X′ and 12Y′) formed on said four sides of the frame and the winding limiting edges associated therewith; winding supporting outer faces (12Z) perpendicular to one of said axis X and Y and configured to support a third winding (DZ) of conductive wire, orthogonal to the other two windings (DX, DY); and four lower corner protuberances arranged on four vertexes of the magnetic core, including winding limiting edges perpendicular to the winding supporting outer faces), said three windings being arranged orthogonal to one another wound around said magnetic core supported on said winding supporting faces (12X, 12Y, 12Z), confined between the winding limiting edges such that when a current circulates through the mentioned windings (DX, DY, DZ), an electromagnetic field with electromagnetic field vectors coaxial with the axes of each of the windings is generated, wherein: said frame is arranged flush with or above the level of the magnetic core, said winding supporting outer faces (12Z) define four pilasters projecting from the four corners protuberances of the electrical insulating support, wherein an end of each pilaster also project from the frame forming steps determining said winding limiting edges; said winding supporting outer faces extending from lower corner protuberances up to said pilaster end; and said winding supporting outer faces (12Z), where the third winding (DZ) is wound, provide surfaces delimited on one side by said limiting edges of the lower corner protuberances; and said third winding (DZ) is centered with respect to the orthogonal axes X and Y; wherein said two orthogonal windings (DX, DY) and said third winding (DZ) are configured to in combination with the dimensions of the magnetic core define three isotropic orthogonal magnetic fields.

2. The device according to claim 1, wherein said third winding (DZ) around the axis Z is formed by a conductive wire provided with a self-adhesive coating.

3. The device according to claim 1, wherein said magnetic core is formed by: a block which is tightly inserted in said part with a cavity forming the electrically insulating support, a magnetic cement set inside the cavity of said electrically insulating support, or a PBM or PB SM material injected into the mentioned cavity.

4. The device according to claim 3, wherein the mentioned magnetic core is coated with a polymer resin or epoxy resin layer occupying said open face of the electrically insulating support, and wherein the height of the magnetic core is smaller than the depth of the inner cavity of the electrically insulating support, and said epoxy resin layer has a thickness equal to the difference existing between said height of the magnetic core and depth of the inner cavity of the electrically insulating support.

5. The device according to claim 1, wherein the magnetic core is a cubic core and the dimensions of the three windings (DX, DY, DZ) are uniform, providing an inductor with isotropic properties.

6. The inductor device according to claim 1, wherein each of the three windings (DX, DY, DZ) of conductive wire has a conductive wire entry point and a conductive wire exit point that are different from one another and connected to the ends of electrically conductive elements integrated in each of said lower corner protuberances.

7. The inductor device according to claim 6, wherein the mentioned electrically insulating support includes conductive wire guiding configurations of each of the three windings (DX, DY, DZ) between the conductive wire entry point and the corresponding electrically conductive element thereof and between the conductive wire exit point and the corresponding electrically conductive element thereof, said guiding configurations being formed by a notch, stepped recess or groove, such that a tensioned conductive wire is precisely positioned in relation to the winding supporting outer faces (12X, 12Y and 12Z) and in the winding up direction at said conductive wire entry point or at said conductive wire exit point.

8. The device according to claim 1, wherein the winding supporting outer faces (12X, 12Y and 12Z) comprise winding supporting outer faces (12X) for supporting the winding (DX) wound around the axis X, winding supporting outer faces (12Y) for supporting the winding (DY) wound around the axis Y, and winding supporting outer faces (12Z) for supporting the winding (DZ) wound around the axis Y, the faces corresponding to two different bisecting windings arranged at a different level and linked in stepped intersections, said step defining winding limiting edges, and wherein two of said sides of the frame are at a lower level with respect to the other two sides.

9. A method of manufacturing an inductor device, comprising: producing an electrically insulating support by injection molding, being made of a single hollow part open on one of the faces thereof with a rectangular prismatic cavity, provided for completely housing a magnetic core, and being accessible through an opening surrounded by a frame having four sides arranged opposite one another in pairs, said support being provided with: two orthogonal winding up channels dimensioned to delimit respective two orthogonal windings (DX, DY), said winding up channels being defined by winding supporting outer faces (12X, 12Y and 12Z) each perpendicular to one axis X, Y or Z, winding limiting edges perpendicular to the winding supporting outer faces (12X, 12Y), four additional winding supporting outer faces (12X and 12Y) formed on said four sides of the frame and the winding limiting edges associated therewith; winding supporting outer faces (12Z) perpendicular to one of said axis X and Y and configured to support a third winding (DZ) orthogonal to the other two windings (DX, DY); and four lower corner protuberances including winding limiting edges perpendicular to the winding supporting outer faces (12X, 12Y and 12Z), providing, inside said rectangular prismatic cavity of the electrically insulating support, a rectangular prismatic magnetic core with eight vertexes and three pairs of opposite faces facing and parallel to one another, defining said three axes X, Y and Z orthogonal to one another each perpendicular to one of said pairs of faces and passing through the geometric center of the faces; providing three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wound around said magnetic core and supported on the winding supporting faces (12X, 12Y and 12Z), confined between the winding limiting edges; wherein the method includes: produce the electrically insulating support through a two-part mold lacking of upper corner protuberances in correspondence with the remaining four vertexes of the magnetic core, with said frame being arranged flush with or above the level of the magnetic core, and with the two orthogonal winding up channels being centered with respect to the orthogonal axes X, Y and Z, wound the third winding (DZ) on said winding supporting outer faces (12Z) delimited on one side by said limiting edges of the lower corner protuberances, centered with respect to the orthogonal axes X and Y, configured so that in combination with the dimensions of the magnetic core and with the other two orthogonal windings (DX, DY) define three isotropic orthogonal magnetic fields, wherein removable upper corner protuberances are furthermore provided before winding up the winding (DZ) around the axis Z and are removed when said winding up ends, such that the winding supporting faces (12Z) for supporting the winding (DZ) around the axis Z are demarcated between the electrically insulating support and said removable upper corner protuberances during the winding up step.

10. The method according to claim 9, wherein the winding (DZ) is a conductive wire wound around the axis Z and fixed therein with a self-adhesive coating of said conductive wire.

11. The method according to claim 9, wherein said magnetic core is formed by: a block which is tightly inserted into said cavity of the electrically insulating support, a magnetic cement which is poured into, contained in and sets inside said cavity of the electrically insulating support, or a PBM or PB SM material injected into the mentioned cavity.

12. The method according to claim 9, wherein the electrically insulating support is produced including electrically conductive elements integrated in each of said lower corner protuberances; and wherein each winding (DX, DY, DZ) of conductive wire has a conductive wire entry point and a conductive wire exit point that are different from one another and connected to the ends of said electrically conductive elements; and wherein the electrically insulating support is produced including guiding configurations for guiding the conductive wire of each of the windings (DX, DY, DZ) between the corresponding conductive wire entry point and the electrically conductive element thereof and between the corresponding conductive wire exit point and the electrically conductive element thereof, said guiding configurations being formed by a notch, stepped recess or groove.

13. The method according to claim 12, wherein the winding up process for winding up the three windings (DX, DY, DZ) is performed in three successive steps, each of which includes: automatically positioning a tensioned conductive wire in its corresponding guiding configuration, a portion of said conductive wire being precisely positioned in relation to the winding supporting outer face (12X, 12Y and 12Z) at said conductive wire entry point and in the winding up direction; automatically winding up said conductive wire around the magnetic core on the winding supporting outer faces (12X, 12Y and 12Z) from said conductive wire entry point to the corresponding conductive wire exit point, the winding being confined between the corresponding winding limiting edges; automatically positioning a portion of said tensioned conductive wire from the conductive wire exit point in its corresponding guiding configuration, being precisely positioned in relation to said conductive wire exit point.

14. The method according to claim 12, wherein said automatic winding up process includes electrically connecting in an automatic manner each end of the conductive wire forming a winding (DX, DY, DZ) to a corresponding electrically conductive element of a lower corner protuberance, said conductive wire being arranged in tension between the mentioned electrical connection, the guiding configuration, and the conductive wire entry or exit point of the winding (DX, DY, DZ).

15. The device according to claim 2, wherein said magnetic core is formed by: a block which is tightly inserted in said part with a cavity forming the electrically insulating support, a magnetic cement set inside the cavity of said electrically insulating support, or a PBM or PBSM material injected into the mentioned cavity.

16. A transmitting or receiving antenna including an inductor device comprising: a rectangular prismatic magnetic core with eight vertexes and three pairs of opposite faces facing and parallel to one another defining an axis X, an axis Y, and an axis Z orthogonal to one another each perpendicular to one of said pairs of opposite faces and passing through the geometric center of the opposite faces, an electrically insulating support surrounding all but one of the opposite faces of the magnetic core and made of a single part with a rectangular prismatic cavity arranged around said magnetic core, said cavity completely housing the rectangular prismatic magnetic core and being accessible through an opening surrounded by a frame having four sides arranged opposite one another in pairs, said electrically insulating support being provided with: two orthogonal winding up channels dimensioned to delimit respective two orthogonal windings of conductive wire, said winding up channels being defined by winding supporting outer faces each perpendicular to one of said axis X, Y, winding limiting edges perpendicular to the winding supporting outer faces, four additional winding supporting outer faces formed on said four sides of the frame and the winding limiting edges associated therewith; winding supporting outer faces perpendicular to one of said axis X and Y and configured to support a third winding of conductive wire, orthogonal to the other two windings, and four lower corner protuberances arranged on four vertexes of the magnetic core, including winding limiting edges perpendicular to the winding supporting outer faces, said three windings being arranged orthogonal to one another wound around said magnetic core supported on said winding supporting faces, confined between the winding limiting edges such that when a current circulates through the mentioned windings, an electromagnetic field with electromagnetic field vectors coaxial with the axes of each of the windings is generated, wherein: said frame is arranged flush with or above the level of the magnetic core, said winding supporting outer faces define four pilasters projecting from the four corners protuberances of the electrical insulating support, wherein an end of each pilaster also project from the frame forming steps determining said winding limiting edges, said winding supporting outer faces extending from lower corner protuberances up to said pilaster end; and said winding supporting outer faces, where the third winding is wound, provide surfaces delimited on one side by said limiting edges of the lower corner protuberances, and said third winding is centered with respect to the orthogonal axes X and Y, wherein said two orthogonal windings and said third winding are configured to, in combination with the dimensions of the magnetic core, define three isotropic orthogonal magnetic fields.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing and other advantages and features will be netter understood based on the following detailed description of an embodiment in reference to the attached drawings which must be interpreted in an illustrative and non-limiting manner, in which:

(2) FIG. 1 shows a top perspective view of the electrically insulating support, without the magnetic core and windings, showing the inner cavity and the opening thereof, according to an embodiment provided with lower corner protuberances including electrically conductive elements and guiding configurations, and without upper corner protuberances;

(3) FIG. 2 shows a top perspective view of the electrically insulating support, without the magnetic core and windings, showing the inner cavity and the opening thereof, according to another embodiment provided with lower corner protuberances including electrically conductive elements and guiding configurations, and also provided, according to a feature not claimed in this document but a feasible alternative embodiment of the invention, with upper corner protuberances;

(4) FIG. 3 shows the same electrically insulating support shown in FIG. 2 but seen from a lower part;

(5) FIG. 4 shows a perspective view of the magnetic core;

(6) FIG. 5a shows a view of the same embodiment shown in FIG. 1 but with a magnetic core inserted into the cavity of the electrically insulating support;

(7) FIG. 5b shows a view of the same embodiment shown in FIG. 2 but with a magnetic core inserted into the cavity of the electrically insulating support;

(8) FIG. 6a shows a view of the same embodiment shown in FIG. 5a after winding up the three orthogonal windings;

(9) FIG. 6b shows a view of the same embodiment shown in FIG. 5b after winding up the three orthogonal windings;

(10) FIG. 7 shows the same wound up electrically insulating support shown in FIG. 6b, but seen from a lower part;

(11) FIG. 8 shows an inductor device completed with a casing for covering the windings;

(12) FIG. 9 shows a cross-section of the electrically insulating support containing a cubic magnetic core sealed by an epoxy resin layer, said section being obtained through a plane perpendicular to the axis X.

(13) FIG. 10 shows an example of performing the method using an electrically insulating support devoid of upper corner protuberances.

DETAILED DESCRIPTION OF AN EMBODIMENT

(14) The attached drawings show illustrative, non-limiting embodiments of the present invention.

(15) According to a first embodiment of the present invention, the inductor device consists of a cubic magnetic core 1 having six squares faces, defining an axis X, an axis Y, and an axis Z, said core being tightly inserted into an also cubic inner cavity 11 of an electrically insulating support 10, completely covering five of the six faces of the magnetic core 1 and leaving the sixth face of the magnetic core exposed through an opening for accessing the mentioned inner cavity 11.

(16) Said electrically insulating support 10 has winding supporting outer faces 12X, 12Y and 12Z, parallel to the faces of the magnetic core, and four lower corner protuberances 20 arranged on four vertexes of the magnetic core 1, including winding limiting edges 22 perpendicular to the winding supporting outer faces 12X, 12Y and 12Z.

(17) Furthermore (see FIGS. 3, 9 and 10), the winding supporting outer faces 12X, 12Y and 12Z comprise supporting outer faces for supporting the winding DX (coaxial to the axis X) known as 12X, supporting outer faces for supporting the winding DY (coaxial to the axis Y) known as 12Y, and supporting outer faces for supporting the winding DZ (coaxial to the axis Z) known as 12Z, the faces corresponding to two different bisecting windings being arranged at a different level and linked in the stepped intersections, said step defining winding limiting edges 22.

(18) The winding supporting outer faces 12X, 12Y and 12Z, together with the stepped intersections and with the winding limiting edges 22, form independent winding up channels at different level for each of the three windings DX, DY DZ.

(19) The opening providing access to the inner cavity 11 of the electrically insulating support 10 is surrounded by a frame 50 having four sides 51 arranged opposite one another in pairs, said frame 50 being arranged flush with or above the level of the magnetic core 1 and said four sides 51 forming four additional winding supporting outer faces 12X and 12Y, having winding limiting edges 22 associated therewith, the three windings DX, DY and DZ being supported on said winding supporting faces 12X, 12Y and 12Z, confined between the winding limiting edges 22 and centered with respect to the three orthogonal axes X, Y, Z, such that said electrically insulating support 10 assures symmetry and orthogonality of said electromagnetic field vectors generated by the mentioned inductor device.

(20) Since said electrically insulating support 10 is produced by a precision injection molding method, the regularity of all the inductors produced is assured. The geometry of said electrically insulating support 10 assures correct positioning of the three windings DX, DY and DZ arranged orthogonal to one another, in an automatic winding up process. This property allows significant savings in the processes of calibrating the individual inductors produced.

(21) In the present embodiment, the winding DX around the axis X is the first to be made, and it is made on a continuous winding up channel surrounding three faces of the electrically insulating support 10 and also the opening of the inner cavity 11, said winding up channel being defined by continuous winding supporting outer faces 12X running the entire length of the outer faces of the electrically insulating support 10 with a width equivalent to the width existing between two opposite winding limiting edges 22 of the lower corner protuberances 20, said winding supporting faces 12X being connected at their ends and by the two winding supporting outer faces 12X of a lower level of the frame 50 of the opening of the cavity.

(22) Winding up around the axis Y is the second to be done in this example, and it consists of a continuous winding up channel surrounding three faces of the electrically insulating support 10 and also the opening of the inner cavity, crossing the winding up around the axis X on the base of the support and also on the opening of the inner cavity 11, on opposite sides of the electrically insulating support 10.

(23) Said winding up channel is defined by two continuous winding supporting outer faces 12Y running the entire length of two opposite outer faces of the electrically insulating support 10 with a width equivalent to the width existing between two opposite winding limiting edges 22 of the lower corner protuberances 20. This winding up channel is furthermore demarcated by two symmetrical winding supporting outer faces arranged on one and the same outer face of the base of the electrically insulating support, on opposite sides of the winding up channel for winding up around the axis X, and separated from same by means of a step, being at a higher level, and by the two winding supporting outer faces of a higher level of the frame 50 of the opening of the cavity 11, thereby determining that both windings X and Y cross one another at a different height both in the base and in the opening of the inner cavity 11.

(24) Finally, winding up around the axis Z is the third to be done in this example, and it consists of a continuous winding up channel surrounding four outer faces of the electrically insulating support 10, crossing the windings DX and DY around the axes X and Y on each of said four outer faces.

(25) Said winding up channel of the axis Z is defined by two symmetrical winding supporting outer faces 12Z arranged on each of the four outer faces of the electrically insulating support 10, on opposite sides of the winding up channel for winding up around the axes X or Y, and separated from same by means of a step, being arranged at a higher level, thereby determining that both windings DX and DY cross one another at a different height. In the electrically insulating support 10, said configuration determines winding supporting outer faces 12Z in the form of pilasters projecting from the four vertical corners of the electrically insulating support.

(26) According to one embodiment, said four pilasters project from the frame defining the opening of the inner cavity, forming steps with respect to the respective four winding supporting outer faces 12X and 12Y defining said frame 50, determining winding limiting edges 22 of the windings DX and DY wound around axes X and Y crossing one another on said opening of the inner cavity 11.

(27) According to another alternative embodiment, not claimed in this document but a feasible alternative embodiment of the invention, the electrically insulating support 10 further consists of four upper corner protuberances 21 arranged on four vertexes of the magnetic core 1, and likewise including winding limiting edges 22 perpendicular to the winding supporting outer faces 12X, 12Y and 12Z, the mentioned projecting pilasters in said embodiment being confined between the opposite winding limiting edges 22 of the upper corner protuberances 21 and lower corner protuberances 20.

(28) The magnetic core 1 can be a block inserted in said cavity 11, but in a preferred embodiment it can be a magnetic cement poured in liquid or viscous state into the inner cavity of the electrically insulating support which will act as a container and mold during the setting of said magnetic cement until the hardening thereof. In an alternative embodiment, the mentioned core can be formed from a PBM or PBSM material which is provided by injection into the mentioned cavity (11).

(29) Preferably, said hardened magnetic cement or said block does not occupy the entire inner cavity, an upper portion of the cavity being close to the opening that is not occupied. A polymer or epoxy resin is poured into said upper portion of the cavity that is not occupied, filling it, and being confined therein where it hardens, sealing the opening, retaining and insulating the magnetic core.

(30) Some or all of the lower corner protuberances 20 are also proposed to include electrically conductive elements 23 to which the ends of the conductive wires 40 forming the respective three windings DX, DY and DZ are connected. Said electrically conductive elements 23 are metal strips partially embedded inside said lower corner protuberances 20, and are provided as electrical contacts which allow coupling said inductor device directly to a printed circuit (SMD mounting). In this example, three lower corner protuberances 20 each include two electrically conductive elements 23, each connected to an end of a conductive wire of one of the windings DX, DY and DZ.

(31) Furthermore, each conductive wire 40 is guided from the electrically conductive element 23 to an entry point 41 or an exit point 42 (FIG. 3) of the corresponding winding thereof.

(32) For such purpose, the mentioned electrically insulating support 10 includes guiding configurations 15 (FIGS. 1-3) for guiding the conductive wire 40 of each of the windings DX, DY, DZ, between the entry point 41 and the corresponding electrically conductive element 23 thereof and between the exit point 42 and the corresponding electrically conductive element 23 thereof, said guiding configurations 15 being formed by a notch, stepped recess or groove, such that a tensioned conductive wire 40 is precisely positioned in relation to the winding supporting outer face 12X, 12Y and 12Z and the winding up direction at said entry point.

(33) In this example, a first lower corner protuberance 20 includes a guiding configuration 15 for guiding the conductive wire 40 of the winding DX around the axis X from the electrically conductive element 23 to the entry point 41 thereof located on a winding supporting outer face 12X, corresponding to a lower outer face of the support, in a position adjacent to the winding limiting edge 22. Said guiding configuration 15 consists of a curved step.

(34) The remaining guiding configurations 15 will be the same but are adapted for their respective positions and their respective entry point 41 and exit point 42.

(35) FIG. 8 shows a casing 60 for covering all three windings DX, DY and DZ for better protecting same, with only the lower corner protuberances 20 with their electrically conductive elements projecting therefrom.

(36) It is understood that different parts forming the invention described in one embodiment may be freely combined with parts described in other different embodiments, even if said combination has not been explicitly described, provided that such combination is not a detriment.