Method for manufacturing a choke coil, choke coil and electrical component including the choke coil

Abstract

An inductor, the inductor comprising: a conductor element (2) having a plurality of coil turns; a first terminal member (41) adapted to electrically connect the inductor to a first circuit terminal (61) of a circuit; and a second terminal member (42) adapted to electrically connect the inductor to a second circuit terminal (62) of the circuit. The first terminal member (41) is adapted to compensate for a lateral dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), and the second terminal member (42) is adapted to compensate for a longitudinal dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), wherein the lateral dimension difference is perpendicular to a longitudinal direction of the inductor extending between the first terminal member (41) and the second terminal member (42), and the longitudinal dimension difference is parallel to the longitudinal direction.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an inductor, to an inductor, and to an electrical component including the inductor. Background Art

[0002] A known method for manufacturing an inductor includes: forming a plurality of coil turns into an elongate piece of conductive material; and forming a first terminal member at a first end of the elongate piece and a second terminal member at a second end of the elongate piece. The first terminal member is adapted to electrically connect the inductor to a first circuit terminal of a circuit, and the second terminal member is adapted to electrically connect the inductor to a second circuit terminal of the circuit. Forming the first terminal member and the second terminal member includes flattening the ends of the elongate piece of conductive material and machining the same rectangular orifice in the terminal members.

[0003] One problem associated with the above-known method is that the method requires several stages, many of which are typically carried out manually. In addition, due to the several stages required to manufacture the inductor, the dimensional differences between the positions of the terminal members are sometimes relatively large. Summary of the Invention

[0004] An object of the present invention is to provide a method for manufacturing an inductor and an inductor in order to solve the above problems. The object of the present invention is achieved by the method and the inductor described hereinafter.

[0005] The present invention is based on the idea that the first terminal member of the inductor provides a first orifice and provides a second orifice for the second terminal member of the inductor, such that the first orifice is adapted to compensate for the lateral dimensional difference between the positions of the first circuit terminal and the second circuit terminal of the circuit, and the second orifice is adapted to compensate for the longitudinal dimensional difference between the positions of the first circuit terminal and the second circuit terminal, wherein the lateral dimensional difference is perpendicular to the longitudinal direction of the inductor, and the longitudinal dimensional difference is parallel to the longitudinal direction.

[0006] In the method according to the present invention, the first orifice of the first terminal member and the second orifice of the second terminal member are formed by bending an elongate piece of the same conductive material, and a plurality of coil turns of the inductor are formed from the elongate piece of conductive material.

[0007] The advantages of the method of the present invention are that no machining operations are required to form the first orifice and the second orifice, thereby reducing the stages required to manufacture the inductor. The advantages of the inductor of the present invention are that the lateral dimensional difference and the longitudinal dimensional difference between the positions of the first terminal member and the second terminal member and / or the lateral dimensional difference and the longitudinal dimensional difference between the positions of the first circuit terminal and the second circuit terminal can be simply compensated by changing the position of the inductor. Brief Description of the Drawings

[0008] In the following, the present invention will be described in more detail by way of preferred embodiments with reference to the accompanying drawings, in which:

[0009] Figures 1 to 4 Chokes according to embodiments of the present invention are shown from different directions;

[0010] Figure 5 is Figure 1 an enlarged view of a first terminal member of the choke;

[0011] Figure 6 shows an electrical assembly including Figure 1 the choke;

[0012] Figure 7 shows the electrical assembly of Figure 6 in a case where the relative positions between a first circuit terminal and a second circuit terminal of the electrical assembly have been changed to illustrate a dimensional difference between the positions of the first circuit terminal and the second circuit terminal;

[0013] Figure 8 shows an electrical assembly including a choke according to an alternative embodiment of the present invention; and

[0014] Figure 9 shows the electrical assembly of Figure 8 in a case where the relative positions between a first circuit terminal and a second circuit terminal of the electrical assembly have been changed to illustrate a dimensional difference between the positions of the first circuit terminal and the second circuit terminal. Detailed Description of the Embodiments

[0015] Figure 1 Shows a choke that includes a conductor element 2, a first terminal member 41, and a second terminal member 42. The conductor element 2 has a first end 21, a second end 22, and a plurality of turns of wire located between the first end 21 and the second end 22. The first terminal member 41 is provided at the first end 21 of the conductor element 2, and the second terminal member 42 is provided at the second end 22 of the conductor element 2. The first terminal member 41 is adapted to electrically connect the choke to a first circuit terminal of a circuit, and the second terminal member 42 is adapted to electrically connect the choke to a second circuit terminal of the circuit. The choke has a longitudinal direction extending between the first terminal member 41 and the second terminal member 42.

[0016] The conductor element 2 is made of a copper material and coated with an insulating paint. In an alternative embodiment, the conductor element is made of an aluminum material. Herein, the copper material is an alloy including at least fifty-five percent by mass of copper, and the aluminum material is an alloy including at least fifty-five percent by mass of aluminum. In another alternative embodiment, the conductor element is made of some other suitable conductive material.

[0017] The first terminal member 41 includes a first aperture 11 that extends in a first transverse direction perpendicular to the longitudinal direction and is adapted to receive a first mounting member for electrically connecting the first terminal member 41 to a first circuit terminal of a circuit. The second terminal member 42 includes a second aperture 12 that extends in a second transverse direction perpendicular to the longitudinal direction and is adapted to receive a second mounting member for electrically connecting the second terminal member 42 to a second circuit terminal of the circuit. In Figure 1 , the longitudinal direction is the vertical direction, and the first and second transverse directions are directions perpendicular to the image plane.

[0018] Figure 2 The choke coil is shown from a direction perpendicular to the longitudinal direction and the first transverse direction. Figure 1 of the choke coil. Figure 3 The choke coil is shown from a direction parallel to the longitudinal direction. Figure 1 of the choke coil. Figure 3 It is shown that a plurality of coil turns are elliptical. In an alternative embodiment, the plurality of coil turns have a circular shape. In another alternative embodiment, the plurality of coil turns are substantially rectangular in shape.

[0019] Figure 3 It is shown that in a plane perpendicular to the longitudinal direction, the projections of the first terminal member 41 and the second terminal member 42 are located inside the projection of the plurality of coil turns.

[0020] The first aperture 11 is defined by a first bent portion of the conductor element 2, and the second aperture 12 is defined by a second bent portion of the conductor element 2. The first aperture 11 has a different shape from the second aperture 12. The first terminal member 41 is adapted to compensate for a lateral dimension difference between the positions of the first circuit terminal and the second circuit terminal, and the second terminal member 42 is adapted to compensate for a longitudinal dimension difference between the positions of the first circuit terminal and the second circuit terminal. The lateral dimension difference is perpendicular to the longitudinal direction and the first transverse direction. The longitudinal dimension difference is parallel to the longitudinal direction.

[0021] In the plurality of coil turns, the conductor element 2 has a circular cross-section. In an alternative embodiment, in the plurality of coil turns, the conductor element has a cross-section of a different shape.

[0022] Each of the first terminal member 41 and the second terminal member 42 has a flat cross-section such that the first terminal member 41 includes a first planar contact surface and a second planar contact surface with opposite normal directions and parallel to the first transverse direction, and the second terminal member 42 includes a first planar contact surface and a second planar contact surface with opposite normal directions and parallel to the second transverse direction. The flat cross-sections of the first terminal member 41 and the second terminal member 42 are inFigure 4 is best observed Figure 4 is shown from a direction inclined with respect to the longitudinal direction and the first transverse direction Figure 1 of the choke coil.

[0023] The first orifice 11 is adapted to provide a pivot point for the choke coil to rotate about the central axis of the first orifice 11. The second orifice 12 is an adjustment slot that is dimensioned greater in the longitudinal direction than in a direction perpendicular to both the longitudinal direction and the second transverse direction.

[0024] Figure 5 An enlarged view of the first terminal member 41 is shown. Figure 5 The first bent portion of the conductor element 2 is shown to be about 340° at a first angle α1 about the central axis of the first orifice 11. In an alternative embodiment, the first angle is greater than 200°. The first bent portion of the conductor element 2 has a first arcuate portion that has a circular arc form and is opposed to a second angle α2 of about 220°. In an alternative embodiment, the second angle is greater than or equal to 180°.

[0025] The second bent portion of the conductor element 2 includes a U-shaped section whose branches 281 and 282 are parallel to the longitudinal direction such that the free ends 229 of the U-shaped section generally point towards the first terminal member 41. The U-shaped section provides an adjustment slot for the second terminal member 42.

[0026] In one embodiment, the first orifice is defined by the first bent portion of the conductor element and the second orifice is defined by the second bent portion of the conductor element such that each of the first and second bent portions includes a U-shaped section. The branches of the U-shaped section of the first bent portion are perpendicular to the longitudinal direction. The branches of the U-shaped section of the second bent portion are parallel to the longitudinal direction.

[0027] In an alternative embodiment, the first orifice is defined by the first bent portion of the conductor element and the second orifice is defined by the second bent portion of the conductor element such that each of the first and second bent portions includes a U-shaped section. The branches of the U-shaped section of the first bent portion and the branches of the U-shaped section of the second bent portion are both parallel to the longitudinal direction. The functionality of this alternative embodiment generally corresponds to Figure 1 of the choke coil. However, it should be noted that Figure 1 the first orifice 11 of the choke coil of

[0028] Figure 6shows an electrical component including a first circuit terminal 61, a second circuit terminal 62, a first mounting member 301, a second mounting member 302, and Figure 1 a choke coil. The first terminal member 41 is electrically connected to the first circuit terminal 61 by means of the first mounting member 301 extending through the first aperture 11. The second terminal member 42 is electrically connected to the second circuit terminal 62 by means of the second mounting member 302 extending through the second aperture 12.

[0029] The first mounting member 301 is a bolt whose bolt head presses the first terminal member 41 against the first circuit terminal 61. The second mounting member 302 is a bolt whose bolt head presses the second terminal member 42 against the second circuit terminal 62. The electrical component includes internal threads adapted to mate with the external threads of the first mounting member 301 and the second mounting member 302. In one embodiment, the internal threads are in a nut located on the side of the circuit terminal opposite to the bolt head. In an alternative embodiment, the internal threads are formed in the circuit terminal.

[0030] Figure 7 shows the electrical component in a case where the relative positions between the first circuit terminal 61 and the second circuit terminal 62 have been changed to illustrate the dimensional differences between the positions of the first circuit terminal and the second circuit terminal. Figure 6 In Figure 7 , the first circuit terminal 61 has been moved relative to the second circuit terminal 62 in two directions. The first circuit terminal 61 has been moved relative to the second circuit terminal 62 in a direction parallel to the longitudinal direction such that the second circuit terminal 62 is closer to the first circuit terminal 61 than in Figure 6 . In this context, this is the longitudinal dimensional difference. In addition, the first circuit terminal 61 has been moved relative to the second circuit terminal 62 in a direction perpendicular to both the longitudinal direction and the first transverse direction. In this context, this is the transverse dimensional difference.

[0031] Figure 7 shows that the transverse dimensional difference is compensated by rotating the choke coil about the central axis of the first aperture 11. When the first mounting member 301 has been sufficiently loosened, it is possible to rotate the choke coil about the pivot point provided by the first aperture 11. Due to the dimensions of the first mounting member 301, the first terminal member 41 cannot be disengaged from the first mounting member 301. The bolt head diameter of the first mounting member 301 is too large such that the bolt head cannot be assembled through the first aperture 11. The diameter of the shank of the first mounting member 301 has been selected such that it is impossible to disengage the first mounting member 301 from the first aperture 11 in a direction perpendicular to the first transverse direction. In addition, the diameter of the shank of the first mounting member 301 has been selected such that there is only a small clearance between the shank and the first aperture 11.

[0032] Figure 7 It is also shown that the longitudinal dimension difference has been compensated by sliding the second mounting member 302 in the adjustment slot of the second terminal member 42 in a direction away from the bottom of the U-shaped section of the second terminal member 42.

[0033] Figure 8 An electrical assembly including a choke coil according to an alternative embodiment of the present invention is shown. Figure 8 The choke coil of Figure 1 differs from the choke coil of Figure 8 in that the second terminal member 42' has been bent 90° about the longitudinal direction relative to the first terminal member 41' such that the second transverse direction - along which the second orifice extends - is perpendicular to both the longitudinal direction and the first transverse direction. In other respects, Figure 6 the electrical assembly of

[0034] In Figure 8 , the electrical assembly is shown from a direction parallel to the first transverse direction. The second transverse direction is the horizontal direction. Due to the position of the second terminal member 42', the nut 322' is visible, the internal thread of which mates with the external thread of the second mounting member 302'.

[0035] Figure 9 The electrical assembly of Figure 8 in Figure 9 is shown in a case where the mutual positions between the first circuit terminal 61' and the second circuit terminal 62' have been changed in order to illustrate the dimensional difference between the positions of the first circuit terminal and the second circuit terminal. In Figure 6 and Figure 7 , the first circuit terminal 61' has been moved relative to the second circuit terminal 62' in two directions that are the same as the directions in which the first circuit terminal 61 moves between

[0036] Figure 1 The choke coil of

[0037] In one embodiment, forming the first and second apertures by bending the elongate piece of conductive material and forming the plurality of coil turns as the elongate piece of conductive material are both carried out using a winding and bending machine. It is known to use such a machine to manufacture steel springs. The winding and bending machine is well-suited for shaping an elongate piece having a circular cross-section.

[0038] When using a winding and bending machine to manufacture the choke according to the present invention, in many cases, it is advantageous to form one of the first and second apertures by bending the elongate piece of conductive material before forming the plurality of coil turns as the elongate piece of conductive material. In one embodiment, the elongate piece of conductive material is coated with an insulating material, such as insulating paint, before forming the plurality of coil turns and the first and second terminal members.

[0039] The method for manufacturing Figure 1 the choke further includes flattening the first terminal member 41 and the second terminal member 42 such that each of them has a flat cross-section. In one embodiment, the flattening of the first and second terminal members is carried out after winding the plurality of coil turns and forming the first and second apertures.

[0040] In one embodiment, the winding and bending machine includes a controller, a plurality of sensors, and a computer vision system. The controller is adapted to control the winding and bending of the elongate piece of conductive material and receives information from the plurality of sensors and the computer vision system. The plurality of sensors includes at least one sensor suitable for monitoring the hardness of the elongate piece of conductive material. With the information received from the plurality of sensors and the computer vision system, the controller can ensure that the dimensions and positions of the first and second apertures are accurate.

[0041] It will be apparent to those skilled in the art that the concepts of the present invention can be implemented in various ways. The present invention and its embodiments are not limited to the above examples, but can vary within the scope of the claims.

Claims

1. A method for manufacturing an inductor, the method comprising: providing an elongate piece of conductive material; forming a plurality of coil turns in the elongate piece of conductive material; forming a first terminal member (41) to the elongate piece of conductive material, the first terminal member (41) being spaced apart from the plurality of coil turns and adapted to electrically connect the inductor to a first circuit terminal (61) of a circuit; forming a second terminal member (42) to the elongate piece of conductive material, the second terminal member (42) being spaced apart from the plurality of coil turns and adapted to electrically connect the inductor to a second circuit terminal (62) of the circuit, wherein the inductor has a longitudinal direction extending between the first terminal member (41) and the second terminal member, and the plurality of coil turns are located between the first terminal member (41) and the second terminal member (42), characterized in that the formation of the first terminal member (41) includes forming a first aperture (11) by bending the elongate piece of conductive material, and the formation of the second terminal member (42) includes forming a second aperture (12) by bending the elongate piece of conductive material, wherein the first terminal member (41) is adapted to compensate for a lateral dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), and the second terminal member (42) is adapted to compensate for a longitudinal dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), wherein the lateral dimension difference is perpendicular to the longitudinal direction, and the longitudinal dimension difference is parallel to the longitudinal direction, wherein the first aperture (11) extends in a first lateral direction perpendicular to the longitudinal direction, and the second aperture (12) extends in a second lateral direction perpendicular to the longitudinal direction, wherein the first aperture (11) is adapted to provide a pivot point for the inductor to rotate about a central axis of the first aperture (11), and the second aperture (12) is an adjustment slot, the dimension of the adjustment slot in the longitudinal direction being greater than the dimension in a direction perpendicular to both the longitudinal direction and the second lateral direction, wherein the first aperture (11) is defined by a first bent portion of a conductor element (2), and the second aperture (12) is defined by a second bent portion of the conductor element (2), and wherein the first bent portion of the conductor element (2) is at a first angle (α1) greater than 200° about the central axis of the first aperture (11).

2. The method according to claim 1, wherein, Forming one of the first aperture (11) and the second aperture (12) by bending the elongate piece of conductive material is performed before forming the plurality of coil turns in the elongate piece of conductive material.

3. The method according to claim 1, wherein, The method includes flattening the first terminal member (41) and the second terminal member (42) such that each of the first terminal member (41) and the second terminal member (42) has a flat cross-section, wherein the first terminal member (41) includes a first planar contact surface and a second planar contact surface with opposite normal directions, and the second terminal member (42) includes a first planar contact surface and a second planar contact surface with opposite normal directions.

4. The method according to claim 1, wherein Forming the first orifice (11) and the second orifice (12) by bending the elongate piece of the conductive material and forming the plurality of turns of the coil into the elongate piece of the conductive material are performed using a winding and bending machine.

5. An inductor, comprising: A conductor element (2) having a first end (21) and a second end (22) and made of a conductive material, the conductor element (2) including a plurality of turns of coil located between the first end (21) and the second end (22); A first terminal member (41) provided at the first end (21) of the conductor element (2); And A second terminal member (42) provided at the second end (22) of the conductor element (2), wherein the first terminal member (41) is adapted to electrically connect the inductor to a first circuit terminal (61) of a circuit, and the second terminal member (42) is adapted to electrically connect the inductor to a second circuit terminal (62) of the circuit, and the inductor has a longitudinal direction extending between the first terminal member (41) and the second terminal member (42), The first terminal member (41) includes a first orifice (11) that extends in a first transverse direction perpendicular to the longitudinal direction and is adapted to receive a first mounting member (301) for electrically connecting the first terminal member (41) to the first circuit terminal (61) of the circuit, and The second terminal member (42) includes a second orifice (12) that extends in a second transverse direction perpendicular to the longitudinal direction and is adapted to receive a second mounting member (302) for electrically connecting the second terminal member (42) to the second circuit terminal (62) of the circuit, characterized in that the first terminal member (41) is adapted to compensate for a lateral dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), and the second terminal member (42) is adapted to compensate for a longitudinal dimension difference between the positions of the first circuit terminal (61) and the second circuit terminal (62), wherein the lateral dimension difference is perpendicular to the longitudinal direction, and the longitudinal dimension difference is parallel to the longitudinal direction. Wherein, the first orifice (11) extends in a first transverse direction perpendicular to the longitudinal direction, and the second orifice (12) extends in a second transverse direction perpendicular to the longitudinal direction. Wherein, the first orifice (11) is adapted to provide a pivot point for the choke coil to rotate about the central axis of the first orifice (11), and the second orifice (12) is an adjustment slot, the size of which in the longitudinal direction is greater than the size in a direction perpendicular to both the longitudinal direction and the second transverse direction. Wherein, the first orifice (11) is defined by a first bent portion of the conductor element (2), and the second orifice (12) is defined by a second bent portion of the conductor element (2), and Wherein, the first bent portion of the conductor element (2) is around the central axis of the first orifice (11) at a first angle (α1) greater than 200°.

6. The choke coil according to claim 5, wherein, The first bent portion of the conductor element (2) has a first arc portion, the first arc portion having a circular arc form and facing a second angle (α2) greater than or equal to 180°.

7. The choke coil according to claim 5, wherein, The second bent portion of the conductor element (2) includes a U-shaped section, the branches (281, 282) of the U-shaped section being parallel to the longitudinal direction, such that the free end (229) of the U-shaped section points to the first terminal member (41).

8. The choke coil according to claim 5, wherein, Each turn of the plurality of turns of the conductor element (2) has a circular cross-section.

9. The choke coil according to claim 5, wherein, Each of the first terminal member (41) and the second terminal member (42) has a flat cross-section, such that the first terminal member (41) includes a first planar contact surface and a second planar contact surface with opposite normals and parallel to the first transverse direction, and the second terminal member (42) includes a first planar contact surface and a second planar contact surface with opposite normals and parallel to the second transverse direction.

10. The choke coil according to claim 5, wherein, The conductor element (2) is made of copper material or aluminum material.

11. An electrical component, comprising: A first circuit terminal (61); A second circuit terminal (62); A first mounting member (301); A second mounting member (302); and The choke coil according to claim 5, wherein the first terminal member (41) is electrically connected to the first circuit terminal (61) by means of the first mounting member (301) extending through the first orifice (11), and the second terminal member (42) is electrically connected to the second circuit terminal (62) by means of the second mounting member (302) extending through the second orifice (12).

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