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 the priority of German Patent Application CN2022 1108 2851.6, the content of which is incorporated herein by reference.

[0002] The present invention relates to a header component for attaching 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 Art

[0003] Headers or pin headers are known from the prior art. These are used as electrical connectors for connecting electronic components to a substrate, particularly a printed circuit board. For that purpose, the header comprises pins or terminals for establishing an electrical connection to the substrate, particularly the conductor pattern of the substrate. Patent Document 1 discloses a header for a transformer, and the transformer is arranged within the housing of the header. The header is introduced into the housing through an opening on the side.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The object of the present invention is to improve a header component for attaching an inductive component to a substrate, and particularly to provide a header component that enables simple and automated assembly of the inductive component.

Means for Solving the Problems

[0006] This objective is achieved by a header component having the features of claim 1. The header component comprises a housing for housing an inductive component within a cavity, the housing restricting the cavity to a bottom surface and at least three sides, the housing having an upper opening to the cavity on the top surface opposite the bottom surface, the upper opening configured so that the inductive component can be inserted into the cavity through the upper opening. The header component further comprises 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 has an upper opening on the side opposite the terminals. Thus, the inductive component can be easily placed from above into the cavity of the housing, and in particular, can be placed vertically by conventional pick-and-place techniques. Furthermore, the upper opening faces away from the substrate to which the inductive component is mounted using the header component. Thus, the upper opening does not impair the insulation of the inductive component from the substrate and other devices mounted adjacent to the inductive component on the substrate. The header component can advantageously improve the shielding of the inductive component from the substrate and / or other components. In particular, there is no need to provide lateral openings that could impair insulation and / or shielding of the sides.

[0007] Generally, terms such as “bottom,” “bottom surface,” “top,” “upper surface,” and “side” are not meant to be understood restrictively in terms of any direction in space, but are used only to illustrate the relative arrangement of the header component, especially its housing, and the components of the inductive device including the header component. Generally, the “bottom surface” refers to the surface of the inductive device that faces the substrate when the inductive device is mounted on the substrate, and in particular is parallel to the substrate. The “upper surface” refers to the surface of the inductive device or its header component that faces away from the substrate when mounted. The “side surface” refers to the surface that extends away from the substrate in the mounting configuration, in particular is perpendicular to the substrate.

[0008] The housing of a header component limits the cavity to the bottom and at least three sides. The housing may include a bottom, in particular a bottom plate. The housing may further include side walls to limit the cavity to each side. For example, the side walls and the bottom may be formed integrally. It is also possible to form a housing by connecting different components to each other.

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

[0010] A header component comprises multiple terminals for electrically connecting inductive components to a substrate. In particular, the terminals can be connected to one or more coils of the inductive components. For example, the terminals can be directly connected to the leads of each coil, in particular to the leads formed by the wires wound to form the coils. It is also possible to provide electrical connection via an intermediate conductor, in particular an intermediate conductor that is part of the header component.

[0011] Multiple terminals may be divided into different groups. For example, terminals may be divided into a group of primary terminals and a group of secondary terminals, each connected to the primary or secondary circuit of an inductive component. For example, an inductive component may be a transformer including 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 each other. For example, terminals can be aligned along opposite sides of an inductor. This is particularly suitable when terminals on one side are connected to the primary coil and terminals on the opposite side are connected to the secondary coil of the inductor. In this way, the creepage distance of each circuit can be increased by utilizing the physical distance between terminals.

[0013] Header components offer a special advantage: they maximize the insulation and safety distance of inductive components. In particular, sufficient insulation can be achieved without the need to pot the inductive components. Therefore, the adverse effects of potting materials on the magnetic properties of inductive devices are avoided. Furthermore, the absence of potting materials facilitates compliance with regulations such as the European Union Directive 2011 / 65 / EU and other directives on the restriction of certain hazardous substances (RoHS Directive).

[0014] The terminals protrude outward from the housing at the bottom surface. In particular, the terminals protrude 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 to surface mount and / or through-hole mount header components to the circuit board. For example, the terminals may include mounting portions used for soldering header components to the circuit board. The terminals may also, alternatively or additionally, include pins that can be inserted into each through-hole of the circuit board.

[0016] The housing, particularly the side walls, may include guide elements for guiding the leads of the induction components to their respective terminals. Preferably, the guide elements can be formed as guide grooves within the housing, particularly within one or more side walls. Guide grooves have the advantage of having no elements protruding outside the housing and ensuring that the leads are securely routed within the grooves, thus eliminating the possibility of damage during subsequent handling, especially when mounting the header components to the board.

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

[0018] The header component described in 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 facilitates the insertion of the guide component into the cavity. Furthermore, the side opening can facilitate inspection of the placement of the guide component into the cavity, in particular its positioning within the cavity.

[0019] The side openings can be advantageously used to route lead wires of induction components from the cavity to each terminal. For example, at least some of the terminals can be positioned adjacent to the side openings. In this way, the lead wires of the induction components can be connected to their respective terminals without having to route them along the housing and outside the cavity. Particularly preferable, 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, different groups of terminals can be reliably spaced apart from each other while still being easily accessible for connecting the lead wires of the induction components to their respective terminals. For example, lead wires, particularly in the form of insulated wires, can be routed from the cavity through the side openings, around the perimeter of the housing, and to terminals located on the opposite side. Particularly preferable, the lead wires can be routed in their respective guide grooves incorporated into the side wall of the housing connecting the side openings to the opposite side.

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

[0021] It is also possible for all terminals to have their respective connectors extending from the bottom to the top surface, in particular, each connector protruding from the upper end of each side wall. Preferably, the first group of terminals, in particular terminals arranged along one side of the housing, have their respective connectors. Another group of terminals, in particular terminals arranged on the side opposite to the first group of terminals, do not need to have their respective connectors. In this way, different groups of terminals can be connected to the respective leads of the inductive components in different ways. This can increase the insulation distance and safety distance between different circuits of the inductive components, in particular between different coils.

[0022] The header component described in claim 5 is particularly robust and secure. Embedding the connector within the side wall of the housing ensures that each terminal is securely and stably fixed through the connector. Particularly preferable is that the middle portion of the connector, extending from the bottom to the upper edge of the side wall, is completely embedded in the side wall, and the ends of the connector protrude beyond the upper edge of the side wall.

[0023] A further object of the present invention is to improve induction devices for mounting on a substrate, and in particular to provide induction devices that can be assembled easily and economically and that meet high safety requirements, especially with respect to insulation and material safety.

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

[0025] The inductive part is preferably a transformer. Suitable inductive parts, in particular suitable transformers, are known from the prior art. Particularly preferably, the inductive part is a bobbin-wound transformer. Since the bobbin-wound transformer has a small form factor, the size of the inductive device is reduced, and accordingly the footprint (occupied area) on the substrate is also reduced.

[0026] A particularly preferred bobbin-wound transformer can comprise one or more primary coils and one or more secondary coils. Preferably, insulated electric wires can be used to wind the primary coil and / or the secondary coil. Particularly preferably, insulated electric wires are used for the winding of the primary coil or the secondary coil, and the other one or more coils can be wound with non-insulated electric wires respectively. By using non-insulated electric wires for the secondary coil or the primary coil, the cost can be reduced without affecting the insulation with respect to the other respective coils wound with insulated electric wires.

[0027] Particularly preferably, the terminals connected to the lead wires of the primary coil are arranged on a different side surface from the terminals connected to the lead wires of the secondary coil. The creepage distance between the terminals of different coils is increased.

[0028] The inductive device according to claim 7 is particularly stable and suitable for automatic assembly. The contacts protruding from the upper opening simplify the electrical connection to respective terminals. Further parts of the inductive device, such as a cover, can be electrically and / or mechanically connected to the inductive part via the contacts. In particular, since there is no need to wire each lead wire out of the cavity, the risk of damage to the lead wires during operation is reduced.

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

[0030] The cover can be attached to the housing and / or inductor components of the header component. Attaching the cover to the housing and inductor components has the advantage of mechanically securing the inductor components. In particular, the inductor components are not only mechanically connected to the header component via electrical connections between the coil and its respective terminals. This reduces the risk of damage to the electrical connections during further handling and / or use.

[0031] The housing may have one or more fastening elements for securing the housing. For example, one or more fastening projections (anchor projections) may protrude from the upper end of one or more side walls for connection to the cover. For example, the fastening projections may be inserted into each through-hole of the cover.

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

[0033] The inductive device described in claim 9 is particularly stable and can be easily handled, for example, during mounting to a substrate. Particularly preferably, the cover can be connected to the inductive component before the inductive component is placed in the cavity. Thus, the cover can simplify the 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 component. This attachment can be achieved particularly 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 described in claim 10 provides reliable electrical connections and is particularly suitable for automated assembly. Conductor patterns can be formed on the surface of a cover, especially on the cover facing the housing. Conductor patterns can also be formed on the inside of the cover to ensure protection of the conductor patterns from the environment. For example, conductor patterns can be brought into contact with the contacts of inductive components protruding from the upper opening, for example, by surface mounting or through-hole mounting. Electrical connections using conductor patterns eliminate the need to route the leads of 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 one of the leads of the multiple coils. These contacts can be used to connect to a cover, particularly a circuit board. In this way, the mechanical attachment of the cover to the inductive component can be improved. For example, insulated contacts may be attached to the insulated contact pads of the cover.

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

[0037] Particularly preferred is that one group of terminals is connected to its respective lead wires via a conductor pattern within the cover. Another group of terminals can be connected to its respective lead wires by drawing the lead wires out of the cavity and routing them around the housing to their respective terminals. Various connection techniques can enhance the insulation of each coil of the inductive component. In this regard, it is particularly advantageous if the lead wires exiting the cavity, especially through the upper opening, are formed of insulated wires. This enhances insulation, and in particular, ensures that contact with the conductor pattern on the cover is avoided.

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

[0039] The cover may be a printed circuit board in particular. A cover in the form of a circuit board should not be confused with a board on which inductive devices are attached via terminals, especially a circuit board.

[0040] The induction device described in claim 13 is easily handled and, in particular, can be mounted on a substrate. The cover is particularly suitable for removal without tools. The removable cover is also called a cap. The removable cap can be used to protect the induction components during further handling, in particular during mounting the induction device to the substrate. The removable cover or cap can provide a gripping surface for, for example, pick-and-place techniques, in particular for mechanical or pneumatic grippers. After mounting the induction device to 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, the removable cover has the advantage of not having to meet all the 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 improve the method of assembling induction devices, and in particular to provide an efficient and economical method.

[0042] This problem is solved by the method of claim 14. A header component of the present invention is provided. An inductive component, in particular a transformer, comprising one or more coils is provided. The inductive component is placed in a cavity of the housing of the header component, at least partially through an upper opening, in particular through only an upper opening. The leads of one or more coils of the inductive component are electrically connected to the respective terminals of the header component. This method is advantageous because the header can be inserted vertically into the housing through the upper opening using pick-and-place techniques, in particular automated pick-and-place techniques. This enables simple and efficient assembly of the inductive device. Manufacturing costs and scrap rates due to incorrect insertion of the inductive component are reduced.

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

[0044] Particularly preferably, the provision of the induction component includes winding one or more coils from insulated wires and one or more coils from uninsulated wires. In particular, the insulated wires may be left as flying leads. In addition, or alternatively, portions of the wires, particularly uninsulated wires, may be terminated at each contact of the induction component. In particular, it is possible to automatically terminate the wires at each contact.

[0045] The method according to claim 15 leads to a reduction in material costs. By directly connecting the lead wires of at least one coil to their respective terminals, no intermediate components are required to establish the connection. For example, each lead wire, especially one made of insulated wire, can be drawn out from an opening in the housing, especially a top opening and / or a side opening, and connected to its respective terminal. When providing the inductive component, the lead wires that are directly connected to their respective terminals can be left as flying leads. This simplifies the provision of the inductive component.

[0046] The method according to claim 16 is particularly efficient. Terminating the leads of at least one coil of the inductive component to their respective contacts can preferably be established during the manufacturing of the inductive component, for example, by automatically terminating each wire when winding each at least one coil. In this method, there is no need to manually remove each lead from the cavity in order to connect the leads to their respective terminals.

[0047] The method according to claim 17 is particularly suitable for automation. Connecting the leads of 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 the electrical connection to the leads. Particularly preferably, the connection can be established via the contacts of an inductive component to which the leads of at least one coil are terminated.

[0048] Particularly preferable is to attach the cover, especially the circuit board, to the inductive component before inserting the inductive component into the cavity. The 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 portion of each terminal protrudes from the upper end of the housing. The connection portion can automatically connect to the conductor pattern of the cover, in particular when the inductive components are placed in the cavity and thereby the cover is also placed above the upper opening. For example, the connection portion passes through each through-hole in the cover, in particular 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, especially when the inductive device is mounted to the substrate device. The cover can then be removed so as not to further affect the properties of the inductive device and the final product.

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

[0052] [Figure 1] This is a perspective side view of an exemplary embodiment of an induction device, including an induction component in the form of a transformer and a header component. [Figure 2] This figure shows a longitudinal cross-section of the induction device along the cutting line II-II in Figure 1. [Figure 3] Figure 1 shows a schematic diagram (part 1) illustrating the different steps involved in assembling the induction device. [Figure 4] This is a schematic diagram (part 2) illustrating the different steps in assembling the induction device shown in Figure 1. [Figure 5] This is a schematic diagram (part 3) illustrating the different steps in assembling the induction device shown in Figure 1. [Figure 6] Figure 1 shows a schematic diagram (part 4) illustrating the different steps involved in assembling the induction device. [Figure 7] This is a perspective front view of a further exemplary embodiment of the induction device. [Figure 8] Figure 7 is a perspective rear view of the induction device. [Modes for carrying out the invention]

[0053] A first exemplary embodiment of the induction device 1 will be described with reference to Figures 1 and 2. The induction device 1 comprises an induction component 2 and a header component 3 for mounting the induction component 2 to a substrate (not shown). The induction device 1 further comprises a cover 4.

[0054] The header component 3 comprises a housing 5 that accommodates the guide component 2. The housing 5 defines a cavity 6 in which the guide component 2 is placed. The housing 5 comprises a bottom portion 7 that limits the cavity 6 to its bottom surface and side walls 8 that limit the cavity to all four sides. The housing 5 comprises an upper opening 9 to the cavity 6. The upper opening 9 is located on the upper surface of the housing 5 opposite the bottom portion 7. The upper opening 9 is sized and shaped so that the guide component 2 can be inserted into the cavity through the upper opening 9. In the illustrated embodiment, the upper opening 9 has dimensions corresponding to the cross-section of the cavity 6 parallel to the bottom surface of the housing 5. In this way, the upper opening 9 is enclosed by the upper ends 10 of the side walls 8 of the housing 5.

[0055] In general, terms such as “bottom,” “bottom surface,” “top,” “upper surface,” and “side” should not be understood restrictively in relation to any direction 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, Figure 1 shows a Cartesian coordinate system x, y, z. In Figure 1, the bottom surface of the housing 5, particularly its bottom 7, is positioned perpendicular to the z axis. The side surface of the housing 5, particularly its side wall 8, extends along the z axis. The top surface of the housing 5, particularly the upper opening 9, is perpendicular to the z axis. The substrate on which the induction device 1 is mounted can be positioned in the xy plane such that the substrate and the bottom 7 are parallel to each other.

[0056] The header component 3 comprises a plurality of terminals 11 and 12. The terminals 11 and 12 comprise a group of primary terminals 11 and a group of secondary terminals 12. In the illustrated embodiment, the header component 3 comprises four primary terminals 11 and four secondary terminals 12. The primary terminals 11 are arranged along one side wall. The secondary terminals 12 are arranged along one side wall 8 opposite to the side wall where the primary terminals 11 are located.

[0057] 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. Terminals 11 and 12 protrude perpendicularly from the bottom surface of the housing 5 to the bottom 7. Each terminal 11 and 12 is provided with a mounting portion 13. The mounting portion 13 is formed by extensions of terminals 11 and 12 that are bent to extend laterally. The mounting portion 13 functions as a fixing area, in particular a soldering area, through which terminals 11 and 12 can be fixed, in particular soldered, to the substrate. By fixing 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 embodiments not shown, the mounting portion may extend perpendicularly to the bottom 7, for example, in the form of connecting pins. Such embodiments may be particularly suitable for mounting the inductive device 1 to the substrate using through-hole technology (THT).

[0058] The primary terminal 11 is equipped with 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 secondary terminal 12 is equipped with a connection portion 15 embedded in each side wall 8 of the housing 5. The connection 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 each side wall 8. The connection portion 15 protrudes from the upper end 10 of the side wall 8 on the top surface.

[0060] In the illustrated embodiment, the induction component 2 is a transformer, specifically a bobbin-wound transformer. The induction component 2 includes a transformer core 20. The transformer core 20 is inserted into a bobbin mount 19, and primary wires 21 and secondary wires 22 are wound around it to form primary coils 23 and secondary coils 24, respectively. The transformer core 20, the bobbin mount 19, and the 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 in known ways, which are not detailed in the figure. 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. This has the advantage of relaxing the requirements regarding material compliance regulations. For example, the case may be formed by a transformer housing in which the transformer core is placed. In a particularly advantageous embodiment, the sealing portion 25 can be provided by bonding the transformer core with an adhesive. 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 induction component 2 comprises a primary contact 26 and a secondary contact 27. The induction component 2 is positioned within the cavity 6 such that the contacts 26 and 27 protrude from the upper opening 9. The induction component 2 is positioned within the cavity 6 such that the primary contact 26 is located on the side adjacent to the side wall 8 where the primary terminal 11 is located. The secondary terminal 27 is adjacent to the side wall 8 where the secondary terminal 12 is located.

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

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

[0065] The secondary contact 27 and secondary contact pad 29 contribute to electrically connecting the secondary coil 24 to the secondary terminal 12, as will be described later.

[0066] The housing 5 of the header component 3 is provided with a fixing projection 31 that protrudes from at least one upper end 10 of the side wall 8. In the illustrated embodiment, the fixing projection 31 is located at the upper end 10 of the side wall 8 opposite to the side wall 8 in which the connection portion 15 of the secondary terminal 12 is embedded. The ends of the fixing projection 31 and the connection portion 15 protruding from the upper end 10 reach the respective through-holes 32 of the cover 4, thereby mechanically connecting the cover 4 to the header component 3.

[0067] In the assembled induction device 1, the cover 4 covers the upper opening 9 of the housing 5 from above. The cover 4 protects the induction component 2. Furthermore, the upper surface 33 of the cover 4 provides a gripping surface that can grip the induction device 1, allowing for further manufacturing steps, such as placing the induction device 1 on a substrate. In particular, the upper surface 33 can function as a mechanical or pneumatic gripper gripping surface, thereby enabling easy and efficient handling of the induction device 1, especially automated handling.

[0068] The following describes the electrical connection between coils 23 and 24 and their respective terminals 11 and 12. When winding the primary coil 23, the ends of the insulated wires 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 lead wires 35 are routed along the outside of the side wall 8 to each primary terminal 11 and connected to them. Through these lead wires 35, the coil 23 is directly connected to each terminal 11 in an easy and simple manner.

[0069] Guide elements can be provided on each side wall 8 of the housing 5 for routing the lead wires 35. In the illustrated embodiment, a guide groove 36 is formed at the upper end 10 of the side wall 8. The lead wires 35 exit the cavity 6 through the guide groove 36. Guide projections 37 are formed at the lower end of the side wall 8, and the lead wires 35 are routed between them to their respective primary terminals 11.

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

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

[0072] The electrical connections to terminals 11 and 12 of coils 23 and 24 maximize the creepage distance and clearance distance of the inductive device 1. The primary terminal 11 and secondary terminal 12 are positioned along two opposing side walls of the housing 5 of the header component. Therefore, the creepage distance corresponds to the physical distance from the primary terminal 11 to the secondary terminal 12, as shown in Figure 2. In this way, the inductive device 1 combines the advantages of a compact design with increased creepage distance.

[0073] Figures 3 to 6 illustrate the method for assembling the induction device. This method is particularly suitable for assembling induction device 1 shown in Figures 1 and 2. Furthermore, this method is suitable for assembling various variations of the induction device. For simplicity, the components of the induction device to be assembled are shown schematically only in Figures 3 to 6 and are indicated by the same reference numbers as induction device 1 in Figures 1 and 2.

[0074] As shown in Figure 3, coils 24 and 23 are wound on a bobbin mount 19. Contacts 26 and 27 protrude from the flange 30 of the bobbin mount 19. The ends of the insulated wires 21 are left as flying leads 35. The lead wires 38 of the uninsulated wires are terminated at the secondary contact 27.

[0075] The winding of coils 23 and 24 may be performed automatically. For example, a multi-arbor automatic winding machine can be used. Particularly preferred is that the lead wires 38 of the non-insulated wires are automatically terminated at their respective secondary contacts.

[0076] After winding coils 23 and 24, the induction component 2 is assembled by introducing the transformer core 20 into the bobbin mount 19 and housing (sealing) the coils 23 and 24 at least partially within the case 25. The assembled induction component 2 is shown in Figure 4.

[0077] As shown in Figure 5, the induction component 2 is connected to the cover 4 via contacts 26 and 27, for example, by soldering the contacts 26 and 27 to the cover, particularly to their respective contact pads. The cover 4 is a circuit board. The connection between contacts 26 and 27 can 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 both mechanical and electrical connections with the cover 4, particularly with the conductor pattern 39.

[0078] Connecting the cover 4 to the guide component 2 before inserting the guide component 2 into the cavity 6 of the header component 3 has the advantage that the upper surface 33 of the cover 4 can be used as a gripping surface, and the guide component 2 can be positioned in the cavity 6 through the upper opening 9.

[0079] As shown in Figure 6, the guide component 2 is placed inside the cavity 6 of the header component 3. The guide component 2 is placed inside the cavity through the upper opening 9. This makes it easy and convenient to automate the placement of the guide component 2 inside the header component 3 from above.

[0080] The induction component 2 is positioned within the cavity 6 such that its contacts 26 and 27 protrude from the upper opening 9.

[0081] By positioning the induction component 2 within the cavity 6, the cover 4 is also positioned relative to the header component 3. The cover 4 covers the upper 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 their respective primary terminals 11. The routing and connection of the lead wires 35 can be done, for example, manually.

[0082] In the illustrated embodiment, the primary coil is connected to its respective terminals via insulated wires routed around the housing. The secondary coil is connected to its respective terminals via a conductor pattern within the cover and terminal connections extending to the cover. Many other variations of the inductive device are possible. For example, the primary and secondary coils can be wound with insulated wires, each wire routed around its respective sidewall, and directly connected to its respective terminal. In this way, material costs and component complexity can be reduced. In some embodiments, a cover over the upper opening is unnecessary. Furthermore, the inductive components do not need to provide their respective contacts.

[0083] In yet another embodiment, the wires of the primary and secondary coils may be terminated at their respective contacts. Connections to the terminals of the header component may, in each case, be established via the terminal cover and the respective conductor patterns of the connection. Such types of connections are particularly suitable for automated assembly of inductive devices.

[0084] In further embodiments, different connections to the cover may be used. For example, the cover may be mechanically connected to the header and / or induction components. Each contact to which the wires are terminated is not required to establish an electrical connection to the conductor pattern of the cover. It is possible to connect the leads of each coil directly to the conductor pattern of the cover.

[0085] Further embodiments of the induction device 101 will be described with reference to Figures 7 and 8. The induction device 101 comprises an induction component 102. The induction component 102 is a bobbin-wound transformer comprising a primary coil and a secondary coil (not shown).

[0086] The guide component 102 is placed in the cavity 106 of the header component 103. The cavity 106 is enclosed by the housing 105 of the header component 103. The housing 105 has a bottom 107 and side walls 108, enclosing the cavity 106 on three sides and the bottom. On the opposite side of the bottom 107 is the upper opening 109 of the housing 105, through which the guide component 102 can be inserted into the cavity 106. One side of the housing 105 is provided with a side opening 141. The upper opening 109 and the side opening 141 form a common insertion opening. The common insertion opening simplifies the insertion of the guide component 102. Furthermore, it simplifies visual inspection to ensure that the guide component 102 is correctly placed in the cavity 106, particularly during the actual placement procedure.

[0087] The header component 103 includes primary terminals 111 and secondary terminals 112. The primary terminals 111 are connected to the primary coil of the inductor component 102. The secondary terminals 112 are connected to the secondary coil of the inductor 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 the housing 105. Terminals 111 and 112 protrude laterally from the bottom 107. The secondary terminal 112 is located adjacent to the side opening 141. The primary terminal 111 is located on the side wall 108 facing the side opening 141.

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

[0090] The lead wires 135 of the primary coil exit the cavity 106 through the side opening 141 and are routed to the opposite side wall 108, where they are connected to their 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 of the housing 105 opposite the side opening 141. The lead wires 135 are securely held within the guide groove 142.

[0091] The induction device 101, and in particular its header component 103, has a simple structure. At the same time, safe isolation of the primary and secondary circuits of the induction component 102 is established, benefiting from a large creepage distance.

[0092] The induction device 101 can be easily assembled using an automated placement technique, particularly for arranging the induction component 102 within the cavity 106. The induction component 102 can be manufactured and supplied using known techniques. The supplied induction component 102 is inserted into the cavity 106 at least partially through the upper opening 109. Lead wires 138 are connected to secondary terminals 112 adjacent to the side opening 141. Lead wires 135 exit the side opening 141, wrap around the adjacent side wall, and are routed to and connected to their respective primary terminals 111.

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

[0094] In a further exemplary embodiment, the lead wire 135 can be routed around the upper end of the side wall opposite the side opening 141. This eliminates the need to route the lead wire 135 along the side wall adjacent to the side opening 141.

[0095] In further exemplary embodiments, the housing may have four side walls, enclosing the cavity on all four sides. In this case, the induction component can be placed inside the cavity through an upper opening. The lead wires of the induction component can be routed around the upper edge of the side walls to their respective terminals.

[0096] The embodiments of the invention, based on the claims at the time of the international application, are described below. (Aspect 1) A header component for mounting inductive components, particularly transformers, on a circuit board, The header component is, - A housing (5;105) that houses the induction component (2;102) within the cavity (6;106), - A plurality of terminals (11, 12; 111, 112) for electrically connecting the induction component (2; 102) to the substrate, wherein the plurality of terminals (11, 12; 111, 112) protrude outward from the bottom surface of the housing (5; 105) and Equipped with, --The housing (5;105) surrounds the cavity (6;106) with its bottom and at least three sides, -- A header component comprising a housing (5;105) having an upper opening (9;109) on its upper surface opposite to the bottom surface, which is configured to allow the guide component (2;102) to be inserted into the cavity (6;106) through the upper opening (9;109). (Aspect 2) The header component according to embodiment 1, wherein the housing (5) surrounds the cavity (6) on all four sides. (Aspect 3) The header component according to embodiment 1, wherein the housing (105) has a side opening (141) to the cavity (106) on one of its sides. (Aspect 4) The header component according to any one of embodiments 1 to 3, wherein at least one of the plurality of terminals (12) has a connecting portion (15) that extends 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). (Appendix 5) The header component according to embodiment 4, wherein the connecting portion (15) is embedded in at least one side wall (8) of the housing (5). (Aspect 6) An induction device mounted on a circuit board. A header component (3;103) as described in any one of the embodiments 1 to 5, Inductive components (2;102) including one or more coils (23, 24), particularly transformers and Equipped with, The induction component (2;102) is located within the cavity (6;106) of the housing (5;105) of the header component (3;103). An inductive device in which the leads (35, 38; 135; 138) of the one or more coils (23, 24) of the inductive component (2; 102) are electrically connected to the respective terminals (11, 12; 111, 112) of the header component (3; 103). (Aspect 7) The induction device according to embodiment 6, wherein the induction component (2) is provided with a contact (27), and the leads (38) of at least one coil (24) of the induction component (2) are connected to the respective terminals (12) via the contact (27), and the induction component (2) is positioned within the cavity (6) such that the contact (27) protrudes from the upper opening (9). (Pattern 8) The induction device according to embodiment 6 or 7, comprising a cover (4) that at least partially covers the upper opening (9). (Aspect 9) The induction device according to embodiment 8, wherein the cover (4) is attached to the induction component (2), particularly to the contacts (26, 27) of the induction component (2). (Aspect 10) The induction device according to embodiment 8 or 9, wherein the leads (38) of at least one coil (24) of the induction component (2) are connected to the respective terminals (12) of the header component (3) via a conductor pattern (39) included in the cover (4). (Aspect 11) The inductive device according to embodiment 10, wherein the conductor pattern (39) included in the cover (4) connects each of the leads (38) of the inductive component (2) to the connection portions (15) of each of the terminals (12) of the header component (3). (Aspect 12) The induction device according to any one of embodiments 8 to 11, wherein the cover (4) comprises a circuit board, and more particularly consists of a circuit board. (Aspect 13) The induction device according to embodiment 8, wherein the cover is removable. (Aspect 14) A method for assembling an induction device, - A step of providing a header component (3;103) according to any one of the embodiments 1 to 5, -The step of providing an inductive component (2;102) comprising one or more coils (23, 24), in particular a transformer, - The step of placing the guide component (2;102) in the cavity (6;106) of the housing (5;105) of the header component (3;103) at least partially through the upper opening (9;109), - The step of electrically connecting the leads (35, 38; 135, 138) of the one or more coils (23, 34) of the induction component (2; 102) to the respective terminals (11, 12; 111, 112) of the header component (3; 103). A method of having. (Aspect 15) The method according to embodiment 14, wherein the leads (35; 135, 138) of at least one coil (24) of the induction component (2; 102) are directly connected to the respective terminals (12; 111, 112). (Aspect 16) The method according to embodiment 14 or 15, wherein the leads (38) of at least one coil (24) of the induction component (2) are terminated on each of the contacts (27) of the induction component (2), and the induction component (2) is positioned in the cavity (6) such that the contacts (27) protrude from the upper opening (9). (Aspect 17) The method according to any one of embodiments 14 to 16, wherein a cover (4) is attached to the induction 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). (Aspect 18) The method according to embodiment 17, wherein the conductor pattern (39) included in the cover (4) is connected to the connection portion (15) of each terminal (12) of the header component (3). (Aspect 19) The method according to any one of embodiments 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 guide component (102). [Explanation of Symbols]

[0097] 1. Induction device 2. Induction components 3 Header components 4 Covers 5 Housing 6 Cavity 7 Bottom 8 side wall 9 Top opening 10 Top 11 Primary terminal 12 Secondary terminal 13 Mounting part 14 Fixed part 15 Connection part 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 pads 29 Secondary contact pads 30 flange 31 Fixing protrusion 32 through-holes 33 Top surface 34 Secondary coil 35, 38, 135, 138 lead wires 36 Guide grooves 37 Guide projection 39 Conductor Patterns 101 Induction Devices 102 Induction components 103 Header component 105 Housing 106 Cavity 107 Bottom 108 Side wall 109 Top opening 111 Primary terminal 112 Secondary terminal 141 Side opening 142 Guide grooves

Claims

1. A header component for mounting inductive components, particularly transformers, on a circuit board, The header component is, - A housing (5;105) that houses the induction component (2;102) within the cavity (6;106), - A plurality of terminals (11, 12; 111, 112) for electrically connecting the induction component (2; 102) to the substrate, wherein the plurality of terminals (11, 12; 111, 112) protrude outward from the bottom surface of the housing (5; 105) and Equipped with, -- The housing (5; 105) surrounds the cavity (6; 106) with its bottom and at least three sides, -- A header component comprising a housing (5; 105) having an upper opening (9; 109) on its upper surface opposite to the bottom surface, which is configured such that the guide component (2; 102) can be inserted into the cavity (6; 106) through the upper opening (9; 109).

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

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

4. The header component according to claim 1, wherein at least one of the plurality of terminals (12) has a connecting portion (15) that extends 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. The header component according to claim 4, wherein the connecting portion (15) is embedded in at least one side wall (8) of the housing (5).

6. An induction device mounted on a circuit board. A header component (3; 103) according to any one of claims 1 to 5, Inductive components (2; 102) including one or more coils (23, 24), particularly transformers and Equipped with, The induction component (2; 102) is located within the cavity (6; 106) of the housing (5; 105) of the header component (3; 103). An inductive device in which the leads (35, 38; 135; 138) of one or more coils (23, 24) of the inductive component (2; 102) are electrically connected to the respective terminals (11, 12; 111, 112) of the header component (3; 103).

7. The induction device according to claim 6, wherein the induction component (2) is provided with a contact (27), and the leads (38) of at least one coil (24) of the induction component (2) are connected to the respective terminals (12) via the contact (27), and the induction component (2) is positioned in the cavity (6) such that the contact (27) protrudes from the upper opening (9).

8. The induction device according to claim 6, further comprising a cover (4) that at least partially covers the upper opening (9).

9. The induction device according to claim 8, wherein the cover (4) is attached to the induction component (2), particularly to the contacts (26, 27) of the induction component (2).

10. The induction device according to claim 8, wherein the leads (38) of at least one coil (24) of the induction 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. The inductive device according to claim 10, wherein the conductor pattern (39) included in the cover (4) connects each of the leads (38) of the inductive component (2) to the connection portions (15) of each of the terminals (12) of the header component (3).

12. The induction device according to claim 8, wherein the cover (4) comprises a circuit board, and more particularly, is made of a circuit board.

13. The induction device according to claim 8, wherein the cover is removable.

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

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

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

17. The method according to claim 14, wherein a cover (4) is attached to the induction 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. The method according to claim 17, wherein the conductor pattern (39) included in the cover (4) is connected to the connection portion (15) of each terminal (12) of the header component (3).

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

Images