Magnetic component

Abstract

The invention relates to a magnetic component (1) comprising a multi-component bobbin (2) and at least one winding unit (3), the multi-component bobbin (2) further comprising a plurality of holding members (4) configured to hold the at least one winding unit (3) wherein the at least one winding unit (3) is pre-wound and comprises one or more coil winding turns, wherein at least one of the retaining members (4) comprises a cylindrical portion (5) which is inserted into at least one winding unit (3) along a longitudinal axis (6) of the winding unit (3) to be surrounded by the winding unit (3), and wherein the cylindrical portion (5) contacts and is attached to a separate retaining member via a form-fitting connection (70). The magnetic component (1) is easy to assemble and only needs fewer manufacturing steps, and the problem that a multi-component bobbin in the prior art is inconvenient and complex to assemble can be solved.

Description

Technical Field

[0001] The invention relates to a magnetic component comprising a multi-component bobbin and at least one winding unit. Background Art

[0002] Magnetic components comprising a multi-component bobbin and a winding unit are known in the prior art, for example for use in transformers. Examples of multi-component bobbin constructions are known from JP 2013-179259, US 6927650 B2 and JP 6479235 B1.

[0003] Typically, multi-component bobbins are used in applications where a single-component bobbin is not feasible for the winding process of the coil, for example, in the case of edge-wise winding, the use of a single-component bobbin may cause damage to the bobbin and / or the coil. Therefore, in such applications a multi-component bobbin may be used, and the coil is pre-wound on a separate device before being attached to the bobbin.

[0004] However, conventional multi-component spools have the disadvantage that assembly is awkward and complex. In some instances, additional gluing of the components is required. Summary of the invention

[0005] At least one object of the present invention is to overcome these drawbacks. In particular, it is an object of the present invention to provide a magnetic component comprising a multi-part bobbin and at least one winding unit which is easy to assemble and requires only a few manufacturing steps. Further objects and advantages of the present invention will be described below.

[0006] Specifically, solutions to these purposes can be achieved by embodiments of the present invention. A magnetic component according to an embodiment of the present invention includes a multi-component bobbin and at least one winding unit. Further, the multi-component bobbin includes a plurality of retaining components, and the plurality of retaining components are configured to retain at least one winding unit, wherein at least one winding unit is pre-wound and includes one or more coil winding turns. Preferably, at least one winding unit is pre-wound in a flat vertical style, that is, includes one or more flat vertical coil winding turns. Wherein, at least one of the retaining components includes a cylindrical portion, which is inserted into at least one winding unit along the longitudinal axis direction of the winding unit to be surrounded by it. Further, the above-mentioned cylindrical portion contacts and is attached to a separate retaining component through a shape-fitting connection.

[0007] Thus, the present invention provides a magnetic component that can be easily assembled.

[0008] In the above and below, the term "winding unit" refers to a coil winding. In order to distinguish it from a single winding (i.e. a "winding turn"), the term "winding unit" is chosen. Further, a winding unit comprises the above-mentioned coil winding turn and preferably comprises the two ends of the above-mentioned coil winding turn. In other words, a single coil comprising two coil (wire) ends is equivalent to a winding unit. Preferably, the ends of the coil winding are characterized in that they extend radially from the other winding parts of the coil winding regardless of their further connection.

[0009] In the above and below, the term "cylindrical" (especially with respect to the "cylindrical part") refers to a cylindrical shape, i.e. a shape that is longitudinally extending and hollow. For example, the cylindrical part is preferably circular cylindrical (i.e. circular cross-section), elliptical cylindrical, square or rectangular (especially with rounded edges) cylindrical, or angular (especially triangular) cylindrical. Preferably, the cross-sectional shape of the cylindrical part corresponds to the cross-sectional shape of the at least one winding unit.

[0010] Preferably, the longitudinal axis of the winding unit is defined parallel to the winding axis of one or more coil winding turns of the winding unit.

[0011] Preferably, a plurality of retaining components are independent, separate components or parts in the multi-component spool. In other words, these retaining components are preferably not integral or unitary with each other.

[0012] Although the magnetic component including one multi-component bobbin and at least one winding unit is specifically described above and below, it should be understood that the magnetic component may preferably include multiple multi-component bobbins. For example, as will be shown in the following embodiments, multiple multi-component bobbins are preferably attached to each other via a common substrate or a common magnetic core.

[0013] Preferably, the form-fit connection is detachable, in particular non-destructively detachable. This not only allows easy connection of the holding part, but also allows disconnection in the event of errors, for example during manufacturing (for example, the holding part is connected without first being inserted into the winding unit).

[0014] In some preferred embodiments, the form-fit connection is a snap-fit ​​connection. Alternatively, or additionally in case of a plurality of form-fit connections, the form-fit connection is a twist-lock connection.

[0015] Preferably, in the case of a snap-fit ​​connection, one component (the cylindrical portion or the plate-like retaining component) comprises a hook or a cantilever and the respective other component comprises a snap-receiving area.

[0016] Preferably, in the case of a twist-lock connection, one component comprises a hook or a cantilever arm, and the respective other component comprises an annular groove or an annular undercut, wherein the groove or undercut comprises along its annular extension one or more depressions into which the hook or cantilever arm can be inserted. By inserting the hook or cantilever arm into the depressions, and twisting the components (rotating around the longitudinal axis), the hook or cantilever arm is placed behind the (non-depression) part of the annular groove / undercut, so that its movement along the longitudinal axis is blocked.

[0017] In some preferred embodiments, at least two separate retaining parts in the retaining parts respectively include the above-mentioned cylindrical parts. Wherein, the two cylindrical parts of the above-mentioned two separate retaining parts are inserted into a single winding unit in at least one winding unit. Further, the two cylindrical parts in the above-mentioned single winding unit are in contact with each other and attached by a shape-fitting connection. In other words, at least one winding unit surrounds the two cylindrical parts of two separate retaining parts, that is, one cylindrical part of one retaining part and one (another) cylindrical part of the other retaining part.

[0018] Preferably, the form-fit connection is arranged inside the respective winding unit. In other words, the respective winding unit preferably surrounds the form-fit connection.

[0019] Advantageously, the respective first end faces of the two cylindrical parts contact each other in the single winding unit. Preferably, the respective components of the form-fitting connection (eg hooks / cantilevers or snap-fit ​​areas) are respectively disposed at the first end faces of the two cylindrical parts.

[0020] In some preferred embodiments, the first end surface of the first cylindrical portion of the two cylindrical portions is tapered so as to be insertable into the second cylindrical portion of the two cylindrical portions.

[0021] Further preferably, the at least two separate retaining components including the cylindrical portion each further include a cover flange portion. Further, each cover flange portion contacts an end face of at least one winding unit along the longitudinal axis. Preferably, the cover flange portion prevents or limits movement of the winding unit along the longitudinal axis. Thereby, the life and electrical insulation of the magnetic component are improved.

[0022] In some advantageous embodiments, the above-mentioned two cylindrical parts are in contact and attached to each other at the central part of the corresponding winding unit along the longitudinal axis. Preferably, the central part is defined as the center or middle of the winding unit within the error range. Preferably, the central part is defined as the center or middle of the winding unit within the error range. For example, the central part is defined by dividing the winding unit along its longitudinal axis (in idea) into eight equal parts, wherein the central part is within the two middle eighth parts. Preferably, the central part is defined by the geometric middle within the range of ±15% (more preferably ±10%) of the total length of the winding unit along the longitudinal axis. Preferably, the total length of the winding unit is determined by its winding part, in particular only by its winding part, that is, in the case where the above-mentioned ends of the winding also extend along the longitudinal axis, these ends are not included.

[0023] Alternatively or additionally, with respect to the different cylindrical parts, for example, of the two cylindrical parts mentioned above, one is longer along the longitudinal axis, so that the two cylindrical parts mentioned above contact and attach to each other at the ends of the corresponding winding unit along the longitudinal axis. Preferably, the contact point at the ends of the two cylindrical parts is defined relative to the winding unit to be within a length range of 25% or less, more preferably 15% or less, further preferably 10% or less or 5% or less from the end of the winding unit (especially its winding part). For example, in the case of 25%, the cylindrical part of one retaining part will be, for example, 75 mm, and the cylindrical part of another retaining part in the same winding unit will be 25 mm long along the longitudinal axis of the winding unit.

[0024] In some preferred embodiments, three of the above-mentioned holding parts of the multi-component bobbin respectively include the above-mentioned cylindrical part. Among them, one of the three holding parts includes two of the above-mentioned cylindrical parts, and is called a "double-sided holding part", wherein each of these cylindrical parts is respectively inserted into a winding unit, and is respectively connected to a cylindrical part of one of the other two holding parts of the above-mentioned three holding parts. For example, one holding part includes a cylindrical part inserted into the winding unit. Further, the double-sided holding part also includes a cylindrical part inserted into the same winding unit. Further, another holding part includes a cylindrical part inserted into a different (second) winding unit. The double-sided holding part includes a cylindrical part also inserted into the different (second) winding unit. Therefore, the multi-component bobbin can carry at least two separate winding units. Preferably, any one or more of the other two holding parts (except those of the above-mentioned double-sided holding parts) can be replaced by another double-sided holding part, thereby allowing many winding units to be carried thereby.

[0025] Preferably, the two cylindrical portions of the double-sided holding member extend in opposite directions along the longitudinal axis. Therefore, a plurality of winding units are preferably stacked along the longitudinal axis.

[0026] Further preferably, each of the two cylindrical parts of the double-sided holding member can be respectively inserted into more than one winding unit. For example, each of the two cylindrical parts of the double-sided holding member can be preferably respectively inserted into two winding units.

[0027] Further preferably, the double-sided holding member comprises a flange portion connecting the two cylindrical portions. In addition, the flange portion separates the two (or more) winding units into which the cylindrical portion of the double-sided holding member is inserted along the longitudinal axis. Thus, the flange portion provides a fixed insulation distance between the two winding units on both sides thereof, especially between those winding units directly on both sides thereof (in the case of multiple winding units on either side).

[0028] In a preferred embodiment of a double-sided holding component having a flange portion, in combination with other holding components including a cover flange portion contacting an end surface of at least one winding unit, each winding unit is clamped between the flange portion of the double-sided holding component and the cover flange portion in one of the other two holding components along the longitudinal axis. Alternatively, in the case of a plurality of double-sided holding components, at least one winding unit may be clamped between the flange portions of two double-sided holding components.

[0029] In another embodiment, at least one retaining component has a plate-like shape and is referred to as a "plate-like retaining component". The plate-like retaining component preferably does not include a cylindrical portion inserted into the winding unit. Wherein, the cylindrical portion of the other retaining component is inserted into the winding unit and attached to the plate-like retaining component. The plate-like retaining component is further in contact with the end face of the winding unit. Preferably, along the longitudinal axis, the end face of the plate-like retaining component is in contact with the end face of the winding unit. More preferably, the above-mentioned winding unit is clamped between the plate-like retaining component and the cover flange of the other retaining component or the flange portion of the double-sided retaining component.

[0030] Further preferably, in an embodiment including at least two winding units, at least two holding components respectively include cylindrical portions, wherein further, the two cylindrical portions are respectively inserted into separate winding units and attached to two end surfaces of the plate-shaped holding component.

[0031] Preferably, the cylindrical portion of at least one holding member comprises at least one slot configured to accommodate at least one ferrite pill or core, respectively. Preferably, the ferrite pill is a (thick) disk-shaped member containing ferrite material, e.g. as pressed powder. Preferably, each slot is configured to accommodate at least one ferrite pill. In other words, the number of slots and the number of ferrite pills are equal.

[0032] Preferably, the cross-sectional shape of the one or more ferrite sheets corresponds to the above cross-sectional shape of the cylindrical portion (circular, oval, angular, with rounded corners, etc.) This has the advantage that the ferrite sheets fit tightly within the cylindrical portion.

[0033] Further preferably, the cylindrical part is hollow and accommodates at least a portion of the magnetic core. For example, the magnetic core is preferably rod-shaped and inserted into the cylindrical part. In other examples, the magnetic core includes a winding leg and a return leg connected via a substrate, wherein the winding legs are respectively inserted into the cylindrical part.

[0034] Preferably, the cylindrical portion has a circular or oval cross-section.

[0035] Preferably, the cylindrical portions of the at least one holding member are respectively inserted into at least two winding units.

[0036] Preferably, the holding part comprises two halves, such as half cylinders, which are connected to each other via a hinged portion, in particular integrally or monolithically. Thus, the magnetic core and / or (one or more) ferrite sheets can be easily inserted into the cylindrical part. Wherein, the cylindrical part comprises two halves, and preferably, the cover flange part comprises two halves.

[0037] The present invention also relates to a method for manufacturing a magnetic component according to any of the above preferred embodiments. The method comprises at least the following steps: inserting a plurality of retaining components longitudinally into a pre-wound winding unit and attaching them to each other via a form-fitting connection. Preferably, in an additional step, the magnetic core is inserted into the cylindrical portion before or after the magnetic core is inserted into the winding unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Further details, advantages and features of the preferred embodiments of the present invention are described in detail with reference to the accompanying drawings, wherein:

[0039] Figure 1 shows a schematic exploded view of a magnetic component according to a first embodiment of the present invention;

[0040] Figure 2 shows a schematic assembly cross-sectional view of a magnetic component according to a first embodiment of the present invention;

[0041] Figure 3shows a schematic exploded view of a magnetic component according to a first embodiment of the present invention;

[0042] Figure 4 shows a schematic assembly view of a magnetic component according to a first embodiment of the present invention;

[0043] Figure 5 shows a schematic exploded view of a magnetic component according to a second embodiment of the present invention;

[0044] Figure 6 shows a schematic assembly cross-sectional view of a magnetic component according to a second embodiment of the present invention;

[0045] Figure 7 shows a schematic exploded view of a magnetic component according to a third embodiment of the present invention;

[0046] Figure 8 shows a schematic assembly cross-sectional view of a magnetic component according to a third embodiment of the present invention;

[0047] Fig. 9 shows a schematic exploded view of a magnetic component according to a third embodiment of the present invention;

[0048] Fig.10 shows a schematic assembly view of a magnetic component according to a third embodiment of the present invention;

[0049] Fig.11 shows a schematic exploded view of a magnetic component according to a fourth embodiment of the present invention;

[0050] Fig.12 shows a schematic assembly cross-sectional view of a magnetic component according to a fourth embodiment of the present invention;

[0051] Fig.13 shows a schematic exploded view of a magnetic component according to a fourth embodiment of the present invention;

[0052] Fig.14 shows a schematic assembly view of a magnetic component according to a fourth embodiment of the present invention;

[0053] Fig.15 shows a schematic exploded view of aspects of a magnetic component according to a fifth embodiment of the present invention;

[0054] Fig.16 another schematic exploded view showing aspects of a magnetic component according to a fifth embodiment of the present invention; and

[0055] Fig.17 A schematic exploded view of an aspect of a magnetic component according to a sixth embodiment of the present invention is shown.

[0056] Reference numerals

[0057] 1: Magnetic components

[0058] 2: Multi-component spool

[0059] 3: Winding unit

[0060] 4: Keep the parts

[0061] 4.1: Hold the halves of the component

[0062] 4.2: Hold the halves of the component

[0063] 4.3: Keep the hinged part of the component

[0064] 5: Cylindrical part

[0065] 6: Longitudinal axis

[0066] 8: First end face

[0067] 9: Cover flange part

[0068] 10: End face

[0069] 11: Center

[0070] 12: End

[0071] 13: Slot

[0072] 14: Ferrite sheet

[0073] 15: Magnetic core

[0074] 16: Coil end

[0075] 17: Nose

[0076] 18: Periphery

[0077] 19: Winding Leg

[0078] 20: Loop leg

[0079] 21: Substrate

[0080] 22: Circuit Board

[0081] 23: Slot

[0082] 41: Double-sided retaining parts

[0083] 42: Flange part

[0084] 70: Form-fit connection

[0085] 71: Buckle area

[0086] 72: Hook or cantilever

[0087] 73: Hook or cantilever

[0088] 74: Depression

[0089] 75: Groove or undercut DETAILED DESCRIPTION

[0090] Figure 1 A schematic exploded view of a magnetic component 1 according to a first embodiment of the present invention is shown. Figure 2 A schematic assembled cross-sectional view of a magnetic component 1 according to a first embodiment of the present invention is shown.

[0091] The magnetic member 1 of this embodiment comprises a multi-component bobbin 2 and a winding unit 3. However, as will be described below (see, for example, Figure 3 ), the present embodiment is not limited to a single multi-component bobbin 2 and a single winding unit 3.

[0092] Therein, the winding units 3 are pre-wound, comprising one or more coil winding turns. For the sake of simplicity and overview, individual coil windings are not shown in the figure. Further, the winding units 3 are flat-standing pre-wound (also commonly referred to as "side-wound"), wherein the windings are wound on their short sides (opposite to their flat sides). In other words, the coil windings are essentially flat, elongated (much longer than wide) windings with a rectangular cross-section, which are also referred to as "flat coils". Further, a single winding unit 3 comprises the above-mentioned coil winding turns, and the above-mentioned coil winding turns comprise two ends 16. In other words, a single coil comprising two coil (wire) ends 16 is equivalent to the winding unit 3. Preferably, regardless of their further connection, the ends 16 of the coil windings extend radially from the other wound parts of the coil winding, for example Figure 1 shown.

[0093] The multi-component bobbin 2 comprises a plurality of holding components 4 configured to hold the winding unit 3. The plurality of holding components 4 are independent, separate components or parts of the multi-component bobbin 2. In other words, the holding components 4 are preferably not integral or unitary with each other.

[0094] Each holding member 4 comprises a cylindrical portion 5 which is inserted on either side of the winding unit 3 along a longitudinal axis 6 of the winding unit 3 parallel to the winding axis, whereby each cylindrical portion 5 is surrounded. Figure 2 In the assembled state shown, the cylindrical parts 5 are in contact with each other.

[0095] Preferably, each cylindrical portion 5 can be inserted into a plurality of winding units 3. In particular, the plurality of winding units 3 can be connected in parallel, in particular in order to provide more windings.

[0096] The two cylindrical parts 5 that are in contact with each other in the winding unit 3 are attached to each other via a form-fit connection 70. In the present embodiment, the form-fit connection 70 consists of a snap-fit ​​connection 71 / 72, which consists of a hook 72 (or cantilever) on one cylindrical part 5 and a receiving snap-fit ​​area 71 (see also Figure 2 ). The snap-fit ​​connection 71 / 72 is detachable, in particular non-destructively detachable. This not only allows easy connection of the holding component 4, but also allows disconnection in the event of an error, for example during manufacturing (for example, the holding component 4 is incorrectly connected without first being inserted into the winding unit 3).

[0097] like Figure 2 As shown, the snap-fit ​​connection 71 / 72 is placed inside the winding unit 3. In other words, the winding unit 3 surrounds the snap-fit ​​connection 71 / 72.

[0098] Advantageously, the respective first end faces 8 of the two cylindrical parts 5 are in contact with each other within the winding unit 3. The respective components of the form-fitting connection, such as the hook / cantilever 72 or the snap-on area 71, are respectively placed at the first end faces 8 of the two cylindrical parts 5. In a preferred variant, the first end face 8 of the first of the two cylindrical parts 5 is conical so as to be insertable into the second of the two cylindrical parts 5. In other words, in this preferred variant, the cylindrical part 5 of one holding part 4 can be inserted into the cylindrical part 5 of the other holding part 4.

[0099] Each holding member 4 includes a cover flange portion 9. Each cover flange portion 9 is in contact with an end face 10 of the winding unit 3 along the longitudinal axis 6. Figure 2 A gap is shown between the end face 10 of the winding unit 3 and the cover flange portion 9, which may be preferred in some cases (particularly according to manufacturing tolerances and with respect to thermal expansion of the winding unit 3), but the end face 10 is preferably in contact with the cover flange portion 9. The cover flange portion 9 prevents or limits movement of the winding unit 3 along the longitudinal axis 6. Thereby, the life and electrical insulation of the magnetic component 1 are improved.

[0100] like Figure 2 As shown, the cover flange portion 9 preferably includes a nose 17, which further holds the winding unit 3. In a preferred variant, the nose 17 completely or almost completely (at least 80%) surrounds the winding unit 3 along the outer periphery 18 (perpendicular to the longitudinal axis 6) of the winding unit 3, and leaves space for the end 16 to extend through. In addition, the noses 17 can extend along half of the length of the winding unit 3 along its longitudinal axis 6, so as to contact or nearly contact each other along the longitudinal axis 6.

[0101] Therein, the two cylindrical parts 5 are in contact and attached to each other at a central part 11 of the winding unit 3 along the longitudinal axis 6. Preferably, the central part 11 is defined as the center or middle of the winding unit 3 within a tolerance range. For example, the central part 11 is defined by dividing the winding unit 3 along its longitudinal axis 6 (ideologically) into eight equal parts, wherein the central part 11 is within the two middle eighth parts. Preferably, the central part 11 is defined by the geometric middle within the range of ±15% (more preferably ±10%) of the total length of the winding unit 3 along the longitudinal axis 6. Preferably, the total length of the winding unit 3 is determined only by its winding part, i.e. in the case where the above-mentioned end 16 of the winding also extends along the longitudinal axis 6 (for example, in Figure 2 1 or 2 (bent upward or downward along the longitudinal axis 6), excluding these ends 16.

[0102] In the present embodiment, the cylindrical portion 5 of each holding member 4 comprises a groove 13 configured to accommodate a ferrite sheet 14. The ferrite sheet 14 is a disc-shaped member comprising a ferrite material, for example made in pressed powder.

[0103] Although the foregoing describes a magnetic component 1 comprising one multi-component bobbin 2 and one winding unit 3, it should be understood that the magnetic component 1 may preferably comprise a plurality of multi-component bobbins 2 and a plurality of winding units 3. Figure 3 and Figure 4 This is explained. Figure 3 shows a schematic exploded view of a magnetic component 1 according to a first embodiment of the present invention, Figure 4 Shows Figure 3 FIG. 1 is a schematic assembly view of a magnetic component 1 according to a first embodiment of the present invention. In other words, Figure 4 Show Figure 3 assembly status.

[0104] Depend on Figure 3 It can be seen that the magnetic component 1 of this example further includes two magnetic cores 15. The cylindrical parts 5 are hollow and each accommodates a portion of the magnetic core 15. Specifically, in this embodiment, each cylindrical part 5 accommodates a winding leg 19 on each side thereof, and the magnetic core 15 further includes a return leg 20 for closing the magnetic circuit. The magnetic core 15 also includes a base plate 21, which connects the winding leg 19 and the return leg 20 and closes the magnetic circuit.

[0105] The coil end 16 is inserted into and connected to the circuit board 22 .

[0106] This configuration is particularly suitable for PFC choke components.

[0107] Will refer to Figure 5 and Figure 6 A second embodiment of the present invention will be described. Figure 5shows a schematic exploded view of a magnetic component 1 according to a second embodiment of the present invention, Figure 6 A schematic assembled cross-sectional view of a magnetic component 1 according to a second embodiment of the present invention is shown.

[0108] like Figure 5 As shown, Figure 1 In contrast to the circular shape of the cover flange portion 9 of the retaining member 4, the cover flange portion 9 of each retaining member 4 has a combined rectangular and circular shape. In addition, the cover flange portion 9 includes a slot 23 for inserting the coil end 16.

[0109] Further, the magnetic core 15 of the present embodiment is a cylindrical magnetic piece, which is inserted into the cylindrical portion 5 of the holding member 4 , specifically, inserted between the cylindrical portions 5 of the holding member 4 .

[0110] This configuration is particularly suitable for filter choke or EMI choke applications.

[0111] Will refer to Figure 7 , Figure 8 , Fig. 9 and Fig.10 A third embodiment of the present invention will be described. Figure 7 FIG. 4 shows a schematic exploded view of a magnetic component 1 according to a third embodiment of the present invention, Figure 8 shows a schematic assembly cross-sectional view of a magnetic component 1 according to a third embodiment of the present invention, Fig. 9 FIG. 4 shows a schematic exploded view of a magnetic component 1 according to a third embodiment of the present invention, Fig.10 A schematic assembly view of a magnetic component 1 according to a third embodiment of the present invention is shown.

[0112] Especially from Figure 7 and Figure 8 As can be seen from the figure, in this embodiment, with respect to the different cylindrical parts 5 in the two cylindrical parts 5, one cylindrical part 5 ( Figure 7 On the left side, Figure 8 The bottom of the winding unit 3 is longer along the longitudinal axis 6, so that the cylindrical parts 5 are in contact and attached to each other at the end 12 of the winding unit 3 along the longitudinal axis 6. Figure 8 and Figure 2 As shown in the comparison of , since the lengths of the cylindrical portions 5 of the respective retaining members 4 are different, the contact point here is not at the central portion 11 .

[0113] Preferably, the contact point at the end 12 of the two cylindrical parts is defined within 25% or less, more preferably 15% or less, further preferably 10% or less or 5% or less of the length from the end of the winding unit 3 (particularly its winding part) with respect to the winding unit 3. In the example shown, their contact point is within about 20% of the length from the end of the winding unit 3 along its longitudinal axis 6.

[0114] like Fig. 9 and Fig.10 As shown, this allows the magnetic core 15 to have another different geometry. In this example, the magnetic core 15 is three-legged, each magnetic core comprising two winding legs 19 and one return leg 20. Further, the magnetic component 1 comprises a bar core 15 ( Fig. 9 legs).

[0115] This configuration is particularly suitable for six-switch PFC choke applications.

[0116] Will refer to Fig.11 , Fig.12 , Fig.13 and Fig.14 A fourth embodiment of the present invention will be described. Fig.11 1 shows a schematic exploded view of a magnetic component 1 according to a fourth embodiment of the present invention, Fig.12 1 shows a schematic assembly cross-sectional view of a magnetic component 1 according to a fourth embodiment of the present invention, Fig.13 1 shows a schematic exploded view of a magnetic component 1 according to a fourth embodiment of the present invention, Fig.14 A schematic assembly view of a magnetic component 1 according to a fourth embodiment of the present invention is shown.

[0117] Especially from Fig.11 and Fig.12 As can be seen in FIG. 1 , in this embodiment, the magnetic component 1 comprises three holding components 4. The three holding components 4 of the multi-component bobbin 2 respectively comprise a cylindrical portion 5.

[0118] Among them, one of the three holding members 4 includes the two above-mentioned cylindrical portions 5 , and is referred to as a “double-sided holding member” 41 .

[0119] Further, as shown in the figure, each of the cylindrical portions 5 of the double-sided holding member 41 is respectively inserted into one winding unit 3 and respectively connected to one cylindrical portion 5 of one of the other two holding members 4 among the three holding members 4 .

[0120] On the other hand, each cylindrical portion 5 of the double-sided holding member 41 can be inserted into the multiple winding unit 3 respectively.

[0121] In other words, if Fig.11 and Fig.12 As can be seen in FIG. 1 , one holding member 4 (left side) includes a cylindrical portion 5, which is inserted into the winding unit 3. Further, the double-sided holding member 41 also includes a cylindrical portion 5 inserted into the same winding unit 3. Still further, the other holding member 4 includes a cylindrical portion 5 (right side) inserted into a different (second) winding unit 3. The double-sided holding member 41 includes a cylindrical portion also inserted into the different (second) winding unit.

[0122] Thus, the multi-component bobbin 2 is capable of carrying at least two separate winding units 3. Preferably, any one or more of the other two holding components 4 (except those of the above-mentioned double-sided holding component 41) can be replaced by another double-sided holding component 41, thereby allowing many winding units 3 to be carried thereby.

[0123] The two cylindrical portions 5 of the double-sided holding member 41 extend in opposite directions along the longitudinal axis 6 .

[0124] Furthermore, the double-sided holding member 41 comprises a flange portion 42, which connects the two cylindrical portions 5, in particular, integrally or integrally. In addition, the flange portion 42 separates the two winding units 3 along the longitudinal axis 6, wherein the cylindrical portion 5 of the double-sided holding member 41 is inserted into the two winding units 3. Thus, the flange portion 42 provides a fixed insulation distance between the two winding units 3 on both sides thereof.

[0125] In addition, in the present embodiment, the other two holding members 41 have cover flange portions 9. In this combination, each winding unit 3 is sandwiched between the flange portion 42 of the double-sided holding member 41 and the cover flange portion 9 in one of the other two holding members 4 along the longitudinal axis 6. The thickness of the flange portion 42 on the longitudinal axis 6 is set to set the DM inductance of the CM choke.

[0126] Alternatively, in the case of a plurality of double-sided holding members 41 , at least one winding unit 3 may be sandwiched between flange portions 42 of two adjacent double-sided holding members 41 .

[0127] Preferably, the thickness of the flange portion 42 along the longitudinal axis 6 is predetermined based on, for example, a predetermined DM inductance of a CM choke in which the magnetic component 1 is employed.

[0128] like Fig.13 and Fig.14 As shown in , the magnetic core 15 of this embodiment is preferably a three-leg magnetic core, an "RM" type pot core or an EP magnetic core. This configuration is particularly suitable for DCCM choke applications.

[0129] Will refer to Fig.15 and Fig.16 A fifth embodiment of the present invention will be described. Fig.15 shows a schematic exploded view of various aspects of a magnetic component 1 according to a fifth embodiment of the present invention, Fig.16 Another schematic exploded view of aspects of a magnetic component 1 according to a fifth embodiment of the invention is shown.

[0130] In this embodiment, one holding member 4 has a plate-like shape and is referred to as a “plate-like holding member” 43. The plate-like holding member 43 does not include the cylindrical portion 5 inserted into the winding unit 3. The cylindrical portion 5 of the other holding member 4 is inserted into the winding unit 3 and attached to the plate-like holding member 43.

[0131] Here, preferably, the thickness of the plate-shaped holding component 43 along the longitudinal axis 6 serves to set a predetermined DM inductance of a CM choke employing the magnetic component 1 .

[0132] The plate-shaped holding member 43 further contacts the end surface 10 of the winding unit 3. Further, the winding unit 3 is sandwiched between the plate-shaped holding member 43 and the cover flange portion 9 of the other holding member 4 or the flange portion 42 of the double-sided holding member (see Fig.11 ).

[0133] Furthermore, if Fig.16 As shown, when the magnetic component 1 includes two winding units 3, the two holding components 4 each include a cylindrical portion 5. The two cylindrical portions are respectively inserted into the individual winding units 3 and attached to both sides of the plate-like holding component 43 via a shape-fitting connection 70.

[0134] In the present embodiment, the form-fitting connection 70 is a twist-lock connection 73, 74, 75. Therein, one component (e.g., a cylindrical portion of one of the retaining components 4 other than the plate-like retaining component 43) comprises a hook or cantilever 73, and the corresponding other component (e.g., the plate-like retaining component 43) comprises an annular groove or annular undercut 75, wherein the groove or undercut 75 comprises one or more recesses 74 along its annular extension, into which the hook or cantilever 73 can be inserted. By inserting the hook or cantilever 73 into the recess 74 and twisting the component 4 / 5 and / or 43 (about the longitudinal axis 6), the hook or cantilever 73 is placed behind the (non-recessed) part of the annular groove / undercut 75, so that its movement along the longitudinal axis 6 is blocked.

[0135] Will refer to Fig.17 A sixth embodiment of the present invention will be described.

[0136] Here, the holding part 4 comprises two halves 4 . 1 , 4 . 2 , for example half cylinders, which are connected to each other, in particular integrally or monolithically, via a hinge portion 4 . 3 . Furthermore, the holding part 4 comprises a slot 13 for accommodating a ferrite sheet 14 .

[0137] Thus, the above-mentioned magnetic core 15 and / or the ferrite sheet(s) 14 can be easily inserted into the cylindrical part 5 comprising the two halves 4.1, 4.2.

[0138] In this case, the magnetic core 15 and / or the ferrite sheet 14 is inserted into one half 4.1, 4.2 of the holding part 4, which is closed via the hinged portion 4.3 and further inserted into the winding unit 3. Preferably, these halves 4.1, 4.2 each comprise a form-fitting connection, in particular a snap-fitting connection, for attaching the two halves 4.1, 4.2 together once closed.

[0139] It should be noted that the embodiments of the present invention may be combined. Figure 8 The configuration can be applied to Figure 4 , i.e., its PFC choke assembly. For example, some winding units 3 may be around two holding parts 4 of the same length, or around two holding parts 4 of different lengths. The ferrite sheets 14 may be inserted or omitted depending on the application. In addition, each holding part 4 may also include multiple slots 13 for more ferrite sheets 14. Any or all of these holding parts 4 may include two halves 4.1, 4.2.

[0140] In addition to the foregoing written instructions, see also explicitly Figures 1 to 17 , wherein these figures show configuration examples of the present invention in detail and specifically show the shapes of elements of the magnetic component 1.

Claims

1. A magnetic component (1), comprising a multi-component bobbin (2) and at least one winding unit (3), the multi-component bobbin (2) further comprising: A plurality of holding members (4) configured to hold the at least one winding unit (3), wherein the at least one winding unit (3) is pre-wound and comprises one or more coil winding turns, wherein at least one of the holding members (4) comprises a cylindrical portion (5), the cylindrical portion (5) being inserted into the at least one winding unit (3) along a longitudinal axis (6) of the winding unit (3) so as to be surrounded thereby, as well as Therein the cylindrical portion (5) is in contact and attached to a separate holding component via a form-fitting connection (70).

2. The magnetic component (1) according to claim 1, wherein the form-fit connection (70) is a snap-fit ​​connection (71 / 72) or a twist-lock connection (73, 74, 75).

3. The magnetic component (1) according to claim 1, wherein at least two individual retaining components (4) of the retaining components (4) respectively include the cylindrical portion (5), wherein the two cylindrical portions (5) of the two individual retaining components (4) are inserted into a single winding unit (3) of the at least one winding unit (3), and wherein the two cylindrical portions (5) within the single winding unit (3) are in contact with each other and attached via the shape-fitting connection (70).

4. The magnetic component (1) according to claim 3, wherein the respective first end surfaces (8) of the two cylindrical portions (5) are in contact with each other within the single winding unit (3).

5. The magnetic component (1) according to claim 4, wherein the first end surface (8) of the first cylindrical part (5) of the two cylindrical parts (5) is tapered so as to be insertable into the second cylindrical part (5) of the two cylindrical parts (5).

6. A magnetic component (1) according to claim 4, wherein the at least two separate retaining components (4) including the cylindrical portion (5) each further include a cover flange portion (9), and wherein each cover flange portion (9) is in contact with an end face (10) of the at least one winding unit (3) along the longitudinal axis (6).

7. The magnetic component (1) according to claim 3, wherein the two cylindrical parts (5) are in contact and attached to each other at a central part (11) of the corresponding winding unit (3) along the longitudinal axis (6).

8. A magnetic component (1) according to claim 3, wherein among the two cylindrical parts (5), one cylindrical part (5) is longer along the longitudinal axis (6), so that the two cylindrical parts (5) are in contact and attached to each other at the ends (12) of the corresponding winding units (3) along the longitudinal axis (6).

9. The magnetic component (1) according to claim 3, wherein three of the retaining components (4) of the retaining components (4) respectively include the cylindrical part (5), wherein one of the three retaining components (4) is a double-sided retaining component (41), which includes two of the cylindrical parts (5), wherein each of the cylindrical parts (5) is respectively inserted into one winding unit (3) and is respectively connected to a cylindrical part (5) of one of the other two of the three retaining components (4 / 41).

10. A magnetic component (1) according to claim 9, wherein the two cylindrical parts (5) of the double-sided holding component (41) extend in opposite directions along the longitudinal axis (6), and the double-sided holding component (41) also includes a flange part (41), which connects the two cylindrical parts (5) and separates the two winding units (3) inserted into the cylindrical part (5) of the double-sided holding component (41) along the longitudinal axis (6).

11. A magnetic component (1) according to claim 1, wherein at least one of the retaining components (4) has a plate-like shape, and as a plate-like retaining component, the cylindrical portion (5) of another retaining component (4) is inserted into the winding unit (3) and attached to the plate-like retaining component (41), and the plate-like retaining component (41) contacts the end surface of the winding unit (3).

12. The magnetic component (1) according to claim 1, wherein the cylindrical portion (5) comprises at least one slot (13) configured to accommodate at least one ferrite sheet (14) or magnetic core (15), respectively.

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