Device having winding carrier and magnetic core, and manufacturing method thereof

Abstract

To provide a device including an improved winding carrier.SOLUTION: A device (1) includes a winding carrier (2), at least one winding (3), a magnetic core (7), and first and second terminals (5, 6). The winding carrier (2) surrounds the magnetic core (7) in a defined area such that an insulation path between the terminals along the underside (14) of the device (1) does not include bridging by the magnetic core (7). In particular, the lower side (14) of the winding carrier (2) is in a closed configuration.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The present invention relates to a device comprising a winding carrier with a winding and a magnetic core. It is for example a transformer. It can be another device with a magnetic core. [Background technology]

[0002] In the case of electrical equipment such as transformers, for example, prescribed insulation distances, in particular according to IEC standards, must be observed between the electrical terminals. Therefore, the insulation distances between the terminals, i.e. the shortest possible creepage and / or clearance distances along the insulating material, should be sufficiently large. For example, insulation distances must be observed between the terminals on the power supply side and the terminals on the consumer side.

[0003] Since the insulation distance can be bridged by the conductive magnetic core, the distance between the terminals is correspondingly long. For example, at operating altitudes of more than 4 km above sea level, long clearance distances are required. To ensure a sufficient insulation path, the distance from the electrical terminals to the magnetic core is usually chosen to be appropriately large. This leads, among other things, to an undesirable increase in the size of the device, since the size of the insulation path and the magnetic core to be protected are summed up.

[0004] To prevent the insulation path from being bridged, the core itself may be encapsulated in a plastic housing and placed in an insulated state within the device. It is also known to cast the part as a whole, for example a wound toroidal core, with only the terminals protruding from the casting. However, this has drawbacks in terms of cost and part size.

[0005] It is also known from patent document 1 that the coil with the magnetic core is inserted together into a housing open on one side, insulating the magnetic core from the terminal pins and in this way increasing the clearance distance. The wire ends are then led from the windings to the pins via the outside of the housing. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 9,646,755 Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present invention to identify an improved device and method for manufacturing the device. [Means for solving the problem]

[0008] According to a first aspect of the invention, the device comprises a winding carrier and at least one winding arranged around the winding carrier. The winding can be, for example, a winding of a wire, such as a round or flat wire, or can be a printed winding. The winding carrier is, inter alia, made of an electrically insulating material. For example, it is a plastic material. The winding carrier is, inter alia, used to position the winding. In particular, the winding is wound directly on a predetermined area of ​​the winding carrier. The winding carrier, for example, has a single-piece design. In particular, the winding carrier can be manufactured by injection molding.

[0009] Additionally, the device includes a magnetic core. The magnetic core includes, for example, a ferrite material. Among other things, the magnetic core encases a predetermined area of ​​the winding. For example, the magnetic core forms a closed magnetic circuit. The magnetic core can include a number of magnetic core sections. For example, the magnetic core includes an I-shaped core section and a U-shaped core section. Other magnetic core shapes are also possible. For example, the magnetic core sections are glued together.

[0010] The device includes at least one first electrical terminal and at least one second electrical terminal. The device is, for example, configured as a transformer. The first electrical terminal is, for example, formed on the primary side and the second terminal is formed on the secondary side. The first terminal may in particular be a terminal on the power supply side and the second terminal a terminal on the consumer side.

[0011] The device may have a plurality of first terminals and a plurality of second terminals. The terminals may be, for example, in the form of pins. For example, the first terminals are arranged side by side in a first row and the second terminals are arranged side by side in a second row. The first terminals are, for example, electrically connected in pairs with one or more first windings and the second terminals are, for example, electrically connected in pairs with one or more second windings. The terminals may be, for example, arranged in a lower area of ​​the winding carrier. The first terminals and the second terminals are, for example, arranged on opposite edges of the winding carrier. The terminals may be directly attached to the winding carrier. For example, the terminals are co-injected in an injection molding process.

[0012] The winding carrier is designed as at least a partial insulator of the magnetic core. Therefore, no additional insulation of the magnetic core is necessary. In particular, a separate casting or a separate housing for the magnetic core is not required. In particular, the winding carrier at least partially surrounds the magnetic core, such that the insulation path between the terminals along the underside of the device does not include bridging by the magnetic core. The insulation path here is the shortest clearance and / or creepage path. So, for example, the minimum creepage distance does not extend towards the magnetic core, but only along the winding carrier.

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

[0014] The winding carrier therefore insulates the magnetic core from the terminals in such a way that the insulation path between the terminals is not shortened by the presence of the magnetic core. By insulating the magnetic core, the component size can be reduced. For example, it is sufficient to place the terminals at a distance equal to the minimum insulation distance. The component size can be minimized without having to consider bridging of the insulation path through the magnetic core.

[0015] For example, the winding carrier comprises an underside. The underside is the mounting side of the winding carrier or device, i.e. the side facing, for example, a printed circuit board on which the winding carrier may be mounted. The first terminal is, for example, arranged at a first edge when viewed from the underside, and the second terminal is, for example, arranged at an opposite, second edge. The winding carrier does not, for example, comprise a cut-out on the underside through which the magnetic core is exposed. In particular, no such cut-out is provided in the area laterally bounded by the first and second terminals. In this way, the insulating path between the terminals along the underside is prevented from comprising a bridge through the magnetic core.

[0016] However, it is possible that the part of the magnetic core beyond the terminals, i.e. away from the centre of the device, is not enclosed by the winding carrier, however this does not result in bridging of the insulating path between the terminals.

[0017] The winding carrier may comprise at least one opening through which the magnetic core or a core part of a magnetic core can be inserted into the winding carrier. On the lower side, for example, there is no such opening, which allows the lower winding carrier to have a closed design.

[0018] In one embodiment, at least one opening is arranged on a side of the winding carrier. Thus, the magnetic core can be inserted laterally into the winding carrier. In addition, the winding carrier may include at least one opening on its upper side. For example, the winding carrier includes an opening on the side and an opening on the upper side. Two magnetic cores can be inserted through these openings. For example, an I-shaped magnetic core is inserted through one of the openings and a U-shaped magnetic core is inserted through the other opening.

[0019] In a further embodiment, the winding carrier may include one or more openings for inserting the cores only on its upper side. In this way, the sides of the winding carrier do not need to be provided with openings, which can further insulate the cores. So, in case of multiple cores, all cores are inserted into the winding carrier from the top side. For example, the first core can be inserted first through the opening on the top side, then the winding can be applied, and then the second core can be inserted.

[0020] If the openings in the winding carrier are appropriately positioned, the core can be enveloped by the winding carrier not only from below but also from the sides. This makes it possible to particularly well prevent the core from bridging the insulation path. For example, the core is completely insulated from the outside by the winding carrier on at least one side. It is also possible for the core to be completely insulated from the outside by the winding carrier on two or more sides.

[0021] Depending on the design of the enclosure of the core by the housing, the insulation can be symmetrical or asymmetrical with respect to the terminals. For example, the housing increases the insulation path between the core and one of the terminals. The insulation path between the core and both terminals can also be increased.

[0022] For example, the first terminal is arranged on a first side of the winding carrier and the second terminal is arranged on a second side of the winding carrier. For example, the magnetic core is completely surrounded by the winding carrier on at least one of these sides. Therefore, a bridge of an insulating path through the magnetic core cannot be formed along this side. The magnetic core is not completely enclosed on the side, but only to a predominant extent. For example, a smaller portion of the magnetic core may be exposed at the top end of the side.

[0023] The winding carrier may include a leadthrough along the winding axis. The magnetic core may be arranged in the leadthrough. By being arranged in the leadthrough, the magnetic core is also insulated from the winding carrier on the outside, e.g. towards the sides.

[0024] According to one embodiment, at least one of the terminals is arranged in a recess. For example, the recess terminal is attached to an area of ​​a side surface of the winding carrier that is recessed inwardly with respect to another area of ​​the side surface. In this way, the dimensions of the component can be reduced. As a result, the distance between the first and second terminals can be reduced with the insulation of the magnetic core not falling below the minimum insulation distance. For example, the spacing between the terminals can be equal to the minimum insulation spacing. Thus, the overall component size can also be limited to the minimum insulation dimension.

[0025] According to another aspect of the invention, an apparatus includes a winding carrier and at least one winding of a wire arranged around the winding carrier. The apparatus includes a magnetic core and at least a first electrical terminal and at least one second electrical terminal, the winding carrier including an underside, the terminals being arranged opposite each other with respect to the underside. The winding carrier does not include a cutout through which the magnetic core is exposed, at least in an area of ​​the underside laterally bounded by the first terminal and the second terminal. The apparatus may include all of the structural and functional features of the aforementioned apparatus.

[0026] The closed configuration of the winding carrier underneath insulates the lower core from the terminals and the safety gap in this area is not bridged by the core.

[0027] According to a further aspect of the invention, a method for manufacturing the device is provided.The device and all of its components, for example the winding carrier, terminals and magnetic core, may be constructed as described above.

[0028] According to the method, a winding carrier is provided which includes one or more openings on the side and / or top side. A first magnetic core is inserted into the winding carrier through one of the openings. A second magnetic core is inserted into the winding carrier through one of the openings. The second magnetic core can be inserted through the same opening as the first core or through a different opening. Thus, the magnetic core is inserted through an opening on the side and / or top side but not on the underside of the winding carrier. Thus, the underside can be formed without such openings.

[0029] For example, one of the cores is I-shaped and the other of the cores is U-shaped. After insertion into the winding carrier, the cores may form a closed magnetic circuit. For example, the cores are glued together after insertion.

[0030] In one embodiment, one of the cores is inserted through an opening on the side and the other core is inserted through an opening on the top. In this case, the windings can be wound on the winding carrier before inserting both cores. For example, a winding mandrel is inserted into the winding carrier through one of the openings on the top side and removed after winding.

[0031] In one embodiment, two magnetic cores are inserted through the same opening on the top side. For example, a first magnetic core is positioned along the winding axis in the winding carrier. For example, after insertion of the first magnetic core, a winding is applied to the winding carrier. For example, a winding is applied around the winding carrier and the magnetic core. Then, a second magnetic core is inserted.

[0032] If the winding shaft is occupied by a first core before the windings are applied, the winding mandrel cannot be inserted into the winding shaft. For example, the winding carrier includes a retention device on its outer surface that allows the winding carrier to be secured to a winding machine.

[0033] The present invention comprises several aspects, inter alia apparatus and methods, and embodiments described with respect to one aspect apply correspondingly to other aspects.

[0034] Moreover, the description of the objects disclosed herein is not limited to individual specific embodiments. Rather, the features of the individual embodiments may be combined with each other to the extent that is technically useful.

[0035] In the following, the subject matter described herein is explained in more detail by means of schematic embodiments. [Brief description of the drawings]

[0036] [Figure 1A] FIG. 1A is a cross-sectional view of an embodiment of a device. [Figure 1B] FIG. 1B shows the device of FIG. 1A viewed obliquely from above. [Figure 1C] FIG. 1C shows the device of FIG. 1 viewed obliquely from below. [Diagram 2] FIG. 2 shows a further embodiment of the device seen obliquely from above. [Figure 3A] FIG. 3A illustrates one embodiment of a winding carrier from a top-down perspective. [Figure 3B] FIG. 3B is a longitudinal cross-sectional view of the winding carrier of FIG. 3A. [Figure 4A] FIG. 4A is a side view of a further embodiment of the device from an oblique top view. [Figure 4B] FIG. 4B is a further side view of the device of FIG. 4A, taken obliquely from above. [Figure 4C] FIG. 4C shows the device of FIG. 4A viewed obliquely from below. [Figure 4D] FIG. 4D shows the device of FIG. 4A from a top view. [Diagram 5] FIG. 5 is a side view of a further embodiment of the device seen obliquely from above. [Figure 6A] 6A-6E are method steps for manufacturing components of the device of FIG. [Figure 6B] 6A-6E are method steps for manufacturing components of the device of FIG. [Figure 6C] 6A-6E are method steps for manufacturing components of the device of FIG. [Figure 6D] 6A-6E are method steps for manufacturing components of the device of FIG. [Figure 6E] 6A-6E are method steps for manufacturing a component of the device of FIG. [Figure 7] FIG. 7 shows a side view of a further embodiment of the device, seen obliquely from above.

[0037] Preferably, in the following drawings, functionally or structurally corresponding parts of the various embodiments are designated by the same reference symbols. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] Figure 1A shows a longitudinal cross section of one embodiment of the device 1. Figure 1B shows the device 1 viewed obliquely from above, and Figure 1C shows the device 1 viewed obliquely from below.

[0039] The device 1 is configured, for example, as a transformer. The device 1 can also be configured as a device having a different function, in particular in a device in which maintaining an insulating path between electrical terminals is of particular importance.

[0040] The device 1 comprises a winding carrier 2 on which at least one winding 3 of wire 4 is wound. Here, the winding 3 is arranged in an upright manner, i.e. the winding axis is arranged perpendicular to the underside 14 of the device 1. The underside 14 corresponds to the mounting side of the device 1 in case of, for example, fixing to a printed circuit board. The winding carrier 2 is made from an electrically insulating material. The winding carrier 2 is made, for example, non-magnetic. The winding carrier 2 may also be made from a plastic material. For example, the winding carrier 2 is manufactured by an injection molding process.

[0041] A number of windings may be applied around the winding carrier 2, in particular one or more primary windings and one or more secondary windings of a transformer. Wherever one winding is mentioned in this specification, this also applies to multiple windings. The winding carrier 2 has flange-like boundaries 10, 11 on both sides, between which the winding 3 is arranged.

[0042] The wire 4 comprises a metallic material, for example copper. The wire 4 is sheathed with an insulator, for example triple insulated (TIW "triple insulated wire"), so that the wire 4 or the windings 3 do not need to be separately coated or additionally insulated.

[0043] The device 1 comprises at least a first terminal 5 and a second terminal 6. The terminals 5, 6 are attached directly to the winding 2, for example by co-injection moulding when manufacturing the winding carrier 2 in an injection moulding process. The ends of the winding 3 are connected to the terminals 5, 6. Currently, a number of the first terminals 5 are arranged in a row, and a number of the second terminals 6 are arranged in a row. The first terminals 5 and the second terminals 6 are arranged on both side surfaces 16, 24 of the device 1.

[0044] In this regard, all of the first terminals 5 may be primary side terminals, i.e. power supply side terminals, and all of the second terminals 6 may be secondary side terminals, i.e. consumer side terminals. For example, the first terminals 5 are for connection to a supply network and the second terminals 6 are for connection to a consumer, e.g. a refrigerator. For example, two of the first terminals 5 are each connected to a first primary winding and two of the second terminals 6 are each connected to a secondary winding.

[0045] The device 1 comprises a magnetic core 7. The magnetic core 7 comprises, for example, a ferrite material or another magnetic material. The magnetic core 7 is not formed as a winding carrier itself, but is a separate element attached to the winding carrier 2. The magnetic core 7 is of a different material than the winding carrier 2. In particular, the magnetic core 7 has a greater electrical conductivity than the winding carrier 2.

[0046] In the present case, the magnetic core 7 is made up of several parts. The first magnetic core 8 comprises an I-shape. The second magnetic core 9 comprises a U-shape. The magnetic cores 8, 9 can also comprise other shapes, for example both magnetic cores 8, 9 can be U-shaped. The magnetic cores 8, 9 together form a closed magnetic circuit. The magnetic cores 8, 9 are for example glued together.

[0047] The magnetic core 7 is typically more electrically conductive than the winding carrier 2 and can lead to an electrical bridge of the insulation path between the first terminal 5 and the second terminal 6. Therefore, the magnetic core 7 does not contribute to the insulation path between the first terminal 5 and the second terminal 6, and therefore an insulation clearance must be maintained separately from the magnetic core 7.

[0048] Here, the insulation path 28 between the first terminal 5 and the second terminal 6 is in particular the shortest creepage distance between the terminals 5, 6 along the surface of the component 1 and / or the shortest clearance distance between the terminals 5, 6. For such insulation paths, a minimum length, for example according to IEC standards, must be observed. In the case of multiple first terminals 5 and multiple second terminals 6, the insulation path is the shortest of the insulation paths between the first terminal 5 and the second terminal 6. In other words, the spacing and insulation path conditions described herein may be applied to any pair of first terminals 5 and second terminals 6.

[0049] 1B, a first insulating path 12 is shown between the magnetic core 7 and the first terminal 5. In addition, a second insulating path 13, specifically the shortest air gap, is shown between the magnetic core 7 and the second terminal 6. Here, the insulating path between the first terminal 5 and the second terminal 6 along the top side 15 of the device is the sum of the first insulating path 12 and the second insulating path 13.

[0050] In Fig. 1C the device 1 is shown from its underside 14. The winding carrier 2 is closed at the bottom. In particular there are no cutouts on the underside 14 through which the magnetic core 7 can protrude from the winding carrier 2 or through which the magnetic core 7 can be pressed into the winding carrier 2. The magnetic core 7 is therefore insulated by the winding carrier 2 in the area of ​​the underside 14 between the first terminal 5 and the second terminal 6. The arrangement of the magnetic core 7 inside the winding carrier 2 ensures a space-saving insulation. The magnetic core 7 protrudes only laterally from the winding carrier 2. At least in the area of ​​the underside 14 bounded laterally by the first terminal 5 and the second terminal 6, the winding carrier 2 does not include any cutouts through which the magnetic core 7 is exposed.

[0051] In this way, the insulation path 28 between the second terminals 6 along the underside 14 is not bridged by the magnetic core 7. As can be seen, the insulation path 29 from the second terminal 6 to the magnetic core 7 is increased by envelopment by the insulating winding carrier 2. The magnetic core 7 is therefore partially insulated from the outside by the winding carrier 2 such that the minimum creepage or clearance distance between the first terminal 5 and the second terminal 6 along the underside 14 of the device 1 does not include bridging by the magnetic core. The magnetic core 7 therefore does not bridge or shorten the insulation path between the terminals 5, 6.

[0052] Therefore, at the underside 14, the size of the device 1 can be reduced since the magnetic core 7 does not affect the insulating path 28 between the terminals 5, 6. In particular, at the underside 14, the distance d of the first terminal 5 from the second terminal 6 can be minimized to a minimum insulating distance. It is only necessary to ensure that the required minimum insulating distance is maintained along the upper side 15, even in the bridge by the magnetic core 7.

[0053] In particular, the magnetic core 7 is enclosed by the winding carrier 2 such that the sum of the insulating path 12 between the first terminal 5 and the magnetic core 7 and the insulating path 13 between the second terminal 6 and the magnetic core 7 is at least as large as the geometric distance between the first terminal and the second terminal 6.

[0054] On the underside, the winding carrier also includes a recess 23 through which an insulating path 29 between the second terminal 6 and the magnetic core 7 can extend.

[0055] The magnetic core 7 protrudes from the winding carrier 2 only at a side surface 16 of the winding carrier 2. In particular, the winding carrier 2 comprises a first opening 17 (see Figures 3A, 3B) at the side surface 16, through which the magnetic core 7 protrudes from the winding carrier 2. In addition, the winding carrier 2 comprises a second opening 18 (see Figures 3A, 3B) at its top side 15, through which the magnetic core 7 protrudes from the winding carrier 2.

[0056] The magnetic core 7 protrudes into the first opening 17, penetrates the winding carrier 2 via the leadthrough 19 and exits the winding carrier 2 via the second opening 18. The leadthrough 19 (see Figures 3A, 3B) extends along the winding axis in a first region 30 and parallel to the underside 14 in a second region 31. Inside the leadthrough 19, i.e. from the first opening 17 to the second opening 18, the magnetic core 7 is surrounded by the winding carrier 2 without interruption.

[0057] 1A, 1B and 1C, the magnetic core 7 is asymmetrically positioned and insulated with respect to the winding carrier 2 and the terminals 5, 6. Therefore, the insulation path 12 between the magnetic core 7 and the first terminal 5 is small, but the insulation path 13 between the magnetic core 7 and the second terminal 6 is quite large.

[0058] The first core 8 is I-shaped and the second core 9 is U-shaped. The I-shaped first core 8 is arranged parallel to the underside 14. The U-shaped second core 9 is arranged with its legs along the winding axis. In other embodiments, the I-shaped first core may be arranged along the winding axis and the U-shaped second core may be arranged with its legs parallel to the underside. Also, both cores 8, 9 may be U-shaped, for example.

[0059] In the following, a method for manufacturing the device 1 is described.

[0060] A winding carrier 2 is provided and a winding 3 is applied to the winding carrier 2. For this purpose, for example, a winding mandrel (not shown here) is inserted into a first opening 17 (see Figures 3A, 3B). After applying the winding 3, the winding mandrel is removed and an I-shaped first magnetic core 8 is inserted laterally into the first opening 17. Subsequently, a U-shaped second magnetic core 9 is inserted from the top side 15 into a second opening 18 (see Figures 3A, 3B). The first magnetic core 8 and the second magnetic core 9 can be glued to one another.

[0061] 2 shows a further embodiment of the device 1. In contrast to the embodiment described above, the device 1 comprises two first terminals 5 on a first side 15 and four second terminals 6 on a second side 24.

[0062] The first terminal 5 is configured for example for connection to a supply network and the second terminal 6 is configured for connection to a consumer. The first terminal 5 is for example connected to the first winding 3 and the second terminal 6 is pair-connected to two further windings 20. The first winding 3 is for example arranged above the second winding 20 in the direction of the winding axis. The second winding 20 is arranged in the same position, for example one above the other with respect to the winding axis. Since the windings are insulated from the outside, the windings 3, 20 can be arranged differently, for example all in the same position with respect to the winding axis.

[0063] The present invention is not limited to the number and arrangement of the first and second terminals and windings shown, for example, there may be only two first terminals and two second terminals and two windings.

[0064] Also, in the embodiment shown, since the underside 14 of the winding carrier 2 is completely closed, in order to maintain the minimum insulation path at the underside 14 of the device 1, it is sufficient to select the distance between the opposing terminals 5, 6 to be equal to the minimum insulation path.

[0065] In addition, the winding carrier 2 has a protrusion on its upper side 15, which increases the creepage and clearance distances between the magnetic core 7 and the second terminal 6 along the upper side 15. A first protrusion 21 extends upwards in the area of ​​the winding carrier 2. A second protrusion 22 extends the winding carrier 2 towards one side. Both protrusions 21, 22 are selected so as not to increase the external dimensions of the device 1.

[0066] Figure 3A shows an embodiment of the winding carrier 2 as viewed obliquely from above. Figure 3B shows a longitudinal section through the winding carrier 2. The winding carrier 2 is essentially configured as the winding carrier 2 of Figure 2, except that it does not include the additional protrusions 21, 22.

[0067] The winding carrier 2 comprises a first opening 17 at its side surface 16 and a second opening 18 at its top side 15. In the cross-sectional view of FIG. 3B it can be seen that there is a leadthrough 19. The leadthrough 19 comprises a first region 30 extending parallel to the winding axis (vertical in this case) and a second region 31 extending perpendicular to the winding axis. The second region 31 extends parallel to the bottom side 14. The leadthrough 19 is configured generally in an L-shape. The leadthrough 19 is completely enclosed by the winding carrier 2 and is therefore only accessible from the outside at the openings 17, 18.

[0068] Figure 4A shows a side view of one embodiment of the device 1, viewed at an angle from above. Figure 4B shows another side view of the device, viewed at an angle from above. Figure 4C shows the device, viewed at an angle from below. Figure 4D shows a top view of the device.

[0069] For clarity, the device 1 is shown without windings. In the finished device 1, the windings are applied directly around the winding carrier 2. In contrast to the embodiments described above, the winding axis runs parallel to the underside 14 of the device 1. The winding carrier 2 comprises two flange-like borders 10, 11 which bound the windings on either side.

[0070] The first terminals 5 and the second terminals 6 are provided directly on the winding carrier 2. In the present case there are only two first terminals 5 and two second terminals 6.

[0071] Here, the magnetic core 7 includes an I-shaped first magnetic core portion 8 and a U-shaped second magnetic core portion 9 (see FIG. 4B). The first magnetic core portion 8 is disposed on the winding carrier 2 along the horizontal winding axis.

[0072] The winding carrier 2 completely encases the magnetic core 7 on the underside 14. In this case, the lower area of ​​the magnetic core 7 is formed by the I-shaped core part 8, which is enclosed by the winding carrier 2 from almost all sides. Only the area of ​​the I-shaped core part 8 facing towards the further side 24 is open. Towards the first side 16, the magnetic core 7 is completely insulated from the winding carrier 2 towards the outside. Therefore, the magnetic core area cannot be seen from the view of the underside 14 as well as from the view of the side 16. Overall, a large area of ​​the magnetic core 7 is integrated into the winding carrier 2 and is therefore arranged so that it is hidden and insulated from the terminals 5, 6.

[0073] So, again, the insulation path between the first terminal 5 and the second terminal 6 along the underside 14 of the device 1 is not bridged by the magnetic core 7. Depending on the shape of the device 1, the insulation path, i.e. the minimum creepage or clearance distance between the first terminal 5 and the second terminal 6, runs along the underside 14 or along the side surfaces 16, 24 of the device 1. Again, the sum of the insulation path between the first terminal 5 and the magnetic core 7 and the insulation path between the second terminal 6 and the magnetic core 7 is at least as large as the geometrical distance d between the first terminal 5 and the second terminal 6.

[0074] Therefore, the distance d between the first terminal 5 and the second terminal 6 can be selected to be equal to the minimum insulation distance. As can be easily seen in Fig. 4D, the first terminal 5 and the second terminal 6 are offset inwards. In particular, the area of ​​the winding carrier 2 to which the terminals 5, 6 are fixed is further inside than the area laterally enveloping the magnetic core 7. Therefore, the winding carrier 2 is configured with steps on the side surfaces 16, 24.

[0075] This allows a further reduction in the size of the component 1 without violating the required minimum insulation distances. This miniaturization is made possible by insulating the magnetic core 7 by the winding carrier 2 with respect to the terminals 5, 6.

[0076] In the following, a method for manufacturing the device 1 is described.

[0077] A winding carrier 2 is provided and windings are applied to the winding carrier 2 (not shown). For this purpose, for example, a winding mandrel (not shown here) is inserted into the first opening 17 (FIG. 4B). After applying the windings, the winding mandrel is removed and an I-shaped first magnetic core 8 is inserted into the first opening 17. Then, a U-shaped second magnetic core 9 is inserted from the top side 15 into the second opening 18. The first magnetic core 8 and the second magnetic core 9 can be glued to each other.

[0078] In other embodiments, for example, an I-shaped core may be inserted into the upper left-most opening and a U-shaped core may be inserted laterally. The present invention is not limited to I-shaped and U-shaped cores.

[0079] Figure 5 shows a further embodiment of the device 1. Figures 6A-6E show a method for manufacturing the device, and therefore also show the internal structure of the device 1 of Figure 5.

[0080] Similar to the embodiment described above, the winding carrier 2 also forms a housing for the magnetic core 7 to insulate it from the first terminal 5 and / or the second terminal 6. The winding carrier 2 encases the magnetic core 7 from the underside 14 such that no area of ​​the magnetic core 7 is exposed between the terminals 5, 6. As in the embodiment of Figures 4A-4D, the magnetic core 7 is completely encased by the underside 14 such that no area of ​​the magnetic core 7 is exposed.

[0081] Again, the magnetic core 7 comprises a first magnetic core 8 (FIG. 5) and a second magnetic core 9 (FIG. 6A). The first magnetic core 8 is U-shaped and the second magnetic core 9 is I-shaped.

[0082] In contrast to the previous embodiment, the core 7 is inserted completely, i.e. both cores 8, 9 (see FIG. 6A for core 8), into the winding carrier 2 from the upper side 15. In particular, the winding carrier 2 comprises an opening 18 only on the upper side 15 for inserting both cores 8, 9. The housing 2 also extends partially on two further side surfaces 25, 26. The lower core 8 is not visible from the outside. Only the upper side of the upper core 9 is visible.

[0083] The magnetic core 7 is thus likewise insulated from the first terminal 5 and from the second terminal 6. In particular, the insulating path between the first terminal 5 and the magnetic core 7 is of the same length as the insulating path between the second terminal 6 and the magnetic core 7. Overall, there is a symmetrical allocation of the insulating paths between the magnetic core 7 and the first terminal 5 and between the magnetic core 7 and the second terminal.

[0084] As shown in Fig. 6A, the winding carrier 2 is provided during the manufacture of the device 1. Terminals 5, 6 are attached to the winding carrier 2. No wires are attached to the winding carrier 2 yet. A U-shaped first magnetic core 8 is inserted into the winding carrier 2 via an opening 18 in the upper side 15. In particular, the first magnetic core 8 is inserted into the open winding axis of the winding carrier 2.

[0085] 6B shows the winding carrier 2 with the U-shaped first core 8 inserted. The winding carrier 2 encases the first core 8 from the bottom side 14 and all side surfaces 16, 24, 25, 26. The first core 8 is exposed only on the top side 15. Then the wire 4 is wound on the winding carrier 2 and the winding 3 is applied.

[0086] 6C shows the winding carrier 2 with the windings 3. The windings 3 are arranged horizontally with their winding axes parallel to the underside 14 of the device 1. The wire ends of the windings 3 are guided via guide grooves in the winding carrier 2 to the terminals 5, 6 and are electrically connected to the terminals 5, 6. At the terminals 5, 6, the insulating layer is removed from the wires and the wires are, for example, soldered or laser welded to the respective terminals 5, 6.

[0087] As shown in Fig. 6D, the second core 9 is then inserted into the winding carrier 2 from the top side 15 through the opening 18. In the present case the second core 9 is I-shaped. However, it is also possible to use cores 8, 9 of different shapes, for example cores 8, 9 that are both U-shaped.

[0088] Fig. 6E shows the completed device 1. The first core 8 forms a closed magnetic circuit together with the second core 9. The first core 8 is, for example, glued to the second core 9. The second core 9 is completely enclosed on two sides 16, 24 by the winding carrier 2. The winding carrier 2 fits tightly with the cores 8, 9 and therefore defines the position of the cores 8, 9. This allows an automatic and well-controllable positioning and gluing of the cores 8, 9.

[0089] Figure 7 shows a variant of the device 1 of figures 5 to 6E. Here, the winding carrier 2 comprises a lateral holding device 27 for fixing the winding carrier 2 to a winding machine. The holding device 27 comprises, for example, a web on which a two-part spindle can be attached to the winding carrier 2.

[0090] 1A to 4D, in the embodiment of Figures 5 to 7 the winding carrier 2 does not include an opening through which a spindle can be inserted onto the winding shaft during manufacture of the windings. Prior to application of the windings, the first magnetic core 8 is placed in the winding carrier 2 such that space is already occupied by the first magnetic core 8. [Explanation of symbols]

[0091] 1 device 2 Winding Carrier 3 Winding 4 Wire 5 First Terminal 6 Second Terminal 7 magnetic core 8 First magnetic core 9 Second magnetic core 10 boundaries 11 Boundary 12 Insulation path between the first terminal and the magnetic core 13 Insulation path between the second terminal along the side and the magnetic core 14 Lower side 15 Upper 16 Side 17 Side opening 18 Upper opening 19 Lead Through 20 Further Windings 21 First protrusion 22 Second protrusion 23 Recess 24 Further aspects 25 Further aspects 26 Further Aspects 27 Holding device 28 Insulation path between the first and second terminals along the underside 28 Insulation path between the second terminal and the core along the underside 30 First area of ​​lead-through 31 Second area of ​​lead-through d Distance

Claims

1. A winding carrier, a winding of at least one wire disposed around the winding carrier, a magnetic core, at least one first electrical terminal, and at least one second electrical terminal, An apparatus comprising: The winding carrier encloses the magnetic core in at least a predetermined region such that an insulating path between terminals along the lower side of the apparatus does not include a bridge by the magnetic core, The magnetic core includes a first magnetic core portion and a second magnetic core portion, The winding carrier includes an upper side, a lower side opposite the upper side, and a side surface disposed between the upper side and the lower side, The winding carrier includes a through portion, the magnetic core is disposed within the through portion, the winding carrier includes a first opening in the side surface for inserting the first magnetic core portion, and a second opening in the upper side for inserting the second magnetic core portion, and the through portion is accessible from the outside only through the first opening and the second opening, An apparatus in which a winding axis of the winding of the at least one wire is disposed parallel to the lower side of the apparatus.

2. The apparatus according to claim 1, wherein the through portion is L-shaped.

3. The apparatus according to claim 1 or 2, wherein the winding carrier is integrally formed.

4. The magnetic core is enclosed by the winding carrier such that a sum of an insulating path between the first electrical terminal and the magnetic core and an insulating path between the second electrical terminal and the magnetic core is at least as large as a geometric distance between the first electrical terminal and the second electrical terminal. The apparatus according to any one of claims 1 to 3.

5. The apparatus according to any one of claims 1 to 4, wherein the apparatus is designed as a transformer, the first electrical terminal is on the primary side, and the second electrical terminal is on the secondary side.

6. The apparatus according to any one of claims 1 to 5, wherein the lower side of the winding carrier does not include a notch exposing the magnetic core.

7. The apparatus according to any one of claims 1 to 6, wherein one of the first magnetic core portion and the second magnetic core portion is I-shaped and the other is U-shaped.

8. The apparatus according to any one of claims 1 to 7, wherein the first electrical terminal is disposed on a first side surface of the winding carrier, and the second electrical terminal is disposed on a second side surface of the winding carrier.

9. The device according to any one of claims 1 to 8, wherein at least one of the first electrical terminal and the second electrical terminal is fixed to a part of one of the side surfaces, and the part is recessed in a direction toward another side surface of the side surfaces with respect to a further part of the one side surface of the side surfaces.

10. The device according to any one of claims 1 to 9, wherein the magnetic core is completely or mainly enclosed by the winding carrier on at least one of the side surfaces.

11. The device according to any one of claims 1 to 10, wherein the through portion extends at least partially along the winding axis.

12. The device according to any one of claims 1 to 11, wherein the first opening is located on a side surface on which at least one of the first electrical terminal and the second electrical terminal is disposed.

13. A winding carrier, a winding of at least one wire disposed around the winding carrier, a magnetic core, at least one first electrical terminal, and at least one second electrical terminal, wherein the device comprises: the winding carrier includes an upper side, a lower side opposite to the upper side, and side surfaces disposed between the upper side and the lower side, the first electrical terminal and the second electrical terminal are disposed opposite to each other with respect to the lower side, the winding carrier does not include a notch in the region of the lower side where the magnetic core is exposed, the magnetic core includes a first magnetic core portion and a second magnetic core portion, the winding carrier includes a through portion, the magnetic core is disposed in the through portion, the winding carrier includes a first opening in the side surface for inserting the first magnetic core portion, and a second opening in the upper side for inserting the second magnetic core portion, and the through portion is accessible from the outside only through the first opening and the second opening, the winding axis of the winding of the at least one wire is disposed parallel to the lower side of the device.

14. The device according to claim 13, wherein the magnetic core is completely or mainly enclosed by the winding carrier on the other of the side surfaces, and the second opening for inserting the second magnetic core portion into the winding carrier is disposed on the upper side.

15. A method for manufacturing the device according to any one of claims 1 to 14, comprising: A) providing the winding carrier and providing a first magnetic core portion and a second magnetic core portion; B) inserting the first magnetic core portion into the first opening; C) inserting the second magnetic core portion into the second opening; A method comprising the above steps.

Images