Device having a winding carrier and a magnetic core and method of manufacturing the device

Abstract

The device (1) includes a winding carrier (2), at least one winding (3), a magnetic core (7), and first and second terminals (5, 6). The winding carrier (2) surrounds the magnetic core (7) in a predetermined area such that the insulation path between terminals along the underside (14) of the device (1) does not include a bridge through the magnetic core (7). In particular, the underside (14) of the winding carrier (2) has a closed configuration.

Description

Technical Field

[0001] The present invention relates to a device including a winding carrier having windings and a magnetic core. It is, for example, a transformer. It can be another device having a magnetic core.

Background Art

[0002] In the case of electrical equipment such as transformers, for example, a specified insulation distance, especially in accordance with IEC standards, between electrical terminals must be maintained. Therefore, the insulation distance between the terminals, that is, the shortest possible creepage distance and / or clearance distance along the insulating material should be made sufficiently large. For example, it is necessary to maintain an insulation distance between the power supply side terminal and the consumer side terminal.

[0003] Since the insulation distance can be bridged by a conductive magnetic core, the distance between the terminals increases accordingly. For example, at operating altitudes exceeding 4 km above sea level, a long clearance distance is required. To ensure a sufficient insulation path, the distance from the electrical terminal to the magnetic core is usually selected to be appropriately large. This leads, in particular, to an undesirable increase in the size of the device because the insulation path to be maintained and the size of the magnetic core are added together.

[0004] To prevent the insulation path from being bridged, its own magnetic core can be enclosed in a plastic housing and placed in the device in an insulated state. It is also known to cast the entire toroidal core, for example, such that only the terminals protrude from the casting. However, this has drawbacks in terms of cost and component size.

[0005] From Patent Document 1, it is also known to insert a coil having a magnetic core into a housing open on one side together to insulate the magnetic core from the terminal pins and increase the clearance distance in such a way. Then, the wire ends are led from the winding to the pins through the outside of the housing.

Prior Art Documents

Patent Documents

[0006] [Patent Document 1] U.S. Patent No. 9646755 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] The object of the present invention is to identify improved apparatus and methods for manufacturing the apparatus. [Means for solving the problem]

[0008] According to a first aspect of the present invention, the apparatus includes a winding carrier and at least one winding arranged around the winding carrier. The winding may be a wire winding, such as a circular or flat wire, or a printed winding. The winding carrier is formed from, among other things, an electrical insulating material. For example, it may be a plastic material. The winding carrier is used, among other things, to position the winding. In particular, the winding is wound directly over a predetermined area of ​​the winding carrier. The winding carrier may have, for example, a single-piece design. In particular, the winding carrier can be manufactured by injection molding.

[0009] In addition, the apparatus includes a magnetic core. The magnetic core includes, for example, a ferrite material. In particular, the magnetic core encloses a predetermined region of the winding. For example, the magnetic core forms a closed magnetic circuit. The magnetic core may include several core sections. For example, the magnetic core includes an I-shaped core section and a U-shaped core section. Other core section shapes are also possible. For example, the core sections are bonded to each other.

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

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

[0012] The winding carrier is designed to be at least a partial insulator of the magnetic core. Therefore, no additional insulation of the magnetic core is required. In particular, a separate casting or separate housing is not needed for the magnetic core. In particular, the winding carrier at least partially surrounds the magnetic core so that the insulating path between terminals along the underside of the device does not include bridging by the magnetic core. The insulating path here is the shortest clearance and / or creepage path. For example, the minimum creepage distance extends only along the winding carrier and not toward the magnetic core.

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

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

[0015] For example, the winding carrier includes a lower side. The lower side is the mounting side of the winding carrier or device, i.e., the side facing a printed circuit board to which the winding carrier may be mounted. The first terminal is located, for example, on the first edge when viewed from below, and the second terminal is located on the second edge on the opposite side. The winding carrier does not include, for example, a notch on the lower side in which the magnetic core is exposed. In particular, such a notch is not provided in an area laterally bordered by the first and second terminals. In this way, the insulating path between the terminals along the lower side is prevented from including a bridge through the magnetic core.

[0016] However, the portion of the magnetic core beyond the terminals, i.e., the portion away from the center of the device, may not be enclosed by the winding carrier. However, this does not create a bridge in the insulating path between the terminals.

[0017] The winding carrier may include at least one opening into which a magnetic core or the magnetic core portion of a magnetic core can be inserted. For example, the lower side may not have such an opening. This allows for a closed design of the lower winding carrier.

[0018] In one embodiment, at least one opening is located on the side of the winding carrier. This allows the magnetic core to be inserted into the winding carrier from the side. In addition, the winding carrier may include at least one opening on its upper side. For example, the winding carrier may include an opening on the side and an opening on the upper side. Two magnetic core portions can be inserted through these openings. For example, an I-shaped magnetic core portion may be inserted through one of the openings, and a U-shaped magnetic core portion may be inserted through the other opening.

[0019] In further embodiments, the winding carrier may include one or more openings for inserting the magnetic core only on its upper side. In this way, there is no need to provide openings on the sides of the winding carrier, so the sides can further insulate the magnetic core. Therefore, in the case of multiple magnetic cores, all magnetic cores are inserted into the winding carrier from above. For example, the first magnetic core can be inserted first through the upper opening, then the winding can be applied, and then the second magnetic core can be inserted.

[0020] If the openings in the winding carrier are properly positioned, the magnetic core can be enclosed not only on the bottom but also on the sides. This allows for particularly good prevention of bridging of the insulation path by the magnetic core. For example, the magnetic core is completely insulated from the outside by the winding carrier on at least one side. It is also possible to completely insulate the magnetic core from the outside by the winding carrier on two or more sides.

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

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

[0023] The winding carrier may include a lead-through along the winding axis. The magnetic core may be placed within the lead-through. Placing it within the lead-through also insulates the magnetic core from the winding carrier outwards, for example, to the sides.

[0024] According to one embodiment, at least one of the terminals is disposed in a recess. For example, a recessed terminal is attached to a region on the side surface of a winding carrier that is recessed inward with respect to another region on the side surface. In this way, the dimensions of the component can be reduced. As a result, the distance between the first terminal and the second terminal can be reduced by the insulation of the magnetic core that does not fall below the minimum insulation distance. For example, the spacing between the terminals can be made equal to the minimum insulation spacing. Therefore, the overall component size can also be limited to the minimum insulation dimension.

[0025] According to another aspect of the present invention, the device includes a winding carrier and at least one winding of a wire disposed around the winding carrier. The device includes a magnetic core, at least a first electrical terminal, and at least one second electrical terminal, the winding carrier includes a lower side, and the terminals are disposed opposite to each other with respect to the lower side. The winding carrier does not include a notch through which the magnetic core is exposed in at least a region of the lower side that is laterally bounded by the first terminal and the second terminal. The device may include all of the structural and functional features of the device described above.

[0026] The form in which the winding carrier is closed at the lower side insulates the lower side magnetic core from the terminals, and the safety gap in this region is not bridged by the magnetic core.

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

[0028] According to this method, a winding carrier including one or more openings on the side surface and / or the upper side is provided. A first magnetic core part is inserted into the winding carrier through one of the openings. A second magnetic core part is inserted into the winding carrier through one of the openings. The second magnetic core part may be inserted through the same opening as the first magnetic core part or through a different opening. Therefore, the magnetic core part is inserted through an opening on the side surface and / or the upper side rather than the lower side of the winding carrier. Therefore, the lower side can be formed without such an opening.

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

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

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

[0032] If the winding shaft is occupied by the first magnetic core before the winding is applied, the winding mandrel cannot be inserted into the winding shaft. For example, a winding carrier includes a retaining device on its outer surface that can secure the winding carrier to a winding machine.

[0033] The present invention includes several embodiments, in particular apparatus and methods. Embodiments described in one embodiment are applicable accordingly to other embodiments.

[0034] Furthermore, the description of the objectives disclosed herein is not limited to individual specific embodiments. Rather, the features of individual embodiments can be combined with each other to a technically useful degree.

[0035] The subject matter described herein will be explained in more detail below using schematic embodiments. [Brief explanation of the drawing]

[0036] [Figure 1A] Figure 1A is a cross-sectional view of an embodiment of the apparatus. [Figure 1B] Figure 1B shows the apparatus of Figure 1A viewed from above at an oblique angle. [Figure 1C] Figure 1C shows the apparatus of Figure 1 viewed from below at an angle. [Figure 2] Figure 2 shows a further embodiment of the device viewed obliquely from above. [Figure 3A] Figure 3A shows one embodiment of a winding carrier viewed obliquely from above. [Figure 3B] Figure 3B is a longitudinal cross-sectional view of the winding carrier shown in Figure 3A. [Figure 4A] Figure 4A is a side view of a further embodiment of the device, viewed from an oblique angle above. [Figure 4B] Figure 4B is a further side view of the apparatus shown in Figure 4A, viewed from above at an oblique angle. [Figure 4C] Figure 4C shows the apparatus of Figure 4A viewed from below at an angle. [Figure 4D] Figure 4D shows the apparatus of Figure 4A viewed from above. [Figure 5] Figure 5 is a side view of a further embodiment of the device, viewed from above at an angle. [Figure 6] Figures 6A to 6E show the steps of the method for manufacturing the components of the apparatus shown in Figure 5. [Figure 7] Figure 7 is a side view of a further embodiment of the device, viewed from above at an angle.

[0037] Preferably, in the following drawings, the same reference numerals are used to indicate functionally or structurally corresponding parts of various embodiments. [Modes for carrying out the invention]

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

[0039] Device 1 is configured, for example, as a transformer. Device 1 can also be configured as a device having a different function, in particular as a device for which maintaining the insulating path between electrical terminals is especially important.

[0040] The apparatus 1 includes a winding carrier 2 on which at least one winding 3 of a wire 4 is wound. Here, the winding 3 is arranged in an upright position; that is, the winding axis is positioned perpendicular to the lower side 14 of the apparatus 1. The lower side 14 corresponds to the mounting side of the apparatus 1, for example, when it is fixed to a printed circuit board. The winding carrier 2 is formed from an electrically insulating material. The winding carrier 2 is formed, for example, non-magnetic. The winding carrier 2 may be formed from a plastic material. For example, the winding carrier 2 is manufactured by an injection molding process.

[0041] Multiple windings may be arranged around the winding carrier 2, specifically one or more primary windings and one or more secondary windings of a transformer. Where a single winding is referred to herein, this also applies to multiple windings. The winding carrier 2 has flange-like boundaries 10, 11 on both sides, with the windings 3 arranged between them.

[0042] The wire 4 contains a metallic material, such as copper. The wire 4 is sheathed with an insulator and is, for example, triple-insulated (TIW "triple-insulated wire"). Therefore, the wire 4 or winding 3 does not need to be separately covered or additionally insulated.

[0043] The apparatus 1 includes at least a first terminal 5 and a second terminal 6. Terminals 5 and 6 are directly attached to the winding 2 and are co-injection molded, for example, when the winding carrier 2 is manufactured in an injection molding process. The ends of the winding 3 are connected to terminals 5 and 6. Currently, a plurality of first terminals 5 are arranged in a row, and a plurality of second terminals 6 are arranged in a row. The first terminals 5 and the second terminals 6 are located on both sides 16 and 24 of the apparatus 1.

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

[0045] Apparatus 1 includes a magnetic core 7. The magnetic core 7 includes, for example, a ferrite material or another magnetic material. The magnetic core 7 is not formed as a winding carrier by itself, but is a separate element attached to the winding carrier 2. The magnetic core 7 is made of a different material from the winding carrier 2. Specifically, the magnetic core 7 has greater electrical conductivity than the winding carrier 2.

[0046] In this case, the magnetic core 7 is composed of multiple parts. The first magnetic core part 8 includes an I-shape. The second magnetic core part 9 includes a U-shape. The magnetic core parts 8 and 9 may also include other shapes; for example, both magnetic core parts 8 and 9 may be U-shaped. The magnetic core parts 8 and 9 together form a closed magnetic circuit. The magnetic core parts 8 and 9 are, for example, bonded to each other.

[0047] The magnetic core 7 typically has higher electrical conductivity than the winding carrier 2 and can lead to an electrical bridge in the insulating path between the first terminal 5 and the second terminal 6. Therefore, since the magnetic core 7 does not contribute to the insulating path between the first terminal 5 and the second terminal 6, an insulating clearance must be maintained separately from the magnetic core 7.

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

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

[0050] Figure 1C shows the device 1 from its lower side 14. The winding carrier 2 is closed at the bottom. In particular, there are no notches on the lower side 14 that would allow the magnetic core 7 to protrude from or be pushed into the winding carrier 2. Therefore, the magnetic core 7 is insulated by the winding carrier 2 in the region of the lower side 14 between the first terminal 5 and the second terminal 6. Placing the magnetic core 7 inside the winding carrier 2 ensures space-saving insulation. The magnetic core 7 protrudes from the winding carrier 2 only laterally. At least in the region of the lower side 14 laterally bounded by the first terminal 5 and the second terminal 6, the winding carrier 2 does not contain any notches that would expose the magnetic core 7.

[0051] Thus, the insulating path 28 between the second terminals 6 along the lower side 14 is not bridged by the magnetic core 7. As can be seen from the figure, the insulating path 29 from the second terminals 6 to the magnetic core 7 is increased by being enclosed by the insulating winding carrier 2. Therefore, the magnetic core 7 is partially insulated from the outside by the winding carrier 2 so that the minimum creepage distance or clearance distance between the first terminals 5 and the second terminals 6 along the lower side 14 of the device 1 does not include bridging by the magnetic core. As a result, the magnetic core 7 does not bridge or shorten the insulating path between terminals 5 and 6.

[0052] Therefore, in the lower section 14, the magnetic core 7 does not affect the insulation path 28 between terminals 5 and 6, allowing the size of the device 1 to be reduced. In particular, in the lower section 14, the distance d of the first terminal 5 from the second terminal 6 can be minimized to the minimum insulation distance. Even in the bridge formed by the magnetic core 7, it is only necessary to ensure that the required minimum insulation distance is maintained along the upper section 15.

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

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

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

[0056] The magnetic core 7 protrudes into the first opening 17, penetrates the winding carrier 2 through the lead-through 19, and exits the winding carrier 2 through the second opening 18. The lead-through 19 (see Figures 3A and 3B) extends along the winding axis within the first region 30 and parallel to the lower side 14 within the second region 31. Inside the lead-through 19, i.e., from the first opening 17 to the second opening 18, the magnetic core 7 is uninterrupted and surrounded by the winding carrier 2.

[0057] In the embodiments shown in Figures 1A, 1B, and 1C, the magnetic core 7 is positioned asymmetrically with respect to the winding carrier 2 and terminals 5 and 6, and is insulated from them. Therefore, the insulating path 12 between the magnetic core 7 and the first terminal 5 is small, but the insulating path 13 between the magnetic core 7 and the second terminal 6 is considerably large.

[0058] The first magnetic core portion 8 is I-shaped, and the second magnetic core portion 9 is U-shaped. The I-shaped first magnetic core portion 8 is positioned parallel to the lower part 14. The U-shaped second magnetic core portion 9 is positioned along the winding axis together with the legs. In other embodiments, the I-shaped first magnetic core portion may be positioned along the winding axis, and the U-shaped second magnetic core portion may be positioned parallel to the lower part together with the legs. Alternatively, both magnetic core portions 8 and 9 may be U-shaped, for example.

[0059] The following describes the method for manufacturing apparatus 1.

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

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

[0062] The first terminal 5 is configured, for example, for connection to a supply network, and the second terminal 6 is configured for connection to a consumer. The first terminal 5 is connected, for example, to the first winding 3, and the second terminal 6 is connected in pairs to two other windings 20. The first winding 3 is positioned, for example, above the second winding 20 in the direction of the winding axis. The second winding 20 is positioned in the same location, for example, above and below the winding axis. Since the windings are insulated from the outside, the windings 3 and 20 can be positioned in different ways, for example, they can all be positioned in the same location with respect to the winding axis.

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

[0064] Furthermore, in the illustrated embodiment, since the lower side 14 of the winding carrier 2 is completely closed, in order to maintain the minimum insulating path at the lower side 14 of the device 1, it is sufficient to select the distance between opposing terminals 5 and 6 so that it is equal to the minimum insulating path.

[0065] In addition, the winding carrier 2 has a projection on its upper side 15, which increases the creepage and clearance distance between the magnetic core 7 and the second terminal 6 along the upper side 15. The first projection 21 extends upward within the region of the winding carrier 2. The second projection 22 extends the winding carrier 2 to one side. Both projections 21 and 22 are selected so as not to increase the external dimensions of the device 1.

[0066] Figure 3A shows one embodiment of the winding carrier 2 viewed obliquely from above. Figure 3B shows a longitudinal cross-section of the winding carrier 2. The winding carrier 2 is basically constructed as the winding carrier 2 in Figure 2, except that it does not include the additional protrusions 21 and 22.

[0067] The winding carrier 2 includes a first opening 17 on its side 16 and a second opening 18 on its upper side 15. In the cross-sectional view of Figure 3B, a lead-through 19 is visible. The lead-through 19 includes a first region 30 extending parallel to the winding axis (in this case perpendicular) and a second region 31 extending perpendicular to the winding axis. The second region 31 extends parallel to the lower side 14. The lead-through 19 is configured in an L-shape overall. Since the lead-through 19 is completely enclosed by the winding carrier 2, it is accessible from the outside only through the openings 17 and 18.

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

[0069] For clarity, apparatus 1 is shown without windings. In the finished apparatus 1, the windings are applied directly around the winding carrier 2. In contrast to the embodiments described above, the winding axis extends parallel to the lower side 14 of apparatus 1. The winding carrier 2 includes two flange-like boundaries 10, 11 that touch the windings on both sides.

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

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

[0072] The winding carrier 2 completely encloses the magnetic core 7 on its lower side 14. In this case, the lower region of the magnetic core 7 is formed by an I-shaped magnetic core portion 8 and is enclosed by the winding carrier 2 on almost all sides. Only the region of the I-shaped magnetic core portion 8 facing the further side 24 is open. Towards the first side 16, the magnetic core 7 is completely insulated from the winding carrier 2 on the outside. Therefore, the magnetic core region cannot be seen from the diagram of the lower side 14 and the diagram of the side 16. Overall, a large area of ​​the magnetic core 7 is incorporated into the winding carrier 2 and is positioned to be hidden and insulated from the terminals 5 and 6.

[0073] Therefore, here too, the insulating path between the first terminal 5 and the second terminal 6 along the lower side 14 of the device 1 is not bridged by the magnetic core 7. Depending on the shape of the device 1, the insulating path, i.e., the minimum creepage or clearance distance between the first terminal 5 and the second terminal 6, extends along the lower side 14 or along the sides 16, 24 of the device 1. Here again, the sum of the insulating path between the first terminal 5 and the magnetic core 7 and the insulating path between the second terminal 6 and the magnetic core 7 is at least as large as the geometric distance d between the first terminal 5 and the second terminal 6.

[0074] Therefore, the distance d between the first terminal 5 and the second terminal 6 can be selected to be equal to the minimum insulation distance. As can be easily seen in Figure 4D, the first terminal 5 and the second terminal 6 are offset inward. In particular, the region of the winding carrier 2 to which terminals 5 and 6 are fixed is further inward than the region that laterally encloses the magnetic core 7. For this reason, the winding carrier 2 is configured with steps on its sides 16 and 24.

[0075] This allows for further reduction in the size of component 1 without violating the required minimum insulation distance. This miniaturization is made possible by insulating the magnetic core 7 from terminals 5 and 6 with the winding carrier 2.

[0076] The following describes the method for manufacturing apparatus 1.

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

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

[0079] Figure 5 shows a further embodiment of apparatus 1. Figures 6A to 6E show a method for manufacturing the apparatus, and thereby also show the internal structure of apparatus 1 in Figure 5.

[0080] Similar to the embodiments described above, the winding carrier 2 also forms a housing for the magnetic core 7 to insulate the magnetic core 7 from the first terminal 5 and / or the second terminal 6. The winding carrier 2 encloses the magnetic core 7 from the bottom 14 so that no region of the magnetic core 7 is exposed between the terminals 5 and 6. As shown in the embodiments of Figures 4A to 4D, the magnetic core 7 is completely enclosed at the bottom 14 so that no region of the magnetic core 7 is exposed.

[0081] Here too, the magnetic core 7 includes a first magnetic core portion 8 (Figure 5) and a second magnetic core portion 9 (Figure 6A). The first magnetic core portion 8 is U-shaped, and the second magnetic core portion 9 is I-shaped.

[0082] In contrast to the previously described embodiment, the magnetic core 7 is fully inserted into the winding carrier 2 from the upper side 15, i.e., both of the magnetic core portions 8 and 9 (see Figure 6A for magnetic core portion 8). In particular, the winding carrier 2 includes an opening 18 only on the upper side 15 for inserting both of the magnetic core portions 8 and 9. The housing 2 also partially extends onto two further sides 25 and 26. The lower magnetic core portion 8 is not visible from the outside. Only the upper side of the upper magnetic core portion 9 is visible.

[0083] Therefore, the magnetic core 7 is similarly insulated from the first terminal 5 and the second terminal 6. In particular, the insulation path between the first terminal 5 and the magnetic core 7 is the same length as the insulation path between the second terminal 6 and the magnetic core 7. Overall, the allocation of insulation paths between the magnetic core 7 and the first terminal 5 and between the magnetic core 7 and the second terminal is symmetrical.

[0084] As shown in Figure 6A, the winding carrier 2 is provided during the manufacture of the apparatus 1. Terminals 5 and 6 are attached to the winding carrier 2. The wires are not yet attached to the winding carrier 2. The U-shaped first magnetic core 8 is inserted into the winding carrier 2 through the opening 18 located on the upper side 15. In particular, the first magnetic core 8 is inserted into the opening winding shaft of the winding carrier 2.

[0085] Figure 6B shows the winding carrier 2 into which the U-shaped first magnetic core 8 is inserted. The winding carrier 2 encloses the first magnetic core 8 from the bottom 14 and all sides 16, 24, 25, 26. The first magnetic core 8 is exposed only from the top 15. Subsequently, the wire 4 is wound around the winding carrier 2, and the winding 3 is applied.

[0086] Figure 6C shows a winding carrier 2 having a winding 3. The winding 3 is positioned horizontally such that its winding axis is parallel to the lower side 14 of the device 1. The wire ends of the winding 3 are guided to terminals 5 and 6 via guide grooves in the winding carrier 2 and are electrically connected to terminals 5 and 6. At terminals 5 and 6, the insulating layer is removed from the wire, and the wire is soldered or laser-welded to, for example, each terminal 5 and 6.

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

[0088] Figure 6E shows the completed apparatus 1. The first magnetic core 8 forms a closed magnetic circuit together with the second magnetic core 9. The first magnetic core 8 is, for example, bonded to the second magnetic core 9. The second magnetic core 9 is completely enclosed by the winding carrier 2 on two sides 16 and 24. The winding carrier 2 defines the positions of the magnetic cores 8 and 9 by fitting securely with them. This enables automatic and well-controllable placement and bonding of the magnetic cores 8 and 9.

[0089] Figure 7 shows a modified example of apparatus 1 of Figures 5 to 6E. Here, the winding carrier 2 includes a lateral retaining device 27 for fixing the winding carrier 2 to the winding machine. The retaining device 27 includes, for example, a web to which a two-part spindle can be attached to the winding carrier 2.

[0090] In contrast to the embodiments shown in Figures 1A to 4D, in the embodiments shown in Figures 5 to 7, the winding carrier 2 does not include an opening into which the spindle can be inserted onto the winding shaft during the manufacturing of the winding. The space is already occupied by the first magnetic core 8 by placing it inside the winding carrier 2 before the winding is applied. [Explanation of Symbols]

[0091] 1 device 2 Winding carrier 3 windings 4 wires 5. First terminal 6. Second terminal 7 magnetic core 8. First magnetic core 9. Second magnetic core 10 boundaries 11 Boundary 12 Insulation path between the first terminal and the magnetic core 13. Insulation path between the second terminal and the magnetic core along the side. 14 Lower side 15 Upper side 16 Side view 17. Side openings 18 Upper opening 19 Lead-through 20 Further winding 21 First projection 22 Second projection 23 Recess 24 Further Aspects 25 Further Aspects 26 Further Aspects 27 Holding device 28 Insulation path between the first and second terminals along the lower side 28 Insulation path between the second terminal and the magnetic core along the lower side 30. The first domain of lead-through 31. The second domain of lead-through d distance

Claims

1. a winding carrier and at least one winding of wire disposed around the winding carrier; a magnetic core, at least one first electrical terminal, and at least one second electrical terminal; An apparatus comprising: A device wherein the winding carrier encases the magnetic core in at least a predetermined area such that an insulation path between terminals along the underside of the device does not include bridging through the magnetic core.

2. 2. The apparatus of claim 1, wherein the magnetic core is encased by the winding carrier such that the sum of an insulation path between the first terminal and the magnetic core and an insulation path between the second terminal and the magnetic core is at least as large as the geometric distance between the first terminal and the second terminal.

3. 3. The device according to claim 1 or 2, wherein the device is designed as a transformer, the first terminal being on the primary side and the second terminal being on the secondary side.

4. 4. The apparatus of claim 1, wherein the underside of the winding carrier does not include a cutout through which the magnetic core is exposed.

5. 5. The apparatus of claim 1, wherein the winding carrier includes at least one opening through which the magnetic core can be inserted into the winding carrier, and wherein a bottom side of the winding carrier does not include the opening.

6. The apparatus of claim 5 , wherein the opening is located on a side of the winding carrier.

7. The apparatus of claim 5 , wherein the opening is located on an upper side of the winding carrier, and the side surface does not include an opening.

8. 8. The apparatus of claim 1, wherein the magnetic core includes at least two magnetic core parts, the winding carrier includes an opening on an upper side, and both of the magnetic core parts are inserted into the winding carrier through the opening on the upper side.

9. 9. The apparatus of claim 1, wherein the magnetic core comprises a first magnetic core portion and a second magnetic core portion, one of the magnetic core portions being I-shaped and the other of the magnetic core portions being U-shaped.

10. 10. The apparatus of claim 1, wherein the first terminal is arranged on a first side of the winding carrier, the second terminal is arranged on a second side of the winding carrier, and the magnetic core is completely or predominantly enclosed by the winding carrier on at least one of the sides.

11. 11. The apparatus of claim 1, wherein the winding carrier includes a leadthrough along a winding axis, the magnetic core being arranged within the leadthrough.

12. 12. The device of claim 1, wherein at least one of the terminals is laterally recessed.

13. 13. The device according to claim 1, wherein the winding carrier includes at least one opening for inserting the magnetic core on the side where at least one of the terminals is located.

14. 1. A method for manufacturing a device, comprising: A) providing a winding carrier including one or more openings on a side or top side; B) inserting a first magnetic core into one of the openings; C) inserting a second magnetic core into the same or another of the openings; A method comprising:

15. 15. The method of claim 14, wherein after inserting the first magnetic core (8), a winding is applied to the winding carrier, after which the second magnetic core is inserted.

16. 16. The method of claim 14 or 15, wherein the first magnetic core and the second magnetic core are inserted into the same opening.

17. 16. The method of claim 14 or 15, wherein one of the magnetic cores is inserted into the side opening and the other of the magnetic cores is inserted into the top opening.

18. a winding carrier and at least one winding of wire disposed around the winding carrier; a magnetic core, at least one first electrical terminal, and at least one second electrical terminal; An apparatus comprising: the winding carrier includes a bottom side; the terminals are disposed opposite one another with respect to the underside; The apparatus, wherein the winding carrier does not include a notch through which the magnetic core is exposed, at least in the lower region laterally bounded by the first terminal and the second terminal.

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