Magnetic core-case arrangement and method for manufacturing a magnetic core-case arrangement

Abstract

Magnetic core-housing arrangement for interference suppression of lines and cables, comprising a magnetic core (2), a housing (3), a first housing part (4) and a second housing part (5), and in which the magnetic core (2) is arranged, wherein the housing (3) forms an annular interior (8) which is bounded by an inner annular wall (9), an outer annular wall (10) and a connecting housing part base (11) of the first housing part (4) and by an inner annular wall (12), an outer annular wall (13) and a housing part base (14) of the second housing part (5), wherein at least one spacer (15, 17) is arranged on each housing part (4, 5) such that a filling space (21, 22) is formed between the respective housing part (4, 5) and the magnetic core (2) in the annular interior (8), wherein the at least one spacer (15, 17) is formed in one piece with the respective housing part (4, 5),wherein the annular interior (8) has a radial width B and for a radial dimension A of the at least one spacer (15, 17) the following applies: 0.4 · B ≤ A ≤ 1.0 · B, wherein at least one of the housing parts (4, 5) has at least one through-opening (23, 24) which opens into at least one of the filling chambers (21, 22), and wherein the respective filling chamber (21, 22) is filled with a filler material (25).

Description

[0001] The invention relates to a magnetic core-housing arrangement according to the preamble of claim 1. The invention further relates to a method for manufacturing a magnetic core-housing arrangement.

[0002] A magnetic core-housing arrangement is known from DE 10 2007 034 532 A1 (corresponding to US 2010 / 0265016 A1). To manufacture the magnetic core-housing arrangement, an adhesive is applied to the inner wall of a first housing part, and a magnetic core is inserted into the housing part. The first housing part is then joined to a second housing part, so that the magnetic core is located within the housing formed by the two parts. During insertion, the magnetic core comes into contact with the adhesive and adheres to it. After drying, the adhesive fixes the magnetic core in the housing, being elastic enough to compensate for mechanical stresses. The magnetic core is thus effectively protected from mechanical stresses and therefore retains good magnetic properties over the long term. A disadvantage is that the magnetic core-housing arrangement is complex to manufacture.

[0003] The invention is based on the objective of creating a magnetic core-housing arrangement that enables simple and automated manufacturing.

[0004] This problem is solved by a magnetic core-housing arrangement with the features of claim 1. At least one spacer is arranged on at least one housing part, extending into an interior space of the housing. The magnetic core is arranged in this interior space and rests against the at least one spacer. Due to the at least one spacer, at least one filling space is formed between the at least one housing part and the magnetic core. The at least one filling space serves to receive a filler material with which the magnetic core is fixed in the housing or in the interior space of the housing. For supplying the filler material, the at least one housing part has at least one through-opening that opens into the at least one filling space.During manufacturing, the filler material was fed into the at least one filling chamber through the at least one through-opening, so that the at least one filling chamber is at least partially, preferably completely, filled with the filler material. The filler hardens after being fed in, preventing it from escaping through the at least one through-opening and ensuring that the magnetic core is sufficiently fixed within the housing. The at least one spacer and the at least one through-opening thus enable the magnetic core-housing assembly to be manufactured by first arranging the magnetic core in the housing and then introducing the filler material into the at least one filling chamber through the at least one through-opening. The at least one spacer ensures the formation of the at least one filling chamber.By introducing the filler material into the housing only after the magnetic core has been positioned, the magnetic core can first be arranged in the housing in a simple and automated manner, and then the filler can be introduced in a similarly simple and automated manner. The curing of the filler material is a secondary process to the mechanical assembly, so that the curing of the filler material does not affect or impair the mechanical assembly. The magnetic core is preferably ring-shaped in cross-section. Preferably, the magnetic core is wound from a strip. The magnetic core is made of a soft magnetic material, which is preferably nanocrystalline. The housing is preferably ring-shaped. The filler is preferably an adhesive and / or sealant. The filler is curable or cured within the housing.

[0005] A magnetic core-housing arrangement according to claim 2 ensures simple and automated manufacturing. Because the at least one spacer is arranged on the base of a housing part, the magnetic core rests securely against the spacer during assembly. Furthermore, the spacer arrangement forms the at least one filling chamber at the end face of the magnetic core, thus simplifying the arrangement and formation of the at least one through-opening. The at least one through-opening can be easily formed in the base of the housing part adjacent to the spacer, ensuring that it reliably opens into the at least one filling chamber.Furthermore, the at least one filling chamber is arranged by the arrangement of the at least one spacer in such a way that the filler reliably fixes the magnetic core, in particular the magnetic core designed as a wound tape, at its end face.

[0006] A magnetic core-housing arrangement according to claim 3 ensures simple and automated production of the at least one spacer. The at least one spacer is automatically produced during the manufacture of the at least one housing part and is integrally formed with it due to the shape of the at least one housing part. The at least one housing part is preferably made of a plastic material, so that the at least one spacer is produced by the mold during injection molding of the at least one housing part. Preferably, the at least one housing part has a material thickness in a region defined by the at least one spacer that corresponds to a material thickness outside this region. The region defined by the at least one spacer thus does not have an increased material thickness. This ensures elasticity or...The deformability of at least one spacer is achieved in such a way that dimensional tolerances of the magnetic core can be compensated for.

[0007] A magnetic core-housing arrangement according to claim 4 ensures simple and automated manufacturing. The radial dimension A of the at least one spacer provides a large contact area. This is particularly advantageous when the magnetic core is wound from a strip. The contact area is larger the larger the radial dimension A. Furthermore, a radial dimension A that is smaller than the radial width B of the interior ensures that the at least one spacer does not interrupt the at least one filling chamber, but rather that the filling chamber remains radially adjacent to the at least one spacer and forms at least one channel for the filler material. Preferably, the at least one spacer is arranged radially centrally in the interior, so that the filling chamber forms a channel on both sides of the at least one spacer.Preferably, the radial dimension A is: A ≤ 0.7 · B. .

[0008] A magnetic core-housing arrangement according to claim 5 ensures simple and automated manufacturing. Due to the flat contact surface, the magnetic core rests against the at least one spacer over a large area. This ensures the formation of the filling chamber. This applies particularly when the magnetic core is formed from a wound strip.

[0009] A magnetic core-housing arrangement according to claim 6 ensures simple and automated manufacturing. The greater the number of spacers, the smaller each individual spacer can be, thus ensuring secure support of the magnetic core and the formation of the at least one filling chamber. Preferably, the at least two spacers are arranged rotationally symmetrically about a central longitudinal axis of the housing, so that the magnetic core cannot tilt within the housing. Preferably, the at least one housing part has exactly two spacers. The two spacers are, in particular, arranged opposite each other relative to the central longitudinal axis of the housing.

[0010] A magnetic core-housing arrangement according to claim 7 ensures simple and automated manufacturing. Because each of the housing parts has at least one spacer, the magnetic core is easily and securely held in the housing along the housing's central longitudinal axis. Preferably, the spacers are deformable or elastic due to a constant material thickness of the housing parts, so that dimensional tolerances of the magnetic core can be compensated for on both sides. This is particularly advantageous when the magnetic core is formed from a wound strip. Furthermore, at least one filling space is formed on each side of the magnetic core, which can be filled with filler material. This allows the magnetic core to be fixed on both sides by the filler material in a simple and automated manner.

[0011] A magnetic core-housing arrangement according to claim 8 ensures a simple, automated feeding of the filler. The housing with the magnetic core can, for example, be arranged vertically, so that the bottom of the housing part, with the at least one through-opening on its upper side, is exposed. The filler can thus be easily fed through the at least one through-opening. If required, the housing can be held circumferentially by a holding device.

[0012] A magnetic core-housing arrangement according to claim 9 ensures a simple, automated feeding of the filler material. By providing at least two through-openings, the filler material can be fed into the at least one filling chamber through at least one of the through-openings, and air can be discharged from the at least one filling chamber through at least one of the through-openings.

[0013] A magnetic core-housing arrangement according to claim 10 ensures simple automated manufacturing. Because each of the housing parts has at least one through-opening, filler material can be fed into a corresponding filling chamber through each of these openings. This allows the magnetic core to be fixed on both sides within the housing.

[0014] A magnetic core-housing arrangement according to claim 11 ensures simple automated manufacturing. Because the filler is designed as an adhesive, the magnetic core is securely fixed after the adhesive has cured. Since the adhesive is only introduced into the at least one filling chamber after the magnetic core has been arranged, the introduction of the adhesive is temporally decoupled from the preceding manufacturing steps, in particular the arrangement of the magnetic core in the housing.

[0015] A magnetic core-housing arrangement according to claim 12 ensures simple automated manufacturing. After the magnetic core is arranged in the housing parts, these can be easily bonded to the magnetic core. The housing parts are thus materially bonded to the magnetic core. For this purpose, the adhesive is supplied to the housing. The adhesive is supplied through the at least one through-hole formed in the respective housing part, so that each housing part is bonded to the magnetic core over a large area. The housing parts are preferably designed such that they have an overlap area. This allows dimensional tolerances of the magnetic core in the direction of the housing's central longitudinal axis to be easily compensated without exposing the magnetic core. A frictional and / or positive locking connection can also be formed in the overlap area.

[0016] A magnetic core-housing arrangement according to claim 13 ensures simple automated manufacturing. After the magnetic core is arranged in the housing parts, these can be easily connected to one another. For this purpose, the housing parts form a frictional and / or positive fit. A frictional connection is, for example, designed as an interference fit, whereas a positive fit is, for example, designed as a tongue-and-groove connection or as a screw connection. In addition, the housing parts can be connected to the magnetic core by means of the filler or adhesive.

[0017] A magnetic core-housing arrangement according to claim 14 ensures simple automated manufacturing. Because the housing is made of a plastic material, the housing components can be easily manufactured by injection molding. In this process, the at least one spacer and / or the at least one through-hole can be produced during the manufacturing of the housing component. The plastic material is electrically insulating and / or deformable, which enables advantageous properties of the magnetic core-housing arrangement.

[0018] The invention further aims to create a method that enables the simple and automated production of a magnetic core-housing arrangement.

[0019] This problem is solved by a method with the features of claim 15. The advantages of the method according to the invention correspond to the advantages already described of the magnetic core-housing arrangement according to the invention. In particular, the method can also be further developed with the features of at least one of claims 1 to 14. The housing parts are materially bonded to the magnetic core and / or connected to each other by a force-fit and / or positive-fit connection.

[0020] Further features, advantages, and details of the invention will become apparent from the following description of several exemplary embodiments. These show:

[0021] Fig. 1 a perspective view of a magnetic core-housing arrangement according to a first embodiment,

[0022] Fig. 2 a top view of the magnetic core-housing arrangement in Fig. 1,

[0023] Fig. 3 a sectional view through the magnetic core-housing arrangement along section line III-III in Fig. 2,

[0024] Fig. 4 a sectional view through the magnetic core-housing arrangement along the section line IV-IV in Fig. 2, and

[0025] Fig. 5 a sectional view accordingly Fig. 3 by a magnetic core-housing arrangement according to a second embodiment.

[0026] The following is based on the Fig. 1 to Fig. 4 A first embodiment of the invention is described. A magnetic core-housing arrangement. 1 includes a magnetic core 2 , which is in a housing 3 is arranged. The housing 3 includes a first housing part 4 and a second housing part 5 , which are connected by means of a connecting unit 6 are connected to each other. The housing 3It has a ring-shaped cross-section and a central longitudinal axis of the housing. 7 up. The housing parts 4 , 5 They are made of a plastic material. This plastic material is particularly electrically insulating.

[0027] The case 3 forms a ring-shaped interior 8 from the first part of the housing 4 through an inner ring wall 9 , an outer ring wall 10 and one of the ring walls 9 , 10 connecting housing part bottom 11 and from the second housing part 5 through an inner ring wall 12 , an outer ring wall 13 and one of the ring walls 12 , 13 connecting housing part bottom 14 is limited. The connecting unit 6 is on the inner ring walls 9 , 12 and on the outer ring walls 10 , 13trained. The liaison unit 6 is designed in particular as a force-fit and / or form-fit connection.

[0028] On the bottom of the housing part 11 are two first spacers 15 arranged, extending into the interior 8 extend. The spacers 15 are one piece with the first housing part 4 formed by the bottom of the housing part 11 partially into the interior 8 extends and thus the spacers 15 trains. The spacers 15 are therefore integral with the base of the housing part 11 formed. This is how the first housing part exhibits 4 First indentations on one outer side 16 up. The spacers 15 have a material thickness D A on, which have a material thickness D B of the housing part bottom 11 corresponds.

[0029] The spacers 15 are rotationally symmetrical to the central longitudinal axis of the housing 7 arranged. The spacers 15 have a radial dimension A, for which, relative to a radial width B of the interior 8 The following applies: 0.4·B ≤ A ≤ 1.0·B, in particular 0.5·B ≤ A ≤ 0.9·B, and in particular 0.6·B ≤ A ≤ 0.8·B. The spacers 15 are symmetrical in the radial direction within the interior 8 arranged.

[0030] On the second housing part 5 are second spacers in a corresponding manner 17 arranged, the second recesses 18 train. The explanations regarding the first spacers. 15 The following apply accordingly. When the housing parts are connected 4 , 5 are the spacers 15 , 16 in the direction of the housing's central longitudinal axis 7 for example, arranged in a line with each other.

[0031] The magnetic core 2 is from a band 19 formed, which is wound in a ring shape and has several winding layers 20 forms. The magnetic core 2 is preferably made of a soft magnetic material, which is particularly nanocrystalline. The winding layers 20 The end faces form a first end face S1 and a second end face S2. The end faces S1 and S2 are precisely dimensioned when the band is measured. 19 and an ideally even winding. The first spacers 15 form for the magnetic core 2 The first flat mounting surfaces F1 are formed. The second spacers are formed accordingly. 17 for the magnetic core 2 second level mounting surfaces F2. In the connected state of the housing parts. 4 , 5 The magnetic core is located 2with its end face S1 against the contact surface F1 and with its end face S2 against the contact surface F2. The radial dimension A of the spacers 15 , 17 For example, all layers of wrapping 20 at least partially adjacent to the planting areas F1 and F2.

[0032] The part of the interior 8 , which is due to the spacers 15 , 17 not from the magnetic core 2 When filled, it forms two filling spaces 21 , 22 out. A first filling chamber 21 , which is due to the first spacers 15 is formed between the magnetic core 2 and the first housing part 4 trained. Accordingly, a second filling chamber is provided. 22 , which is due to the second spacer 17 is formed between the magnetic core 2 and the second housing part 5 trained. In the field of spacers15 , 17 is the respective filling space 21 , 22 narrows and forms on both sides of the respective spacer 15 , 17 Channels off.

[0033] In the first housing part 4 are two initial through-openings 23 trained, who are in the first filling chamber 21 open up. The passageways 23 are in the bottom of the housing part 11 formed and extend in the direction of the housing's central longitudinal axis 7 The passageways 23 are rotationally symmetrical to the central longitudinal axis of the housing 7 and symmetrical in the radial direction to the interior 8 arranged. For a diameter D of the through-openings 23 The following holds true: 0.05·B ≤ D ≤ 0.5·B, in particular 0.1·B ≤ D ≤ 0.4·B, and in particular 0.15·B ≤ D ≤ 0.3·B. Furthermore, for the diameter D: D < A.

[0034] In the second part of the housing 5are second passage openings 24 trained, who go into the second filling chamber 22 open up. The passageways 24 are in the bottom of the housing part 14 trained. The explanations regarding the first through-openings. 23 These apply to the second passageways. 24 Accordingly. In the assembled state of the housing parts. 4 , 5 are the passage openings 23 and 24 For example, arranged in a straight line with each other. The passageways. 23 , 24 are particularly around the central longitudinal axis of the housing 7 offset from the spacers 15 , 17 The through-openings are preferably arranged. 23 , 24 around the central longitudinal axis of the housing 7 centered between the spacers 15 , 17 arranged.

[0035] To fix the magnetic core 2 are the filling spaces21 , 22 with a filler 25 filled. The filler 25 It is preferably formulated as an adhesive and / or sealant. Suitable fillers are known and commonly used. Examples of suitable fillers include epoxy resins and silicones.

[0036] The magnetic core-housing arrangement 1 is produced as follows: The magnetic core 2 is in the housing parts 4 , 5 arranged and the housing parts 4 , 5 are then joined together by force-fit and / or form-fit. In the joined state of the housing parts 4 , 5 The magnetic core is located 2 with its end faces S1 and S2 against the corresponding contact surfaces F1 and F2. Dimensional tolerances of the magnetic core 2 , which lead to unevenness of the end faces S1 and S2, are prevented by the elastically deformable spacers 15 , 17and / or through the connecting unit 6 balanced.

[0037] Then, one of the first passage openings is used. 23 Flowable filler 25 into the first filling chamber 21 supplied. By supplying the filler. 25 will be in the first filling chamber 21 The existing air is displaced, passing through the further first opening. 23 escapes. Accordingly, it passes through one of the second passage openings. 24 Flowable filler 25 into the second filling chamber 22 supplied. The ones in the filling chamber 22 The air escapes through the second opening. 24 . Adding the filler 25 This continues until the respective filling chamber 21 , 22 completely filled 25 is filled. The filling chambers 21 , 22can be used with filler simultaneously and / or at different times 25 to be filled. After the filler has hardened. 22 is the magnetic core 2 in the case 3 securely fixed.

[0038] During the formation of the filler 25 The housing parts are used as an adhesive. 4 , 5 with the magnetic core 2 glued and thus joined. The gluing of the housing parts 4 , 5 with the magnetic core 2 can be used in addition to or as an alternative to the connection unit 6 This is intended to be the case when the housing parts are glued together. 4 , 5 with the magnetic core 2 the housing parts 4 , 5 in the direction of the housing's central longitudinal axis 7 an overlap area.

[0039] The assembly of the magnetic core-housing arrangement 1This is preferably carried out automatically using a suitable handling device and / or a suitable holding device. The subsequent feeding of the filler material. 25 This is preferably done automatically using a suitable feeding device. Since the feeding of the filler material 25 Since the assembly process is subordinate in time, the production of the magnetic core-housing assembly is not affected by the hardening of the filler. 25 influenced or impaired.

[0040] The following is based on Fig. Section 5 describes a second embodiment of the invention. In contrast to the previous embodiment, the magnetic core 2 formed from a ring-shaped body. The magnetic core 2 It is therefore not designed as a wound tape. Regarding the further construction and manufacturing of the magnetic core-housing arrangement. 1 Reference is made to the preceding example.

[0041] The magnetic core-housing arrangement according to the invention 1 It is used to eliminate interference in lines and cables. QUOTES INCLUDED IN THE DESCRIPTION

[0042] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0043] DE 102007034532 A1

[0002] US 2010 / 0265016 A1

[0002]

Claims

[1] Magnetic core-case arrangement with – a magnetic core ( 2 ), – a case ( 3 ), – that's a first housing part ( 4 ) and a second housing part ( 5 ) includes, and – in which the magnetic core ( 2 ) is arranged, characterized by that on at least one housing part ( 4 , 5 ) at least one spacer ( 15 , 17 ) is arranged such that between the at least one housing part ( 4 , 5 ) and the magnetic core ( 2 ) at least one filling chamber ( 21 , 22 ) is trained, that at least one housing part ( 4 , 5 ) at least one through-opening ( 23 , 24 ) has which in the at least one filling chamber ( 21 , 22 ) flows into, and that the at least one filling chamber ( 21 ,22 ) with a filler ( 25 ) is filled. [2] Magnetic core housing arrangement according to claim 1, characterized by that the at least one spacer ( 15 , 17 ) on a housing part bottom ( 11 , 14 ) is arranged. [3] Magnetic core housing arrangement according to claim 1 or 2, characterized by that the at least one spacer ( 15 , 17 ) one-piece with at least one housing part ( 4 , 5 ) is trained. [4] Magnetic core housing arrangement according to any one of claims 1 to 3, characterized by that the case ( 3 ) a ring-shaped interior ( 8 ) with a radial width B and for a radial dimension A of the at least one spacer ( 15 , 17 ) it holds that: 0.4·B ≤ A ≤ 1.0·B, in particular 0.5·B ≤ A ≤ 0.9·B, and in particular 0.6·B ≤ A ≤ 0.8·B. [5] Magnetic core housing arrangement according to any one of claims 1 to 4, characterized by that the at least one spacer ( 15 , 17 ) a flat contact surface (F1, F2) for the magnetic core ( 2 ) trains. [6] Magnetic core housing arrangement according to any one of claims 1 to 5, characterized by that at least one housing part ( 4 , 5 ) at least two spacers ( 15 , 17 ) exhibits, in particular rotationally symmetrical about a housing central longitudinal axis ( 7 are arranged. [7] Magnetic core housing arrangement according to any one of claims 1 to 6, characterized by that each of the housing parts ( 4 , 5 ) at least one spacer ( 15 , 17 ), in particular at least two spacers ( 15 , 17 ) exhibits. [8] Magnetic core housing arrangement according to any one of claims 1 to 7, characterized bythat the at least one through-opening ( 23 , 24 ) in a housing part bottom ( 11 , 14 ) is trained. [9] Magnetic core housing arrangement according to any one of claims 1 to 8, characterized by that at least one housing part ( 4 , 5 ) at least two through openings ( 23 , 24 ) exhibits, in particular rotationally symmetrical about a housing central longitudinal axis ( 7 are arranged. [10] Magnetic core housing arrangement according to any one of claims 1 to 9, characterized by that each of the housing parts ( 4 , 5 ) at least one through-opening ( 23 , 24 ), in particular at least two through-openings ( 23 , 24 ). [11] Magnetic core housing arrangement according to any one of claims 1 to 10, characterized by that the filler ( 25 ) is designed as an adhesive. [12] Magnetic core housing arrangement according to claim 11, characterized by that the housing parts ( 4 , 5 ) using the adhesive ( 25 ) with the magnetic core ( 2 are connected. [13] Magnetic core housing arrangement according to any one of claims 1 to 12, characterized by that the housing parts ( 4 , 5 ) a force-fit and / or form-fit connection ( 6 exhibit. [14] Magnetic core housing arrangement according to any one of claims 1 to 13, characterized by that the case ( 3 ) is made of a plastic material. [15] Method for manufacturing a magnetic core-case assembly, comprising the following steps: – Providing a magnetic core ( 2 ) and a housing ( 3 ) with a first housing part ( 4 ) and a second housing part ( 5 ), – Arrangement of the magnetic core ( 2 ) in the housing parts ( 4 ,5 ) such that the magnetic core ( 2 ) on at least one spacer ( 15 , 17 ) at least one of the housing parts ( 4 , 5 ) arranged and between the magnetic core ( 2 ) and at least one housing part ( 4 , 5 ) at least one filling chamber ( 21 , 22 ) is trained, and – Adding a filler ( 25 ) into at least one filling chamber ( 21 , 22 ) through at least one through-opening ( 23 , 24 ), which is located in at least one housing part ( 4 , 5 ) is designed and includes at least one filling chamber ( 21 , 22 ) leads to.

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