Magnetic components

Abstract

The invention relates to a magnetic assembly comprising a magnetic core made of a magnetically soft material and a housing surrounding the magnetic core on all sides, the housing having two housing parts connected to one another. The connected housing parts have an overlapping area around the entire periphery of the magnetic core, one housing part having ribs on all circumferential edges and the other housing part having corresponding grooves on all circumferential edges, in which the ribs engage in a positive-locking manner.

Description

[0001] The invention relates to a magnetic component.

[0002] For example, to enclose and surround soft-magnetic annular cores and protect them from dirt and mechanical influences, a multi-part housing is often used. This housing can, for example, include a plastic slot and a slot cover that closes it. The slots used can have circular, oval, rectangular, or any other basic shape and can be designed as annular or full-surface. The joined housing parts can be connected and secured individually or in combination by gluing, clamping, or snap-on connections.

[0003] During the production of inductive components, encapsulated magnetic cores can be wound with wires of varying thickness and with varying numbers of turns. Consequently, manufacturing steps (e.g., applying the wire windings) introduce mechanical stresses that can affect the shape and dimensional stability of the mating components (e.g., the slot cover and the slot). Deformations caused by manufacturing steps or inherent deformations no longer guarantee a gap-free connection between the slot and the slot cover. The slot interior, which houses the magnetic core and is enclosed by the slot walls and the slot cover, is no longer sealed from the environment.

[0004] To connect the slot to the slot cover, the ring typically has a snap-on connection on the outer or inner circumference on the cover side. The wire wrapped around the encapsulated magnetic core can subject the connection points to severe stresses, which can lead to complete or partial disconnection of the connection. This is particularly true in designs with a longitudinally extending basic housing shape. Material- and manufacturing-related gaps between the mating parts can also occur. The risk of gaps also increases when multiple connections are required, such as in three- and multi-part housings. Therefore, the object of the present invention is to improve the sealing of inductive components at the joints.

[0005] This object is achieved by a magnetic assembly according to independent claim 1, 19 or 21. Exemplary embodiments and developments of the invention are subject matter of the dependent claims.

[0006] According to an exemplary embodiment, such a magnetic assembly comprises a magnetic core made of a soft magnetic material and a housing that surrounds the magnetic core on all sides, the housing comprising two interconnected housing parts. The interconnected housing parts have an overlapping region surrounding the magnetic core. In this overlapping region, one of the housing parts has a circumferential rib, while the other housing part has a corresponding circumferential groove, into which the rib engages with a positive fit.

[0007] According to another embodiment, the assembly includes an annular magnetic core and an annular housing that surrounds the magnetic core on all sides, the housing having two housing parts connected to one another. The housing parts each have a first overlapping region that surrounds the annular magnetic core on the outside and a second overlapping region that surrounds the annular magnetic core on the inside, wherein one of the housing parts has a circumferential rib in both the first and second overlapping regions, and the other of the housing parts has a corresponding circumferential groove in which the corresponding rib engages with a positive fit.

[0008] According to another embodiment, an assembly includes a magnetic core made of a soft magnetic strip material having a maximum strip thickness, and a housing that completely surrounds the magnetic core and has two interconnected housing parts. The housing parts each have an overlapping region surrounding the magnetic core, one of the housing parts having a circumferential rib in the overlapping region, and the other housing part having a corresponding circumferential groove into which the rib engages with a positive fit. In the overlapping region where the rib engages in the groove, a residual gap exists that is smaller than the maximum strip thickness of the magnetic core strip material.

[0009] The present invention will be further described below with reference to the exemplary embodiments shown in the accompanying drawings. The drawings are not to scale, and the present invention is not limited to the examples and aspects shown. Rather, emphasis is placed on providing the principles on which the present invention is based. In the drawings, identical reference numerals denote identical or similar components having identical or similar functions.

[0010] Figure 1 The housing in the form of a rectangular ring, which is assembled from two housing parts, is shown in a perspective view.

[0011] Figure 2 The perspective cross-section shows the Figure 1 The first housing part of the housing.

[0012] Figure 3 The perspective cross-section shows the Figure 1 The second housing part of the housing.

[0013] Figure 4 The perspective cross-section shows the Figure 1 shell.

[0014] Figure 5 The perspective cutaway view shows the Figure 2 An alternative to the first housing part shown in .

[0015] Figure 6 The perspective cutaway view shows the Figure 3 An alternative to the housing components shown in .

[0016] Figure 7 A housing in the form of a rectangular ring assembled from three housing parts is shown in a perspective sectional view.

[0017] Figure 8 The perspective cutaway view shows the Figure 2 An alternative to the first housing part shown in .

[0018] Figure 9 Shown in perspective section Figure 7 An alternative to the housing shown consists of three housing parts.

[0019] Figure 10 Shown in perspective section Figure 9 An alternative to the housing shown consists of three housing parts.

[0020] Figure 11 A housing for accommodating a square magnetic core is shown in a perspective sectional view.

[0021] Figure 12 Shown in perspective Figure 4 A first alternative housing is shown.

[0022] Figure 13 Shown in perspective section Figure 4 A second alternative housing is shown.

[0023] Figure 14 A first housing part in the form of a flat ring is shown in a perspective view.

[0024] Figure 15 The second housing part is shown in a perspective view from below, in the form of a flat ring with a circumferential bead.

[0025] Figure 16 The top view shows the Figure 15 housing parts.

[0026] Figure 17 The first housing part in the form of a circular ring is shown in a perspective view.

[0027] Figure 18 The bottom perspective view shows the Figure 17 The first housing component corresponds to the second housing component in the form of a ring.

[0028] Figure 19 A housing in the form of a hollow cylinder with two covers is shown in a perspective view.

[0029] Figure 20 A housing with three housing parts in the form of flat rings is shown in a perspective view.

[0030] Figure 21 A perspective view shows the Figure 20 An alternative to the housing shown in .

[0031] Figure 22 is a perspective view of the housing with the wire windings.

[0032] The (at least) two-part housing for a magnetic core described herein provides a connection between housing components, such as a slot cover (lid) and a slot bottom (slot), which allows for a largely particle-tight connection between the mating parts, i.e., between the housing components. The housing allows for larger manufacturing tolerances in the individual housing components, such as in the case of undesired bending of planar side walls, withstands higher mechanical loads during the manufacturing process (e.g., during winding), and reduces particle contamination caused by the assembly process of the slot and cover. Furthermore, a permanent connection between the housing components can be achieved without the use of other auxiliary materials (e.g., adhesive tape, screw connections, etc.). Consequently, no necessary elements are required to be fixed in a protruding or raised manner to the slot or cover or both when fixing the mating parts.

[0033] exist Figure 1, an example of a magnetic assembly is shown in perspective view. The magnetic assembly comprises a magnetic core 180 made of soft magnetic material and in the form of a rectangular ring, and a corresponding housing 100 that completely surrounds the magnetic core 180. The housing 100 has the shape of a rectangular ring with a catch axis 101 and (at least) one rectangular opening 102 within the ring. The housing 100 comprises two housing parts 120 and 140, each having a substantially U-shaped profile, which are connected to each other in a form-fitting manner. Thus, the two U-shaped housing parts 120 and 140 enclose a cavity in which the magnetic core 180 is disposed. The housing 100 is symmetrical with respect to the section AA. The cross-sections of the housing parts 120 and 140 are shown in dashed lines in the section AA. The housing parts 120 and 140 are connected to each other along a circumferential overlap region 160 (along the outer circumference of the housing). In overlap region 160, one of housing components 120 or 140 has a circumferential depression with a circumferential rib, and the other has a circumferential groove. The shape of the rib is coordinated with and therefore corresponds to the shape of the groove. When housing components 120 and 140 are assembled, the rib engages in the groove, and the rib and groove together form a positive-locking and at least particle-tight connection between housing components 120 and 140. Housing components 120 and 140 can also be connected to each other along a circumferential overlap region 160' (along the inner circumference of the housing). In overlap region 160', one of housing components 120 or 140 also has a circumferential depression with a circumferential rib, while the other has a circumferential groove (similar to overlap region 160).

[0034] Figure 2 A housing component 120, hereinafter referred to as groove 120, is shown in a perspective sectional view, with the section plane AA being selected. Groove 120 has the shape of, for example, a rectangular, annular cup, closed on three sides and open on one side. Although the basic cup shape is shown as a rectangular ring, any other basic shape, such as a circular or oval one, is possible. Groove 120 has an inner wall 122 and an outer wall 123. A circumferential depression 127 is incorporated into the side of inner wall 122 facing opening 102. Circumferential depression 127 is located on the upper end face 124 of inner wall 122 and, for example, has the shape of a step on the side of inner wall 122 facing opening 102. This depression 127 extends from the upper end face 124 of groove 120 parallel to longitudinal axis 101 to a circumferential shoulder 129 in the inner wall 122 of groove 120.

[0035] Groove 120 also has a circumferential depression 128 on the side of outer wall 123 facing away from opening 102. Circumferential depression 126 is introduced in a stepped manner on the upper end face 125 of outer wall 123 on the side of outer wall 123 facing away from opening 101 and extends from upper end face 125 parallel to longitudinal axis 101 to a circumferential shoulder 128 in outer wall 123 of groove 120. In the region of depressions 127 and 128, groove 120 has circumferential ribs 130 and 131, respectively, each in the form of a section of a cylinder that is divided in its longitudinal direction. Circumferential ribs 130 and 131 extend in the circumferential direction of longitudinal axis 101. The two circumferential ribs 130 and 131 lie in a plane perpendicular to longitudinal axis 101 and extending, for example, over half the height a of depression 126.

[0036] Figure 3 A housing component 140, hereinafter referred to as slot cover 140, is shown in a perspective sectional view, with the section again being cut through plane AA. Slot cover 140 has the basic shape of an annular cup that is closed at a top surface 145 and surrounds opening 102. While the basic shape of the cup is rectangular, it can have any other suitable shape depending on the shape of housing component 120. Slot cover 140 has an inner wall 141 and an outer wall 142, wherein both inner wall 141 and outer wall 142 each have a side facing toward opening 102 and a side facing away from opening 102. In the example shown, i.e., with the housing having the basic shape of a rectangular ring, inner wall 141 and outer wall 142 each have four such sides. Circumferential grooves 143 and 144 are respectively introduced on the side of inner wall 141 facing away from opening 102 and on the side of outer wall 142 facing toward opening 102. The two circumferential grooves 143 and 144 lie, for example, in a plane perpendicular to the longitudinal axis 101 and extending, for example, over half the height b of the groove cover 140. The circumferential grooves 143 and 144 each have the shape of a cylinder divided in the longitudinal direction.

[0037] Figure 4 The housing 100 is shown in a perspective sectional view, wherein the section plane AA is selected as the section. The housing 100 consists of a tank 120 and a tank cover 140. The tank cover 140 is placed on the tank 120 or inserted into the tank 120 or buckled onto the tank 120. In the example shown, the tank cover 140 is buckled onto the tank 120 so that the inner wall 141 and the outer wall 142 of the tank cover 140 extend to Figure 2 The shoulders 128 and 129 of the groove 120 are shown. The groove cover 140 covers the upper end faces 124 and 125 of the inner wall 122 and the outer wall 123 of the groove 120 and at least partially covers the surrounding depressions 126 and 127 (see also Figure 2). The groove 120 and the groove cover 140 can be of the same height, so that the two heights c and d have the same value. The edges of the groove 120 and the groove cover 140 extending parallel to the longitudinal axis 101 can be rounded. Reference numerals 110 and 111 indicate the overlapping areas of the groove 120 and the cover 140 mentioned above (in Figure 1 160 in the same way. Figure 4 , the circumferential ribs 130 and 131 arranged in the first overlapping region 110 and the second overlapping region 111 are shown, as well as corresponding circumferential grooves 144 and 143 , into which the respective rib 130 or 131 engages in a form-fitting manner.

[0038] Figure 5 Housing 200 is shown in a perspective sectional view, with the plane of symmetry of housing 200 selected as the section plane. Housing 200 consists of a groove 220 and a groove cover 240. Groove 220 is, for example, structurally identical to groove 120. Housing 200 differs from housing 100 only in that, unlike groove cover 140, groove cover 240 additionally has a depression in the form of a circumferential bead 243. Bead 243 is arranged, for example, relatively close to inner wall 241 and / or outer wall 242 in order to provide (still) increased resistance to radially occurring forces when winding the housing and / or to compensate for shape deviations (e.g., bends in straight walls) that occur during the manufacturing process (e.g., plastic injection molding of housing components).

[0039] A bead 243 is formed on the top surface 244 of the slot cover 240, connecting the inner wall 241 to the outer wall 242 of the slot cover 240 and extending between the inner wall 241 and the outer wall 242 of the slot cover 240. The bead 243 follows the path of the cavity enclosed by the slot 220 and the slot cover 240, in which the magnetic core is arranged. The circumferential bead 243 is introduced in the direction of the longitudinal axis 201 of the housing 200. In the illustrated embodiment, the depression (facing the housing interior) is in the direction of the longitudinal axis 201, but an outward turn (in the opposite direction along the longitudinal axis 201) can also be used in the same manner. The circumferential outward turn can be, for example, a circumferential overhang on the top surface 244 of the slot cover 240. The bead 243 can have the basic shape of a trapezoidal prism or any other basic shape and circumscribes the opening 201 enclosed by the housing 200 in the top surface 244 of the slot cover 240.

[0040] Figure 6 A perspective cross-sectional view of a double slot cover 300 is shown, wherein the plane of symmetry of the double slot cover 300 is selected as the cross-sectional view, and the longitudinal axis 301 of the double slot cover 300 lies in the cross-sectional view. The double slot cover 300 is plane-symmetrical about plane 302, wherein one of the symmetrical halves is structurally identical to the slot cover 140. Plane 302 extends perpendicular to the longitudinal axis 301, and the double slot cover 300 is rotationally symmetrical about the longitudinal axis 301.

[0041] Figure 7 The housing 400 is shown in a perspective sectional view, wherein a symmetry plane of the housing 400 is selected for the sectional view, in which the longitudinal axis 301 extends. The housing 400 consists of a double groove cover 300 similar to or identical to the double groove cover 300, a first groove 302 and a second groove 303, wherein the first groove 302 and the second groove 303 are, for example, the same as those according to Figure 1 The structure of the slot 120 is the same as that of the slot 120. The slot cover 300 is connected not only to the first slot 302 but also to the second slot 303, forming a connecting member between the first slot 302 and the second slot 303. When the slot cover 300 is engaged with the first slot 302 and the second slot 303, the surrounding ribs of the slots 302 and 303 engage with the surrounding grooves of the slot cover 300, thereby forming a positive connection between the slot cover 300 and the first slot 302 and the slot cover 300 and the second slot 303, respectively.

[0042] Figure 8 The groove 500 is shown in a perspective sectional view, wherein the sectional view selects the symmetry plane of the groove 500, in which the longitudinal axis 501 of the groove 500 extends. The groove 500 is plane-symmetrical with respect to the plane 502, wherein the symmetrical halves are each structurally identical to the groove 120. The plane 502 extends perpendicularly to the longitudinal axis 501, and the groove 500 is rotationally symmetrical with respect to the longitudinal axis 501.

[0043] Figure 9 The housing 600 is shown in a perspective sectional view, wherein a symmetry plane of the housing 600 is selected for the sectional view, in which the longitudinal axis 501 of the housing 600 extends. The housing 600 consists of the slot 500, the first slot cover 601 and the second slot cover 602. Figure 1 The slot 140 has the same structure as the slot covers 601 and 602, and two slot covers 601 and 602 can also be used according to the Figure 2 The slot cover 240 has the same structure as the slot cover.

[0044] The trough 500 is connected not only to the first trough cover 601 but also to the second trough cover 602, and serves as a connecting member between the first trough cover 601 and the second trough cover 602. When the trough 500 is joined to the first trough cover 601 and the second trough cover 602, the circumferential ribs 130 and 131 of the trough covers 601 and 602 respectively engage in the circumferential grooves 510, 511, 512, and 513 of the trough 500, thereby forming a positive connection between the trough 500 and the first trough cover 601 and the trough 500 and the second trough cover 602.

[0045] Figure 10A perspective sectional view shows a housing 700 that is an alternative to housing 600. The symmetry plane of housing 700 has been selected for the sectional view, and the longitudinal axis 701 of housing 700 extends in this symmetry plane. Housing 700 comprises an inner pipe 720, an outer pipe 721, a first slot cover 601, and a second slot cover 602, and surrounds an annular inner opening 702. In the illustrated example, both inner pipe 720 and outer pipe 721 are rectangular pipes, giving housing 700 the basic shape of a rectangular ring. Each of inner pipe 720 and outer pipe 721 has a circumferential depression 722, 723, 724, and 725 at one of its ends, extending in a stepped manner from one of these ends to a circumferential shoulder 726, 727, 728, and 729, respectively. Circumferential depressions 724 and 725 are formed in the inner pipe 720 on the side facing the opening 702 and in the outer pipe 721 on the side facing away from the opening 702. In the region of the circumferential depressions 722, 723, 724, and 725, the inner pipe 720 and the outer pipe 721 each have circumferential ribs 730, 731, 732, and 733. The two slot covers 601 and 602 are placed over the inner pipe 720 and the outer pipe 721 and extend to circumferential shoulders 726, 727, 728, and 729, respectively. The circumferential ribs 730, 731, 732, and 733 of the inner pipe 720 and the outer pipe 721 engage in the grooves 143 and 144 of the two slot covers 601 and 602, thereby connecting the inner pipe 720 and the outer pipe 721 to the two slot covers 601 and 602, respectively, in a form-fitting manner.

[0046] Figure 11 Shown in perspective section Figure 4 An alternative housing 800 to housing 100 is shown. For this sectional view, a symmetry plane of housing 800 is selected, wherein a catch axis 801 is present, with respect to which housing 800 is rotationally symmetrical. In contrast to housing 100, housing 800 has a cup-shaped slot 820 and a cup-shaped slot cover 840. Housing 800 has the basic shape of a cuboid and encloses a cavity in which, for example, a square or rod-shaped magnetic core is housed.

[0047] Groove 820 has a wall 821, which has a circumferential depression 822 at its end facing away from the bottom of groove 820. The circumferential depression 822 is introduced in a stepped manner into the side of wall 821 facing away from the cavity. The circumferential depression 822 extends parallel to longitudinal axis 801 from the end face of groove 820 facing away from the bottom to a circumferential shoulder 823 on wall 821 of groove 800. In the region of depression 822, groove 800 has a circumferential rib 824 in the form of a cylinder that is split along its longitudinal axis. The rib 824 extends in a plane perpendicular to longitudinal axis 801.

[0048] The slot cover 840 has a wall 841, which has a circumferential groove 842 on its side facing the cavity. The circumferential groove 842 is located in a plane perpendicular to the longitudinal axis 801 and has the shape of a cylinder that is separated along its longitudinal axis. In the example shown, the slot cover 840 is placed over the slot 820 so that the slot cover 840 extends to the circumferential shoulder 823 of the slot 820. The circumferential rib 824 in the slot 820 engages the circumferential groove 842 in the slot cover 840, and the slot 820 and the slot cover 840 are connected to each other in a form-fitting manner. The slot cover 840 can also have a flange 850, which in the example shown is implemented as a rectangular annular depression in the cover base as close to the side wall as possible.

[0049] Figure 12 Housing 900 is shown in a perspective sectional view, with the symmetry plane of housing 900 selected as the sectional view. The longitudinal axis 901 of housing 900 lies in this symmetry plane, and housing 900 is rotationally symmetrical relative to this longitudinal axis 901. Housing 900 has the basic shape of a rectangular ring, surrounding an inner opening, and comprises a groove 920 and a groove cover 940. Groove 920 has an inner wall 921 and an outer wall 922. Circumferential depressions 923 and 924 are respectively incorporated into the side of inner wall 921 facing away from the inner opening and the side of outer wall 922 facing the inner opening. Circumferential depressions 923 and 924 are introduced into inner wall 921 and outer wall 922 in a stepped manner along longitudinal axis 901 and are defined by circumferential shoulders 925 and 926, respectively. Circumferential ribs 927 and 928 are respectively arranged in these circumferential depressions 923 and 924. The slot cover 940 also has an inner wall 941 and an outer wall 942. On the side of the inner wall 941 facing the inner ring opening and on the side of the outer wall 942 facing away from the inner ring opening, circumferential depressions 943 and 944 are respectively introduced in the direction of the longitudinal axis 901. The circumferential depressions are stepped and are each delimited by circumferential shoulders 947 and 948. Circumferential grooves 945 and 946 are respectively introduced in these circumferential depressions 943 and 944.

[0050] The shapes of grooves 945 and 946 correspond to the shapes of ribs 927 and 928, and slot cover 940 is connected to slot 920 such that the circumferential ribs 927 and 928 of slot 920 engage with the circumferential grooves 945 and 946 of slot cover 940, thereby forming a positive connection between slot 920 and slot cover 940. In the illustrated example, slot cover 940 is inserted into slot 920 and has end faces 923 and 924, respectively. Circumferential, square-shaped ribs 925 and 926 extend along these end faces 923 and 924, respectively. Slot cover 940 has a bottom face 941, into which two circumferential, square-shaped grooves 942 and 943 are introduced. Grooves 942 and 943 are introduced into bottom face 941 so as to fit into slot 920. Slot 920 and slot cover 940 enclose a cavity in which a magnetic core (not shown) is disposed. Although not explicitly shown, the slot cover 940 may also have a curled edge.

[0051] Figure 13 Housing 1000 is shown in a perspective sectional view. The symmetry plane of housing 1000 is selected as the cutting plane for the sectional view, and longitudinal axis 1001 of housing 1000 also lies in this symmetry plane. Housing 1000 has the basic shape of a rectangular ring that surrounds an opening and is rotationally symmetrical about longitudinal axis 1001. Housing 1000 consists of a slot 1020 and a slot cover 1040. Slot 1020 has an inner wall 1021 and an outer wall 1022 and is closed on the side facing away from slot cover 1040. Thus, slot 1020 and slot cover 1040 enclose a cavity in which a magnetic core (not shown) is arranged. Slot 1020 has two circumferential recesses 1035, 1036, 1037, and 1038, respectively, on the side facing slot cover 1040, both in its inner wall 1021 and in its outer wall 1022. Circumferential recesses 1035, 1036, 1037, and 1038 are respectively introduced into the sides facing toward and away from the opening of the inner wall 1021 and the outer wall 1022. Circumferential ribs 1027, 1028, 1029, and 1030 extend in the recesses 1035, 1036, 1037, and 1038, wherein the circumferential ribs 1027, 1028, 1029, and 1030 extend in a plane perpendicular to the longitudinal axis 1001.

[0052] Slot cover 1040 has a first inner wall 1041 and a second inner wall 1042, as well as a first outer wall 1043 and a second outer wall 1044. First inner wall 1041 and first outer wall 1043 have circumferential grooves 1031 and 1034, respectively, on the sides facing the opening. Second inner wall 1042 and second outer wall 1044 have circumferential grooves 1032 and 1033, respectively, facing the opening. Circumferential grooves 1031, 1032, 1033, and 1034 are in the same plane as circumferential ribs 1027, 1028, 1029, and 1030. In the example shown, the circumferential grooves 1031, 1032, 1033, and 1034 have a shape corresponding to the circumferential ribs 1027, 1028, 1029, and 1030, and the circumferential ribs 1027, 1028, 1029, or 1030 engage in the circumferential grooves 1031, 1032, 1033, and 1034, respectively, thereby connecting the groove 1020 and the groove cover 1040 to each other in a form-fitting manner. In the assembled state, the first inner wall 1041 and the second inner wall 1042 as well as the first outer wall 1043 and the second outer wall 1044 extend to the shoulders 1035, 1036, 1037, and 1038 on the inner wall 1021 and the outer wall 1022 of the groove 1020.

[0053] In addition to the described basic shape of a rectangular ring, the housing can also have any other basic shape, for example a circular or flat ring basic shape.

[0054] Figure 14 Groove 1120 is shown in a perspective view. Groove 1120 has the basic shape of a flat ring surrounding an opening. Groove 1120, which has the basic shape of a flat ring, has two opposing wall regions 1131 and 1132 extending parallel to each other, and two further opposing wall regions 1133 and 1134, which are parallel to longitudinal axis 1001 and convexly shaped in the direction facing away from the opening. Groove 1120 is doubly rotationally symmetrical about longitudinal axis 1135 of groove 1120. Groove 1120 has an inner wall 1121 and an outer wall 1122. Circumferential recesses 1123 and 1124 are respectively introduced into the side of inner wall 1121 facing the opening and the side of outer wall 1122 facing away from the opening. Circumferential recesses 1123 and 1124 are introduced into inner wall 1121 and outer wall 1122 at the ends opposite the bottom surface. Circumferential ribs 1125 and 1126 extend in each of the recesses 1123 and 1124, wherein the circumferential ribs 1125 and 1126 extend in a plane perpendicular to the longitudinal axis 1135. The recesses 1123 and 1124 are introduced into the inner wall 1121 and the outer wall 1122 in a stepped manner and are delimited by circumferential shoulders 1136 and 1137, respectively.

[0055] Figure 15Slot cover 1140 is shown in a bottom perspective view. Slot cover 1140 has the same basic shape as slot 1120, namely, a flat ring, and surrounds the opening. Slot cover 1140 includes an inner wall 1141 and an outer wall 1142. The inner wall 1141, on the side facing away from the opening, and the outer wall 1142, on the side facing the opening, each have circumferential grooves 1143 and 1144. These circumferential grooves 1143 and 1144 have a shape that corresponds to the circumferential ribs 1125 and 1126 of slot 1120. Slot cover 1140 can close slot 1120 so that the circumferential ribs 1125 and 1126 of slot 1120 engage with the grooves 1143 and 1144 of slot cover 1140. As a result, slot 1120 and slot cover 1140 are connected in a form-fitting manner and form an assembled housing.

[0056] Figure 16 The trough cover 1140 is shown in a top perspective view. The trough cover 1140 has a circumferential bead 1150 formed in the top surface 1145 of the trough cover 1140. The bead 1150 is formed in the direction of the longitudinal axis 1143 of the trough cover 1140. Instead of the bead 1150, the trough cover 1140 can also optionally have an overhang or an overhang, wherein the overhang or overhang can have a similar course to the bead 1150.

[0057] Figure 17 Groove 1220 is shown in a perspective view. Groove 1220 has the basic shape of a circular ring and surrounds an inner ring opening. Groove 1220 is rotationally symmetrical with respect to longitudinal axis 1201. Groove 1220 has an inner wall 1221 and an outer wall 1222. Step-shaped, circumferential recesses 1223 and 1224 are respectively introduced into the side of inner wall 1221 facing the inner ring opening and into the side of outer wall 1222 facing away from the inner ring opening. Recesses 1223 and 1224 are delimited in the direction of longitudinal axis 1201 by circumferential shoulders 1227 and 1228, respectively. Circumferential ribs 1225 and 1226 are respectively introduced into circumferential recesses 1223 and 1224, wherein circumferential ribs 1225 and 1226 extend in a plane perpendicular to longitudinal axis 1201. In the groove 1220 , for example, a ring-shaped magnetic core 1230 is inserted, which is wound with, for example, a soft magnetic tape 1231 , so that the magnetic core 1230 is initially protected on three sides by the groove 1220 .

[0058] Figure 18Slot 1240 is shown in a perspective view. The slot cover is rotationally symmetrical about longitudinal axis 1247 and has the basic shape of a circular ring surrounding the opening. Slot cover 1240 has an inner wall 1241 and an outer wall 1242. Circumferential grooves 1243 and 1244 are provided in the side of the inner wall facing the opening and in the side of the outer wall facing away from the opening 102, respectively. Slot 1220 and slot cover 1240 are designed so that when slot 1220 and slot cover 1240 are closed, circumferential ribs 1225 and 1226 engage in circumferential grooves 1243 and 1244. As a result, slot 1220 and slot cover 1240 are connected to each other in a form-fitting manner and form a assembled housing. Consequently, magnetic core 1230 is protected on all sides.

[0059] Figure 19 Housing 1300 is shown in a perspective, cross-sectional view. Housing 1300 has the shape of a hollow cylinder and includes a tubular trough 1320 and a first trough cover 1340 and a second trough cover 1341. Aside from its basic shape, trough 1320 is structurally identical to trough 600, and, aside from the different basic ring shape, trough covers 1340 and 1341 are structurally identical to trough cover 140. As already described in connection with trough 600, trough 1320 also has four circumferential depressions 1321 and 1322 with four circumferential ribs 1323 and 1324. Like trough cover 140, trough covers 1340 and 1341 have circumferential grooves 1342 and 1341. When trough 1320 and trough covers 1340 and 1341 are assembled, circumferential ribs 1323 and 1324 of trough 1320 engage in circumferential grooves 1342 and 1341 of trough covers 1340 and 1341 , thereby connecting trough 1320 and trough covers 1340 and 1341 to each other in a form-fitting manner.

[0060] Figure 20 Housing 1400 is shown in a perspective, cross-sectional view. Housing 1400 comprises a slot 1420, a first slot cover 1440, and a second slot cover 1441. Slot 1420 interconnects slot covers 1440 and 1441. Housing 1400, as well as slot 1420 and slot covers 1440 and 1441, have the basic shape of a flat ring and enclose one (or more) inner openings. Slot covers 1440 and 1441 have circumferentially extending curling edges 1451 and 1452, respectively. For example, slot covers 1440 and 1441 may each include multiple inner openings (not shown), which may be defined by reinforcing struts (not shown).

[0061] Like the grooves described above, groove 1420 also has four circumferential depressions 1421 with four circumferential ribs 1422. Slot covers 1440 and 1441 have corresponding circumferential grooves 1442 and 1443. When groove 1420 and groove covers 1440 and 1441 are assembled, the circumferential ribs 1422 of groove 1420 engage with the circumferential grooves 1442 and 1443 of groove covers 1440 and 1441, thereby connecting groove 1420 and groove covers 1440 and 1441 to each other in a form-fitting manner.

[0062] Figure 21 The housing 1500 is shown in a perspective cross-sectional view. The housing 1500 includes a slot cover 1520, a first slot 1540, and a second slot 1541. The slot cover 1520 connects the first slot 1540 to the second slot 1541, wherein the first slot 1540 and the second slot 1541 have the same structure. The slot cover 1520, the first slot 1540, and the second slot 1541 each have a basic shape of a ring surrounding an inner opening. In one example, the inner opening in the first slot 1540 and the inner opening of the second slot 1541 can be divided into multiple separate openings by reinforcing struts (not shown).

[0063] As in the previously described slot covers, slot cover 1520 also has four circumferential grooves 1521 and 1522. Slots 1540 and 1541 correspond to the previously described slots and have circumferential depressions 1542 and 1544 with circumferential ribs 1543 and 1545. The shape of grooves 1521 and 1522 corresponds to the shape of ribs 1543 and 1545, so that when slot cover 1520 and slots 1540 and 1541 are assembled together, the circumferential ribs 1543 and 1545 of slots 1540 and 1541 engage with the circumferential grooves 1521 and 1522 of slot cover 1520, thereby forming a positive connection between slot cover 1520 and slot covers 1540 and 1541.

[0064] Figure 22 A throttle element 1600 is shown in a top view. The throttle element 1600 comprises a magnetic core (not shown) located in a housing 1601, which has the basic shape of a flat ring surrounding an inner opening 1602. The housing 1601 has a slot (not shown) and a slot cover 1603, which is connected to the slot in a form-fitting manner and has a crimped edge 1604 and is provided with a wire winding 1605. The housing 1600 is wound with one or more coils along its basic shape, and the windings also pass through the opening 1602.

[0065] In addition to the examples described, in which the groove has one or more circumferential depressions, each with a circumferential rib, the groove cover can also have one or more circumferential depressions, each with a circumferential rib. The same applies to the described groove. The groove can also have grooves on the side of the inner wall facing the opening and on the side of the outer wall facing away from the opening. In the described embodiment, not only the ribs but also the grooves have the shape of parts of a cylinder that is divided in the longitudinal direction. As an alternative, the ribs and grooves can also have other shapes that correspond to each other. For example, the ribs and grooves can each have the shape of an equilateral or unequal-sided triangular prism or a trapezoidal prism. In addition, the ribs and grooves can be formed in such a way that the grooves of the groove cover snap onto the ribs of the groove.

[0066] The cavity in the housing that houses the magnetic core can be hermetically sealed by the housing parts. In practice, this can only be achieved to a limited extent due to manufacturing tolerances. Due to manufacturing tolerances, there are tolerable residual gaps in the overlapping area between the two housing parts, especially in the area of grooves and ribs. In the case of magnetic cores made of strip material, such as wound annular strip cores, the residual gap with the maximum strip thickness can be smaller than this maximum strip thickness. This situation has already been mentioned above. Figure 4 In this example, a small gap of gap width t exists in the overlapping regions 110, 111 between the opposing surfaces of the inner wall 141 and the outer wall 142 of the cover 140 and the corresponding walls 122, 123 of the groove 120 (see also FIG. Figure 2 and Figure 3 In practice, the groove 120 and the cover 140 will essentially contact each other along the surrounding ribs and grooves. The amount of particles that may escape (at least in one direction) from the annular core wound around the groove is typically no greater than the thickness of the tape around the annular core. If the remaining gap is less than the maximum or nominal tape thickness, particles are unlikely to escape from the housing.

[0067] In practice, the use of cores wound with nanocrystalline ribbon material often results in particle formation, as the nanocrystalline ribbon material is relatively brittle. To meet standardized requirements for the technical cleanliness of products in various standards and guidelines (e.g., the ZVEI (German Central Electrical and Electronic Industry) guidelines on technical cleanliness in electronics), a tight housing seal is desirable to prevent particle escape. In practice, if the width t of the gaps between the housing components (on both sides of the ribs or grooves) in the unavoidable overlap of the plastic housing is less than the thickness of the ribbon material wound around the core, particles can escape, as described above, after they have already detached from the core.

[0068] The housing described can be wound with one or more coils, thereby making it possible to manufacture inductive components, such as throttles or transformers, from magnetic components. The magnetic core enclosed by the housing can also be wound with one or more coils. The coils of the housing or the core, or both, can be, for example, wire windings. The wire can be insulated or uninsulated, with any cross-sectional size and shape. Examples of wire cross-sections include circular and rectangular cross-sections. An example of an insulated wire is lacquered copper wire.

[0069] The described housing components can be connected to one another in a detachable or non-detachable manner. For example, at least two housing components of one of the described housings can be connected to one another by a force-fitting, form-fitting, or material-fitting connection, or by any combination of the aforementioned joining techniques. Examples of such joining techniques are clamping, adhesive bonding, and snap-on connections. Furthermore, the circumferential ribs and circumferential grooves of the housing components can also be adhesively bonded or welded to one another.

[0070] The circumferential recess can be a fold or a shoulder. The circumferential rib can also be embodied as a ridged strip, and the outer walls of the groove and one or more covers can be connected to each other in a planar manner (as shown in all examples), but can also form steps (not shown). The housing and housing parts described, such as the groove and groove cover, can be made of non-magnetic materials such as plastic, or can be molded parts such as injection molded parts or pressed parts made of plastic and containing other components. As plastic materials, all industrial plastics can be used, such as (not exhaustive) polyamide (PA), polybutylene terephthalate (PBT), polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyoxymethylene (POM), and acrylonitrile butadiene styrene (ABS). The plastic material can be combined with other materials such as glass fiber materials, flame retardant materials, or fillers. The material of the magnetic core can be a soft magnetic strip material. The soft magnetic strip material can be, for example, an amorphous or nanocrystalline strip material.

[0071] The housing described here prevents core metal parts or other unwanted particles from becoming trapped in the joint during the joining process of the slot parts. This is to be avoided because these core metal parts could shear off during further processing and become loose particles that are undesirable for various reasons. Furthermore, unwanted particles could damage the insulation of the winding wire or damage the winding wire when the metal parts are wound around it, thus causing short circuits. Furthermore, the possibility of gaps forming between the slot cover and the slot bottom due to non-contacting joint surfaces of the slot parts should be prevented. This behavior is particularly common with plastic parts with flat surface shapes, such as in many non-circular slots.

[0072] The housing described herein reduces or avoids these obstacles because the connection between the slot cover and the slot base is located laterally to the slot and slot base openings. The slot cover and slot base overlap circumferentially on the outer and inner peripheries of the structure, for example, within a few millimeters, and have a groove-and-tenon (rib)-like profile on the circumferentially overlapping surfaces. The profiled portion, which serves as a groove-and-tenon arrangement, seals particles from the slot interior to the surrounding environment and also provides a latching or other securement between the mating parts.

[0073] Furthermore, mechanical loads caused by winding are reduced or avoided by arranging the connection between the slot cover (lid) and the slot bottom laterally on the open side of the slot cover and the slot bottom. Here, the cover, for example, has a closed surface in the region of its end face (top face) facing laterally (via the edge), which serves to absorb and distribute mechanical loads (e.g., caused by the wire winding and / or the winding process).

[0074] To overcome this, the force is introduced by the wound wires via an integral, closed edge, eliminating the possibility of gap formation. Furthermore, the cover can have a depression or bead (optionally an outward bead) that "shapes" the inwardly recessed groove walls outward and ensures that the groove side walls rest against the inside of the cover. Thus, the depression or bead (outward bead) in the cover counteracts the recessed groove walls, positions them in the ideal vertical orientation, and reinforces the mechanical structure of the housing component (e.g., the cover).

Claims

1. A magnetic component comprising The core is made of soft magnetic material and A housing that fully surrounds the magnetic core, the housing comprising two housing parts connected to one another, wherein The housing parts connected to each other each include a circumferential overlapping area surrounding the magnetic core, in which overlapping area one of the housing parts includes a circumferential rib and the other of the housing parts includes a corresponding circumferential groove, in which the rib is embedded in a form-fitting manner, wherein at least one of the housing parts includes a circumferential inward-turned portion or a circumferential outward-turned portion, wherein the circumferential inward-turned portion or the circumferential outward-turned portion is included in the surface of the housing part and extends between the inner wall and the outer wall of the housing part, and the surface connects the inner wall of the housing part to the outer wall.

2. The assembly according to claim 1, wherein The housing part comprises a plastic material or consists of a plastic material.

3. The assembly according to claim 1 or 2, wherein The housing includes a groove and a groove cover as housing components, wherein the groove cover is placed on the groove, inserted into the groove, or sleeved on the groove.

4. The assembly according to claim 3, wherein The slot cover includes a depressed portion or an outward-turned portion or both in the longitudinal axis direction of the slot.

5. The assembly according to claim 1, wherein The housing includes a further housing component which is connected together with the two housing components and to each other.

6. The assembly according to claim 5, wherein The housing comprises a pipe as housing component and two slot covers which are placed at the end of the pipe or inserted into the pipe or slipped onto the pipe, wherein a circumferential overlap region is respectively present between the pipe and the slot covers.

7. The assembly according to claim 6, wherein At least one of the slot covers has a depression or an outward turn or both in the direction of the longitudinal axis of the pipe.

8. The assembly of claim 1, wherein: The housing comprises two grooves as housing parts, which are aligned centrally and facing each other and are placed one above the other, or one is inserted into the other or is placed on top of the other.

9. The assembly of claim 1, wherein: Two or more of the housing parts are detachably connected to each other.

10. The assembly of claim 1, wherein: Two or more of the housing parts are non-detachably connected to each other.

11. The assembly according to claim 1, wherein The magnetic core comprises a soft magnetic ribbon material.

12. The assembly according to claim 11, wherein The soft magnetic ribbon material includes amorphous or nanocrystalline material.

13. The assembly of claim 11, wherein: The strip material has a strip thickness, and wherein, when the ribs engage in the overlapping region in the grooves, a residual gap exists which is smaller than the strip thickness.

14. The assembly of claim 1, wherein: The housing surrounds one or more internal openings.

15. The assembly of claim 1, wherein The housing is sealed.

16. The assembly of claim 1, wherein The housing is surrounded by wires.

17. The assembly of claim 1, wherein: The ribs and the grooves comprise a latching mechanism for engaging one of the housing components to the other housing component.

18. The assembly of claim 1, wherein The ribs and the grooves are bonded to each other.

19. The assembly of claim 1, wherein: The housing has a non-circular shape.

20. The assembly of claim 1, wherein The housing has a rectangular ring or an oval shape.

21. The assembly of claim 1, wherein The circumferential inward turning portion or the circumferential outward turning portion is arranged relatively close to the inner wall and / or outer wall to prevent the wall of the other shell component from sinking inward and position the groove wall of the other shell component in an ideal vertical direction, while strengthening the structure of the shell component.

22. An assembly comprising: a ring-shaped magnetic core (180), and An annular housing, the housing fully surrounding the magnetic core (180), the housing comprising two housing parts (120, 140) connected to each other; The housing components (120, 140) each include a first overlapping region (110) externally surrounding the magnetic core (180) and a second overlapping region (111) internally surrounding the magnetic core (180). wherein, both in the first overlapping region (110) and in the second overlapping region (111), one of the housing parts (120, 140) comprises a circumferential rib (130, 131), and the other of the housing parts (120, 140) comprises a corresponding circumferential groove (144, 143), into which the rib (130, 131) engages in a form-fitting manner, and At least one of the shell components includes a circumferential inward-turned portion or a circumferential outward-turned portion, wherein the circumferential inward-turned portion or the circumferential outward-turned portion is included in the surface of the shell component and extends between the inner wall and the outer wall of the shell component, and the surface connects the inner wall of the shell component to the outer wall.

23. The assembly according to claim 22, in, The annular magnetic core (180) is made of a soft magnetic strip material, and In the first and second overlapping areas (110, 111), the ribs (130, 131) are embedded in corresponding grooves (144, 143), and a residual gap exists, which is smaller than the strip thickness of the strip material of the magnetic core (180).

24. The assembly of claim 22, wherein: The housing has a non-circular shape.

25. The assembly of claim 22, wherein: The housing has a rectangular ring or an oval shape.

26. The assembly of claim 22, wherein: The circumferential inward turning portion or the circumferential outward turning portion is arranged relatively close to the inner wall and / or outer wall to prevent the wall of the other shell component from sinking inward and position the groove wall of the other shell component in an ideal vertical direction, while strengthening the structure of the shell component.

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