PFC choke arrangement

Abstract

The invention relates to a PFC choke arrangement, comprising a PFC choke (2) with a core (20) and a winding (21), a busbar element (3) for electrically contacting the PFC choke (2), a base plate (4), wherein the PFC choke (2) is arranged on the base plate (4), an electrical contact element (5) which is designed to establish an electrical connection between the busbar element (3) and a printed circuit board (101), wherein the electrical contact element (5) comprises a first electrical contact region (51) designed to electrically contact the busbar element (3), a second electrical contact region (52) designed to electrically contact the printed circuit board (101), and a connecting region (50), wherein the connecting region (50) is connected to the base plate (4).

Description

State of the art

[0001] The present invention relates to a PFC (Power Factor Correction) choke assembly, a printed circuit board assembly and a method for manufacturing the printed circuit board assembly.

[0002] It is known from the prior art to connect PFC chokes to a circuit board by soldering or welding. Due to the winding core and the winding arranged around it, PFC chokes are relatively heavy, which makes them difficult to fix to the circuit board. This results in significant development effort to meet tolerance chains for the assembly of the PFC chokes. Furthermore, mounting the PFC chokes on the circuit board requires considerable manufacturing effort. Disclosure of the invention

[0003] The PFC choke assembly according to the invention with the features of claim 1 has the advantage that a very simple and secure fixing of a PFC choke to a circuit board is possible. In particular, no soldering or welding process or the like is required to securely attach the PFC choke, which has a relatively high weight, to the circuit board. Furthermore, the present invention allows the PFC choke to be fixed to the circuit board in such a way that the PFC choke does not necessarily have to be fixed on a circuit board level, but can in particular be fixed below the circuit board level. This results in greater variability in production. In particular, additional degrees of freedom can be enabled within the process chain and a production sequence of a circuit board assembly.It is also possible to provide the PFC choke with other components as a pre-assembled module, so that the actual fixing of the PFC choke assembly to the circuit board is possible in a quick and easy manner.

[0004] This is achieved according to the invention in that the PFC choke arrangement has a PFC choke with a winding core, in particular a toroidal core, and a winding as well as a busbar element, in particular a busbar for electrically contacting the PFC choke. The PFC choke arrangement further comprises a base plate on which the PFC choke is arranged, and an electrical contact element. The electrical contact element is designed to establish an electrical connection and / or signal transmission between the busbar element and a printed circuit board. The electrical contact element has a first electrical contact region, designed to electrically contact the busbar element, and a second electrical contact region, designed to electrically contact the printed circuit board, as well as a connection region.The connection area is designed to establish a connection between the base plate and the electrical contact element. This allows for a solderless and / or weld-free connection of the components of the PFC choke assembly and a solderless and weld-free connection to the circuit board.

[0005] The subclaims show preferred developments of the invention.

[0006] Preferably, the connecting region of the electrical contact element is a force-locking and form-locking first press connection. The first press connection is thus formed between the base plate and the connecting region of the electrical contact element.

[0007] Further preferably, the first and second electrical contact regions of the electrical contact element are of identical design. Particularly preferably, the electrical contact element is provided symmetrically.

[0008] More preferably, the first electrical contact region establishes an electrically conductive, force-locking and positive-locking second press connection to the busbar element. Preferably, the second electrical contact region of the electrical contact element is configured to provide an electrically conductive, force-locking and positive-locking third press connection to a printed circuit board. This allows all connections of the electrical contact element to be formed as press connections, which can be implemented quickly and easily and do not require any soldering and / or welding processes or the like.

[0009] The electrical contact element is preferably designed as a contact pin. The connecting region of the electrical contact element is arranged in a central region of the contact pin. The first electrical contact region is arranged at a first free end of the contact pin, and the second electrical contact region is arranged at a second free end of the contact pin.

[0010] Preferably, the first and second electrical contact areas have two electrical contacting elements.

[0011] Further preferably, the contact pin has a stop that rests against a support area of ​​the base plate. This allows a defined position of the contact pin relative to the busbar element to be defined. This is particularly advantageous with regard to the necessary tolerance requirements. The stop is preferably provided centrally on the contact pin.

[0012] The PFC choke assembly further preferably comprises a shielding device for shielding the PFC choke. The base plate and / or the busbar element is preferably arranged between the PFC choke and the shielding device.

[0013] The base plate preferably includes a support area configured for support on a housing. This allows, in particular, the heavy weight of the PFC choke, which is connected to the base plate, to be supported.

[0014] Furthermore, the shielding device is preferably plate-shaped and has a through-opening through which the electrical contact element is guided. The connecting region is thus arranged in the through-opening.

[0015] The base plate preferably has a receiving area in which the electrical contact element is at least partially arranged. The receiving area preferably protrudes perpendicularly from the base plate and is hollow-cylindrical. Alternatively, the receiving area has two or three or more arms.

[0016] The receiving area is preferably arranged above the support area.

[0017] Further preferably, the PFC choke, the busbar element, the base plate and the electrical contact element are a pre-assembled assembly.

[0018] The invention further relates to a printed circuit board arrangement comprising a printed circuit board and a PFC choke arrangement according to the invention.

[0019] The present invention further relates to a method for producing the printed circuit board assembly. The method comprises the steps of providing a PFC choke with a busbar element and a base plate, the step of pressing the electrical contact element into the busbar element to form a preassembled module, the step of arranging the module in a housing of the printed circuit board assembly, the step of connecting the printed circuit board to a shielding element for the PFC choke, the step of connecting the shielding device to the housing, and the step of simultaneously pressing the electrical contact element at the second electrical contact area into the printed circuit board. This enables simple and secure fixing and electrical contacting of the PFC choke. Short description of the drawings

[0020] The invention is described below using exemplary embodiments in conjunction with the figures. Preferably, all identical components, elements, and / or units are provided with the same reference numerals in all figures. In the drawing: Fig. 1 a schematic sectional view of a printed circuit board arrangement with a PFC choke arrangement according to a preferred embodiment of the invention and Fig. 2 a schematic side view of an electrical contact element of the PFC choke arrangement of Fig. 1. Preferred embodiments of the invention

[0021] The following is based on the Fig. 1 and Fig. 2 a PFC choke arrangement 1 of a printed circuit board arrangement 100 and a method for producing the printed circuit board arrangement 100 are described in detail.

[0022] Fig. 1 shows a schematic sectional view arrangement 100 with a PFC choke arrangement 1.

[0023] The PFC choke assembly 1 is fixed to a circuit board 101 and electrically contacted.

[0024] The PFC choke assembly 1 comprises a PFC choke 2 with a core 20 and a winding 21, which is at least partially wound around the core 20. Due to its general construction, the PFC choke 2 is a relatively heavy component that must be securely attached to the printed circuit board 101.

[0025] The PFC choke assembly further comprises a busbar element 3 for electrically contacting the PFC choke 2. An electrical terminal 11 is provided on the PFC choke 2 and is electrically connected to the busbar element 3.

[0026] The PFC choke assembly 1 further comprises a base plate 4 made of an electrically insulating material. The PFC choke 2 is arranged on the base plate 4. The base plate 4 has two extensions 41, 42, which hold the core 20 of the PFC choke 2, for example, by means of a force-fit connection.

[0027] The PFC choke assembly 1 further comprises an electrical contact element 5, which is designed to establish an electrical connection between the busbar element 3 and the printed circuit board 101.

[0028] The electrical contact element 5 in this embodiment is a contact pin, which in detail consists of Fig. 2. The electrical contact element 5 has a first electrical contact region 51, which is designed to contact the busbar element 3. Furthermore, the electrical contact element 5 comprises a second electrical contact region 52, which is designed to electrically contact the printed circuit board 101. The first electrical contact region 51 and the second electrical contact region 52 are connected to one another via a connecting region 50. The electrical contact element 5 is made of an electrically conductive material.

[0029] How to continue Fig. 2, the pin-shaped electrical contact element 5 has at least one or more electrical contacts on both the first electrical contact area 51 and the second electrical contact area 52.

[0030] As is particularly evident from Fig. As can be seen in Figure 1, the connecting region 50 of the electrical contact element 5 has a force-locking and form-locking first fitting connection 6, which is formed with the base plate 4. The base plate 4 has a cylindrical receiving region 43.

[0031] A stop 53 is also provided on the connecting area 50 of the electrical contact element 5. As can be seen from Fig. As can be seen in Figure 1, the stop 53 comes into contact with a stop area 40 on the receiving area 43 of the base plate 4. This ensures precise positioning of the electrical contact element 5, particularly in the direction perpendicular to the circuit board 101.

[0032] How to continue Fig. As can be seen in Figure 1, the first electrical contact area 51 has an electrically conductive, force-locking and form-locking second press connection 7 to the busbar element 3. The second electrical contact area 52 has an electrically conductive, force-locking and form-locking third press connection 8 to the circuit board 101.

[0033] Thus, the winding 21 is electrically connected to the circuit board 101 via the electrical connection 11 and the busbar element 3 and the electrical contact element 5.

[0034] As in detail Fig. As can be seen from Figure 2, the electrical contact element 5, designed as a contact pin, thus has the first electrical contact region 51 at a first free end 5a and the second electrical contact region 52 at a second free end 5b. Preferably, the two electrical contact regions 51, 52 are constructed identically.

[0035] The PFC choke assembly 1 further comprises a shielding device 9. The shielding device 9 is arranged between the circuit board 101 and the PFC choke 2. More precisely, the shielding device 9 is arranged between the circuit board 101 and the busbar element 3. The shielding device 9 can, in particular, shield the circuit board 101 and the components arranged thereon against electromagnetic fields that can occur during operation due to the PFC choke.

[0036] The base plate 4 further comprises a support area 44, with which the base plate 4 rests on a housing 10. This allows the weight of the PFC choke 2 to be easily supported on the housing 10.

[0037] How to continue Fig. As can be seen in Figure 1, the shielding device 9 has a through-opening 90. The electrical contact element 5 is guided through the through-opening 90. This achieves a particularly compact design of the PFC choke arrangement below the printed circuit board 101.

[0038] How to continue Fig. 1, the receiving area 43 is arranged vertically above the support area 44 of the base plate 4. This makes it possible, in particular, to maintain tolerances perpendicular to the circuit board 101 very precisely, since the electrical contact element 5 is supported on the receiving area 43 of the base plate 4 via the stop 53, and the base plate 4 itself is supported on the housing 10.

[0039] How to continue Fig.As is clear from Figure 1, it is possible for the PFC choke 2, the busbar element 3, the base plate 4, and the electrical contact element 5 to be provided in advance as a pre-assembled assembly. This can simplify, in particular, the assembly of the PFC choke assembly 1.

[0040] The method according to the invention for producing the printed circuit board assembly 100 is preferably carried out such that, in a first step, the PFC choke 2 is provided with the busbar element 3. This can be achieved, for example, by connecting the electrical connection 11 to the busbar element 3. Preferably, the busbar element 3 is already a pre-assembly together with the base plate 4, so that this pre-assembly is fixed together to the PFC choke 2. Subsequently, the electrical contact element 5 is pressed into the busbar element 3 at the first electrical contact area 51. This creates the second press connection 7. Since the electrical contact element 5 rests with the stop 53 on the receiving area 43 with the support area 44, tolerances can be maintained very precisely.Thus, a pre-assembled assembly comprising the PFC choke 2, the busbar element 3, the base plate 4 and the electrical contact element 5 is provided.

[0041] Subsequently, in a next step, this pre-assembled module can be connected to the circuit board 101, to which the shielding device 9 is already fixed. In this case, the shielding device 9, which is connected to the circuit board 101, for example, by means of fixing pins 12, is preferably connected to the housing 10 with additional fixing pins 12, and at the same time, the electrical contact is established at the second electrical contact area 52 of the electrical contact element 5 to the circuit board 101.

[0042] Thus, the PFC choke arrangement has three force-locking and form-locking connections on the electrical contact element 5, namely the first press fit 6 between the electrical contact element 5 and the base plate 4 and the two electrically conductive force-locking and form-locking connections (second and third press fits 7, 8) on the first and second electrical conducting areas 51, 52.

[0043] Thus, according to the invention, a PFC choke assembly 1 can be provided on a printed circuit board 101 without a welded connection and / or without a soldered connection. This considerably simplifies the manufacturing process, since no corresponding welding or soldering station needs to be provided. It is also possible for essential parts of the PFC choke assembly 1, as explained above, to be provided as a preassembled module. The PFC choke 2 can thus be easily arranged below the printed circuit board level. The second press connection 7 and the third press connection 8 establish secure electrical contacts between the components. All contacts can be provided using a press-fit technology.

Claims

[1] PFC choke assembly comprising: - a PFC choke (2) with a core (20) and a winding (21), - a busbar element (3) for electrically contacting the PFC choke (2), - a base plate (4), wherein the PFC choke (2) is arranged on the base plate (4), - an electrical contact element (5) which is designed to establish an electrical connection between the busbar element (3) and a printed circuit board (101), - wherein the electrical contact element (5) comprises a first electrical contact region (51) configured for electrically contacting the busbar element (3), a second electrical contact region (52) configured for electrically contacting the printed circuit board (101), and a connecting region (50), wherein the connecting region (50) is connected to the base plate (4). [2] PFC choke arrangement according to claim 1, wherein the connecting region (50) of the electrical contact element (5) establishes a force-locking and form-locking first press connection (6) to the base plate (4). [3] PFC choke arrangement according to one of the preceding claims, wherein the first electrical contact region (51) and the second electrical contact region (52) are of identical design. [4] PFC choke arrangement according to one of the preceding claims, wherein the first electrical contact region (51) establishes an electrically conductive, non-positive and positive second press connection (7) to the busbar element (3). [5] PFC choke arrangement according to one of the preceding claims, wherein the second electrical contact region (52) is configured to produce an electrically conductive, force-locking and form-locking third press connection (8) to a printed circuit board (101). [6] PFC choke arrangement according to one of the preceding claims, wherein the electrical contact element (5) is a contact pin and the first electrical contact region (51) is arranged at a first free end (5a) of the contact pin and the second electrical contact region (52) is arranged at a second free end (5b) of the contact pin and the connecting region (50) forms a central region of the contact pin. [7] PFC choke arrangement according to claim 6, wherein the contact pin has a stop (53) which bears against a support region (40) of the base plate (4) and defines a defined position of the contact pin to the base plate (4) and defined positions of the first and second electrical contact regions. [8] PFC choke arrangement according to one of the preceding claims, further comprising a shielding device (9) for shielding the PFC choke (2), wherein the base plate (4) and / or the busbar element (3) are arranged between the PFC choke (2) and the shielding device (9). [9] PFC choke arrangement according to claim 8, wherein the shielding device (9) is plate-shaped and has a through-opening (90) through which the electrical contact element (5) is passed, so that the connecting region (50) is arranged in the through-opening (90). [10] PFC choke arrangement according to one of the preceding claims, wherein the base plate (4) has a receiving area (43) in which the electrical contact element (5) is at least partially arranged. [11] PFC choke arrangement according to one of the preceding claims, wherein the base plate (4) has a support area (44) which is designed for support on a housing (10). [12] PFC choke assembly according to claim 11, wherein the receiving area (43) is arranged above the support area (44). [13] PFC choke arrangement according to one of the preceding claims, wherein the PFC choke (2), the busbar element (3), the base plate (4) and the electrical contact element (5) form a pre-assembled assembly. [14] Printed circuit board assembly comprising a printed circuit board (101) and a PFC choke assembly (1) according to one of the preceding claims. [15] A method for manufacturing a printed circuit board assembly (100) according to the preceding claim, comprising the steps: - Providing a PFC choke (2) with a busbar element (3) and a base plate (4), - pressing an electrical contact element (5) at a first electrical contact area (51) into the busbar element (3) so that a pre-assembled assembly is formed, - arranging the pre-assembled module in a housing (10), - connecting a printed circuit board (101) to a shielding device (9) and - Connecting the shielding device (9) to the housing (10) and simultaneously pressing the electrical contact element (5) at the second electrical contact area (52) into the printed circuit board (101).

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