Abstract
An integrated magnetic component comprises a common mode inductance and a differential mode inductance. The common mode inductance is formed by a common mode core surrounding a winding window and at least two windings wound around the common mode core and through the winding window. The differential mode inductance is formed by the at least two windings and a differential mode core being spaced from the common mode core by a gap. The differential mode core comprises at least one surface being adjacent to each of the at least two windings. Further, a filter for attenuating electromagnetic interference comprises an integrated magnetic component according to the invention. Even further, the integrated magnetic component according to the invention is used for attenuating electromagnetic interference, preferably in a vehicle, a data center, or a telecommunication unit. A method for manufacturing an integrated magnetic component according to the invention comprises two steps. One step comprises providing a common mode inductance formed by a common mode core surrounding a winding window, and at least two windings wound around the core and through the winding window. Another step comprises providing a differential mode core and spacing it from the common mode core by a gap, such that at least one surface of the differential mode core is adjacent to each of the least two windings.
Claims
1. Integrated magnetic component, comprising; a common mode inductance formed by a common mode core surrounding a winding window and at least two windings wound around the common mode core and through the winding window, and a differential mode inductance formed by the at least two windings and a differential mode core being spaced from the common mode core by a gap, wherein the differential mode core comprises at least one surface being adjacent to each of the at least two windings; wherein the common mode core is a toroidal core and the differential mode core comprises a rod or a pipe arranged in the winding window; wherein the differential mode core is fully physically separated from the common mode core; and wherein a longitudinal axis of the rod or the pipe passes through the winding window without touching or hitting the common mode core.
2. Integrated magnetic component according to claim 1, wherein the at least one surface is an edgeless surface.
3. Integrated magnetic component according to claim 1, wherein the at least one surface is adjacent to each turn of the at least two windings.
4. Integrated magnetic component according to claim 1, wherein each turn of the at least two windings is going through the gap.
5. Integrated magnetic component according to claim 1, wherein the gap has a length which is constant.
6. Integrated magnetic component according to claim 1, wherein a shortest distance between the at least one surface and each winding of the at least two windings is essentially equal to a shortest distance between the common mode core and each winding of the at least two windings.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The drawings used to explain the embodiments show:
(2) FIG. 1 an exploded view of an integrated magnetic component with a toroidal common mode core and a rod-shaped differential mode core,
(3) FIG. 2 an assembled integrated magnetic component with a toroidal common mode core and a rod-shaped differential mode core,
(4) FIG. 3 an exploded view of an integrated magnetic component with a toroidal common mode core and a rod-shaped differential mode core with a flat insulator,
(5) FIG. 4 an exploded view of an integrated magnetic component with a toroidal common mode core and a rod-shaped differential mode core with a tubular insulator,
(6) FIG. 5 an exploded view of an integrated magnetic component with a toroidal common mode core and a plate-shaped differential mode core arranged above the common mode core,
(7) FIG. 6 an exploded view of an integrated magnetic component with a toroidal common mode core and a plate-shaped differential mode core arranged under the common mode core,
(8) FIG. 7 an exploded view of an integrated magnetic component with a rectangular common mode core and a plate-shaped differential mode core arranged above the common mode core,
(9) FIG. 8 an exploded view of an integrated magnetic component with a rectangular common mode core and a plate-shaped differential mode core arranged under the common mode core,
(10) FIG. 9 an exploded view of an integrated magnetic component with a toroidal common mode core and a plate-shaped differential mode core with a hole,
(11) FIG. 10 an exploded view of an integrated magnetic component with a toroidal common mode core and two plate-shaped differential mode cores,
(12) FIG. 11 an exploded view of an integrated magnetic component with a rectangular common mode core and a plate-shaped differential mode core with a hole,
(13) FIG. 12 an exploded view of an integrated magnetic component with a rectangular common mode core and two plate-shaped differential mode cores,
(14) FIG. 13 an exploded view of an integrated magnetic component with a toroidal common mode core and two plate-shaped differential mode cores with one of them having a hole,
(15) FIG. 14 an exploded view of an integrated magnetic component with a rectangular common mode core and two plate-shaped differential mode cores with one of them having a hole,
(16) FIG. 15 an exploded view of an integrated magnetic component with a toroidal common mode core and a differential mode core comprising both a rod and a plate,
(17) FIG. 16 an exploded view of an integrated magnetic component with a rectangular common mode core and a differential mode core comprising both a rectangular cuboid and a plate,
(18) FIG. 17 an exploded view of an integrated magnetic component with a toroidal common mode core and a differential mode core comprising both a rod and two plates,
(19) FIG. 18 an exploded view of an integrated magnetic component with a rectangular common mode core and a differential mode core comprising both a rectangular cuboid and two plates,
(20) FIG. 19 an exploded view of an integrated magnetic component with a toroidal common mode core and a differential mode core comprising two parts with each of them having both a rod and a plate, and
(21) FIG. 20 an exploded view of an integrated magnetic component with a rectangular common mode core and a differential mode core comprising two parts with each of them having both a rectangular cuboid and a plate.
(22) In the figures, the same components are given the same reference symbols.
PREFERRED EMBODIMENTS
(23) FIG. 1 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2. Two windings 4 are wound around the common mode core 2 and through the winding window 3. A rod-shaped differential mode core 5 comprises one surface 6 which, when placed within the remaining space of the winding window 3, is adjacent to each of the two windings 4 (see also FIG. 2). The surface 6 of rod-shaped differential mode core 5 has the same distance to each of the two windings 4 as the common mode core 2 has. In other words, the two windings 4 are wound tightly around the common mode core 2, and the rod-shaped differential mode core 5 fits tightly into the remaining space of the winding window 3. Each of the two windings 4 comprises two terminals 7 (only one terminal per winding is shown) which are arranged to pass through openings 8 of a printed circuit board (PCB) 9.
(24) FIG. 2 shows an assembled integrated magnetic component 1 according to FIG. 1 with a toroidal common mode core 2 and a rod-shaped differential mode core 5. The rod-shaped differential mode core 5 is placed such that it concentrates substantial leakage field of the common mode inductance and, thereby, achieves a high differential mode inductance. Gap 14 is located between the differential mode core 5 and the common mode core 2. All turns of the two windings 4 are located in the gap 14.
(25) FIG. 3 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and a rod-shaped differential mode core 5. In addition to the embodiment shown in FIG. 1 and FIG. 2, the embodiment shown in FIG. 3 comprises a flat insulator 11 which can be placed, for example, in a groove 10 of differential mode core 5. The flat insulator 11 may also comprise two guiding protrusions 12 which may also serve as insulation between the two windings 4.
(26) FIG. 4 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and three windings 4 wound therearound, preferably for use in phase applications. Rod-shaped differential mode core 5 with one surface 6 can be placed in a tubular insulator 11 with three guiding protrusions 12. The three guiding protrusions 12 may also serve as insulation between the three windings 4.
(27) FIG. 5 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and three windings 4 wound therearound. Instead of a rod-shaped differential mode core, a circular plate-shaped differential mode core 5 is arranged above the common mode core 2. One surface 6 cannot be seen in FIG. 5 as the one surface 6 is located at the lower side of plate-shaped differential mode core 5.
(28) FIG. 6 shows also an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and three windings 4 wound therearound. However, the circular plate-shaped differential mode core 5 is arranged under the common mode core 2. One surface 6 can now be seen as it is located at the upper side of plate-shaped differential mode core 5. Plate-shaped differential mode core 5 is sized to fit between terminals 7 when placed directly under common mode core 2.
(29) FIG. 7 shows an exploded view of an integrated magnetic component 1 with a rectangular common mode core 2 and four windings 4 wound therearound and, therefore, being preferred for three-phase applications. A rectangular plate-shaped differential mode core 5 is arranged above the common mode core 2. One surface 6 cannot be seen in FIG. 7 as the one surface 6 is located at the lower side of plate-shaped differential mode core 5.
(30) FIG. 8 shows also an exploded view of an integrated magnetic component 1 with a rectangular common mode core 2 and four windings 4 wound therearound. However, the rectangular plate-shaped differential mode core 5 is arranged under the common mode core 2. One surface 6 can now be seen as it is located at the upper side of plate-shaped differential mode core 5. Plate-shaped differential mode core 5 is sized to fit between terminals 7 when placed directly under common mode core 2.
(31) FIG. 9 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and three windings 4 wound therearound. A circular plate-shaped differential mode core 5 is arranged under the common mode core 2. Plate-shaped differential mode core 5 comprises a hole 13 to allow some of the terminals 7 to pass therethrough in order to be connected to the printed circuit board 9. Plate-shaped differential mode core 5 is sized to fit between terminals 7 when placed directly under common mode core 2.
(32) FIG. 10 shows an exploded view of an integrated magnetic component 1 with a toroidal common mode core 2 and three windings 4 wound therearound. However, a circular plate-shaped differential mode core 5 is arranged above the common mode core 2 and another circular plate-shaped differential mode core 5 is arranged under the common mode core 2.
(33) FIG. 11 shows an exploded view of an integrated magnetic component 1 with a rectangular common mode core 2 and four windings 4 wound therearound. A rectangular plate-shaped differential mode core 5 is arranged under the common mode core 2. Plate-shaped differential mode core 5 comprises a hole 13 to some of the terminals 7 to pass therethrough in order to be connected to the printed circuit board 9. Plate-shaped differential mode core 5 is sized to fit between terminals 7 when placed directly under common mode core 2.
(34) FIG. 12 shows an exploded view of an integrated magnetic component 1 with a rectangular common mode core 2 and four windings 4 wound therearound. However, a rectangular plate-shaped differential mode core 5 is arranged above the common mode core 2 and another rectangular plate-shaped differential mode core 5 is arranged under the common mode core 2.
(35) The embodiment shown in FIG. 13 differs from that shown in FIG. 10 in that the circular plate-shaped differential mode core 5 located under the common mode core 2 comprises a hole 13.
(36) The embodiment shown in FIG. 14 differs from that shown in FIG. 11 in that the rectangular plate-shaped differential mode core 5 located under the common mode core 2 comprises a hole 13.
(37) The embodiment shown in FIG. 15 differs from the previous embodiments in that differential mode core 5 comprises both a circular plate and a rod, and in that insulator 11 comprises both a tubular insulator with guiding protrusions and a plate-shaped insulator.
(38) The embodiment shown in FIG. 16 differs from the previous embodiments in that differential mode core 5 comprises both a rectangular plate and a rectangular cuboid, and in that insulator 11 comprises both a rectangular-profiled insulator with guiding protrusions and a plate-shaped insulator.
(39) The embodiment shown in FIG. 17 differs from the embodiment shown in FIG. 15 in that the embodiment shown in FIG. 17 comprises a further circular differential mode core 5 which is arranged under common mode core 2.
(40) The embodiment shown in FIG. 18 differs from the embodiment shown in FIG. 16 in that the embodiment shown in FIG. 18 comprises a further rectangular differential mode core 5 which is arranged under common mode core 2.
(41) The embodiment shown in FIG. 19 differs from the embodiment shown in FIG. 17 in that the embodiment shown in FIG. 19 comprises a further circular differential mode core 5 with a rod, and in that there is a further insulator 11 comprising both a plate-shaped insulator and a tubular-shaped insulator. The two insulators 11 and the two differential mode cores 5 might be identical.
(42) The embodiment shown in FIG. 20 differs from the embodiment shown in FIG. 18 in that the embodiment shown in FIG. 20 comprises a further rectangular differential mode core 5 with a rectangular cuboid, and in that there is a further insulator 11 comprising both a plate-shaped insulator and a rectangular-profiled insulator. The two insulators 11 and the two differential mode cores 5 might be identical.
(43) In summary, it is to be noted that although already a plurality of different embodiments have been shown, further embodiments are possible by combining the particular features of the above presented embodiments.
