Inductor Devices

Abstract

An inductor device (100, 200, 300, 400, 500) comprises: at least one electric conductor (10a, 10b); a coil body (110, 210, 310, 410, 510) having a hollow winding body (111, 211, 311, 411, 511) for winding the at least one electric conductor (10a, 10b); and a magnetic core (120, 220, 320, 420, 520) arranged in a cavity (1) of the winding body (111, 211, 311, 411). The at least one electric conductor (10a, 10b) is surrounded by a casting material (20). The casting material (20) has no direct adhesive contact with the magnetic core (120, 220, 320, 420, 520), so that the magnetic core (120, 220, 320, 420, 520) is decoupled from the casting material (20).

Description

Technical Field

[0001] The invention relates to an inductive component, in particular a transformer and a choke, which has one or more windings and a magnetic core. Background Art

[0002] An inductive component, such as a transformer, has a magnetic core around which a coil is arranged. The coil may include a coil body on which an electrical conductor is wound. In order to ensure a sufficient degree of high-voltage safety in such an inductive component, especially in a small-sized design, the coil and the magnetic core may be installed in a housing and surrounded by a casting material, so that the electrical conductor, the coil body and the magnetic core are completely embedded in the casting material.

[0003] Due to the different temperature behavior of the magnetic core and the casting material, in particular the different thermal expansion coefficients, mechanical stresses can occur in the cast composite in the event of temperature fluctuations. Even in the event of small temperature fluctuations, the magnetic and electrical parameters of the material of the magnetic core can change due to the mechanical stresses that occur in the core material, so that there is a risk that the inductive component no longer meets the required specifications. In the event of higher temperature fluctuations, magnetic cores that are sensitive to material stresses, such as ferrite cores, can be damaged or destroyed. Summary of the invention

[0004] The object of the present invention is to specify an inductive component in which mechanical stresses within the core material of the inductive component can be largely avoided in the event of temperature fluctuations and in which the electrical properties of the inductive component are affected as little as possible.

[0005] The implementation of such an inductive component is described in the configuration according to the present invention.

[0006] According to one possible embodiment, the inductor device comprises: at least one electrical conductor; a coil body having a hollow winding body, on the surface of which the at least one electrical conductor is wound around the winding body; and a magnetic core arranged in a cavity of the winding body. The at least one electrical conductor is surrounded by a casting material, but the casting material does not have direct adhesive contact with the magnetic core.

[0007] In the case of the inductor component according to the invention, the magnetic core is therefore not embedded in the casting material together with the coil body and the at least one electrical conductor wound thereon. Instead, only the at least one electrical conductor is encapsulated by the casting material. The coil body can also be embedded in the casting material. The magnetic core is decoupled from the casting material, so that when the temperature changes, no mechanical stresses occur in the core material due to the different expansion coefficients of the casting material and the material of the magnetic core. Since the core is located outside the at least one cast electrical conductor, only a few defined mechanical forces, which are essentially caused by the coil, act on the core.

[0008] Inductive components can be designed in particular as transformers or chokes with one or more wound electrical conductors. If the inductive component contains two or more electrical conductors belonging to different windings, the electrical conductors are isolated from each other and galvanically isolated from each other toward the core by the casting material for safe voltage isolation. The windings are thus insulated from each other and from the core.

[0009] According to a possible embodiment, the coil body and at least one electrical conductor wound thereon can be arranged in a protective body for protecting the at least one electrical conductor. The casting material is located in the cavity between the at least one electrical conductor or the coil body and the protective body. Here, the protective body acts as a casting container, into which the casting material is filled in a fluid or viscous form during the manufacture of the device, and then the casting material subsequently hardens.

[0010] According to a preferred embodiment, the protective body or casting container and the coil body are matched to each other by forming measures so that no fluid casting material flows out from the gap between the coil body and the protective body during casting. The coil body and the protective body can be fixed to each other in a self-sealing manner, for example, by a notch and tenon connection. Therefore, the magnetic core of the inductor component does not come into contact with the casting material during manufacturing. The self-sealing connection between the coil body and the protective body eliminates additional cost-increasing measures, such as bonding the magnetic core to the casting material or subsequently cleaning the magnetic core. The type of core-coil configuration can be applied to most other core forms, such as E-shaped cores, U-shaped cores, I-shaped cores, PQ cores or rod cores. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The invention is further explained below with reference to the accompanying drawings, which show an embodiment of the invention in particular as a transformer.

[0012] Figure 1 shows an exploded view of a first embodiment of an inductor device;

[0013] Figure 2 A top view of a first embodiment of an inductor device is shown;

[0014] Figure 3A A back view of a first embodiment of an inductive device without a casting material is shown;

[0015] Figure 3B A back view of a first embodiment of an inductive component having a casting material is shown;

[0016] Figure 4A A cross-sectional view of a first embodiment of an inductor device is shown in a perspective view;

[0017] Figure 4Bshows a cross section of a first embodiment of an inductor device;

[0018] Figure 5 shows a back view of a first embodiment of an inductor device having a notch and tongue connection between a coil body and a protective body of the inductor device;

[0019] Fig. 6A shows an exploded view of a second embodiment of an inductor device;

[0020] Figure 6B shows a top view of a second embodiment of an inductor device;

[0021] Fig. 7A shows an exploded view of a third embodiment of an inductor device;

[0022] Figure 7B shows a top view of a third embodiment of an inductor device;

[0023] Fig. 8A shows an exploded view of a fourth embodiment of an inductor device;

[0024] Figure 8B shows a top view of a fourth embodiment of an inductor device;

[0025] Fig. 9A shows an exploded view of a fifth embodiment of an inductor device;

[0026] Fig. 9B shows a cross section of a fifth embodiment of an inductor device;

[0027] Fig. 9C A perspective view of a fifth embodiment of an inductor component is shown. DETAILED DESCRIPTION

[0028] In the following, different embodiments of an inductor component are described, which is designed as a transformer with two electrical conductors 10a and 10b. However, the inductor component can have only one electrical conductor, for example in an embodiment as a choke or autotransformer, or can also have more than two electrical conductors, for example in an embodiment as a current-compensated choke.

[0029] Figure 1 An exploded view of a first embodiment 100 of an inductance component, such as a transformer, is shown. The inductance component comprises a coil body 110 having a hollow winding body 111, on the surface of which electrical conductors 10a, 10b belonging to different windings are wound. In addition, the inductance component comprises a magnetic core 120, which is arranged in a cavity 1 of the winding body 111. The magnetic core 120 has a partial body 121 and a partial body 122 which are connected to each other, for example, bonded to each other.

[0030] exist Figure 1 In the embodiment shown in , the two partial bodies 121, 122 of the magnetic core are respectively configured as E-shaped cores. The two core halves are introduced into the cavity 1 of the coil body 110 from different sides, so that the corresponding legs of each core half 121, 122, for example the middle leg 123, are arranged in the cavity 1 of the winding body 111, and the other legs 124 of each partial body 121, 122 are arranged outside the cavity 1 of the winding body 111. The two partial bodies can be bonded to each other at the end faces of their legs.

[0031] In addition, the inductor device includes a protective body 130 having a covering element 131 for protecting the electrical conductors 10a, 10b. The coil body 110 and the protective body 130 are configured such that the coil body 110 can be fixed on the protective body 130 and the electrical conductors 10a, 10b are covered by the covering element 131 and thus protected.

[0032] The winding body 111 has a winding area 112 for winding with electrical conductors 10a and 10b, and a fixing area 113 for fixing the coil body 110 on the protective body 130. The fixing area 113 is arranged on the winding body 111 at the side of the winding area 112. The coil body 110 has a contact area 115 for contacting the electrical conductors 10a, 10b and for applying voltage to the electrical conductors 10a, 10b. In order to apply voltage, a contact pin 116 is arranged at the contact area 115. The protective body 1130 includes a receiving area 134, which is used to accommodate the contact area 115 when the coil body 110 is arranged in the protective body 130.

[0033] Figure 2 The inductor device is shown in the assembled Figure 1 1. A top view of the different components shown in FIG. 1. In the assembled state of the inductor, the coil body 110 together with the electrical conductors 10a and 10b wound thereon is placed in the protective body 130 and fixed on the protective body. After the coil body 110 is fixed on the protective body 130, the electrical conductors 10a, 10b are surrounded by the covering element 131 of the protective body 130 and are thus protected. The magnetic core 120 is fixed to the device consisting of the coil body 120 and the protective body 130. The corresponding middle legs 123 of the two partial bodies 121, 122 of the magnetic core are arranged in the cavity 1 of the coil body 110. The corresponding outer legs 124 of each partial body are arranged outside the cavity 1.

[0034] Figure 3A FIG. 1 shows a rear view of the inductor device of the embodiment 100, wherein the coil body 110 is placed in the protection body 130. Figure 3A As will become apparent, coil body 110 and protective body 130 are shaped such that contact region 115 of the coil body is arranged in receiving region 134 of the protective body in the assembled state of the component. Contact pins 116 protrude from contact region 115 and thus at the underside of protective body 130 .

[0035] A cavity 2 is formed between the electrical conductors 10a and 10b and the cover element 131. A casting material 20 is arranged in the cavity 2. The cavity 2 is filled with the casting material 20 so that the electrical conductors 10a and 10b are embedded in the casting material. The casting material may also be in contact with the winding body 111. Figure 3B The back side of the inductor device after casting is shown. The protective body 130 acts as a casting container for filling the casting material during casting. The casting material can be, for example, a casting resin. Figure 3B In the variant shown in FIG. 1 , the casting material 20 surrounds the coil body 110 with the electrical conductors 10 a and 10 b, so that only the contact pins 116 are not covered by the casting material and protrude from the underside of the protective body 130 . Figure 2 The windings are shown as having no contact or no direct adhesive contact with the magnetic core 120. As a result, no mechanical stresses occur in the core material of the magnetic core 120 due to temperature fluctuations and different expansion coefficients of the casting material and the material of the magnetic core. In addition, the windings are isolated from each other and from the core current.

[0036] In order to prevent the casting material 20 and the magnetic core 120 from contacting each other, the coil body 110 and the protective body 130 are constructed so that the winding body 111 is self-sealingly fixed on the protective body 130 and prevents the casting material 20 from flowing out of the cavity 2 between the conductors 10a, 10b and the covering element 131 of the protective body 130.

[0037] Figure 4A and 4B The embodiment of the inductor device 100 is shown in a three-dimensional or simple cross section. The conductors 10a and 10b are wound on the winding area 112 of the winding body 111. On both sides of the winding area 112, fixing areas 113 are respectively provided for fixing the coil body 120 on the protection body 130.

[0038] According to one embodiment, the covering element 131 may have a bottom portion 132 opposite to the electrical conductors 10a, 10b. The bottom portion 132 of the covering element may have side portions 133 on both sides. The winding body 111 may have a flange 114 for limiting the winding area 112. According to a possible embodiment, the flange 114 of the coil body may either have a recess 30, respectively, and the side portions 133 of the covering element may have a bridge 40, respectively. According to another embodiment, the flange 114 may have a bridge 40, respectively, and the side portions 133 may have a recess 30, respectively. The coil body 110 is fixed to the protective body 130 in the following manner, that is, each of the bridges 40 engages in one of the recesses 30. The recesses 30 and the bridges 40 are configured so that the casting material 20 is prevented from flowing out of the cavity 2 between the electrical conductors 10a, 10b and the covering element 131 of the protective body 130 in the region of the recesses 30 and the bridges 40.

[0039] Through the inductor Figure 4A and 4B In the embodiment shown in , in which the flanges 114 respectively have a recess 30 and the side portions 133 of the protective body respectively have a bridging portion 40 , the fixing area 113 of the coil body 110 and the side portions 133 of the protective body 130 are formed so that a groove and tenon connection is formed between the fixing area 113 and the protective body 130. Figure 5 The notch and tongue connection between the coil body 110 and the protective body 130 is shown in the fixing region 113. The notch and tongue connection is designed in particular to achieve a self-sealing connection between the coil body 110 and the protective body 130. This prevents the casting material 20 from flowing out of the cavity 2 between the electrical conductors 10a, 10b and the covering element 131 of the protective body.

[0040] Fig. 6A 1 shows an exploded view of a second embodiment of an inductor device having a coil body 210 with a hollow winding body 211, on the surface of which an electrical conductor can be wound into a plurality of windings. The winding body 211 comprises a winding area 212 for winding the electrical conductor. Figure 1 The electrical conductors 10a and 10b are not shown. The coil body 210 also has a contact region 215 for contacting the electrical conductors and for applying a voltage to the electrical conductors. Contact pins 216 are arranged at the contact region 215 .

[0041] The inductor has a magnetic core 220, which is arranged in the cavity 1 of the winding body 211 in the assembled state of the inductor. The magnetic core 220 includes two partial bodies 221, 222, which are connected to each other in the assembled state. Fig. 6A and 6B In the embodiment shown in , the two partial bodies are each configured as a U-shaped core. For this purpose, the partial bodies 221, 222 can be bonded to each other at the end faces of their legs 223, 224. In addition, the inductor component comprises a protective body 230, which has a covering element 231 for protecting the electrical conductors 10a, 10b placed on the winding body 211. The protective body 230 has a receiving area 234 for receiving the contact area 215.

[0042] When installing the inductor Fig. 6A When the coil body 220 is a single component shown in FIG, the protective body 230 is arranged on the coil body 210 and fixed on the coil body. The electrical conductor arranged on the coil body 210 is surrounded by the covering element 231. The winding body 211 includes a fixing area 213 for fixing the coil body 220 on the protective body 230. The fixing area 213 is arranged on the side of the winding area 212.

[0043] Figure 6B The inductor device of the embodiment 200 is shown in FIG. Fig. 6A The combined state of the monomer components shown in . The coil body 210 is placed in the protective body 230. The contact area 215 is arranged in the accommodating area 234 of the protective body. A cavity is formed between the electric conductor placed on the coil body 210 and the covering element 231. The cavity is filled with a casting material 20 so that the electric conductor is surrounded by the casting material, and the electric conductor is surrounded by the casting material, and only the contact pin 216 extends out from the protective body 230 on the lower side of the device. According to another embodiment, the coil body 210 can also be surrounded by the casting material 20 or embedded in the casting material. The casting material can be, for example, a casting resin, which is filled into the cavity between the electric conductor and the covering element in a fluid or viscous state, and then hardened. Through the casting material, the electric conductors are insulated from each other and insulated from each other toward the core for voltage isolation.

[0044] However, the casting material 20 has no contact or no direct adhesion contact with the magnetic core 220. Figure 6B As shown in FIG, each leg 223 of the two partial bodies of the core 220 is arranged in the cavity 1 of the winding body 211. The corresponding other legs 224 of the two partial bodies are arranged outside the cavity 1 of the winding body 211. Therefore, the magnetic core 220 is not in contact with the casting material 20 and is decoupled from the casting material.

[0045] To prevent the casting material 20 from escaping from the cavity between the conductor and the cover element 231 of the protective body, the wrap-around body 211 is fixed to the protective body 230 in a self-sealing manner. This fixing can be carried out, for example, by a groove and tongue connection between the fixing area 213 and the protective body 230.

[0046] The covering element 231 may, for example, have a bottom portion 232, which is opposite to the electrical conductor in the assembled state. Side portions 233 may be provided on both sides of the bottom portion 232. The winding body 210 may have a flange 214 for limiting the winding area 211. According to a possible embodiment, in order to make a notch and tenon connection, the flange may have a recess 30, respectively, and the side portion 233 may have a bridge 40, respectively. According to another scheme for realizing the notch and tenon connection, the flange 214 may have a bridge 40, respectively, and the side portion 233 may have a recess 30, respectively. The coil body 210 may be fixed on the protective body 230 in the following manner, that is, each of the bridges 40 engages in one of the recesses 30. Here, the recesses 30 and the bridges 40 are configured so that the casting material 20 is prevented from flowing out of the cavity between the electrical conductor and the covering element 131 in the region of the recesses 30 and the bridges 40.

[0047] Fig. 7A 3 shows an exploded view of a third embodiment of an inductor component 300. The inductor component comprises a coil body 310 having a hollow winding body 311, on the surface of which an electrical conductor is arranged. Fig. 7A 3 shows only the coil body 310 without the electrical conductors 10a and 10b. The coil body 310 comprises a contact region 315 for contacting the two electrical conductors and for applying a voltage to the electrical conductors.

[0048] Furthermore, the inductor device comprises a magnetic core 320, which is arranged in the cavity 1 of the winding body 311. The magnetic core 320 comprises two partial bodies 321 and 322. The partial body 321 of the magnetic core can be implemented as a U-shaped core, and the partial body 322 of the magnetic core can be implemented as an I-shaped core. In the assembled state, the two partial bodies 321, 322 are connected to each other in that the partial body 322 is adhered to the end faces of the legs 323, 324 of the partial body 320, for example, by an adhesive connection. Furthermore, the inductor device comprises a protective body 330, which has a covering element 331 for protecting the two electrical conductors 10a and 10b. The protective body 330 has a receiving area 334 for receiving the contact area 315.

[0049] Figure 7BA top view of an embodiment 300 of an inductor component in an assembled state is shown. In the assembled state of the inductor component, the coil body 310 is placed in the protective body 330, in which the protective body 330 is sleeved onto the coil body 310 and fixed on the coil body, so that the two electrical conductors arranged on the coil body are surrounded by the covering element 331. In the assembled state, the contact area 315 is arranged in the receiving area 334 of the protective body and is therefore covered by the receiving area 334, so that only the contact pins 316 of the coil body 310 protrude from the protective body 330. The magnetic core 320 is arranged in the cavity 1 of the winding body 311, in which one of the two legs 323 of the partial body 321 is arranged in the cavity 1, and the other leg 324 is arranged outside the cavity 1. The partial body 321 is bonded to the partial body 322 of the magnetic core at the end faces of the two legs 323, 324.

[0050] In the assembled state of the inductor, a cavity is formed between the two electrical conductors on the coil body and the covering element 331, which cavity is filled with the casting material 20. As a result, the two electrical conductors are surrounded by the casting material. The casting material can also be in contact with the winding body 311. The casting material does not have direct adhesive contact with the magnetic core 320.

[0051] The casting material can first be filled into the cavity between the electrical conductor and the covering element of the protective body in a fluid state, and then hardened. In order to prevent the casting material from flowing out of the cavity between the two wire windings and the covering element 331, the winding body 311 can be fixed to the protective body 330 in a self-sealing manner. The winding body 311 has a winding area 312 for winding with two electrical conductors, and a fixing area 313 for fixing the coil body 320 on the protective body 330. The fixing area 313 is arranged on the side of the winding area 312. The self-sealing connection between the winding body 311 and the protective body 330 can be achieved by a notch and tenon connection between the fixing area 313 and the protective body 330.

[0052] The covering element 331 may have a bottom portion 332 opposite to the electrical conductor. On both sides of the bottom portion, side portions 333 may be arranged respectively. The winding body 311 has a flange 314 for limiting the winding area. In order to realize the groove and tenon connection, the flange 314 may have a recess 30 respectively according to a possible embodiment, and the side portion 333 may have a bridge 40 respectively. According to another embodiment, the flange 314 may have a bridge 40 respectively, and the side portion 333 may have a recess 30 respectively. The coil body 310 is fixed to the protective body 330 in a self-sealing manner, in which each of the bridges 4 engages into one of the recesses 30. The recess 30 and the bridge 40 are constructed so that the casting material 20 is prevented from flowing out of the cavity between the electrical conductor and the covering element 131 in the region of the recess 30 and the bridge 40.

[0053] Fig. 8A FIG. 4 shows an exploded view of a fourth embodiment of an inductor component 400, which comprises a coil body 410 having a hollow winding body 411, on the surface of which an electrical conductor is arranged. For the sake of simplicity of illustration, two electrical conductors are shown in FIG. Fig. 8A Unlike the embodiments of the coil bodies 110, 210 and 310 shown in the previous figures, which have a rectangular cross section, the coil body 410 has a circular cross section. The inductor has a magnetic core 420, which is arranged in the cavity 1 of the winding body 411 in the assembled state of the inductor. The magnetic core 420 is designed as a rod core according to the embodiment 400.

[0054] In addition, the inductor device has a protective body 430, which has a covering element 431 for protecting two electrical conductors. The coil body 410 is fixed on the protective body 430 in the assembled state. Here, the electrical conductor arranged on the coil body is surrounded by the covering element 431. The coil body 410 has a contact area 415 for applying a voltage and for contacting the electrical conductor. The protective body 430 includes a receiving area 434 for receiving the contact area 415.

[0055] Figure 8BAn inductor device in a combined state according to embodiment 400 is shown. The coil body 410 is placed in the protective body 430 so that the protective body surrounds the coil body. Two electrical conductors arranged on the coil body 410 are surrounded by the covering element 431. In addition, the contact area 415 is arranged in the accommodating area 434 of the protective body 430. A cavity is formed between the two electrical conductors and the covering element 431, and the casting material 20 is filled into the cavity. After the casting material, which is first a fluid, hardens, the electrical conductor is embedded in the casting material. The casting material can also be in contact with the winding body 411. The magnetic core 420 has no contact or no direct adhesive contact with the casting material.

[0056] In order to prevent the casting material from flowing out of the cavity between the two electrical conductors and the covering element 431 of the protective body 430, the winding body 411 is fixed to the protective body 430 in a self-sealing manner. The winding body 411 can have a winding area 412 for winding with two electrical conductors, and a fixing area 413 for fixing the coil body 420 to the protective body 430. The fixing area 430 can be arranged on both sides of the winding area 412. In order to achieve a self-sealing connection between the winding body 411 and the protective body 430, a notch and tongue connection can be formed between the fixing area 413 and the protective body 430.

[0057] The covering element 431 may have a bottom portion 432, which is opposite to the electrical conductor. In addition, the covering element 431 may have side portions 433 on both sides of the bottom portion. The winding body 420 includes a flange 414 for limiting the winding area 412. According to a possible embodiment, in order to realize the groove and tenon connection, the flange 414 may have a recess 30, and the side portion 433 may have a bridge portion 40. According to another embodiment, the flange 414 may have a bridge portion 40, and the side portion 433 may have a recess 30, respectively. The coil body 410 is fixed to the protective body 430 in a self-sealing manner, in which each of the bridge portions 40 engages into one of the recesses 30.

[0058] Figures 9A to 9CA fifth embodiment 500 of an inductor device is shown in an exploded view. The inductor device comprises a coil body 510 having a hollow winding body 511, and a magnetic core 520 arranged in a cavity 1 of the winding body 511. The winding body 511 comprises: an inner partial body 511a having a winding area 512 for winding with a first electrical conductor 10a of two electrical conductors; and an outer partial body 511b having a winding area 512 for winding with a second electrical conductor 10b of two electrical conductors. The inner partial body 511a has a cavity 1 for accommodating the magnetic core 520. The outer partial body 511b has a cavity 3, and the inner partial body 511 is arranged in the cavity 3 in the assembled state of the device. The magnetic core 520 is configured as a PQ core having a partial body 521 and a partial body 522. The two partial bodies have an inner leg 523 and an outer leg 524, respectively.

[0059] In order to manufacture the inductor device, the inner part body 511a wound with the electric conductor 10a is moved into the cavity 3 of the outer part body 511b. The outer part body 511 has a contact area 515 for contacting the electric conductors 10a and 10b and for applying a voltage to the electric conductors. Contact pins 516 for applying a voltage to the electric conductors 10a and 10b are arranged on the contact area 515.

[0060] After the inner body part 511 a has been moved into the cavity 3 of the outer body part 511 b , a cavity 4 is formed between the electrical conductor 10 a and the outer body part 511 b . Fig. 9B The cross section of the inductor component in the assembled state is shown. The cavity 4 between the electrical conductor 10a and the outer partial body 511b is filled with a casting material 20, which then hardens. The connection between the inner and outer partial bodies of the winding body 511 is made by a notch and tongue connection 513 in the region of the flange 514 of the two partial bodies 511a, 511b of the winding body 511. The notch and tongue system 513 is designed to prevent the casting material 20 from flowing out of the cavity 4.

[0061] After the coil body is assembled and cast, the two core halves 521 and 522 are connected to each other by inserting the corresponding inner legs 523 of the core halves 521 and 522 from different sides into the cavity 1 of the partial body 511a. The inner and outer legs can be glued to each other at their end faces.

[0062] Fig. 9CThe inductor is shown in the assembled state. The two outer legs 524 of the two core halves at least partially surround the outer part body 511b of the coil body 512. As in the previous embodiments of the inductor, the magnetic core 520 is also decoupled from the casting material 20 in the embodiment 500, so that stresses caused by different temperature behavior between the core material and the casting material are avoided in the core material.

[0063] In the above-mentioned preferred embodiment, the connection between the coil body and the protective body or the casting container is constructed in a self-sealing manner so that the casting material cannot flow out of the casting container. If the gap between the casting container and the coil body should not be completely sealed and therefore casting material still flows out during casting, the core subsequently placed in the cavity of the coil body still has no adhesive contact with the casting material. The core can be bonded to the coil body at several locations. Here, even if bonding with the casting material occurs, there is still no direct adhesive contact between the casting material and the core, because there is an adhesive layer between the core and the coil body / casting material. Due to the small number of locally limited bonding locations, the mechanical force influence of the casting material on the core is very small.

[0064] Except in Figures 1 to 9C In addition to the embodiment of the inductor with a protective body shown in FIG, the protective body can be removed again after the casting material has hardened but before the core is placed, so that the inductor has a coil body with an electrical conductor completely surrounded by the casting material, and a core. The conductors are isolated from each other and from the core galvanically. The core itself has only a small amount of direct contact with the cast winding body. The mechanical influence of the casting material on the core is also very small in this embodiment.

[0065] Reference numerals list

[0066] 1. The cavity of the winding body

[0067] 2 Cavity to be filled with casting material

[0068] 10a, 10b Electrical conductor

[0069] 20 Casting materials

[0070] 100 First Implementation Method of Inductor Device

[0071] 110 Coil body

[0072] 120 Magnetic core

[0073] 130 Protect the body

[0074] 200 Second Implementation Method of Inductor Device

[0075] 210 Coil body

[0076] 220 core

[0077] 230 Protect the main body

[0078] 300 Third Implementation Method of Inductor Device

[0079] 310 Coil body

[0080] 320 core

[0081] 330 Protect the body

[0082] 400 Fourth Implementation Method of Inductor Device

[0083] 410 Coil body

[0084] 420 core

[0085] 430 Protect the body

[0086] 500 Fifth Implementation Method of Inductor Device

[0087] 510 Coil body

[0088] 520 core.

Claims

1. An inductor device, comprising: - at least one electrical conductor (10a, 10b); - a coil body (110, 210, 310, 410, 510) having a hollow winding body (111, 211, 311, 411, 511) on the surface of which the at least one electrical conductor (10a, 10b) is wound around the winding body (111, 211, 311, 411, 511) and having a flange (114, 214, 314, 414); - a magnetic core (120, 220, 320, 420, 520) arranged in the cavity (1) of the winding body (111, 211, 311, 411); - a protective body (130, 230, 330, 430) having a covering element (131, 231, 331, 431) with side portions (133, 233, 333, 433); - wherein the at least one electrical conductor (10a, 10b) is surrounded by a casting material (20), and the casting material (20) has no direct adhesive contact with the magnetic core (120, 220, 320, 420, 520); - wherein the flange (114, 214, 414) and the protective body (130, 230, 330, 430) are fixed to each other by a notch and tenon connection; - wherein the flanges (114, 214, 314, 414) each have two ribs spaced apart from each other, a depression (30) being formed between the ribs, and the side parts (133, 233, 333, 433) each have a bridge (40); - wherein the coil body (110, 210, 310, 410) is fixed to the protective body (130, 230, 330, 430) in such a way that each of the bridges (40) engages in one of the recesses (30); - wherein the corresponding bridge (40) of the side portion (133, 233, 333, 433) does not reach the bottom of the corresponding recess (30) in the flange (114, 214, 314, 414); - wherein a first one of the ribs, which is arranged closer to the winding area than a second one of the ribs, has a greater height than the second one of the ribs; - wherein the magnetic core (120, 220, 320) comprises a first partial body (121, 221, 321) and a second partial body (122, 222, 322), wherein the first partial body (121, 221, 321) and the second partial body (122, 222, 322) are connected to each other; - wherein at least one of the first and second partial bodies of the magnetic core (120, 220, 320) has: a leg (123, 223, 323) arranged in the cavity (1) of the winding body (111, 211, 311); and at least one further leg (124, 224, 324) arranged outside the cavity (1) of the winding body (111, 211, 311); The first part body (121, 221, 321) and the second part body (122, 222, 232) of the magnetic core (120, 220, 320) are configured as a U-shaped core, or the first part body (321) of the magnetic core (320) is configured as a U-shaped core having a leg (323), wherein the leg (323) is arranged in the cavity (1) of the winding body (311), and the second part body (322) of the magnetic core (320) is configured as an I-shaped core.

2. The inductor device according to claim 1, The casting material (20) is in contact with the winding body (111, 211, 311, 411, 511).

3. The inductor device according to claim 1 or 2, The coil body (110, 210, 310, 410) is fixed on a protective body (130, 230, 330, 430), and the at least one electric conductor (10a, 10b) is covered by a covering element (131, 231, 331, 431).

4. The inductor device according to claim 3, A cavity (2) is formed between the at least one electrical conductor (10a, 10b) and the covering element (131, 231, 331, 431), the cavity (2) being at least partially filled with a casting material (20).

5. The inductor device according to claim 3, - wherein the winding body (111, 211, 311, 411) has a winding region (112, 212, 312, 412) for winding at least one electrical conductor (10a, 10b), and a fixing region (113, 213, 313, 413) for fixing the coil body (120, 220, 320, 420) to the protective body (130, 230, 330, 430); - wherein the fixing region (113, 213, 313, 413) is arranged laterally of the winding region (112, 212, 312, 412).

6. The inductor device according to claim 3, wherein the coil body (110, 210, 310, 410) and the protective body (130, 230, 330, 430) are constructed so that the winding body (111, 211, 311, 411) is fixed to the protective body (130, 230, 330, 430) in a self-sealing manner and prevents the casting material (20) from flowing out of the cavity (2) between the at least one electrical conductor (10a, 10b) and the covering element (131, 231, 331, 431) of the protective body (130, 230, 330, 430).

7. An inductor device according to claim 5 or 6, wherein the fixing area (113, 213, 313, 413) and the protective body (130, 230, 330, 430) are shaped so that the groove and tenon connection is formed between the fixing area (113, 213, 313, 413) and the protective body (130, 230, 330, 430) for fixing the coil body (120, 220, 320, 420) on the winding body (111, 211, 311, 411).

8. The inductor device according to claim 6, - wherein the covering element (131, 231, 331, 431) has a bottom portion (132, 232, 332, 432) opposite to the at least one electrical conductor (10a, 10b) and has side portions (133, 233, 333, 433) on both sides of the bottom portion; - wherein the winding body (111, 211, 311, 411) has a flange (114, 214, 314, 414) for limiting the winding area (112, 212, 312, 412); - wherein either the flanges (114, 214, 314, 414) each have a recess (30) and the side parts (133, 233, 333, 433) each have a bridge (40), or the flanges (114, 214, 314, 414) each have a bridge (40) and the side parts (133, 233, 333, 433) each have a recess (30); - wherein the coil body (110, 210, 310, 410) is fixed to the protective body (130, 230, 330, 430) in such a way that each of the bridges (40) engages in one of the recesses (30).

9. An inductor device, comprising: - at least one electrical conductor (10a, 10b); - a coil body (110, 210, 310, 410, 510) having a hollow winding body (111, 211, 311, 411, 511) on the surface of which the at least one electrical conductor (10a, 10b) is wound around the winding body (111, 211, 311, 411, 511) and having a flange (114, 214, 314, 414); - a magnetic core (120, 220, 320, 420, 520) arranged in the cavity (1) of the winding body (111, 211, 311, 411); - a protective body (130, 230, 330, 430) having a covering element (131, 231, 331, 431) with side portions (133, 233, 333, 433); - wherein the at least one electrical conductor (10a, 10b) is surrounded by a casting material (20), and the casting material (20) has no direct adhesive contact with the magnetic core (120, 220, 320, 420, 520); - wherein the flange (114, 214, 414) and the protective body (130, 230, 330, 430) are fixed to each other by a notch and tenon connection; - wherein the flanges (114, 214, 314, 414) each have two ribs spaced apart from each other, a depression (30) being formed between the ribs, and the side parts (133, 233, 333, 433) each have a bridge (40); - wherein the coil body (110, 210, 310, 410) is fixed to the protective body (130, 230, 330, 430) in such a way that each of the bridges (40) engages in one of the recesses (30); - wherein the corresponding bridge (40) of the side portion (133, 233, 333, 433) does not reach the bottom of the corresponding recess (30) in the flange (114, 214, 314, 414); - wherein a first one of the ribs, which is arranged closer to the winding area than a second one of the ribs, has a greater height than the second one of the ribs; - wherein the winding body (511) comprises: an inner partial body (511a) having a winding area (512) for winding a first electrical conductor (10a) of the at least one electrical conductor; and an outer partial body (511b) having a winding area (512) for winding a second electrical conductor (10b) of the at least one electrical conductor; - wherein the inner part body (511a) has a cavity (1) for accommodating a magnetic core (520); - wherein the outer partial body (511b) has a cavity (3) in which the inner partial body (511a) is arranged; - wherein the cavity (4) between the first electrical conductor (10a) and the outer part body (511b) is at least partially filled with a casting material (20); The magnetic core (520) is configured as a PQ core having: an inner leg (523) arranged in a cavity (1) of an inner partial body (511a) of a coil body (510); and an outer leg (524) at least partially surrounding an outer partial body (511b) of the coil body (510).

10. An inductor device, comprising: - at least one electrical conductor (10a, 10b); - a coil body (110, 210, 310, 410, 510) having a hollow winding body (111, 211, 311, 411, 511) on the surface of which the at least one electrical conductor (10a, 10b) is wound around the winding body (111, 211, 311, 411, 511) and having a flange (114, 214, 314, 414); - a magnetic core (120, 220, 320, 420, 520) arranged in the cavity (1) of the winding body (111, 211, 311, 411); - a protective body (130, 230, 330, 430) having a covering element (131, 231, 331, 431) with side portions (133, 233, 333, 433); - wherein the at least one electrical conductor (10a, 10b) is surrounded by a casting material (20), and the casting material (20) has no direct adhesive contact with the magnetic core (120, 220, 320, 420, 520); - wherein the flange (114, 214, 414) and the protective body (130, 230, 330, 430) are fixed to each other by a notch and tenon connection; - wherein the flanges (114, 214, 314, 414) each have two ribs spaced apart from each other, a depression (30) being formed between the ribs, and the side parts (133, 233, 333, 433) each have a bridge (40); - wherein the coil body (110, 210, 310, 410) is fixed to the protective body (130, 230, 330, 430) in such a way that each of the bridges (40) engages in one of the recesses (30); - wherein the corresponding bridge (40) of the side portion (133, 233, 333, 433) does not reach the bottom of the corresponding recess (30) in the flange (114, 214, 314, 414); - wherein a first one of the ribs, which is arranged closer to the winding area than a second one of the ribs, has a greater height than the second one of the ribs; - wherein the coil body (410) has a circular cross-section; - wherein the magnetic core (420) is designed as a rod core.

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