Device with winding carrier and core and method for manufacturing a device

Abstract

A device (1) comprising a winding carrier (2), at least one winding (3), a magnetic core (7), and a first and a second terminal (5, 6). The winding carrier (2) encloses the core (7) at least in a plurality of regions, such that an insulation path (29) between the terminals (5, 6) does not comprise a bridging through the core (7) along an underside (14) of the device (1). In particular, the underside (14) of the winding carrier (2) is in closed form.

Description

Technical Field

[0001] This invention relates to a device comprising a winding carrier with windings and a magnetic core. For example, it is a transformer. It can also be another device having a magnetic core. Background Technology

[0002] In the case of electrical installations such as transformers, the specified insulation distances between electrical terminals must be observed, particularly according to IEC standards. These insulation distances, i.e., the shortest possible creepage distance and / or clearance distance along the insulating material between terminals, must be sufficiently large. For example, the insulation distance between terminals on the power supply side and terminals on the user side must be observed.

[0003] Insulation paths can be bridged via conductive cores, necessitating a corresponding increase in the distance between terminals. For example, at operating altitudes above 4 km above sea level, long clearances are required. To ensure sufficient insulation paths, the distance from the electrical terminal to the core is typically chosen to be appropriately large. This results in an undesirable increase in device size, particularly due to the sum of the core size and the required insulation path.

[0004] To prevent bridging of the insulation path, the core itself can also be encapsulated in a plastic housing and mounted in an insulating manner within the device. It is also known to cast components, for example, with a wound toroidal core, as a single unit, so that only the terminals emerge from the casting. However, this has disadvantages in terms of cost and component size.

[0005] It is also known from document US 9,646,755B2 that the coil and core are inserted together into a housing with an opening on one side to insulate the core from the terminal pins and thus increase the gap distance. The wire ends are then guided from the winding to the pins via the outside of the housing. Summary of the Invention

[0006] The object of the present invention is to provide an improved apparatus and a method for manufacturing the apparatus.

[0007] According to a first aspect of the invention, an apparatus includes a winding carrier and at least one winding arranged around the winding carrier. The winding may be, for example, a winding of wire, such as round or flat wire, or it may be a printed winding. The winding carrier is particularly made of an electrically insulating material. For example, it is a plastic material. The winding carrier is specifically used for positioning the winding. In particular, the winding is wound directly on an area of ​​the winding carrier. The winding carrier, for example, has a one-piece design. In particular, the winding carrier can be manufactured by injection molding.

[0008] Furthermore, the device includes a magnetic core. For example, the core may comprise a ferrite material. Specifically, the magnetic core surrounds a region of the assembly. For example, the core forms a closed magnetic circuit. The core may include multiple core portions. For example, the core may include I-shaped core components and U-shaped core components. Other core shapes are also possible. For example, the core portions may be glued together.

[0009] The device includes at least one first electrical terminal and at least one second electrical terminal. The device is configured, for example, as a transformer. The first electrical terminal is formed, for example, on the primary side, and the second terminal is formed on the secondary side. The first terminal may be a terminal on the power supply side, while the second terminal may be a terminal on the user side.

[0010] The device may have multiple first terminals and multiple second terminals. The terminals may be in the form of pins, for example. For example, the first terminals may be arranged side-by-side in a first row, and the second terminals may be arranged side-by-side in a second row. The first terminals may be electrically connected to ground, for example, with one or more first windings, and the second terminals may be electrically connected to ground with one or more second windings. The terminals may be arranged, for example, in the lower region of the winding carrier. The first and second terminals may be arranged, for example, at opposite edges of the winding carrier. The terminals may be directly attached to the winding carrier. For example, the terminals may be co-injection molded in an injection molding process.

[0011] The winding carrier is designed as at least part of the insulation for the core. Therefore, no additional insulation is required for the core. In particular, no separate casting or separate housing is required for the core.

[0012] Specifically, the winding carrier at least partially surrounds the core such that the insulation path between the terminals along the underside of the device does not include bridging through the core. This insulation path represents the shortest possible gap and / or creepage path. For example, the minimum creepage distance therefore does not extend to the core, but only along the winding carrier.

[0013] For example, the core is surrounded by the winding carrier such that the sum of the insulation path between the first terminal and the core and the insulation path between the second terminal and the core is at least as large as the geometric distance between the first terminal and the second terminal.

[0014] Therefore, the winding carrier insulates the core from the terminals, ensuring that the insulation path between the terminals is not shortened due to the presence of the core. By insulating the core, component size can be reduced. For example, it is sufficient to arrange the terminals at a distance equal to the minimum insulation distance. Component size can be minimized without considering bridging of the insulation path through the core.

[0015] For example, the winding carrier includes a lower side. The lower side is the mounting side of the winding carrier or device, i.e., the side facing, for example, a printed circuit board on which the winding carrier can be mounted. A first terminal is arranged, for example, at a first edge in a view of the lower side, and a second terminal is arranged at an opposite second edge. The winding carrier, for example, does not include cutouts on the lower side that expose the core. In particular, no such cutouts are provided in the area laterally defined by the first and second terminals. This prevents the insulation path between the terminals along the lower side from including bridging through the core.

[0016] However, it is possible that the core extending beyond the terminals, i.e., the core guided away from the center of the device, is not surrounded by the winding carrier. However, this will not result in bridging of the insulation path between the terminals.

[0017] The winding carrier may include at least one opening through which the core or a core component of the core can be inserted into the winding carrier. For example, there is no such opening on the lower side. This allows for a closed design of the winding carrier at the lower side.

[0018] In one embodiment, at least one opening is arranged in the side surface of the winding carrier. Therefore, the core can be inserted laterally into the winding carrier. Furthermore, the winding carrier may also include at least one opening on its upper side. For example, the winding carrier includes an opening on its side surface and an opening on its upper side. Two core components can be inserted through the openings. For example, an I-shaped core component is inserted through one of the openings, and a U-shaped core component is inserted through the other opening.

[0019] In another embodiment, the winding carrier may include one or more openings for inserting the core only on its upper side. Thus, the side surfaces of the winding carrier can further insulate the core, since the openings are not required. Therefore, in the case of multiple core components, all core components are inserted into the winding carrier from the upper side. For example, a first core component may be inserted first through the opening on the upper side, then winding may be applied, and then a second core component may be inserted.

[0020] If the opening in the winding carrier is properly positioned, the core can be surrounded by the winding carrier not only on the underside but also on the sides. Therefore, bridging of the insulation path by the core can be prevented particularly well. For example, the core can be completely insulated from the outside by the winding carrier on at least one side. The core can also be completely insulated from the outside by the winding carrier on two or more sides.

[0021] Depending on the design of the housing surrounding the core, the insulation can be symmetrical or asymmetrical relative to the terminals. For example, the housing increases the insulation path between the core and one of the terminals. It is also possible to increase the insulation path between the core and both terminals.

[0022] For example, a first terminal is disposed on a first side of the winding carrier, and a second terminal is disposed on a second side of the winding carrier. For example, the core is completely surrounded by the winding carrier on at least one of these sides. Therefore, no bridging through the insulation path of the core is formed along that side. Alternatively, the core may not be completely surrounded on the side, but only to a major extent. For example, a smaller portion of the core may be exposed at the upper end of the side.

[0023] The winding carrier may include a leading through along the winding axis. The core may be disposed in this leading through. Furthermore, by being disposed in the leading through, the core is insulated from the winding carrier outward, for example, laterally.

[0024] According to an embodiment, at least one of the terminals is arranged to be recessed. For example, a recessed terminal is attached to a region on the side of the winding carrier that is recessed inward relative to another region on the side. This reduces the component size. The reduced distance between the first and second terminals is possible due to the insulation of the core while maintaining a minimum insulation distance. For example, the spacing between the terminals can be equal to the minimum insulation spacing. Therefore, the overall component size can also be limited to a minimum insulation dimension.

[0025] According to another aspect of the invention, the device includes a winding carrier and at least one winding of wires arranged around the winding carrier. The device includes a magnetic core and at least first and at least second electrical terminals, wherein the winding carrier includes a lower side, and the terminals are arranged opposite to each other relative to the lower side. The winding carrier does not include a cutout at least in the lower side region laterally defined by the first and second terminals, through which the core is exposed. The device may include all the structural and functional features of the aforementioned device.

[0026] The enclosed form of the winding carrier on the lower side insulates the core from the terminals on the lower side, and the safety gap in this area is not bridged by the core.

[0027] According to another aspect of the invention, a method for manufacturing an apparatus is provided. The apparatus and all its components, such as winding carriers, terminals, and cores, can be constructed as described above.

[0028] According to the method, a winding carrier is provided, the winding carrier including one or more openings on the side and / or top side. A first core component is inserted into the winding carrier through one of the openings. A second core component is inserted into the winding carrier through one of the openings. The second core component may be inserted through the same opening as the first core component or through a different opening. Thus, the core components are inserted through the openings on the side and / or top side of the winding carrier, but not through the openings on the bottom side of the winding carrier. Therefore, the bottom side may be configured without such an opening.

[0029] For example, one of the core components is I-shaped, while another is U-shaped. After insertion into the winding carrier, the core components can form a closed magnetic circuit. For example, after insertion, the core components are glued together.

[0030] In one embodiment, one of the core components is inserted through an opening on the side, and another core component is inserted through an opening on the top side. In this case, the winding can be wound onto the winding carrier before the insertion of both core components. For example, the winding mandrel is inserted into the winding carrier through one of the openings on the top side and is removed after winding.

[0031] In one embodiment, two core components are inserted through the same opening on the upper side. For example, the first core component is arranged in the winding carrier along the winding axis. For example, after the first core component is inserted, a winding is applied to the winding carrier. For example, the winding is applied around the winding carrier and the core. Subsequently, the second core component is inserted.

[0032] If the winding axis is occupied by the first core component before the winding is applied, the winding mandrel cannot be inserted into the winding axis. For example, the winding carrier includes a retaining device on its outer surface, by which the winding carrier can be secured in the winding machine.

[0033] The present invention includes several aspects, particularly apparatus and methods. Embodiments described for one aspect are correspondingly applicable to the other aspects.

[0034] Furthermore, the purpose of this disclosure is not limited to any single specific embodiment. Rather, features of individual embodiments may be combined with each other to the extent technically useful. Attached Figure Description

[0035] The subject matter described herein will now be explained in more detail by way of illustrative embodiments.

[0036] They show:

[0037] Figure 1A An embodiment of the device is shown in cross-sectional view.

[0038] Figure 1B Shown from an angled upward view Figure 1A The device,

[0039] Figure 1C Shown in a view from the bottom angle Figure 1A The device,

[0040] Figure 2 Another embodiment of the device is shown in an oblique, top-down view.

[0041] Figure 3AAn embodiment of the winding carrier is shown in an oblique, top-down view.

[0042] Figure 3B A longitudinal cross-sectional view is shown. Figure 3A The winding carrier,

[0043] Figure 4A Another embodiment of the device is shown in a side view from an oblique angle.

[0044] Figure 4B Shown from a diagonally above view on another side. Figure 4A The device,

[0045] Figure 4C Shown in a view from the bottom angle Figure 4A The device,

[0046] Figure 4D Shown in top view Figure 4A The device,

[0047] Figure 5 Another embodiment of the device is shown in a side view from an obliquely upward angle.

[0048] Figures 6A to 6E It shows the manufacturing process. Figure 5 Method steps for the components of the device,

[0049] Figure 7 Another embodiment of the device is shown in a side view from an oblique angle. Detailed Implementation

[0050] Preferably, in the following figures, the same reference numerals denote functionally or structurally corresponding parts of various embodiments.

[0051] Figure 1A An embodiment of device 1 is shown in longitudinal section. Figure 1B The device 1 is shown in a view from an angle above. Figure 1C The device 1 is shown in a view from the lower left.

[0052] For example, device 1 is configured as a transformer. Device 1 can also be configured as a device with different functions, especially in which maintaining an insulating path between electrical terminals is particularly important.

[0053] The device 1 includes a winding carrier 2 around which at least one winding 3 of a conductor 4 is wound. The winding 3 is arranged vertically, i.e., its axis is arranged perpendicular to the lower side 14 of the device 1. The lower side 14 corresponds to the mounting side of the device 1, for example, when fixed to a printed circuit board. The winding carrier 2 is formed of an electrically insulating material. The winding carrier 2 is also formed, for example, in a non-magnetic manner. The winding carrier 2 can be formed of a plastic material. For example, the winding carrier 2 is manufactured by injection molding.

[0054] Multiple windings, particularly one or more primary windings and one or more secondary windings of a transformer, can be applied around the winding carrier 2. The same applies to multiple windings as to the case of a single winding. The winding carrier 2 includes flange-shaped boundaries 10, 11 on both sides, between which the winding 3 is arranged.

[0055] Conductor 4 comprises a metallic material, such as copper. Conductor 4 is covered by an insulating element, such as triple insulation (TIW – “triple insulated conductor”). Therefore, conductor 4 or winding 3 does not need to be separately covered or additionally insulated.

[0056] The device 1 includes at least a first terminal 5 and a second terminal 6. Terminals 5 and 6 are directly attached to the winding carrier 2, for example, by co-injection molding when the winding carrier 2 is manufactured in an injection molding process. The wire ends of the winding 3 are connected to terminals 5 and 6. Currently, a plurality of first terminals 5 are arranged in a row, and a plurality of second terminals 6 are arranged in a row. The first terminals 5 and the second terminals 6 are arranged on opposite sides 16 and 24 of the device 1.

[0057] In this respect, all first terminals 5 can be primary-side terminals, i.e., power supply-side terminals, and all second terminals 6 can be secondary-side terminals, i.e., user-side terminals. For example, first terminals 5 are used to connect to the power supply network, while second terminals 6 are used to connect to the user, such as a refrigerator. For example, each of the two first terminals 5 is connected to a first primary-side winding, and the two second terminals 6 are connected to a secondary-side winding.

[0058] Device 1 includes a magnetic core 7. Core 7 comprises, for example, a ferrite material or another magnetic material. Core 7 is not formed as a winding carrier itself, but is a separate element attached to the winding carrier 2. Core 7 also differs from the winding carrier 2 in its material. In particular, core 7 has a higher conductivity than the winding carrier 2.

[0059] In the current configuration, core 7 is made of several components. The first core component 8 comprises an I-shape. The second core component 9 comprises a U-shape. Core components 8 and 9 may also comprise another shape; for example, the two core components 8 and 9 may be U-shaped. The core components 8 and 9 together form a closed magnetic circuit. For example, core components 8 and 9 may be glued together.

[0060] The magnetic core 7 typically has a higher conductivity than the winding carrier 2 and can cause electrical bridging of the insulation path between the first and second terminals 5, 6. Therefore, the core 7 does not contribute to the insulation path between the first and second terminals 5, 6, and thus must comply with an insulation gap separate from the core 7.

[0061] Here, the insulation path 28 between the first and second terminals 5, 6 refers specifically to the shortest creepage distance along the surface of component 1 between terminals 5, 6 and / or the shortest gap distance between terminals 5, 6. For such an insulation path, a minimum length must be observed, for example, according to IEC standards. In the case of multiple first terminals 5 and multiple second terminals 6, the insulation path is the shortest among all the insulation paths between all the first terminals 5 and all the second terminals 6. In other words, the conditions mentioned herein regarding gaps and insulation paths can be applied to any pair of first terminals 5 and second terminals 6.

[0062] exist Figure 1B In this diagram, a first insulating path 12 is shown between the core 7 and the first terminal 5. Additionally, a second insulating path 13, particularly the shortest air gap, is shown between the core 7 and the second terminal 6. In this document, the insulating path between the first and second terminals 5 and 6 along the upper side 15 of the device is the sum of the first and second insulating paths 12 and 13.

[0063] exist Figure 1C The device 1 is shown in view on its lower side 14. The winding carrier 2 is closed at the bottom. Specifically, there is no cutout on the lower side 14 through which the core 7 protrudes from the winding carrier 2, or through which the core 7 can be pushed into the winding carrier 2. Thus, the core 7 is insulated by the winding carrier 2 on the lower side 14 in the region between the first and second terminals 5, 6. The arrangement of the core 7 within the winding carrier 2 ensures space-saving insulation. The core 7 protrudes only laterally from the winding carrier 2. At least in the region of the lower side 14 laterally defined by the first and second terminals 5, 6, the winding carrier 2 does not include a cutout through which the core 7 is exposed.

[0064] Thus, the insulation path 28 along the lower side 14 between the second terminals 6 is not bridged by the core 7. As can be seen, the insulation path 29 from the second terminal 6 to the core 7 is increased by the enclosure of the insulating winding carrier 2. Therefore, the core 7 is insulated from the external portion by the winding carrier 2, such that the minimum creepage distance or gap distance between the first and second terminals 5, 6 along the lower side 14 of the device 1 does not include bridging through the core. Therefore, the core 7 does not bridge or shorten the insulation path between the terminals 5, 6.

[0065] Therefore, at the lower side 14, core 7 does not affect the insulation path 28 between terminals 5 and 6, allowing the size of device 1 to be reduced. In particular, at the lower side 14, the distance d between the first terminal 5 and the second terminal 6 can be minimized to the minimum insulation distance. It is only necessary to ensure that the required minimum insulation distance is maintained along the upper side 15, even when bridging through core 7.

[0066] Specifically, the core 7 is surrounded by the winding carrier 2 such that the sum of the insulation path 12 between the first terminal 5 and the core 7 and the insulation path 13 between the second terminal 6 and the core 7 is at least as large as the geometric distance between the first terminal 5 and the second terminal 6.

[0067] On the lower side, the winding carrier also includes a recess 23 through which the insulation path 29 between the second terminal 6 and the core 7 can be extended.

[0068] The core 7 protrudes from the winding carrier 2 only at the side 16 of the winding carrier 2. Specifically, the winding carrier 2 includes a first opening 17 at the side 16 (see...). Figure 3A , 3B The core 7 protrudes from the winding carrier 2 through the first opening. Furthermore, the winding carrier 2 includes a second opening 18 at its upper side 15 (see...). Figure 3A , 3B The core 7 protrudes from the winding carrier 2 through the second opening.

[0069] Core 7 protrudes into the first opening 17, is guided through the winding carrier 2 via the guide member 19, and exits from the winding carrier 2 through the second opening 18. Guide member 19 (see...) Figure 3A , 3B The core 7 extends along the winding axis in the first region 30 and parallel to the lower side 14 in the second region 31. Within the inlet 19, i.e., from the first opening 17 to the second opening 18, the core 7 is enclosed by the winding carrier 2 without interruption.

[0070] exist Figure 1A , Figure 1B , Figure 1C In this embodiment, the core 7 is asymmetrically arranged and insulated relative to the winding carrier 2 and the terminals 5, 6. Therefore, the insulation path 12 between the core 7 and the first terminal 5 is small, but the insulation path 13 between the core 7 and the second terminal 6 is quite large.

[0071] The first core component 8 is I-shaped, and the second core component 9 is U-shaped. The I-shaped first core component 8 is arranged parallel to the lower side 14. The U-shaped second core component 8 has legs arranged along the winding axis. In other embodiments, the I-shaped first core component may be arranged along the winding axis, while the U-shaped second core component may be arranged such that its legs are parallel to the lower side. For example, both core components 8 and 9 may also be U-shaped.

[0072] The method for manufacturing apparatus 1 is described below.

[0073] A winding carrier 2 is provided, and a winding 3 is applied to the winding carrier 2. For this purpose, for example, a winding mandrel (not shown here) is inserted into the first opening 17 (see...). Figure 3A , 3B After applying winding 3, the winding mandrel is removed, and the I-shaped first core component 8 is inserted laterally into the first opening 17. Subsequently, the U-shaped second core component 9 is inserted from the upper side 15 into the second opening 18 (see...). Figure 3A , 3B The first and second core components 8 and 9 can be glued together.

[0074] Figure 2 Another embodiment of the device 1 is shown, which, compared with the above embodiment, includes two first terminals 5 on a first side 15 and four second terminals 6 on a second side 24.

[0075] The first terminal 5 is configured, for example, for connection to a power supply network, and the second terminal 6 is configured for connection to a user. The first terminal 5 is connected, for example, to a first winding 3, and the second terminal 6 is connected in pairs to two other windings 20. The first winding 3 is arranged, for example, above the second winding 20 in the direction of the winding axis. The second windings 20 are positioned, for example, one above the other, in the same location relative to the winding axis. Since the winding conductors are insulated from the outside, the windings 3 and 20 can also be arranged differently, for example, all in the same location relative to the winding axis.

[0076] The present invention is not limited to the number and arrangement of the first and second terminals and windings shown. For example, it may also consist of only two first terminals, two second terminals, and two windings.

[0077] In the same embodiment shown, the lower side 14 of the winding carrier 2 is completely closed, such that in order to maintain a minimum insulation path at the lower side 14 of the device 1, it is sufficient to select a distance between the opposite terminals 5 and 6 equal to the minimum insulation path.

[0078] Furthermore, the winding carrier 2 includes protrusions on its upper side 15, through which the creepage distance and clearance distance between the core 7 and the second terminal 6 along the upper side 15 are increased. A first protrusion 21 extends upward into the region of the winding carrier 2. A second protrusion 22 causes the winding carrier 2 to extend to one side. The two protrusions 21 and 22 are chosen such that they do not increase the external dimensions of the device 1.

[0079] Figure 3A An embodiment of the winding carrier 2 is shown in an obliquely upward view. Figure 3BThe winding carrier 2 is shown in longitudinal section. Except for the absence of additional protrusions 21, 22, the winding carrier 2 is essentially constructed as follows: Figure 2 2. Winding carrier.

[0080] The winding carrier 2 includes a first opening 17 on its side 16 and a second opening 18 on its upper side 15. Figure 3B In the cross-sectional view, the inlet member 19 can be seen. The inlet member 19 includes a first region 30 extending parallel to the winding axis (vertical in this case) and a second region 31 extending perpendicular to the winding axis. The second region 31 extends parallel to the lower side 14. The inlet member 19 is constructed in an integral L-shape. The inlet member 19 is completely surrounded by the winding carrier 2 and is therefore only accessible from the outside through the openings 17 and 18.

[0081] Figure 4A An embodiment of device 1 is shown in a side view from an oblique angle. Figure 4B The device is shown from a diagonally above view from the other side. Figure 4C The device is shown in a view from a slightly below-the-angle angle. Figure 4D The device is shown in a top view.

[0082] For clarity, device 1 is shown without winding. The winding is applied directly around the winding carrier 2 in finished device 1. In contrast to the previous embodiment, the winding axis extends parallel to the lower side 14 of device 1. The winding carrier 2 includes two flange-shaped boundaries 10, 11 that define the winding on both sides.

[0083] The first and second terminals 5 and 6 are directly mounted on the winding carrier 2. In the current case, there are only two first terminals 5 and two second terminals 6.

[0084] Here, core 7 also includes a first core component 8 in an I-shape and a second core component 9 in a U-shape (see...). Figure 4B The first core component 8 is arranged in the winding carrier 2 along the horizontal winding axis.

[0085] The winding carrier 2 completely surrounds the core 7 at the lower side 14. In this case, the lower region of the core 7, formed by the I-shaped core member 8, is almost entirely surrounded by the winding carrier 2 from all sides. Only the region of the I-shaped core member 8 pointing to the other side 24 is open. Facing the first side 16, the core 7 is completely insulated from the winding carrier 2 to the outside. Therefore, the core region is not visible from the view on the lower side 14 or the view on the side surface 16. Overall, the larger region of the core 7 is constructed within the winding carrier 2 and is thus arranged to be hidden and insulated from the terminals 5 and 6.

[0086] Therefore, the insulation path between the first and second terminals 5 and 6 along the lower side 14 of the device 1 is not bridged by the core 7. Depending on the geometry of the device 1, the insulation path between the first and second terminals 5 and 6, i.e., the minimum creepage distance or gap distance, extends along the lower side 14 or along the sides 16 and 24 of the device 1. Here, the sum of the insulation paths between the first terminal 5 and the core 7 and the second terminal 6 and the core 7 is at least as large as the geometric distance d between the first and second terminals 5 and 6.

[0087] Therefore, the distance d between the first terminal 5 and the second terminal 6 can be chosen to be equal to the minimum insulation distance. For example... Figure 4D As can be easily seen, the first and second terminals 5 and 6 are offset inward. In particular, the area of ​​the winding carrier 2 that anchors the terminals 5 and 6 is further inward than the area that laterally surrounds the core 7. Therefore, the winding carrier 2 is constructed in a stepped shape at the sides 16 and 24.

[0088] This allows for a further reduction in the size of component 1 without violating the required minimum insulation distance. This reduction in size is made possible by insulating core 7 relative to terminals 5 and 6 via winding carrier 2.

[0089] The method for manufacturing apparatus 1 is described below.

[0090] A winding carrier 2 is provided, and a winding is applied to the winding carrier 2 (not shown here). For this purpose, for example, a winding mandrel (not shown here) is inserted into the first opening 17. Figure 4B After the winding is applied, the winding mandrel is removed, and the I-shaped first core component 8 is inserted into the first opening 17. Then, the U-shaped second core component 9 is inserted into the second opening 18 from the upper side 15. The first and second core components 8 and 9 can be glued together.

[0091] In another embodiment, for example, an I-shaped core component can be inserted into the opening at the upper left end, and a U-shaped core component can be inserted laterally. The invention is not limited to I-shaped and U-shaped core components.

[0092] Figure 5 Another embodiment of device 1 is shown. Figures 6A to 6E The method for manufacturing the device is shown, and thus also shown Figure 5 The internal structure of device 1.

[0093] As in the above embodiment, the winding carrier 2 further forms a housing for the core 7 to insulate the core 7 from the first and / or second terminals 5, 6. The winding carrier 2 surrounds the core 7 from the lower side 14 such that an area of ​​the core 7 is not exposed between the terminals 5, 6. As in the embodiment described above... Figures 4A to 4DIn one embodiment, the core 7 is completely surrounded at the lower side 14, so that the area of ​​the core 7 is not exposed.

[0094] Here, core 7 also includes the first core component 8 ( Figure 5 ) and second core component 9 ( Figure 6A The first core component 8 is U-shaped, and the second core component 9 is I-shaped.

[0095] In contrast to the aforementioned embodiments, core 7 is entirely composed of two core components 8 and 9 (core component 8 is shown in the previous embodiment). Figure 6A The core 7 is inserted into the winding carrier 2 from the top 15. Specifically, the winding carrier 2 includes openings 18 only on the top 15 for inserting the two core components 8 and 9. At the sides 16 and 24, the core 7 is completely surrounded by the housing 2. The housing 2 also extends partially on the other two sides 25 and 26. The lower core component 8 is not visible from the outside. The upper core component 9 is visible only from the top.

[0096] Therefore, core 7 is similarly insulated from the first and second terminals 5 and 6. In particular, the insulation path between the first terminal 5 and core 7 has the same length as the insulation path between the second terminal 6 and core 7. In summary, there is a symmetrical distribution of insulation paths between core 7 and the first terminal 5, and between core 7 and the second terminal 6.

[0097] like Figure 6A As shown, a winding carrier 2 is provided during the manufacture of device 1. Terminals 5 and 6 are attached to the winding carrier 2. No winding is yet attached to the winding carrier 2. A U-shaped first core member 8 is inserted into the winding carrier 2 through an opening 18 at the upper side 15. Specifically, the first core member 8 is inserted into the winding axis of the opening in the winding carrier 2.

[0098] Figure 6B A winding carrier 2 with an inserted U-shaped first core member 8 is shown. The winding carrier 2 surrounds the first core member 8 at the lower side 14 and from all sides 16, 24, 25, 26. The first core member 8 is exposed only at the upper side 15. The wire 4 is then wound around the winding carrier 2, thereby applying the winding 3.

[0099] Figure 6C A winding carrier 2 with winding 3 is shown. The winding 3 is arranged horizontally such that the winding axis extends parallel to the lower side 14 of the device 1. The conductor ends of the winding 3 are guided to terminals 5 and 6 through guide slots in the winding carrier 2 and are electrically connected to terminals 5 and 6. For example, at terminals 5 and 6, the insulation layer is removed from the conductor, and the conductor is soldered or laser-welded to the corresponding terminals 5 and 6.

[0100] like Figure 6DAs shown, the second core component 9 is then inserted into the winding carrier 2 from the upper side 15 through the opening 18. In this example, the second core component 9 is I-shaped. However, core components 8 and 9 with different shapes can also be used, for example, both core components 8 and 9 can be U-shaped cores.

[0101] Figure 6E The finished device 1 is shown. A first core component 8 and a second core component 9 form a closed magnetic circuit. For example, the first core component 8 is glued to the second core component 9. The second core component 9 is completely surrounded by a winding carrier 2 at two sides 16 and 24. The winding carrier 2 fits tightly onto the core components 8 and 9, and thus defines the positions of the core components 8 and 9. Therefore, automatic and well-controlled arrangement and gluing of the core components 8 and 9 are possible.

[0102] Figure 7 It shows Figures 5 to 6E A variation of device 1. Here, the winding carrier 2 includes a lateral holding device 27 for securing the winding carrier 2 in the winding machine. The holding device 27 includes a web, and the two-part spindle can be attached to the winding carrier 2, for example, between the webs.

[0103] and Figures 1A to 4D In contrast to the embodiments, in Figures 5 to 7 In this embodiment, the winding carrier 2 does not include an opening through which the spindle can be inserted into the winding axis during winding production. The space is already occupied by the first core component 8, which is placed in the winding carrier 2 before the winding is applied.

[0104] List of reference numerals

[0105] 1 device

[0106] 2 winding carrier

[0107] 3 windings

[0108] 4 wires

[0109] 5 First terminal

[0110] 6 Second terminal

[0111] 7 cores

[0112] 8 First Core Component

[0113] 9 Second core component

[0114] 10 boundaries

[0115] 11 boundaries

[0116] 12 Insulation path between the first terminal and the core

[0117] 13. Insulation path along the side between the second terminal and the core

[0118] 14 lower side

[0119] 15 upper side

[0120] 16 sides

[0121] 17. Openings on the side

[0122] 18. Opening on the upper side

[0123] 19 Introduction

[0124] 20 additional windings

[0125] 21 First protrusion

[0126] 22 Second protrusion

[0127] 23 concavity

[0128] 24 Another side

[0129] 25 The other side face

[0130] 26 Another side

[0131] 27 Holding device

[0132] 28 Insulation path between the first and second terminals

[0133] 29. Insulation path along the lower side between the second terminal and the core

[0134] 30 Introduction Part First Area

[0135] 31. Second area of ​​the introduction component

[0136] d Distance.

Claims

1. An apparatus having a winding carrier (2) and a magnetic core (7), the apparatus further comprising: At least one winding (3) of the conductor (4) arranged around the winding carrier (2), At least one first electrical terminal (5) and at least one second electrical terminal (6), wherein the winding carrier (2) surrounds the magnetic core (7) in at least a plurality of regions such that the insulation path (29) between the first electrical terminal (5) and the second electrical terminal (6) along the lower side (14) of the device (1) does not include a bridging through the magnetic core (7). The magnetic core (7) includes a first core component (8) and a second core component (9). The winding carrier (2) includes an inlet (19), in which the magnetic core (7) is arranged. The winding carrier (2) includes a first opening (17) on the side (16, 24) for inserting a first core component (8) and a second opening (18) on the upper side (15) for inserting a second core component (9). The inlet (19) can be accessed from the outside only through the first opening (17) and the second opening (18).

2. The apparatus according to claim 1, in, The magnetic core (7) is surrounded by the winding carrier (2) such that the sum of the insulation path (12) between the first electrical terminal (5) and the magnetic core (7) and the insulation path (13) between the second electrical terminal (6) and the magnetic core (7) is at least as large as the geometric distance (d) between the first electrical terminal (5) and the second electrical terminal (6).

3. The apparatus according to any one of claims 1 and 2, wherein the apparatus is designed as a transformer, wherein, The first electrical terminal (5) is located on the primary side, and the second electrical terminal (6) is located on the secondary side.

4. The apparatus according to any one of claims 1 and 2, wherein, The lower side (14) of the winding carrier (2) does not include a cutout, through which the magnetic core (7) is exposed.

5. The apparatus according to any one of claims 1 and 2, wherein, One of the core components is I-shaped, and the other of the core components is U-shaped.

6. The apparatus according to any one of claims 1 and 2, wherein, The first electrical terminal (5) is arranged on the first side (16) of the winding carrier (2), and the second electrical terminal (6) is arranged on the second side (24) of the winding carrier (2), wherein the magnetic core (7) is completely or substantially surrounded by the winding carrier (2) at least in one of these sides (16, 24).

7. The apparatus according to any one of claims 1 and 2, wherein, At least one of the first electrical terminal (5) and the second electrical terminal (6) is arranged to be recessed in the lateral direction.

8. The apparatus according to any one of claims 1 and 2, wherein, The winding carrier (2) includes at least one opening (17) for inserting the magnetic core (7) on a side (16) on which at least one of the first electrical terminal (5) and the second electrical terminal (6) is disposed.

9. A method for manufacturing the apparatus according to any one of claims 1 to 8, comprising the following steps: A) Provide the winding carrier (2) and provide a first core component (8) and a second core component (9), B) Insert the first core component (8) into the first opening (17). C) Insert the second core component (9) into the second opening (18).

10. An apparatus having a winding carrier (2) and a magnetic core (7), the apparatus further comprising: At least one winding (3) of the conductor (4) arranged around the winding carrier (2), At least one first electrical terminal (5) and at least one second electrical terminal (6), wherein the winding carrier (2) includes a lower side (14), wherein the first electrical terminal (5) and the second electrical terminal (6) are arranged opposite to each other relative to the lower side (14), wherein the winding carrier (2) does not include a cutout, and the magnetic core (7) is exposed through the cutout at least in the region laterally defined by the first electrical terminal (5) and the second electrical terminal (6) on the lower side (14). The magnetic core (7) includes a first core component (8) and a second core component (9). The winding carrier (2) includes an inlet (19), in which the magnetic core (7) is arranged. The winding carrier (2) includes a first opening (17) on the side (16, 24) for inserting a first core component (8) and a second opening (18) on the upper side (15) for inserting a second core component (9). The inlet (19) can be accessed from the outside only through the first opening (17) and the second opening (18).

11. The apparatus according to any one of claims 1 and 10, in, The magnetic core (7) is completely or in the main portion surrounded by the winding carrier (2) at one of the sides (16, 24).

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