Header component, induction device, and method for assembling induction device

Abstract

The header component (3) for mounting an inductive component (2) on a substrate includes a housing (5) for accommodating the inductive component (2) in a cavity (6), the housing (5) surrounding the cavity (6) on a bottom surface and at least three sides, and the housing (5) including an upper opening (9) on a top surface opposite the bottom surface to the cavity (6), the upper opening (9) being configured to allow the inductive component (2) to be inserted into the cavity (6) through the upper opening (9). The header component (3) further includes a plurality of terminals (11, 12) for electrically connecting the inductive component (2) to the substrate, the terminals (11, 12) protruding outward from the housing (5) on the bottom surface. An inductive device (1) and a method for assembling the inductive device (1) are also disclosed.

Description

[Technical Field]

[0001] This application claims priority from German patent application CN 2022 1108 2851.6, the contents of which are incorporated herein by reference.

[0002] The present invention relates to a header component for mounting an inductive component, particularly a transformer, to a substrate, particularly a printed circuit board. The present invention further relates to an inductive device including the header component and the inductive component. The present invention further relates to a method of assembling the inductive device. [Background technology]

[0003] Headers or pin headers are known from the prior art. They are used as electrical connectors for connecting electronic components to substrates, in particular printed circuit boards. For this purpose, the headers are provided with pins or terminals for establishing an electrical connection to the substrate, in particular to the conductor patterns of the substrate. Patent document 1 discloses a header for a transformer, in which the transformer is arranged in a housing of the header. The header is introduced into the housing through a side opening. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] US 9,646,755 B2 Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved header assembly for mounting inductive components to a substrate, and in particular to provide a header assembly that allows for simple and automated assembly of the inductive components. [Means for solving the problem]

[0006] This object is achieved by a header component having the features of claim 1. The header component includes a housing for accommodating an inductive component within a cavity, the housing defining the cavity with a bottom surface and at least three side surfaces. The housing has an upper opening to the cavity on a top surface opposite the bottom surface, configured so that the inductive component can be inserted into the cavity through the upper opening. The header component further includes a plurality of terminals for electrically connecting the inductive component to a substrate, the terminals protruding outward from the housing on the bottom surface. The header component of the present invention includes an upper opening opposite the terminals. Therefore, the inductive component can be easily placed into the cavity of the housing from above, particularly vertically, using conventional pick-and-place techniques. Furthermore, the upper opening faces away from the substrate to which the inductive component is attached using the header component. Therefore, the upper opening does not impair the insulation of the inductive component from the substrate and other devices attached adjacent to the inductive component on the substrate. The header component can advantageously improve shielding of the inductive component from the substrate and / or other components. In particular, there is no need for lateral openings which may impair the insulation and / or shielding to the sides.

[0007] In general, terms such as "bottom," "base," "top," "top surface," "side," etc. are not to be understood as limiting with respect to any orientation in space, but are used only to illustrate the relative arrangement of components of an inductive device, including a header component, particularly its housing, and the header component. In general, a "bottom" refers to a surface of an inductive device that faces a substrate, particularly parallel to the substrate, when the inductive device is mounted on the substrate. A "top" refers to a surface of an inductive device or its header component that faces away from the substrate in the mounted state. A "side" refers to a surface that extends away from the substrate in the mounted configuration, particularly perpendicular to the substrate.

[0008] The housing of the header component defines a cavity on a bottom surface and at least three side surfaces. The housing may include a bottom, particularly a bottom plate. The housing may further include side walls for defining the cavity on each side surface. For example, the side walls and the bottom may be integrally formed. The housing may also be formed by connecting different components together.

[0009] The top opening is configured to allow the inductive components to be inserted into the cavities. Preferably, the top opening has the same shape and / or dimensions as the cross-sections of the respective cavities. This allows the inductive components to fill as much of the cavity space as possible. This minimizes unused space within the header component housing. This reduces the space required to accommodate the inductive components. This reduces the footprint of the header component on the board. For example, the top opening may be bordered by the top edge of the side wall of the housing.

[0010] The header component includes a plurality of terminals for electrically connecting the inductive component to the substrate. In particular, the terminals can be connected to one or more coils of the inductive component. For example, the terminals can be directly connected to the leads of the respective coils, in particular the leads formed by the wires wound to form the coils. It is also possible to provide the electrical connection via intermediate conductors, in particular intermediate conductors that are part of the header component.

[0011] The terminals may be divided into different groups, for example, into a group of primary terminals and a group of secondary terminals that connect to the primary circuit and the secondary circuit of the inductive component, respectively. For example, the inductive component may be a transformer that includes one or more primary coils or windings and one or more secondary coils or windings.

[0012] Different terminals, especially different groups of terminals, can be spaced apart from one another. For example, the terminals can be aligned along opposite sides of the inductor. This is particularly suitable when terminals on one side are connected to the primary coil and terminals located on the opposite side are connected to the secondary coil of the inductor. In this way, the physical distance between the terminals can be used to increase the creepage distance of the respective circuits.

[0013] Header components have the particular advantage of maximizing the insulation and safety distance of inductive components. Sufficient insulation can be achieved without the need to specifically pot the inductive components. This avoids the adverse effects of potting materials on the magnetic properties of the inductive device. Furthermore, the elimination of potting materials facilitates compliance with regulations such as the European Union's Directive 2011 / 65 / EU on the Restriction of Certain Hazardous Substances (RoHS).

[0014] The terminals protrude outward from the bottom surface of the housing. In particular, the terminals protrude in a direction away from the cavity. For example, the terminals may protrude perpendicular and / or parallel to the bottom surface of the housing.

[0015] The terminals can be configured for surface mounting and / or through-hole mounting of the header component to the substrate. For example, the terminals may comprise attachment portions used to solder the header component to the substrate. Alternatively or additionally, the terminals may comprise pins that can be inserted into respective through-holes in the substrate.

[0016] The housing, particularly the side walls, may include guide elements for guiding the leads of the inductive component to their respective terminals. Preferably, the guide elements may be formed as guide grooves in the housing, particularly in one or more side walls. Guide grooves have the advantage that the leads can be routed securely within the grooves without any elements protruding outside the housing, which may be damaged during subsequent handling, particularly when the header component is attached to a board.

[0017] The header component according to claim 2 provides particularly good protection, insulation and / or shielding of the inductive component. After the inductive component has been inserted into the cavity, the top opening can be at least partially covered with a cover, so that the inductive component is protected from all sides within the cavity.

[0018] The header component according to claim 3 is particularly simple, particularly suitable for automation, and allows for flexible assembly. Particularly preferably, the side opening and the top opening can form a common insertion opening. This simplifies the insertion of the induction component into the cavity. Furthermore, the side opening can facilitate the placement of the induction component in the cavity, and in particular the inspection of its positioning within the cavity.

[0019] The side openings can be advantageously used to route the leads of the inductive component from the cavity to the respective terminals. For example, at least some of the terminals can be positioned adjacent to the side openings. In this way, the leads of the inductive component can be connected to the respective terminals without having to be routed outside the cavity along the housing. Particularly preferably, a first group of terminals can be positioned adjacent to the side openings, and a second group of terminals can be positioned on the side of the housing opposite the side openings. In this way, the different groups of terminals can be reliably spaced apart while still being easily accessible for connecting the leads of the inductive component to the respective terminals. For example, leads, especially in the form of insulated wires, can be routed from the cavity through the side openings, around the housing, and to terminals located on the opposite side. Particularly preferably, the leads can be routed in respective guide grooves integrated into the lateral side walls of the housing that connect the side openings to the opposite side.

[0020] The header component according to claim 4 provides for easy and stable electrical connection of an inductive component to at least one terminal including a connecting portion. In particular, it is not necessary to route one or more lead wires of the inductive component to the respective terminals outside the housing. The lead wire or wires may be directly or indirectly connected to the connecting portion on the upper side. Particularly preferably, the connecting portion can protrude from the upper end of each side wall. This simplifies the electrical connection to the inductive component via the connecting portion.

[0021] It is also possible for all terminals to have respective connection portions extending from the bottom surface to the top surface, particularly respective connection portions protruding from the upper ends of the respective side walls. Preferably, the terminals of a first group, particularly the terminals arranged along one side of the housing, have respective connection portions. The terminals of another group, particularly the terminals arranged on the side opposite the terminals of the first group, may not have respective connection portions. In this way, the terminals of different groups can be connected to the respective leads of the inductive component in different ways. This allows for increased insulation distances and safety distances between different circuits of the inductive component, particularly between different coils.

[0022] The header component described in claim 5 is particularly robust and safe. By embedding the connection portions within the side walls of the housing, each terminal can be reliably and stably fixed via the connection portions. It is particularly preferable that the middle portion of the connection portion extending from the bottom surface to the upper end of the side wall is completely embedded in the side wall, and the end portion of the connection portion protrudes beyond the upper end of the side wall.

[0023] A further object of the invention is to provide an improved inductive device for mounting on a substrate, in particular to provide an inductive device which can be assembled easily and economically and which meets high safety requirements, in particular with regard to insulation and material safety.

[0024] This object is achieved by an inductive device having the features of claim 6. The inductive device comprises a header part according to the invention and an inductive component, in particular a transformer, including one or more coils. The inductive component is arranged in a cavity in a housing of the header part. Lead wires of one or more coils of the inductive component are electrically connected to respective terminals of the header part. The advantages of the inductive device correspond to those of the header part described above.

[0025] The inductive component is preferably a transformer. Suitable inductive components, in particular suitable transformers, are known from the prior art. Particularly preferably, the inductive component is a bobbin-wound transformer. The small form factor of a bobbin-wound transformer reduces the size of the inductive device and therefore its footprint on the board.

[0026] A particularly suitable bobbin-wound transformer may include one or more primary coils and one or more secondary coils. Preferably, insulated wire may be used to wind the primary coil and / or secondary coil. Particularly preferably, insulated wire may be used to wind the primary coil or secondary coil, while the other one or more coils may be wound with non-insulated wire. Using non-insulated wire for the secondary coil or primary coil can reduce costs without affecting the insulation of the other coils wound with insulated wire.

[0027] It is particularly preferable that the terminals connected to the lead wires of the primary coil are arranged on a different side from the terminals connected to the lead wires of the secondary coil, thereby increasing the creepage distance between the terminals of the different coils.

[0028] The inductive device according to claim 7 is particularly stable and suitable for automated assembly. Contacts protruding from the top opening simplify the electrical connection to the respective terminals. Further components of the inductive device, such as a cover, can be electrically and / or mechanically connected to the inductive component via the contacts. In particular, the risk of damaging the leads during operation is reduced, as there is no need to route the respective leads out of the cavity.

[0029] The guide device according to claim 8 reliably protects the guide components and can be assembled in a manner particularly suitable for automation. The cover at least partially, preferably completely, covers the upper surface of the upper opening. The upper opening does not prevent further handling of the guide device, in particular attachment of the guide device to a substrate. The upper surface of the cover can serve as a holding point, in particular for grip-and-place techniques for handling the guide device, such as mechanical or pneumatic grippers.

[0030] The cover can be attached to the housing and / or the inductive component of the header component. Attaching the cover to the housing and the inductive component has the advantage of mechanically securing the inductive component. In particular, the inductive component is not only mechanically connected to the header component via the electrical connection between the coil and the respective terminal. This reduces the risk of damaging the electrical connection during further handling and / or use.

[0031] The housing may include one or more fixing elements for fixing the housing. For example, one or more anchoring projections may protrude from the upper ends of one or more side walls for connection to the cover. For example, the anchoring projections may be inserted into respective through-holes in the cover.

[0032] Particularly preferably, the housing encloses (surrounds) the cavity on all four sides, and an additional cover also covers the induction component from above, ensuring that the induction component is housed within the cavity.

[0033] The inductive device according to claim 9 is particularly stable and can be easily handled, for example, during mounting on a substrate. Particularly preferably, the cover can be connected to the inductive component before placing the inductive component in the cavity. The cover can thus simplify handling of the inductive component, for example, by providing a gripping surface for grip-and-place techniques. Preferably, the cover is attached to the inductive component via the respective contacts of the conductive components. This attachment can be achieved, in particular, by surface mount technology (SMT) and / or through-hole technology (THT). The cover can also be used to establish electrical connections to the respective terminals.

[0034] The inductive device according to claim 10 provides a reliable electrical connection and allows for assembly that is particularly suitable for automation. The conductor pattern can be formed on the cover, particularly on the surface of the cover facing the housing. To ensure environmental protection of the conductor pattern, it is also possible to form the conductor pattern on the inside of the cover. For example, the conductor pattern can be connected to contacts of an inductive component that protrude from the top opening, for example by surface mounting or through-hole mounting. Electrical connection using the conductor pattern eliminates the need to route the lead wires of each at least one coil outside the cavity, improving the stability and safety of the inductive device.

[0035] The inductive component may include additional contacts that are not electrically connected to the leads of one of the coils. These contacts can be used to connect to the cover, particularly to the circuit board. In this way, the mechanical attachment of the cover to the inductive component can be improved. For example, insulating contacts can be attached to insulating contact pads on the cover.

[0036] The inductive device according to claim 11 is particularly stable and easy and efficient to manufacture. The connection between the contacts of the inductive device and the connection portions of each terminal via the conductor pattern further enhances the stability of the electrical connection. In particular, there is no need to provide additional connection components that may impair the stability of the electrical connection. Furthermore, the connection via the conductor pattern of the cover may enhance the mechanical stability of the inductive device. For example, the protruding connection portions of each terminal can be attached to the cover, for example, by inserting them into respective through-holes in the cover. In this way, the mechanical connection between the header component and the inductive component is established via the cover.

[0037] It is particularly preferred that one group of terminals is connected to the respective lead wires via a conductor pattern in the cover. Another group of terminals can be connected to the respective lead wires by leading the lead wires out of the cavity and running them around the housing to the respective terminals. Various connection techniques can improve the insulation of the respective coils of the inductive component. In this respect, it is particularly advantageous if the lead wires, especially those leaving the cavity through the top opening, are made of insulated wire. This improves the insulation. In particular, it is possible to reliably avoid contact with the conductor pattern on the cover.

[0038] The cover according to claim 12 is particularly suitable for easy and efficient connection to an inductive component and / or a header component. In particular, the circuit board can be attached to the contacts of the inductive component and / or parts of the header component, such as the terminal connections and / or fixing lugs, by surface mounting or through-hole technology.

[0039] The cover may in particular be a printed circuit board. A cover in the form of a circuit board is not to be confused with a substrate, in particular a circuit board, on which the inductive device is attached via terminals.

[0040] The induction device according to claim 13 can be easily handled, particularly mounted on a substrate. The cover is particularly suitable for removal without tools. A removable cover may also be referred to as a cap. The removable cap can be used to protect the induction component during further handling, particularly during mounting of the induction device on a substrate. The removable cover or cap can, for example, provide a gripping surface for pick-and-place techniques, particularly mechanical or pneumatic grippers. After mounting the induction device on the substrate, the cap can be easily removed. After mounting the induction device, the cover is not used to handle the induction device. Furthermore, in the final product, it may not be necessary to cover the top opening. Therefore, a removable cover has the advantage that it does not need to meet all safety requirements and / or regulations required for the final product. The cap can be used in the manufacturing process without affecting the bill of materials (BOM) of the final product.

[0041] A further object of the present invention is to provide an improved method for assembling inductive devices, in particular to provide a method that is efficient and economical.

[0042] This problem is solved by the method of claim 14. A header component is provided. An inductive component, particularly a transformer, including one or more coils is provided. The inductive component is positioned within a cavity of a housing of the header component at least partially through the top opening, particularly only through the top opening. Lead wires of one or more coils of the inductive component are electrically connected to respective terminals of the header component. This method advantageously allows the header to be inserted vertically into the housing through the top opening using pick-and-place techniques, particularly automated pick-and-place techniques. This allows for easy and efficient assembly of the inductive device. This reduces manufacturing costs and scrap rates due to incorrect insertion of the inductive component.

[0043] The inductive component provided may preferably be a transformer, particularly a bobbin-wound transformer. Providing the inductive component includes manufacturing the inductive component, particularly a bobbin-wound transformer. Providing the inductive component includes winding one or more coils onto a mount, particularly a bobbin mount. For example, the one or more coils of the inductive component may be automatically wound, for example, by a multi-arbor automatic winding machine.

[0044] Particularly preferably, providing the inductive element includes winding one or more coils from insulated wire and one or more coils from non-insulated wire. In particular, the insulated wire can be left as flying leads. Additionally or alternatively, a portion of the wire, in particular the non-insulated wire, can be terminated at a respective contact of the inductive element. In particular, it is possible to automatically terminate the wire at the respective contact.

[0045] The method according to claim 15 reduces material costs. By directly connecting the leads of at least one coil to the respective terminals, no intermediate components are required to establish the connection. For example, the respective leads, in particular those made of insulated wire, can be routed through openings in the housing, in particular the top opening and / or the side opening, and connected to the respective terminals. When providing the inductive component, the leads directly connected to the respective terminals can remain as flying leads. This simplifies the provision of the inductive component.

[0046] The method according to claim 16 is particularly efficient: the termination of the wire leads of the at least one coil of the inductive component to the respective contacts can preferably be established during the manufacture of the inductive component, for example by automatically terminating the respective wires when winding the respective at least one coil, such that in this way it is not necessary to manually remove each wire lead from its cavity in order to connect it to the respective terminal.

[0047] The method according to claim 17 is particularly suitable for automation. Connecting the leads of the at least one coil to the conductor pattern of the cover can be achieved by known mounting techniques. Particularly preferably, the cover may include a circuit board that simplifies electrical connection to the leads. Particularly preferably, the connection can be established via contacts of the inductive component to which the leads of the at least one coil are terminated.

[0048] It is particularly preferred to attach a cover, in particular a circuit board, to the inductive component before inserting the inductive component into the cavity, which cover can be used as a gripping surface for pick-and-place techniques when inserting the inductive component into the cavity.

[0049] The method according to claim 18 is particularly efficient. Preferably, the connection portions of the respective terminals protrude from the upper end of the housing. The connection portions can be automatically connected to the conductor patterns of the cover, especially when an inductive component is placed in the cavity and thus the cover is also placed above the upper opening. For example, the connection portions pass through respective through-holes in the cover, especially in the circuit board of the cover.

[0050] The method according to claim 19 is particularly cost-effective: the cover can be used to protect the inductive components during handling, in particular during attachment of the inductive device to the substrate device, after which the cover can be removed without further affecting the properties of the inductive device and the final product.

[0051] Further details, advantages and features of the invention will become apparent from the description of exemplary embodiments with reference to the drawings. [Brief explanation of the drawings]

[0052] [Figure 1] 1 is a perspective side view of an exemplary embodiment of an inductive device including an inductive component in the form of a transformer and a header component; [Figure 2] 2 is a longitudinal cross-sectional view of the induction device taken along the line II-II in FIG. 1; [Figure 3] 2A-2D are diagrams (part 1) showing the different steps of assembling the inductive device according to FIG. 1; [Figure 4] 2A-2D are diagrams (part 2) illustrating different steps in the assembly of the inductive device according to FIG. 1; [Figure 5] 3A-3D are diagrams (part 3) showing different steps of assembling the inductive device according to FIG. 1; [Figure 6] 4A-4D are diagrams (part 4) illustrating the different steps of assembling the inductive device according to FIG. 1; [Figure 7] FIG. 10 is a perspective front view of a further exemplary embodiment of a guidance device. [Figure 8] 8 is a perspective rear view of the guidance device according to FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0053] 1 and 2, a first exemplary embodiment of an induction device 1 will be described. The induction device 1 includes an induction component 2 and a header component 3 for mounting the induction component 2 on a substrate (not shown). The induction device 1 further includes a cover 4.

[0054] The header component 3 includes a housing 5 that accommodates the inductive component 2. The housing 5 defines a cavity 6 in which the inductive component 2 is disposed. The housing 5 includes a bottom 7 that defines the cavity 6 on its bottom surface and sidewalls 8 that define the cavity on all four sides. The housing 5 includes a top opening 9 to the cavity 6. The top opening 9 is located on the top surface of the housing 5 opposite the bottom 7. The top opening 9 is sized and shaped to allow the inductive component 2 to be inserted into the cavity through the top opening 9. In the illustrated embodiment, the top opening 9 has dimensions that correspond to a cross section of the cavity 6 parallel to the bottom surface of the housing 5. As such, the top opening 9 is bounded by an upper edge 10 of the sidewalls 8 of the housing 5.

[0055] In general, terms such as "bottom," "base," "top," "upper," "side," and the like should not be understood as limiting with respect to any orientation in space, but are used only to illustrate the relative arrangement of the components of the induction device 1, particularly the header component 3 and its housing 5. For illustrative purposes only, a Cartesian coordinate system x, y, z is shown in FIG. 1. In FIG. 1, the bottom of the housing 5, particularly its bottom 7, is disposed perpendicular to the z-axis. The sides of the housing 5, particularly its sidewalls 8, extend along the z-axis. The top of the housing 5, particularly the top opening 9, is perpendicular to the z-axis. The substrate on which the induction device 1 is mounted can be disposed in the xy plane such that the substrate and the bottom 7 are parallel to each other.

[0056] The header component 3 includes a plurality of terminals 11, 12. The terminals 11, 12 include a group of primary terminals 11 and a group of secondary terminals 12. In the illustrated embodiment, the header component 3 includes four primary terminals 11 and four secondary terminals 12. The primary terminals 11 are arranged along one of the side walls. The secondary terminals 12 are arranged along one of the side walls 8 opposite the side wall on which the primary terminals 11 are arranged.

[0057] The terminals 11 and 12 serve to electrically connect the inductive component 2 to the substrate and to secure the inductive device 1 to the substrate 1. The terminals 11 and 12 protrude from the bottom surface of the housing 5 in a direction perpendicular to the bottom 7. Each of the terminals 11 and 12 has a mounting portion 13. The mounting portion 13 is formed by an extension of the terminal 11 or 12 that is bent so as to extend laterally. The mounting portion 13 serves as a fixing area, particularly a soldering area, through which the terminals 11 and 12 can be fixed, particularly soldered, to the substrate. By fixing the terminals 11 and 12 to the substrate, an electrical connection between the substrate and the inductive component 2 is established. The inductive device 1 is particularly suitable for mounting using surface mount technology (SMT). In other, not shown, embodiments, the mounting portion may extend perpendicular to the bottom 7, for example in the form of a connection pin. Such an embodiment may be particularly suitable for mounting the inductive device 1 to the substrate using through-hole technology (THT).

[0058] The primary terminal 11 includes a fixing portion 14 that is fixed to one of the side walls 8 of the housing 5. The primary terminal 11 is fixed to the housing 5 via the fixing portion 14.

[0059] Each of the secondary terminals 12 includes a connecting portion 15 embedded in a respective side wall 8 of the housing 5. The connecting portion 15 extends from the bottom surface, where the mounting portion 13 is formed, through the side wall 8 to the upper end 10 of the respective side wall 8. The connecting portion 15 protrudes from the upper end 10 of the side wall 8 on the upper surface.

[0060] In the illustrated embodiment, the inductive component 2 is a transformer, specifically a bobbin-wound transformer. The inductive component 2 includes a transformer core 20. The transformer core 20 is inserted into a bobbin mount 19, around which a primary wire 21 and a secondary wire 22 are wound to form a primary coil 23 and a secondary coil 24, respectively. The transformer core 20, bobbin mount 19, and coils 23 and 24 are at least partially housed in a case (enclosure) 25. The transformer 20, coils 23 and 24, and case 25 can be implemented using known methods and are not shown in detail in the drawings. For example, the case 25 can be formed by potting the coils with a potting material. In other embodiments, the case 25 does not require a potting material, which has the advantage of relaxing requirements regarding material compliance regulations. For example, the case can be formed by a transformer housing in which the transformer core is disposed. In a particularly advantageous embodiment, the seal 25 can be provided by gluing the transformer core. In yet another embodiment, the transformer does not have a case.

[0061] In the illustrated embodiment, the primary wire 21 is an insulated wire, and the secondary wire 22 is an uninsulated wire.

[0062] The inductive component 2 includes a primary contact 26 and a secondary contact 27. The inductive component 2 is disposed within the cavity 6 such that the contacts 26, 27 protrude from the top opening 9. The inductive component 2 is disposed within the cavity 6 such that the primary contact 26 is disposed on the side adjacent to the side wall 8 on which the primary terminal 11 is disposed. The secondary terminal 27 is disposed adjacent to the side wall 8 on which the secondary terminal 12 is disposed.

[0063] The protruding ends of the primary contacts 26 are soldered to respective primary contact pads 28 on the cover 4. The protruding portions of the secondary contacts 27 are soldered to respective secondary contact pads 29 on the cover 4. This secures the cover 4 to the inductive component 2. In the illustrated embodiment, the securement is achieved by surface mounting technology. In other embodiments, the contacts of the inductive component 2 may be connected to the cover 4 by through-hole technology.

[0064] Contacts 26, 27 are fixed within flange 30 of bobbin mount 19. Primary contacts 26 and primary contact pads 28 are electrically isolated from coils 23, 24 of inductive component 2 and terminals 11, 12 of header component 3. Therefore, primary contacts 26 and primary contact pads 28 do not contribute to the electrical connection between coils 23, 24 and terminals 11, 12.

[0065] Secondary contacts 27 and secondary contact pads 29 serve to electrically connect secondary coil 24 to secondary terminals 12, as will be described below.

[0066] The housing 5 of the header component 3 includes a fixing protrusion 31 protruding from an upper end 10 of at least one of the side walls 8. In the illustrated embodiment, the fixing protrusion 31 is disposed on the upper end 10 of the side wall 8 opposite the side wall 8 in which the connecting portion 15 of the secondary terminal 12 is embedded. The ends of the fixing protrusion 31 and the connecting portion 15 protruding from the upper end 10 reach the respective through holes 32 in the cover 4, thereby mechanically connecting the cover 4 to the header component 3.

[0067] In the assembled guidance device 1, the cover 4 covers the upper opening 9 of the housing 5 from above. The cover 4 protects the guidance component 2. Furthermore, the upper surface 33 of the cover 4 provides a gripping surface by which the guidance device 1 can be gripped for further manufacturing steps, such as for example placing the guidance device 1 on a substrate. In particular, the upper surface 33 can serve as a mechanical or pneumatic gripper gripping surface, thereby allowing easy and efficient handling, in particular automatic handling, of the guidance device 1.

[0068] The electrical connections between the coils 23, 24 and the respective terminals 11, 12 will now be described. When winding the primary coil 23, the ends of the insulated wire 21 are left as flying leads 35. The flying leads 35 are drawn out of the cavity 6 from around the upper end 10 of the side wall 8 where the primary terminals 11 are located. The leads 35 are routed along the outside of the side wall 8 to the respective primary terminals 11 and connected thereto. Via these leads 35, the coil 23 is directly connected to the respective terminals 11 in an easy and simple manner.

[0069] For routing the lead wires 35, guide elements may be provided on each side wall 8 of the housing 5. In the illustrated embodiment, a guide groove 36 is formed in the upper end 10 of the side wall 8. The lead wires 35 pass through the guide groove 36 and exit the cavity 6. The lower end of the side wall 8 is formed with guide protrusions 37, between which the lead wires 35 are routed to the respective primary terminals 11.

[0070] The secondary coil 34 is wound from uninsulated wire 22. Leads 38 of the uninsulated wire 22 are terminated at respective secondary contacts 27. Thus, there is an electrical connection between the secondary coil 24 and the secondary contacts 27. The secondary contacts 27 are connected to respective secondary contact pads 29, and thus the secondary coil 24 is electrically connected to the cover 4. The secondary contact pads 29 are part of respective conductor patterns 39 that connect the secondary contacts 27 to the connections 15 of the respective secondary terminals 12. In this manner, the secondary coil 24 is connected to the respective secondary terminals 12 via the secondary contacts and the respective conductor patterns 39 (which are included in the cover 4). This allows a simple and reliable electrical connection to be established simply by connecting the cover 4 to the inductive component 2 and the header component 3.

[0071] In general, the cover can provide connection elements for mechanically and electronically connecting to the inductive component 2 and the header component 3. In the illustrated embodiment, these are through holes 32, contact pads 28, and conductor patterns 39 forming contact pads 29. Advantageously, the cover 4 is a circuit board. The use of a circuit board as the cover 4 allows for easy and reliable mechanical and electrical connections using surface mount and / or through-hole technologies.

[0072] The electrical connection of the coils 23, 24 to the respective terminals 11, 12 maximizes the creepage and clearance distances of the inductive device 1. The primary terminal 11 and the secondary terminal 12 are located along two opposite side walls of the header component housing 5. The creepage distance therefore corresponds to the physical distance from the primary terminal 11 to the secondary terminal 12, as shown in FIG. 2. In this way, the inductive device 1 combines the advantages of a compact design with increased creepage distance.

[0073] A method of assembling an induction device will now be described with reference to Figures 3 to 6. The method is particularly suitable for assembling induction device 1 shown in Figures 1 and 2. Furthermore, the method is suitable for assembling various variations of induction devices. For simplicity, the components of the induction device to be assembled are shown only diagrammatically in Figures 3 to 6 and are designated with the same reference numerals as induction device 1 of Figures 1 and 2.

[0074] As shown in Figure 3, coils 24, 23 are wound on bobbin mount 19. Contacts 26, 27 protrude from flange 30 of bobbin mount 19. The end of insulated wire 21 is left as flying lead 35. Uninsulated wire lead 38 terminates at secondary contact 27.

[0075] The winding of the coils 23, 24 may be automated, for example using a multi-arbor automatic winding machine. It is particularly preferred that the uninsulated wire leads 38 are automatically terminated at their respective secondary contacts.

[0076] After winding the coils 23, 24, the inductive component 2 is assembled, in particular by introducing the transformer core 20 into the bobbin mount 19 and at least partially enclosing (sealing) the coils 23, 24 in the case 25. The assembled inductive component 2 is shown in FIG.

[0077] As shown in FIG. 5 , the inductive component 2 is connected to the cover 4 via contacts 26, 27, for example by soldering the contacts 26, 27 to the cover, in particular to the respective contact pads. The cover 4 is a circuit board. The connection between the contacts 26, 27 may preferably be established by through-hole technology or surface mount technology. In the illustrated embodiment, the primary contact 26 is insulated from the primary coil 23. Thus, the primary contact 26 establishes a mechanical connection with the cover 4. The secondary contact 27 is electrically connected to the secondary coil 24. Thus, the secondary contact 27 establishes a mechanical and electrical connection with the cover 4, in particular with the conductor pattern 39.

[0078] Advantageously, connecting the cover 4 to the induction component 2 before inserting the induction component 2 into the cavity 6 of the header component 3 also allows the upper surface 33 of the cover 4 to be used as a gripping surface to place the induction component 2 into the cavity 6 through the top opening 9.

[0079] As shown in Figure 6, the induction component 2 is placed in a cavity 6 of the header component 3. The induction component 2 is placed in the cavity through an upper opening 9. This allows the induction component 2 to be placed inside the header component 3 from above in an automated and easy manner.

[0080] The inductive component 2 is positioned within the cavity 6 so that the contacts 26 , 27 protrude from the top opening 9 .

[0081] By placing the inductive component 2 in the cavity 6, the cover 4 is also positioned relative to the header component 3. The cover 4 covers the top opening 9. The cover 4 is connected to the connection portion 15 of the secondary terminal 2 to establish an electrical connection from the secondary coil 24 to the secondary terminal 12. The lead wires 35 are routed around the side wall 8 and connected to the respective primary terminals 11. The routing and connection of the lead wires 35 can be performed, for example, manually.

[0082] In the illustrated embodiment, the primary coil is connected to the respective terminals via an insulated wire routed around the housing. The secondary coil is connected to the respective terminals via a conductor pattern in the cover and a connection to the terminal that extends to the cover. Many other variations of the inductive device are possible. For example, the primary and secondary coils could be wrapped with insulated wire, with each wire routed around each side wall and connected directly to the respective terminals. In this way, material costs and component complexity can be reduced. In some embodiments, a cover over the top opening is not required. Furthermore, the inductive component does not need to provide each contact.

[0083] In yet another embodiment, the wires of the primary and secondary coils may be terminated at the respective contacts, and the connection to the terminals of the header part may in each case be established via the respective conductor patterns of the terminal covers and connections, such a type of connection being particularly suitable for automated assembly of the inductive device.

[0084] In still other embodiments, different connections to the cover may be used. For example, the cover may be mechanically connected to a header component and / or an inductive component. Contacts at which wires are terminated are not required to establish electrical connections to the cover's conductor patterns. Each coil lead can be directly connected to the cover's conductor patterns.

[0085] 7 and 8, a further embodiment of the inductive device 101 will be described. The inductive device 101 comprises an inductive component 102. The inductive component 102 is a bobbin-wound transformer comprising a primary coil and a secondary coil (not shown).

[0086] The inductive component 102 is disposed within a cavity 106 of the header component 103. The cavity 106 is enclosed by a housing 105 of the header component 103. The housing 105 includes a bottom 107 and sidewalls 108, enclosing the cavity 106 on three sides and the bottom. Opposite the bottom 107, the housing 105 has a top opening 109 through which the inductive component 102 can be inserted into the cavity 106. One side of the housing 105 has a side opening 141. The top opening 109 and the side opening 141 form a common insertion opening. The common insertion opening simplifies the insertion of the inductive component 102. Furthermore, it simplifies visual inspection of whether the inductive component 102 is correctly positioned within the cavity 106, particularly during the actual placement procedure.

[0087] The header component 103 includes a primary terminal 111 and a secondary terminal 112. The primary terminal 111 connects to the primary coil of the inductive component 102. The secondary component 112 connects to the secondary coil of the inductive component 102. In the illustrated embodiment, the header component 103 includes four primary terminals 111 and four secondary terminals 112.

[0088] Terminals 111 and 112 protrude from the bottom surface of housing 105. Terminals 111 and 112 protrude laterally from bottom 107. Secondary terminal 112 is located adjacent to side opening 141. Primary terminal 111 is located on side wall 108 opposite side opening 141.

[0089] The secondary coil lead wire 138 is routed through the side opening 141 and connected directly to the adjacent secondary terminal 112. The secondary coil and lead wire 138 are formed from uninsulated wire.

[0090] The lead wires 135 of the primary coil exit the cavity 106 through the side opening 141, are routed to the opposite side wall 108, and are connected to the respective terminals 111. A guide groove 142 is provided in the side wall 108 adjacent to the side opening 141, and within this guide groove 142, the lead wires 135 are guided to the side surface of the housing 105 opposite the side opening 141. The lead wires 135 are securely held within the guide groove 142.

[0091] The inductive device 101, especially its header part 103, has a simple structure, while at the same time ensuring safe separation of the primary and secondary circuits of the inductive part 102 and benefiting from a large creepage distance.

[0092] The inductive device 101 can be easily assembled, particularly using automated placement techniques to place the inductive components 102 within the cavity 106. The inductive components 102 can be provided, particularly by manufacturing them using known techniques. The provided inductive components 102 are inserted at least partially into the cavity 106 through the top opening 109. The leads 138 are connected to the secondary terminals 112 adjacent the side openings 141. The leads 135 exit the side openings 141, wrap around adjacent side walls, and are routed to and connected to the respective primary terminals 111.

[0093] In some embodiments, after the inductive component 102 is placed in the cavity 106, a cover can be placed on the housing 105 of the header component 103 to cover the top opening 109. In this way, the top opening 109 is at least temporarily covered, protecting the inductive component 102 in the cavity 106. The cover can also serve as a gripping surface for further handling and manufacturing steps, such as for placing the inductive device 101 on a substrate. In particularly advantageous embodiments, the cover is removably attached to the housing 105. The cover may only be placed on the housing 105 temporarily. In particular, the cover can be removed after the inductive device 101 is attached to the substrate. Using a removable cover has the advantage that the cover does not need to be considered in the bill of materials (BOM) of the final product. Another advantage is that there are fewer limitations on the choice of material for the cover. For example, it is possible to use a material that does not meet certain requirements or regulations of the final product.

[0094] In a further exemplary embodiment, the leads 135 can be routed around the top edge of the side wall opposite the side opening 141. In this way, the leads 135 do not have to be routed along the side wall adjacent to the side opening 141.

[0095] In a further exemplary embodiment, the housing may include four side walls enclosing a cavity on all four sides, in which case the inductive component may be placed into the cavity through the top opening, and the leads of the inductive component may be routed around the top edges of the side walls to their respective terminals. [Explanation of symbols]

[0096] 1. Induction Device 2. Inductive components 3 Header parts 4 Cover 5. Housing 6 cavities 7 Bottom 8 side wall 9 Top opening 10 Top 11 Primary terminal 12 Secondary terminal 13 Mounting part 14 Fixed part 15 Connection 19 Bobbin mount 20 Transformer Core 21 Primary line 22 Secondary Line 23 Primary coil 24 Secondary coil 25 cases 26 Primary contact 27 Secondary contact 28 Primary Contact Pad 29 Secondary Contact Pad 30 flange 31 Fixing protrusion 32 through holes 33 Top surface 34 Secondary coil 35, 38, 135, 138 lead wires 36 Guide groove 37 Guide protrusion 39 Conductor Pattern 101 Induction Device 102 Inductive components 103 Header parts 105 Housing 106 Cavity 107 Bottom 108 Side wall 109 Top opening 111 Primary terminal 112 Secondary terminal 141 Side opening 142 Guide groove

Claims

1. A header component for mounting an inductive component, particularly a transformer, on a substrate, The header part is a housing (5; 105) that houses the inductive element (2; 102) in a cavity (6; 106); a plurality of terminals (11, 12; 111, 112) for electrically connecting said inductive component (2; 102) to a substrate, said plurality of terminals (11, 12; 111, 112) projecting outward from the bottom surface of said housing (5; 105); Equipped with --said housing (5; 105) encloses said cavity (6; 106) on a bottom and at least three sides; --A header part, wherein the housing (5; 105) has an upper opening (9; 109) to the cavity (6; 106) on its upper surface opposite to the bottom surface, the upper opening (9; 109) being configured so that the induction part (2; 102) can be inserted into the cavity (6; 106) through the upper opening (9; 109).

2. 2. The header component of claim 1, wherein the housing (5) surrounds the cavity (6) on all four sides.

3. 2. The header component of claim 1, wherein the housing (105) includes a side opening (141) to the cavity (106) on one of the sides.

4. 4. The header component according to claim 1, wherein at least one of the plurality of terminals (12) has a connection portion (15) extending from the bottom surface to the top surface of the housing (5), in particular to the upper end (10) of the side wall (8) of the housing (5) adjacent to the upper opening (9).

5. 5. The header component according to claim 4, wherein the connection portion (15) is embedded in at least one side wall (8) of the housing (5).

6. An induction device mounted on a substrate A header part (3; 103) according to any one of claims 1 to 5; Inductive component (2; 102), in particular a transformer, including one or more coils (23, 24) Equipped with the induction component (2; 102) is disposed in the cavity (6; 106) of the housing (5; 105) of the header component (3; 103); an inductive device, wherein the leads (35, 38; 135; 138) of the one or more coils (23, 24) of the inductive component (2; 102) are electrically connected to respective terminals (11, 12; 111, 112) of the header component (3; 103).

7. 7. The inductive device according to claim 6, wherein the inductive component (2) comprises contacts (27) through which leads (38) of at least one coil (24) of the inductive component (2) are connected to the respective terminals (12), and the inductive component (2) is disposed in the cavity (6) such that the contacts (27) protrude from the upper opening (9).

8. 8. An induction device according to claim 6 or 7, comprising a cover (4) at least partially covering the upper opening (9).

9. 9. An inductive device according to claim 8, wherein the cover (4) is attached to the inductive element (2), in particular to the contacts (26, 27) of the inductive element (2).

10. 10. The inductive device according to claim 8 or 9, wherein the leads (38) of at least one coil (24) of the inductive component (2) are connected to the respective terminals (12) of the header component (3) via a conductor pattern (39) included in the cover (4).

11. 11. The inductive device according to claim 10, wherein the conductor pattern (39) included in the cover (4) connects the respective leads (38) of the inductive component (2) to the connection portions (15) of the respective terminals (12) of the header component (3).

12. Inductive device according to any one of claims 8 to 11, wherein the cover (4) comprises a circuit board, in particular consists of a circuit board.

13. The inductive device of claim 8 , wherein the cover is removable.

14. 1. A method for assembling an inductive device, comprising: - providing a header component (3; 103) according to any one of claims 1 to 5; - providing an inductive component (2; 102), in particular a transformer, comprising one or more coils (23, 24); - placing said induction element (2; 102) in said cavity (6; 106) of said housing (5; 105) of said header element (3; 103) at least partially through said upper opening (9; 109); - electrically connecting the leads (35, 38; 135, 138) of said one or more coils (23, 34) of said inductive component (2; 102) to the respective terminals (11, 12; 111, 112) of said header component (3; 103); A method having the following.

15. 15. The method of claim 14, wherein the leads (35; 135, 138) of at least one coil (24) of the inductive component (2; 102) are directly connected to the respective terminals (12; 111, 112).

16. 16. The method according to claim 14 or 15, wherein the leads (38) of at least one coil (24) of the inductive component (2) are terminated on respective contacts (27) of the inductive component (2), and the inductive component (2) is positioned in the cavity (6) such that the contacts (27) protrude from the upper opening (9).

17. 17. The method according to any one of claims 14 to 16, wherein a cover (4) is attached to the inductive component (4) and the leads (38) of the at least one coil (24) are connected to a conductor pattern (39) included in the cover (4).

18. 18. The method according to claim 17, wherein the conductor patterns (39) included in the cover (4) are connected to the connecting portions (15) of the respective terminals (12) of the header part (3).

19. 19. The method according to any one of claims 14 to 18, wherein a cover for at least partially covering the upper opening (109) is removably attached to the header component (103) and / or the induction component (102).

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