Inductor coil

Abstract

The present invention relates to an inductor coil comprising a first component (12), a second component (14), and a length of conductor (18), wherein the first component is disposed adjacent to the second component, the first component and the second component form a core (16), the core is disposed along a first portion of a central axis and a second portion of the central axis, and along a third portion of the central axis, the first component is spaced from the second component to form a gap (20, 30) in the core, the third portion of the central axis being between the first portion of the central axis and the second portion of the central axis, a first part of the length of conductor is disposed around the first portion of the central axis, around the second portion of the central axis, and around the third portion of the central axis to form a plurality of turns of conductor surrounding the core and the gap in the core, and at least one section of the first part of the length of conductor is compressed in the direction of the central axis.

Description

Technical Field

[0001] The present invention relates to an inductor coil and a method of forming or manufacturing an inductor coil.

[0002] Background of the Invention Inductor coils use wound copper or ribbon-shaped flat spiral windings for high current applications. This results in a low value of direct current resistance (DCR). While this has significant advantages, there are significant drawbacks associated with AC losses within the elements of the wound flat coils.

[0003] To achieve a low DCR, a thicker flat copper foil of >2 mm is used. However, this amplifies any high frequency (HF) AC losses within the coil to 5 - 20 times that of normal DC losses.

[0004] There are also the effects of other problems associated with coils having such high power densities, which are due to large gaps within the cores of the coils required to achieve the desired maximum saturation current. A large magnetic gap results in a large leakage magnetic field, and any ferromagnetic material placed in close proximity to the magnetic gap experiences eddy current losses. This then results in regions of intense temperature rise in both stranded type coils and flat ribbon wound coils. Some existing methods attempt to solve this problem by devising the shape of the bobbin to avoid temperature hotspots, but this reduces the cross-sectional area available for the copper and also degrades the thermal performance of the coil. Other methods use gaps dispersed within the core to reduce the leakage magnetic field, but this adds a significant cost to the manufacturing cost.

[0005] It is necessary to address these problems.

[0006] Summary of the Invention It is advantageous to have an improved inductor coil.

[0007] The object of the present invention is solved by the subject matter of the independent claims, and further embodiments are incorporated in the dependent claims. It should be noted that the aspects and examples described below of the present invention also apply to an inductor coil and a method of forming an inductor coil.

[0008] In a first aspect, a first component, a second component, and a conductor of a predetermined length are provided to form an inductor coil.

[0009] The first component is arranged adjacent to the second component. A core is formed from the first component and the second component. The core is arranged along a first part of the central axis and a second part of the central axis. Along a third part of the central axis, the first component is spaced apart from the second component to form a gap within the core. The third part of the central axis is between the first part of the central axis and the second part of the central axis. A first part of the conductor of a predetermined length is arranged surrounding the first part of the central axis, surrounding the second part of the central axis, and surrounding the third part of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core. At least one section of the first part of the conductor of a predetermined length is compressed in the direction of the central axis.

[0010] Thus, a coil having a compressed conductor can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0011] In one example, a second part and a third part of the conductor of a predetermined length at the end of the conductor of a predetermined length form part of the connection terminals of the inductor coil.

[0012] In one example, the entire first part of the conductor of a predetermined length is compressed.

[0013] In one example, at least one section of the first part of a conductor of a predetermined length that has been compressed has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0014] In one example, at least one section of the first part of a conductor of a predetermined length between the base portion of the first component and the base portion of the second component is compressed between the base portion of the first component and the base portion of the second component by the base portion of the first component and the base portion of the second component.

[0015] By compressing the conductor during the assembly of the inductor coil, the tension applied to the wire is reduced with respect to a wire that has already been fully compressed and wound around the core. However, the wire can be partially compressed before being wound around and / or disposed around the core. Then, the first and second components are integrated and can be further compressed during further compression of the conductor.

[0016] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed around the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0017] In one example, the first part of a conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base portions of the first and second parts move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0018] In one example, a first part of a conductor of a predetermined length is arranged to surround a first part of a central axis, a second part of the central axis, and is at least partially compressed before being arranged to surround a third part of the central axis.

[0019] In one example, adjacent turns among a plurality of turns of a conductor are joined to each other.

[0020] This facilitates, for example, pre-compression of a first part of a conductor of a predetermined length before it is arranged to surround a core gap within a core of an inductor coil. In this case, the part of the conductor turns may not be under compression between the base part of the first component and the base part of the second component, but remains in a compressed and tight arrangement.

[0021] In one example, each turn of the conductor among a plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner parts of two or more turns of the conductor arranged to surround the first part of the central axis and / or the conductor arranged to surround the second part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner parts of one or more turns of the conductor arranged to surround the third part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0022] In other words, the turns of the conductor at the position of the gap within the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be done by laterally displacing the turns or deforming the inner part of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by conductive materials present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0023] In one example, the spacer is disposed within a gap in the core so as to form a gap surrounding the core. The outer surface of a portion of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surface of the first component forming the core and the outer surface of the second component.

[0024] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is disposed surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap within the core, either by actually pushing the conductor turns laterally and / or deforming the inner portions of each conductor turn at the location of the gap within the core.

[0025] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the first component and the outer surface of the second component in the direction of the central axis is greater than the dimension of the gap within the core in the direction of the central axis.

[0026] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a third portion of the central axis.

[0027] In one example, the spacer includes a non-conductive material.

[0028] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0029] In one example, the first component includes a ferrite material.

[0030] In one example, the second component includes a ferrite material.

[0031] In one example, the conductor includes a multi-strand wire.

[0032] In one example, the conductor includes a litz wire.

[0033] In a second aspect, a first component, a second component, a conductor of a predetermined length, and an inductor coil including the same are provided.

[0034] The first component is disposed adjacent to the second component. A core is formed from the second component. The core is disposed along a first portion of a central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form a gap within the core. The second portion of the central axis is between the first portion of the central axis and the first component. A first part of the conductor of the predetermined length is disposed surrounding the first portion of the central axis and disposed surrounding the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core. At least one section of the first part of the conductor of the predetermined length is compressed in a direction of the central axis.

[0035] Thus, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0036] In one example, a second part and a third part of the conductor of the predetermined length at an end of the conductor of the predetermined length form part of a connection terminal of the inductor coil.

[0037] In one example, the entire first part of the conductor of the predetermined length is compressed.

[0038] In one example, at least one section of the first part of the compressed conductor of the predetermined length has a dimension of the conductor in a direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0039] In one example, at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component is compressed by the base portion of the first component and the base portion of the second component between the base portion of the first component and the base portion of the second component.

[0040] By compressing the conductor during the assembly of the inductor coil, for a wire that has already been fully compressed and wound around the core, the tension applied to the wire is reduced. However, the wire can be partially compressed before being wound around the core and / or disposed around the core. Then, the wire can be further compressed when the first and second components are integrated to further compress the conductor.

[0041] In one example, the entire first part of the conductor of a predetermined length can be compressed before being disposed surrounding the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0042] In one example, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0043] In one example, the first part of the conductor of a predetermined length is disposed surrounding a first portion of the central axis and is at least partially compressed before being disposed surrounding a second portion of the central axis.

[0044] In one example, adjacent turns among the plurality of turns of the conductor are joined to each other.

[0045] This facilitates, for example, the pre-compression of the first part of the conductor of a predetermined length before it is arranged surrounding the core gap within the core of the inductor coil. In this case, the parts of the conductor turns may not be under compression between the base part of the first component and the base part of the second component, but remain in a compressed and tight arrangement.

[0046] In one example, each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner parts of the conductors among two or more turns of the conductor arranged surrounding the first part of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner parts of the conductors among one or more turns of the conductor arranged surrounding the second part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0047] In other words, the turns of the conductor at the position of the gap within the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be done by laterally displacing the turns or deforming the inner parts of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0048] In one example, the spacer is arranged within the gap in the core so as to form a gap surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distance from the central axis of the outer surface of the second component forming the core.

[0049] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is disposed surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap within the core, either by actually pushing the conductor turns laterally and / or deforming the inner portions of each conductor turn at the location of the gap within the core.

[0050] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the second component in the direction of the central axis is larger than the dimension of the gap within the core in the direction of the central axis.

[0051] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0052] In one example, the spacer includes a non-conductive material.

[0053] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0054] In one example, the first component includes a ferrite material.

[0055] In one example, the second component includes a ferrite material.

[0056] In one example, the conductor includes a multi-strand wire.

[0057] In one example, the conductor includes a litz wire.

[0058] In a third aspect, a first component, a second component, a conductor of a predetermined length, and an inductor coil is provided.

[0059] The first component is arranged adjacent to the second component. A core is formed from the first component and the second component. The core is arranged along a first part of the central axis and a second part of the central axis. Along a third part of the central axis, the first component is spaced apart from the second component to form a gap within the core. The third part of the central axis is between the first part of the central axis and the second part of the central axis. A first part of a conductor of a predetermined length is arranged surrounding the first part of the central axis, surrounding the second part of the central axis, and surrounding the third part of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core. Each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner parts of two or more turns of the conductor arranged surrounding the first part of the central axis and / or the conductor arranged surrounding the second part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner parts of one or more turns of the conductor arranged surrounding the third part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0060] In other words, the turns of the conductor at the position of the gap within the core are spaced further from the axis of the inductor coil than the other turns surrounding the core. This can be done by laterally displacing the turns or deforming the inner part of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0061] In one example, a second part and a third part of the conductor of a predetermined length at the end of the conductor of a predetermined length form part of the connection terminals of the inductor coil.

[0062] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0063] In one example, the spacer is disposed within a gap in the core so as to form a gap surrounding the core. The outer surface of a part of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surfaces of the first component forming the core and the outer surface of the second component.

[0064] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when the first part of a conductor of a predetermined length is disposed surrounding the core and the gap in the core, the spacer forms a space surrounding the outer extent of the gap in the core, either by actually pushing the conductor turns laterally and / or deforming the inner part of each conductor turn at the location of the gap in the core.

[0065] In one example, the dimension of a part of the spacer adjacent to the outer surfaces of the first component and the outer surface of the second component in the direction of the central axis is greater than the dimension of the gap in the core in the direction of the central axis.

[0066] In one example, the outer surface of a part of the spacer is configured to contact one or more turns of a conductor disposed surrounding a third part of the central axis.

[0067] In one example, the spacer includes a non-conductive material.

[0068] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0069] In one example, at least one section of the first part of a conductor of a predetermined length is compressed in the direction of the central axis.

[0070] Thus, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0071] In one example, at least one section of the first part of a conductor of a predetermined length that has been compressed has dimensions in the direction of the central axis that are smaller than the dimensions of the conductor in a direction perpendicular to the central axis.

[0072] In one example, at least one section of the first part of a conductor of a predetermined length between the base portion of the first component and the base portion of the second component is compressed between the base portion of the first component and the base portion of the second component by the base portion of the first component and the base portion of the second component.

[0073] By compressing the conductor during the assembly of the inductor coil, the tension applied to the wire is reduced for a wire that has already been fully compressed and wound around the core. However, the wire can be partially compressed before being wound around and / or disposed around the core. The wire can then be further compressed when the first and second components are integrated to further compress the conductor.

[0074] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed around the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0075] In one example, the first part of a conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0076] In one example, a first part of a conductor of a predetermined length is disposed surrounding a first portion of a central axis, surrounding a second portion of the central axis, and at least partially compressed before being disposed surrounding a third portion of the central axis.

[0077] The inductor coil according to any one of claims 31 to 40, wherein adjacent turns among a plurality of turns of the conductor are joined to each other.

[0078] This facilitates, for example, the pre-compression of the first part of the conductor of a predetermined length before it is disposed surrounding a core gap in the core of the inductor coil, in which case the part of the conductor turn may not be under compression between the base part of the first component and the base part of the second component, but remains in a compressed and tight arrangement.

[0079] In a fourth aspect, a first component, a second component, a conductor (18) of a predetermined length, and an inductor coil is provided.

[0080] The first component is arranged adjacent to the second component. A core is formed from the second component. The core is arranged along a first portion of the central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form a gap within the core. The second portion of the central axis is between the first portion of the central axis and the first component. A first part of a conductor of a predetermined length is arranged surrounding the first portion of the central axis, arranged surrounding the second portion of the central axis, and forms a plurality of turns of the conductor surrounding the core and the gap within the core. Each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of the conductor of two or more turns of the conductor arranged surrounding the first portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of the conductor of one or more turns of the conductor arranged surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0081] In other words, the turns of the conductor at the position of the gap within the core are spaced further from the axis of the inductor coil than the other turns surrounding the core. This can be done by laterally displacing the turns or deforming the inner portions of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0082] In one example, a second part and a third part of the conductor of a predetermined length at the end of the conductor of a predetermined length form part of the connection terminals of the inductor coil.

[0083] In one example, the entire first part of the conductor of a predetermined length is compressed.

[0084] In one example, the spacer is disposed within a gap in the core so as to form a gap surrounding the core. The outer surface of a portion of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surface of the second component forming the core.

[0085] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is disposed surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap within the core by either actually pushing the conductor turns laterally and / or deforming the inner portion of each conductor turn at the location of the gap within the core.

[0086] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension of the gap within the core in the direction of the central axis.

[0087] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0088] In one example, the spacer includes a non-conductive material.

[0089] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0090] In one example, at least one section of the first part of the conductor of a predetermined length is compressed in the direction of the central axis.

[0091] Thus, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil, while at the same time, the AC losses are not 5 - 20 times the DC losses, but rather only 1 - 3 times the DC losses.

[0092] In one example, at least one section of the first part of a conductor of a predetermined length that has been compressed has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0093] In one example, at least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component is compressed between the base part of the first component and the base part of the second component by the base part of the first component and the base part of the second component.

[0094] By compressing the conductor during the assembly of the inductor coil, the tension applied to the wire is reduced for a wire that has already been fully compressed and wound around the core. However, the wire can be partially compressed before being wound around and / or disposed around the core. The wire can then be further compressed when the first and second components are integrated to further compress the conductor.

[0095] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed around the core and the gap within the core. In one example, the first and second base parts can have base parts that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base parts of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base parts.

[0096] In one example, the first part of a conductor of a predetermined length can be disposed around the core and the gap within the core, and then the base parts of the first and second parts move towards each other, and only the conductor at the angular position where the base parts face each other is compressed.

[0097] In one example, a first part of a conductor of a predetermined length is disposed surrounding a first portion of a central axis and is at least partially compressed before being disposed surrounding a second portion of the central axis.

[0098] In one example, adjacent turns among a plurality of turns of a conductor are joined to each other.

[0099] This facilitates, for example, a prior compression of a first part of a conductor of a predetermined length before it is disposed surrounding a core gap within a core of an inductor coil, in which case the part of the conductor turns may not be under compression between a base part of a first component and a base part of a second component, but remains in a compressed and tight arrangement.

[0100] In one example, the first component includes a ferrite material.

[0101] In one example, the second component includes a ferrite material.

[0102] In one example, the conductor includes a multi-strand wire.

[0103] In one example, the conductor includes a litz wire.

[0104] In a fifth aspect, a method of forming an inductor coil, comprising disposing a first component adjacent to a second component, a core being formed from the first component and the second component, the core being disposed along a first portion of a central axis and a second portion of the central axis, along a third portion of the central axis, the first component being spaced apart from the second component to form a gap within the core, the third portion of the central axis being between the first portion of the central axis and the second portion of the central axis; disposing a first part of a conductor of a predetermined length surrounding the first portion of the central axis, surrounding the second portion of the central axis, and surrounding the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core; Compressing at least one section of a first part of a conductor of a predetermined length in the direction of a central axis; A method is provided that includes this.

[0105] In this way, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0106] In one example, a second part and a third part of the conductor of a predetermined length at an end of the conductor of a predetermined length form part of a connection terminal of an inductor coil.

[0107] In one example, the entire first part of the conductor of a predetermined length is compressed.

[0108] In one example, at least one section of the first part of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0109] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component.

[0110] By compressing the conductor during the assembly of the inductor coil, for a wire that has already been fully compressed and wound around a core, the tension applied to the wire is reduced. However, the wire can be partially compressed before being wound around and / or disposed around the core. The wire can then be further compressed when the first and second components are integrated to further compress the conductor.

[0111] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed to surround the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0112] In one example, the first part of a conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0113] In one example, the method includes at least partially compressing the first part of a conductor of a predetermined length before disposing it to surround a first portion of the central axis, a second portion of the central axis, and a third portion of the central axis.

[0114] In one example, the method includes joining adjacent turns among a plurality of turns of the conductor to each other.

[0115] This facilitates, for example, the pre-compression of the first part of a conductor of a predetermined length before it is disposed to surround the core gap within the core of an inductor coil, where the part of the conductor turn may not be under compression between the base portion of the first component and the base portion of the second component, but remains in a compressed and tight arrangement.

[0116] In one example, the method includes arranging a conductor of a predetermined length such that each turn of the conductor among a plurality of turns of the conductor has an inner portion of the conductor spaced apart from a central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of two or more turns of the conductor arranged surrounding a first portion of the central axis and / or arranged surrounding a second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of one or more turns of the conductor arranged surrounding a third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0117] In other words, the turns of the conductor at the position of the gap in the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be done by displacing the turns laterally or by deforming the inner portions of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0118] In one example, the method includes placing a spacer in a gap within a core so as to form a gap surrounding the core. The outer surface of a portion of the spacer is disposed at a distance from the central axis greater than the distance from the central axis of the outer surfaces of a first component and a second component forming the core.

[0119] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is arranged surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap in the core, either by actually pushing the conductor turns laterally and / or by deforming the inner portions of each conductor turn at the position of the gap in the core.

[0120] In one example, the dimensions of a portion of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are greater than the dimensions of the gap within the core in the direction of the central axis.

[0121] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed to surround a third portion of the central axis.

[0122] In one example, the spacer includes a non-conductive material.

[0123] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0124] In one example, the first component includes a ferrite material.

[0125] In one example, the second component includes a ferrite material.

[0126] In one example, the conductor includes a multi-strand wire.

[0127] In one example, the conductor includes a Litz wire.

[0128] In a sixth aspect, a method of forming an inductor coil, arranging a first component adjacent to a second component, wherein a core is formed from the second component, the core is disposed along a first portion of a central axis, along a second portion of the central axis, the first component is spaced apart from the second component to form a gap within the core, and the second portion of the central axis is between the first portion of the central axis and the first component; arranging a first part of a conductor of a predetermined length to surround the first portion of the central axis and to surround the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core; compressing at least one section of the first part of the conductor of the predetermined length in the direction of the central axis. A method is provided that includes.

[0129] In this way, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0130] In one example, the second and third parts of a conductor of a predetermined length at the end of the conductor form part of the connection terminals of the inductor coil.

[0131] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0132] In one example, at least one of the first parts of a compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0133] In one example, the method includes compressing at least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component.

[0134] By compressing the conductor during the assembly of the inductor coil, for a wire that is already fully compressed and wound around the core, the tension applied to the wire is reduced. However, the wire can be partially compressed before being wound around and / or disposed around the core. Then, the wire can be further compressed when the first and second components are integrated to further compress the conductor.

[0135] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed to surround the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0136] In one example, the first part of a conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0137] In one example, the method includes at least partially compressing the first part of a conductor of a predetermined length before disposing it to surround a first portion of the central axis and to surround a second portion of the central axis.

[0138] In one example, the method includes joining adjacent turns among a plurality of turns of the conductor to each other.

[0139] This facilitates, for example, the pre-compression of the first part of a conductor of a predetermined length before it is disposed to surround the core gap within the core of an inductor coil, in which case the portions of the conductor turns may not be under compression between the base portion of the first component and the base portion of the second component, but remain in a compressed and tight arrangement.

[0140] In one example, the method includes arranging a conductor of a predetermined length such that each turn of the conductor among a plurality of turns of the conductor has an inner portion of the conductor spaced apart from a central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of the conductor of two or more turns of the conductor arranged surrounding a first portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of the conductor of one or more turns of the conductor arranged surrounding a second portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0141] In other words, the turns of the conductor at the position of the gap in the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be done by displacing the turns laterally or deforming the inner portions of the conductor turns facing the axis of the inductor coil. Thus, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0142] In one example, the method includes arranging a spacer within a gap in the core so as to form a gap surrounding the core. The outer surface of a portion of the spacer is arranged at a distance from the central axis greater than the distance from the central axis of the outer surface of a second component forming the core.

[0143] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is arranged surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap within the core, either by actually pushing the conductor turns laterally and / or deforming the inner portions of each conductor turn at the position of the gap within the core.

[0144] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the second component in the direction of the central axis is larger than the dimension of the gap in the core in the direction of the central axis.

[0145] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0146] In one example, the spacer includes a non-conductive material.

[0147] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0148] In one example, the first component includes a ferrite material.

[0149] In one example, the second component includes a ferrite material.

[0150] In one example, the conductor includes a multi-strand wire.

[0151] In one example, the conductor includes a litz wire.

[0152] In a seventh aspect, a method of forming an inductor coil, disposing a first component adjacent to a second component, wherein a core is formed from the first component and the second component, the core is disposed along a first portion of a central axis and a second portion of the central axis, along a third portion of the central axis, the first component is spaced apart from the second component to form a gap in the core, and the third portion of the central axis is between the first portion of the central axis and the second portion of the central axis; placing a first part of a conductor of a predetermined length to surround a first portion of the central axis, to surround a second portion of the central axis, and to surround a third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap in the core; Arrange a first part of a conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. A method is provided that includes this. The inner parts of the conductor of two or more turns of the conductor arranged surrounding the first part of the central axis and / or the conductor arranged surrounding the second part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner parts of the conductor of one or more turns of the conductor arranged surrounding the third part of the central axis are spaced apart from the central axis by at least a predetermined second distance that is greater than at least the predetermined first distance.

[0153] In other words, the turns of the conductor at the position of the gap in the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be done by laterally displacing the turns or deforming the inner parts of the conductor turns facing the axis of the inductor coil. In this way, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. Thereby, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0154] In one example, the second and third parts of the conductor of a predetermined length at the end of the conductor of a predetermined length form part of the connection terminals of the inductor coil.

[0155] In one example, the entire first part of the conductor of a predetermined length is compressed.

[0156] In one example, the method includes arranging a spacer in a gap within the core so as to form a gap surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis that is greater than the distance from the central axis of the outer surfaces of the first component and the second component forming the core.

[0157] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when a first part of a conductor of a predetermined length is disposed surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap within the core by either actually pushing the conductor turns laterally and / or deforming the inner portion of each conductor turn at the location of the gap within the core.

[0158] In one example, the dimensions of a portion of the spacer adjacent to the outer surface of the first component and the outer surface of the second component in the direction of the central axis are greater than the dimensions of the gap within the core in the direction of the central axis.

[0159] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed surrounding a third portion of the central axis.

[0160] In one example, the spacer includes a non-conductive material.

[0161] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0162] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length in the direction of the central axis.

[0163] Thus, the compressed coil can achieve a DCR that is lower than or equal to that of the existing coil. At the same time, the AC loss is not 5 - 20 times the DC loss, but only 1 - 3 times the DC loss.

[0164] In one example, at least one of the first parts of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0165] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component.

[0166] By compressing the conductor during the assembly of the inductor coil, for a wire that has already been fully compressed and wound around the core, the tension applied to the wire is reduced. However, the wire can be partially compressed before being wound around and / or disposed around the core. The wire can then be further compressed when the first and second components are integrated to further compress the conductor.

[0167] In one example, the entire first part of the conductor of a predetermined length can be compressed before being disposed around the core and a gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed around the core and a gap within the core, and then the base portions of the first and second parts move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0168] In one example, the first part of the conductor of a predetermined length can be disposed around the core and a gap within the core, and then the base portions of the first and second parts move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0169] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before disposing it around a first portion of a central axis, around a second portion of the central axis, and around a third portion of the central axis.

[0170] In one example, adjacent turns among a plurality of turns of the conductor are joined to each other.

[0171] This facilitates, for example, the pre - compression of the first part of a conductor of a predetermined length before it is arranged surrounding a core gap within the core of an inductor coil. In this case, the part of the conductor turn may not be under compression between the base part of the first component and the base part of the second component, but remains in a compressed and tight arrangement.

[0172] In an eighth aspect, a method of forming an inductor coil, comprises arranging a first component adjacent to a second component, wherein a core is formed from the second component, the core is arranged along a first part of a central axis, along a second part of the central axis, the first component is spaced apart from the second component to form a gap within the core, and the second part of the central axis is between the first part of the central axis and the first component; arranging a first part of a conductor of a predetermined length to surround the first part of the central axis and to surround the second part of the central axis to form a plurality of turns of a conductor surrounding the core and the gap within the core; arranging the first part of the conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis; A method is provided. The inner parts of two or more turns of the conductor arranged surrounding the first part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner parts of one or more turns of the conductor arranged surrounding the second part of the central axis are spaced apart from the central axis by at least a predetermined second distance that is greater than at least the predetermined first distance.

[0173] In other words, the turns of the conductor at the position of the gap within the core are further spaced apart from the axis of the inductor coil than the other turns surrounding the core. This can be achieved by displacing the turns laterally or by deforming the inner portion of the conductor turns facing the axis of the inductor coil. In this way, the inductor coil is prevented from generating eddy currents that may be caused by the conductive material present in these leakage magnetic fields. As a result, temperature hot spots are avoided, the available cross-sectional area of the conductor is maximized, and the thermal performance of the coil is maximized.

[0174] In one example, the second and third parts of a conductor of a predetermined length at the end of the conductor form part of the connection terminals of the inductor coil.

[0175] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0176] In one example, the method includes placing a spacer within the gap in the core so as to form a gap surrounding the core. The outer surface of a part of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surface of the second component forming the core.

[0177] In other words, the spacer is positioned within the gap in the core and is wider than the diameter of the core. Also, when the first part of a conductor of a predetermined length is disposed surrounding the core and the gap within the core, the spacer forms a space surrounding the outer extent of the gap in the core by either actually pushing the conductor turns laterally and / or deforming the inner portion of each conductor turn at the position of the gap in the core.

[0178] In one example, the dimension of a part of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension of the gap within the core in the direction of the central axis.

[0179] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed to surround a second portion of the central axis.

[0180] In one example, the spacer includes a non-conductive material.

[0181] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0182] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length in a direction of the central axis.

[0183] Thus, the compressed coil can achieve a DCR that is lower than or equal to that of an existing coil. At the same time, the AC loss is not 5 to 20 times the DC loss, but only 1 to 3 times the DC loss.

[0184] In one example, at least one section of a first part of a conductor of a predetermined length that is compressed has a dimension in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0185] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component.

[0186] By compressing the conductor during the assembly of the inductor coil, the tension applied to the wire is reduced for a wire that has already been fully compressed and wound around the core. However, the wire can be partially compressed before being wound around and / or disposed surrounding the core. The wire can then be further compressed when the first and second components are integrated to further compress the conductor.

[0187] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed to surround the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0188] In one example, the first part of a conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0189] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before disposing it to surround a first portion of a central axis and to surround a second portion of the central axis.

[0190] In one example, the method includes joining adjacent turns among a plurality of turns of a conductor to each other.

[0191] This facilitates, for example, the pre-compression of the first part of a conductor of a predetermined length before it is disposed to surround a core gap within an inductor coil core, where in this case the portions of the conductor turns may not be under compression between the base portion of the first component and the base portion of the second component, but remain in a compressed and tight arrangement.

[0192] In one example, the first component includes a ferrite material.

[0193] In one example, the second component includes a ferrite material.

[0194] In one example, the conductor includes a multi-strand wire.

[0195] In one example, the conductor includes a litz wire.

[0196] Advantageously, the benefits provided by any of the above aspects apply equally to all of the other aspects, and vice versa.

[0197] The above aspects and examples will become apparent from and will be elucidated with reference to the embodiments described below.

Brief Description of the Drawings

[0198] Exemplary embodiments will be described below with reference to the following drawings.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

[0199] Detailed Description of Embodiments Figures 1 to 13 relate to an inductor coil and a method of forming or manufacturing the inductor coil.

[0200] In one example, the inductor coil includes a first component 12, a second component 14, and a conductor 18 of a predetermined length. The first component is arranged adjacent to the second component. A core 16 is formed from the first component and the second component. The core is arranged along a first portion of the central axis and a second portion of the central axis. Along a third portion of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 within the core. The third portion of the central axis is between the first portion of the central axis and the second portion of the central axis. A first part of the conductor of the predetermined length is arranged surrounding the first portion of the central axis, surrounding the second portion of the central axis, and surrounding the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core. At least one section of the first part of the conductor of the predetermined length is compressed in the direction of the central axis.

[0201] In one example, a second part and a third part of the conductor of the predetermined length at the end of the conductor of the predetermined length form part of the connection terminals of the inductor coil.

[0202] In one example, the entire first part of the conductor of the predetermined length is compressed.

[0203] In one example, at least one section of the first part of a conductor of a predetermined length that has been compressed has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0204] In one example, at least one section of the first part of a conductor of a predetermined length between the base portion of the first component and the base portion of the second component is compressed between the base portion of the first component and the base portion of the second component by the base portion of the first component and the base portion of the second component.

[0205] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed surrounding the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0206] In one example, the first part of a conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0207] In one example, the first part of a conductor of a predetermined length is at least partially compressed before being disposed surrounding the first part of the central axis, surrounding the second part of the central axis, and surrounding the third part of the central axis.

[0208] In one example, adjacent turns among a plurality of turns of a conductor are joined to each other.

[0209] In one example, each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of two or more turns of the conductor disposed surrounding the first portion of the central axis and / or the conductor disposed surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of one or more turns of the conductor disposed surrounding the third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0210] In one example, the spacer 30 is disposed within the gap in the core so as to form a gap 22 surrounding the core. The outer surface of a portion of the spacer is disposed at a distance from the central axis greater than the distance from the central axis of the outer surfaces of the first component and the second component forming the core.

[0211] In one example, the dimension of a portion of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0212] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of the conductor disposed surrounding the third portion of the central axis.

[0213] In one example, the spacer includes a non-conductive material.

[0214] In one example, the spacer includes a central hole 32 configured to be disposed surrounding the central axis.

[0215] In one example, the first component includes a ferrite material.

[0216] In one example, the second component includes a ferrite material.

[0217] In one example, the conductor includes a multi-strand wire.

[0218] In one example, the conductor includes a litz wire.

[0219] In one example, the inductor coil includes a first component 12, a second component 14, and a conductor 18 of a predetermined length. The first component is arranged adjacent to the second component. A core 16 is formed from the second component. The core is arranged along a first portion of the central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 within the core. The second portion of the central axis is between the first portion of the central axis and the first component. A first part of the conductor of the predetermined length is arranged surrounding the first portion of the central axis and surrounding the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core. At least one section of the first part of the conductor of the predetermined length is compressed in the direction of the central axis.

[0220] In one example, a second part and a third part of the conductor of the predetermined length at the end of the conductor of the predetermined length form part of the connection terminals of the inductor coil.

[0221] In one example, the entire first part of the conductor of the predetermined length is compressed.

[0222] In one example, at least one section of the first part of the compressed conductor of the predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0223] In one example, at least one section of the first part of the conductor of the predetermined length between the base part of the first component and the base part of the second component is compressed between the base part of the first component and the base part of the second component by the base part of the first component and the base part of the second component.

[0224] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed to surround the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0225] In one example, the first part of a conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0226] In one example, the first part of a conductor of a predetermined length is disposed to surround the first part of the central axis and is at least partially compressed before being disposed to surround the second part of the central axis.

[0227] In one example, adjacent turns among a plurality of turns of a conductor are joined to each other.

[0228] In one example, each turn of the conductor among a plurality of turns of the conductor has an inner portion of the conductor that is spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of the conductors of two or more turns of the conductor disposed to surround the first part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of the conductors of one or more turns of the conductor disposed to surround the second part of the central axis are spaced apart from the central axis by at least a predetermined second distance that is greater than at least the predetermined first distance.

[0229] In one example, the spacer 50 is disposed within the gap in the core so as to form a gap 42 surrounding the core. The outer surface of a portion of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surface of the second component forming the core.

[0230] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0231] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding the second portion of the central axis.

[0232] In one example, the spacer includes a non-conductive material.

[0233] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0234] In one example, the first component includes a ferrite material.

[0235] In one example, the second component includes a ferrite material.

[0236] In one example, the conductor includes a multi-strand wire.

[0237] In one example, the conductor includes a litz wire.

[0238] In one example, the inductor coil comprises a first component 12, a second component 14, and a conductor 18 of a predetermined length. The first component is arranged adjacent to the second component. A core 16 is formed from the first component and the second component. The core is arranged along a first portion of the central axis and a second portion of the central axis. Along a third portion of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 within the core. The third portion of the central axis is between the first portion of the central axis and the second portion of the central axis. A first part of the conductor of the predetermined length is arranged surrounding the first portion of the central axis, surrounding the second portion of the central axis, and surrounding the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core. Each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of two or more turns of the conductor arranged surrounding the first portion of the central axis and / or the conductor arranged surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of one or more turns of the conductor arranged surrounding the third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0239] In one example, a second part and a third part of the conductor of the predetermined length at the end of the conductor of the predetermined length form part of the connection terminals of the inductor coil.

[0240] In one example, the whole of the first part of the conductor of the predetermined length is compressed.

[0241] In one example, the spacer 30 is arranged within the gap in the core so as to form a gap 22 surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distance from the central axis of the outer surfaces of the first component and the second component forming the core.

[0242] In one example, the dimensions of a portion of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0243] In one example, the outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a third portion of the central axis.

[0244] In one example, the spacer includes a non-conductive material.

[0245] In one example, the spacer includes a central hole 32 configured to be disposed surrounding the central axis.

[0246] In one example, at least one section of the first part of a conductor of a predetermined length is compressed in the direction of the central axis.

[0247] In one example, at least one section of the first part of the compressed conductor of a predetermined length has a dimension in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0248] In one example, at least one section of the first part of a conductor of a predetermined length between the base portion of the first component and the base portion of the second component is compressed between the base portion of the first component and the base portion of the second component by the base portion of the first component and the base portion of the second component.

[0249] In one example, the entire first part of a conductor of a predetermined length can be compressed before being disposed to surround the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0250] In one example, the first part of a conductor of a predetermined length can be disposed to surround the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and only the conductor at the angular positions where the base portions face each other is compressed.

[0251] In one example, the first part of a conductor of a predetermined length is disposed to surround the first part of the central axis, disposed to surround the second part of the central axis, and at least partially compressed before being disposed to surround the third part of the central axis.

[0252] In one example, adjacent turns among a plurality of turns of the conductor are joined to each other.

[0253] In one example, the inductor coil includes a first component 12, a second component 14, and a conductor 18 of a predetermined length. The first component is disposed adjacent to the second component. A core 16 is formed from the second component. The core is disposed along a first portion of a central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 within the core. The second portion of the central axis is between the first portion of the central axis and the first component. A first part of the conductor of the predetermined length is disposed surrounding the first portion of the central axis and surrounding the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core. Each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of the conductor of two or more turns of the conductor disposed surrounding the first portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of the conductor of one or more turns of the conductor disposed surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0254] In one example, a second part and a third part of the conductor of the predetermined length at an end of the conductor of the predetermined length form part of a connection terminal of the inductor coil.

[0255] In one example, the entire first part of the conductor of the predetermined length is compressed.

[0256] In one example, the spacer 50 is disposed within the gap in the core so as to form a gap 42 surrounding the core. The outer surface of a part of the spacer is disposed at a distance from the central axis greater than the distance from the central axis of the outer surface of the second component forming the core.

[0257] In one example, the dimension of a part of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension 24 of the gap in the core in the direction of the central axis.

[0258] In one example, an outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0259] In one example, the spacer includes a non-conductive material.

[0260] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0261] In one example, at least one section of a first part of a conductor of a predetermined length is compressed in a direction of the central axis.

[0262] In one example, at least one section of a first part of a compressed conductor of a predetermined length has a dimension of the conductor in a direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0263] In one example, at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component is compressed between the base portion of the first component and the base portion of the second component by the base portion of the first component and the base portion of the second component.

[0264] In one example, an entirety of a first part of a conductor of a predetermined length can be compressed before being disposed surrounding a core and a gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a specific angular range. In this case, a first part of a conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts can move towards each other, and then the conductor of the predetermined length over these angular ranges can be further compressed by the base portions.

[0265] In one example, a first part of a conductor of a predetermined length can be arranged to surround a core and a gap within the core, and then the base parts of the first and second parts move towards each other such that only the conductor at an angular position where the base parts face each other is compressed.

[0266] In one example, a first part of a conductor of a predetermined length is arranged to surround a first part of a central axis and is at least partially compressed before being arranged to surround a second part of the central axis.

[0267] In one example, adjacent turns among a plurality of turns of a conductor are joined to each other.

[0268] In one example, the first component includes a ferrite material.

[0269] In one example, the second component includes a ferrite material.

[0270] In one example, the conductor includes a multi-strand wire.

[0271] In one example, the conductor includes a litz wire.

[0272] In one example, a method of forming an inductor coil includes arranging a first component 12 adjacent to a second component 14. A core 16 is formed from the first component and the second component. The core is arranged along a first part of a central axis and a second part of the central axis. Along a third part of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 within the core. The third part of the central axis is between the first part of the central axis and the second part of the central axis. The method includes arranging a first part of a conductor 18 of a predetermined length to surround a first part of a central axis, surround a second part of the central axis, and surround a third part of the central axis to form a plurality of turns of a conductor surrounding the core and the gaps within the core, Compressing at least one section of the first part of a conductor of a predetermined length in the direction of the central axis, is included.

[0273] It should be noted that the method steps can be executed in a different order, certain steps can be executed simultaneously, and certain steps can be executed more than once (for example, the compression step).

[0274] In one example, the second and third parts of a conductor of a predetermined length at the ends of the conductor of a predetermined length form part of the connection terminals of an inductor coil.

[0275] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0276] In one example, at least one section of the first part of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0277] In one example, the method includes compressing at least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component.

[0278] In one example, the entire first part of a conductor of a predetermined length can be compressed before being arranged to surround the core and the gap in the core. In one example, the first and second base parts can have base parts that extend only laterally over a specific angular range. In this case, the first part of a conductor of a predetermined length can be arranged to surround the core and the gap in the core, then the base parts of the first and second parts can move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base parts.

[0279] In one example, a first part of a conductor of a predetermined length can be arranged to surround a core and a gap within the core, and then the base portions of the first and second parts move towards each other such that only the conductor at the angular position where the base portions face each other is compressed.

[0280] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of a central axis, a second part of the central axis, and a third part of the central axis.

[0281] In one example, the method includes joining adjacent turns among a plurality of turns of a conductor to each other.

[0282] In one example, the method includes arranging a conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner portions of two or more turns of the conductor arranged to surround the first part of the central axis and / or the conductor arranged to surround the second part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of one or more turns of the conductor arranged to surround the third part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0283] In one example, the method includes arranging a spacer 30 within a gap in a core so as to form a gap 22 surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distances from the central axis of the outer surfaces of the first component and the second component forming the core.

[0284] In one example, the dimension of a part of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0285] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed to surround a third portion of the central axis.

[0286] In one example, the spacer includes a non-conductive material.

[0287] In one example, the spacer includes a central hole 32 configured to be disposed surrounding the central axis.

[0288] In one example, the first component includes a ferrite material.

[0289] In one example, the second component includes a ferrite material.

[0290] In one example, the conductor includes a multi-strand wire.

[0291] In one example, the conductor includes a litz wire.

[0292] In one example, a method of forming an inductor coil includes disposing a first component 12 adjacent to a second component 14. A core is formed from the second component. The core is disposed along a first portion of the central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 within the core. The second portion of the central axis is between the first portion of the central axis and the first component. The method includes disposing a first part of a conductor (18) of a predetermined length surrounding a first portion of the central axis and surrounding a second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core, compressing at least one section of the first part of the conductor of the predetermined length in a direction of the central axis, and including.

[0293] Note that the method steps can be executed in different orders, certain steps can be executed simultaneously, and certain steps can be executed more than once (e.g., the compression step).

[0294] In one example, the second and third parts of a conductor of a predetermined length at the end of the conductor form part of the connection terminals of the inductor coil.

[0295] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0296] In one example, at least one of the first parts of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0297] In one example, the method includes compressing at least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component.

[0298] In one example, the entire first part of a conductor of a predetermined length can be compressed before being arranged to surround the core and the gap within the core. In one example, the first and second base parts can have base parts that extend only laterally over a specific angular range. In this case, the first part of the conductor of a predetermined length can be arranged to surround the core and the gap within the core, then the base parts of the first and second parts move towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base parts.

[0299] In one example, the first part of a conductor of a predetermined length can be arranged to surround the core and the gap within the core, then the base parts of the first and second parts move towards each other, and only the conductor at the angular position where the base parts face each other is compressed.

[0300] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of a central axis and to surround a second part of the central axis.

[0301] In one example, the method includes joining adjacent turns among a plurality of turns of a conductor to each other.

[0302] In one example, the method includes arranging a conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner parts of the conductor of two or more turns of the conductor arranged to surround the first part of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner parts of the conductor of one or more turns of the conductor arranged to surround the second part of the central axis are spaced apart from the central axis by at least a predetermined second distance that is greater than at least the predetermined first distance.

[0303] In one example, the method includes arranging a spacer 50 in a gap within a core so as to form a gap 42 surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis that is greater than the distance from the central axis of the outer surface of the second component forming the core.

[0304] In one example, the dimension of a part of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0305] In one example, the method includes contacting the outer surface of a part of the spacer with one or more turns of a conductor arranged to surround the second part of the central axis.

[0306] In one example, the spacer includes a non-conductive material.

[0307] In one example, the spacer includes a central hole configured to be arranged surrounding the central axis.

[0308] In one example, the first component includes a ferrite material.

[0309] In one example, the second component includes a ferrite material.

[0310] In one example, the conductor includes a multi-strand wire.

[0311] In one example, the conductor includes a litz wire.

[0312] In one example, a method of forming an inductor coil includes disposing a first component 12 adjacent to a second component 14. A core 16 is formed from the first component and the second component. The core is disposed along a first portion of a central axis and a second portion of the central axis. Along a third portion of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 within the core. The third portion of the central axis is between the first portion of the central axis and the second portion of the central axis. The method includes disposing a first part of a conductor 18 of a predetermined length to surround a first portion of the central axis, to surround a second portion of the central axis, and to surround a third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core; disposing the first part of the conductor of the predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis; and. The inner portions of two or more turns of the conductor disposed to surround the first portion of the central axis and / or the conductor disposed to surround the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of one or more turns of the conductor disposed to surround the third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0313] Note that the method steps can be executed in different orders and certain steps can be executed simultaneously.

[0314] In one example, the second and third parts of a conductor of a predetermined length at the end of the conductor of the predetermined length form part of the connection terminals of the inductor coil.

[0315] In one example, the entire first part of a conductor of a predetermined length is compressed.

[0316] In one example, the method includes placing a spacer 30 in a gap within the core so as to form a gap 22 surrounding the core. The outer surface of a part of the spacer is disposed at a distance from the central axis that is greater than the distance from the central axis of the outer surfaces of the first component and the second component forming the core.

[0317] In one example, the dimension of a part of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis.

[0318] In one example, the method includes contacting an outer surface of a part of the spacer with one or more turns of a conductor disposed surrounding a third part of the central axis.

[0319] In one example, the spacer includes a non-conductive material.

[0320] In one example, the spacer includes a central hole 32 configured to be disposed surrounding the central axis.

[0321] In one example, the method includes compressing at least one section of the first part of a conductor of a predetermined length in the direction of the central axis.

[0322] In one example, at least one of the compressed first parts of the conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0323] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component.

[0324] In one example, the entire first part of the conductor of a predetermined length can be compressed before being disposed surrounding a core and a gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0325] In one example, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and only the conductor at the angular position where the base portions face each other is compressed.

[0326] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before disposing it surrounding a first portion of a central axis, surrounding a second portion of the central axis, and surrounding a third portion of the central axis.

[0327] In one example, adjacent turns among a plurality of turns of the conductor are joined to each other.

[0328] In one example, a method of forming an inductor coil is It includes arranging the first component 12 adjacent to the second component 14. A core 16 is formed from the second component. The core is arranged along a first portion of the central axis. Along a second portion of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 within the core. The second portion of the central axis is between the first portion of the central axis and the first component. The method includes arranging a first part of a conductor 18 of a predetermined length to surround the first portion of the central axis and to surround the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core. Arranging the first part of the conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. It includes. The inner portions of the conductor of two or more turns of the conductor arranged to surround the first portion of the central axis are spaced apart from the central axis by at least a predetermined first distance. The inner portions of the conductor of one or more turns of the conductor arranged to surround the second portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance.

[0329] In one example, a second part and a third part of the conductor of a predetermined length at the end of the conductor of a predetermined length form part of the connection terminals of the inductor coil.

[0330] In one example, the entire first part of the conductor of a predetermined length is compressed.

[0331] In one example, the method includes arranging a spacer 50 within the gap in the core to form a gap 42 surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distance from the central axis of the outer surface of the second component forming the core.

[0332] In one example, the dimension of a portion of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension of the gap 24 within the core in the direction of the central axis.

[0333] In one example, the method includes contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed surrounding the second portion of the central axis.

[0334] In one example, the spacer includes a non-conductive material.

[0335] In one example, the spacer includes a central hole configured to be disposed surrounding the central axis.

[0336] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length in the direction of the central axis.

[0337] In one example, at least one section of the first part of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0338] In one example, the method includes compressing at least one section of a first part of a conductor of a predetermined length between the base portion of the first component and the base portion of the second component.

[0339] In one example, the entire first part of the conductor of a predetermined length can be compressed before being disposed surrounding the core and the gap within the core. In one example, the first and second base portions can have base portions that extend only laterally over a particular angular range. In this case, the first part of the conductor of a predetermined length can be disposed surrounding the core and the gap within the core, and then the base portions of the first and second parts can be moved towards each other, and then the conductor of a predetermined length over these angular ranges can be further compressed by the base portions.

[0340] In one example, a first part of a conductor of a predetermined length can be arranged to surround a core and a gap within the core, and then the base parts of the first and second parts move towards each other, and only the conductor at the angular position where the base parts face each other is compressed.

[0341] In one example, the method includes at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of a central axis and also to surround a second part of the central axis.

[0342] In one example, the method includes joining adjacent turns among a plurality of turns of a conductor to each other.

[0343] In one example, the first component includes a ferrite material.

[0344] In one example, the second component includes a ferrite material.

[0345] In one example, the conductor includes a multi-strand wire.

[0346] In one example, the conductor includes a litz wire.

[0347] Thus, in certain embodiments, for example, by compressing a conductor wire including a deformable conductor formed from a multi-strand wire or a litz wire / coil, and including after being formed to surround a core region shape, copper packing is provided, and also a method of gap dispersion of leakage magnetic fields is utilized to achieve a high-performance coil with low heat generation and excellent heat transfer by avoiding leakage magnetic fields, and new technologies have been developed.

[0348] Specifically, 1) The compressed multi-strand coil can be made to fill the window area to a higher level (copper fill factor exceeding 80%) than a flat wire or a standard litz-wound coil. This novel inductor coil can be made from any of a plurality of multi-strand wire bundles or twists (litz) that are very loose bundles, and actually from other deformable wires. It should be noted that when the wire is made with twists, the twists should be "loose" so that wire deformation occurs to obtain an optimal copper fill factor within the window area. In other techniques, uncompressed litz wire is used, which achieves only a sub-standard copper fill factor, and in those other techniques, a pre-compressed type 8 litz wire is used, which causes tension in the wire when winding around the pole area, and again a near-optimal copper fill factor can be achieved. 2) By controlling the positioning and deformation of the strands, it becomes possible to manipulate the copper into a shape that can be used to avoid the leakage magnetic fields seen in transformers and inductors with gaps. The copper can be compressed so that it does not induce eddy currents caused by the conductive material present in these leakage magnetic fields.

[0349] Next, referring again to FIGS. 1 - 13, specific embodiments will be described.

[0350] Figure 1 shows a cross-sectional view of a particular detailed embodiment of an inductor coil. A first component part 12 of ferrite material is shown at the top. This has a base portion and a cylindrical core portion extending downward. The outer rim portion extends downward and is spaced from the core portion, and turns of a conductor 18 in the form of a multi-strand wire can be disposed therein. A second component part 14 is also of ferrite material and is shown at the bottom. This also has a base portion, a cylindrical core portion 16 extending upward, and an outer rim portion extending upward and spaced from the core portion in which turns of the conductor 18 can be disposed. The core portion of the first component part and the core portion of the second component part form the core 16. The center 20 of the core is shown between the two component parts, and the center gap has a dimension 24. The dimension 24 can be, for example, 1 mm, but can be larger or smaller than this. Six turns of a multi-strand wire are shown wound around the core and the gap within the core, but there can be fewer or more than this. In addition to the gap 20 being provided between the cores, a gap 22 is formed surrounding this center gap, and the wire turns do not penetrate into this gap 22 and, as shown, the wire turns are deformed and maintained outside this gap 22. Thus, Figure 1 shows that although the cross-section of each turn is kept the same, under compression, free space is generated to avoid the gap generated by the ferrite. The center gap 20 is an area where a spacer 30 of non-conductive material forming the gap 22 can be disposed, which will be described in more detail below.

[0351] Figure 2 shows a cross-section of a particular detailed embodiment of an inductor coil, which is the same as that shown in Figure 1 except that the gaps are dispersed across the combination of rim portions such that the wire turns in the region of the center 20 do not enter the inner 22 and also do not enter the outer gap 26. Thus, in addition to the gap 20 in the core 16, there is also a gap 26 in the outer rim portion. Both of these gaps can be filled with space and form the inner gap 22 and the outer gap 26.

[0352] FIG. 3 shows a cross-section of six wire turns of the embodiment of FIG. 1, showing the wire turns of the coil after compression and showing the shape of the gap 22 formed to avoid the leakage magnetic field of the core with a central gap. This can also be the same for gaps or distributed gaps offset from the center at multiple positions between the two core components. This shape can be further retained by using such multi-strand wire or Litz wire having self-bonding characteristics.

[0353] FIG. 4 shows a cross-sectional view of a particular embodiment of the inductor coil in detail. A first component part 12 of a ferrite material is shown at the top. This has a base portion. A second component part 14, also of ferrite material, is shown at the bottom. This also has a base portion and has a cylindrical core 16 extending upward. The outer rim portion extends upward and is spaced from the core, within which turns of a conductor 18 in the form of a multi-strand wire can be arranged. The core 16 is spaced from the base portion of the first component part to form a gap 40 within the core. Six turns of the multi-strand wire are shown wound around the core and the gap within the core, but this can be fewer or more. In addition to the gap 40 being provided between the core and the first component part, a gap 42 is effectively formed within the core between the core and the first component part, and the wire turns do not penetrate into this gap 42 and, as shown, the wire turns are deformed and maintained outside this gap 42. Thus, also in this case, FIG. 4 shows that the cross-section of each turn is kept the same, but free space is generated under compression to avoid the gap generated by the ferrite. The upper gap 40 is an area where a spacer 50 of non-conductive material forming the gap 42 can be placed, which will be described in more detail below.

[0354] FIG. 5 shows a particular detailed embodiment of an inductor coil having a central gap 20 within a core, such as shown in FIG. 1. The first component part 12 and the second component part 14 are shown separated from each other, and a spacer 30 is shown having a central hole 32. As shown, there is a space 60 for winding of a conductor 18 in the form of a multi-strand wire on both the first and second component parts. Thus, this figure shows a non-conductive insert (spacer 30) extending over a very long length. This can be used regardless of the presence or absence of the central hole 32 in the non-conductive part. This can be added during or after compression of the wire so that the wire does not enter the leakage magnetic field after compression.

[0355] FIG. 6 shows a representative cross-section of the inductor coil, showing the outer rim of the first component part 12 or the second component part 14 and the upper surface of the core 16 of one of the two component parts. In the central cross-section of the gap spacer 30, the outer rim of the first component part or the second component part is actually not cut and is the upper surface. FIG. 7 shows on the left how the turns of the wire can be laterally pushed by the spacer 30, and on the right how the turns of the wire conductor 18 can be deformed by the spacer 30 in the region of the central gap 20 to keep the turns of the wire outside the leakage magnetic field. Thus, the figure shows how the ring-shaped spacer 30 can be used to compress the conductive wire 18 or to enable the bundle or strands to jump over the space containing the leakage magnetic field, and shows how the wire can form a bump 80 outside the core shape, and the space 70 can be a space into which the wire can freely enter. Thus, the spacer 30 causes heat generation by keeping the part of the wire conductor outside the leakage magnetic field, thereby improving thermal stability.

[0356] FIG. 8 shows a cross-sectional view of a particular detailed embodiment of an inductor coil, such as shown in FIG. 1. This shows that the wire conductor 18, in the form of a multi-strand wire, can be partially compressed before being disposed surrounding a core 16 formed from a first component part 12 and a second component part 14. Here, the wire conductor 18 is wound surrounding a spacer 30 having a central hole 32, and the spacer 30 has a cylindrical sleeve 33. Next, the wire is compressed, and since the ends of the spacer 30 are wider than the diameter of the cylindrical core 16, a wire-free space 22 is formed surrounding the spacer 30. When the first component part and the second component part are integrated, the core portion slides within the wire turns, and the depth of the already compressed wire turns is slightly deeper than these available spaces, and thus, the wire is further compressed by the mounting force. For example, the outer rims of the first component part 12 and the second component part 14 can be integrated as shown in FIG. 1, but the core portions do not contact, forming a core 16 having a gap 20. The sleeve 33 is not necessary, and it is actually possible to deform the wire to provide a space 22 that would be disposed surrounding the gap 20 of the core 16 without the need for the spacer 30.

[0357] FIG. 9 shows, at the top, a cross-section of a detailed specific embodiment of an inductor coil as shown, for example, in FIG. 4, and at the bottom, the terminal connections to both ends of the conductor 18 in the form of a multi-strand wire. Thus, a ferrite cage is provided, a gap 40 in the core 16 is provided at the top, and the spacer 50 is arranged to create a gap 42 surrounding the gap in the core, whether or not the conductor winding intrudes. In this embodiment, it is possible to facilitate attaching the spacer 50 more easily than when attaching the spacer 30 at the center. The spacer 50 can actually be used as a push-up technique for moving the filaments or strands of the wire turns and causing the necessary deformation of at least one winding at the top. Thus, in this embodiment, the copper winding can be deformed into different geometric shapes by a pusher portion that functions like a robust eddy current relaxation element. The top view shows the upper terminal 94 and the lower terminal 92, and for example, the ends of the windings can be prepared to connect to a power electronic substrate such as a PCB. Various mechanisms can be utilized to connect the ends of the required conductor wires. For example, in a compressed coil terminal that is generally used for mechanical fixation, the compressed coil terminals are irregularly arranged on, for example, a tin-plated brass multi-terminal connector and then soldered to the PCB.

[0358] FIG. 10 shows a cross-sectional view of a detailed specific embodiment of an inductor coil as shown, for example, in FIG. 4. The spacer component forms a gap 42 surrounding a gap 40 between the core 16 of the second component part 14 and the first component part 12. The wire conductor 18 is disposed on and deformed from the core. The wire conductor 18 is in the form of a multi-strand wire having a bundle of wires 18a - 18n. In one embodiment, the wire conductor 18 is compressed while forming the winding, then disposed surrounding the core 16, and then further compressed when the first component part 12 is connected to the second component part 14. The spacer 50 deforms one or more turns of the conductor when pushed downward. In fact, all turns of the conductor 18 can be further compressed when the first and second component parts are connected to each other. FIG. 10 shows how, in a novel inductor coil, when the wire moves away from the gap in the core to provide the advantages described above, the cross-section of the multi-strand wire can be deformed and its overall cross-section and thus current-carrying capacity maintained.

[0359] FIG. 11 shows a combination of a first member 12 and a second member 14 that form a flux cage, which is designed to support a coil made from a conductor 18 of a predetermined length. A magnetic field 60 at least partially penetrates the materials of the first and second members. There is a leakage magnetic field 62 in the space surrounding the gap between the first and second members, and the leakage magnetic field 62 reaches the space designed to support the coil. The coil is not shown in FIG. 11. The leakage magnetic field 62 immediately causes eddy current losses when the leakage magnetic field alternates or changes. The losses increase as the frequency increases. The conductor 18 of a predetermined length (not shown) preferably includes a number of partially parallel strands or fibers and forms a braided filament wire rope or a twisted wire or a litz wire. The advantage of using thin filaments is that the generation of eddy currents is reduced, and in the case of thinner filaments, the eddy currents are smaller. This novel solution combines the use of electrically parallel filaments in each turn with the freedom of the spatial volume of the leakage magnetic field 62 not occupied by the wire or filament.

[0360] FIG. 12 shows an embodiment having two symmetrical parts 12 and 14 (which need not be symmetrical) forming core 16 and gap 20. FIG. 12 shows a coil made from a conductor 18 of a predetermined length partially inserted into a first member 12 and a second member 14 in an as-yet-open state. The cross-sectional shape of the winding of the conductor 18 of a predetermined length includes a deformation of the cross-sectional shape of at least turns 18.3 and 18.4 in the vicinity of the leakage magnetic field. This deformation involves the rearrangement of groups of electrically parallel filaments. There may also be a deformation of a single fiber. The deformation of the fiber bundle associated with the turns of the winding of the conductor 18 is designed to create a free space 22 that surrounds and opens the gap 20 between part 12 and part 14. The free space 22 can be filled with a spacer made of a magnetically inert material to prevent wires and / or fibers from entering or moving within the free space 22. However, since the wires and / or fibers can be arranged, for example, by connecting the wires or fibers to each other, so as not to enter or move into the free space 22, the spacer is not essential, and the spacer provides a mechanism to prevent the wires or fibers from moving into the "free space 22" occupied by the magnetically inert material of the spacer.

[0361] Figure 13 shows a preformed coil, which includes a conductor 18 of a preformed predetermined length before attaching this coil to the free space inside the flux cage. The flux cage comprises an upper part 12 and a lower part 14, and a core 16 that is short enough to form a flux gap between the upper part 12 and the lower part 14. The upper part 12 may have a part of a recess or may be flat to form an exact gap as shown in Figure 13. The preformed coil 18 includes at least the winding closest to the flux gap and the deformation of the leakage magnetic field there. The conductor 18 preferably includes electrically parallel wires or fibers and may be a litz wire or a stranded wire or a laminated conductor. The preformed conductor 18 may be pre-compressed before attachment and may relax after removal of the pre-compression means. The coil 18 may be re-compressed after fixing the upper part 12 and the lower part 14 to generate a stable flux cage for the inductor. The re-compression can result in compression of the conductor 18 in the axial direction and a slight expansion of the coil at the outer radius in the radial direction of the coil. There may be mechanical contact between the outer surface of the coil 18 and the outer parts of the flux cage 12, 14, but free space 22 is left between the inner surface of the coil 18 and the gap region and surrounding the gap region. There may be mechanical contact between the lower region of the core 16 and the inner surface of the coil. The mechanical contact between the coil and the flux cage 12, 14 can be used to conduct thermal energy from the conductor to the flux cage 12, 14.

[0362] Additional examples regarding preforming techniques: In one example, a preformed conductor 18 including a preformed free space 22 is manufactured using a winding machine that sequentially controls and shapes the cross-sectional shape of the conductor 18 in a design that provides a helical arrangement of the windings along the central axis 10 of the coil. Such an arrangement is shown in Figures 12 and 13. The windings are pre-compressed in the axial direction and bent in a helical plane about the central axis.

[0363] In one example, the coil winding is preformed into a helical arrangement about a central axis having an inner opening diameter, which inner opening diameter is designed to fit within the opening volume of the flux ring made from components 12 and 14. Next, the helical winding is at least partially axially compressed, and the winding cross-section expands radially in accordance with this compression. Since the total cross-sectional area of the winding can remain substantially the same through the compression, the compression and change in cross-sectional shape relate to the geometric rearrangement of the thin wires or fiber filaments of conductor 18 that form the compressed portion of the conductor.

[0364] Thus, a new inductor coil having a gap within the core is provided centered between or adjacent to one of the ferrite components. The gap can be either an air gap or have a non-conductive spacer. The gap can be important in inductor design as it can be used for controlling magnetic resistance in the magnetic circuit. However, here, since the wire is held away from the coil, eddy currents in the coil winding are prevented. Further, the copper density throughout the winding of the inductor coil is increased due to the deformation of the winding caused by compression that can occur before and / or during the mounting process. When using a non-conductive spacer, the non-conductive spacer serves to keep the conductor outside the eddy current space, acts like a pusher to keep at least one winding in a deformed geometric shape, and actually provides a reverse twist to create a (more parallel than twisted) partially multi-strand wire.

[0365] The following relates to an embodiment providing specific details regarding some possible structures of the inductor coil and specific details regarding some possible methods of forming the inductor coil.

[0366] Example 1. An inductor coil, comprising: a first component 12, a second component 14, a conductor 18 of a predetermined length, and The first component is arranged adjacent to the second component, a core 16 is formed from the first component and the second component, the core is arranged along a first part of the central axis and a second part of the central axis, along a third part of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 in the core, and the third part of the central axis is between the first part of the central axis and the second part of the central axis, a first part of a conductor of a predetermined length is arranged surrounding the first part of the central axis, surrounding the second part of the central axis, and surrounding the third part of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps in the core, at least one section of the first part of the conductor of a predetermined length is compressed in the direction of the central axis, an inductor coil.

[0367] Example 2. The inductor coil according to Example 1, wherein at least one section of the first part of the conductor of a predetermined length that is compressed has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0368] Example 3. The inductor coil according to Example 1 or 2, wherein at least one section of the first part of the conductor of a predetermined length between the base part of the first component and the base part of the second component is compressed between the base part of the first component and the base part of the second component by the base part of the first component and the base part of the second component.

[0369] Example 4. The inductor coil according to any one of Examples 1 to 3, wherein the first part of the conductor of a predetermined length is at least partially compressed before being arranged surrounding the first part of the central axis, surrounding the second part of the central axis, and surrounding the third part of the central axis.

[0370] Example 5. The inductor coil according to any one of Examples 1 to 4, wherein adjacent turns among a plurality of turns of the conductor are joined to each other.

[0371] Example 6. Each turn of the conductor among a plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, and is arranged to surround a first portion of the central axis and / or an inner portion of the conductor among two or more turns of the conductor arranged to surround a second portion of the central axis is spaced apart from the central axis by at least a predetermined first distance, and an inner portion of the conductor among one or more turns of the conductor arranged to surround a third portion of the central axis is spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance. The inductor coil according to any one of Examples 1 to 5.

[0372] Example 7. A spacer 30 is disposed in the gap within the core so as to form a gap 22 surrounding the core, and an outer surface of a portion of the spacer is disposed at a distance from the central axis greater than a distance from the central axis of the outer surfaces of the first component and the second component forming the core. The inductor coil according to any one of Examples 1 to 6.

[0373] Example 8. The dimensions of a portion of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are greater than the dimensions 24 of the gap within the core in the direction of the central axis. The inductor coil according to Example 7.

[0374] Example 9. The inductor coil according to Example 7 or 8 when dependent on Example 6, wherein an outer surface of a portion of the spacer is configured to contact one or more turns of the conductor arranged to surround a third portion of the central axis.

[0375] Example 10. The inductor coil according to any one of Examples 7 to 9, wherein the spacer includes a non-conductive material.

[0376] Example 11. The inductor coil according to any one of Examples 7 to 10, wherein the spacer includes a central hole 32 configured to be disposed surrounding a central axis.

[0377] Example 12. The inductor coil according to any one of Examples 1 to 11, wherein the first component includes a ferrite material.

[0378] Example 13. The inductor material according to any one of Examples 1 to 12, wherein the second component includes a ferrite material.

[0379] Example 14. The inductor coil according to any one of Examples 1 to 13, wherein the conductor includes a multi-strand wire.

[0380] Example 15. The inductor coil according to any one of Examples 1 to 14, wherein the conductor includes a Litz wire.

[0381] Example 16. An inductor coil, a first component 12, a second component 14, a conductor 18 of a predetermined length, and comprising the first component is disposed adjacent to the second component, a core 16 is formed from the second component, the core is disposed along a first portion of the central axis, along a second portion of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 in the core, and the second portion of the central axis is between the first portion of the central axis and the first component, a first part of the conductor of the predetermined length is disposed surrounding the first portion of the central axis and disposed surrounding the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps in the core, at least one section of the first part of the conductor of the predetermined length is compressed in the direction of the central axis, the inductor coil.

[0382] Example 17. At least one section of the first part of a conductor of a predetermined length that is compressed has dimensions of the conductor in the direction of the central axis that are smaller than the dimensions of the conductor in a direction perpendicular to the central axis, the inductor coil according to Example 16.

[0383] Example 18. At least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component is compressed between the base part of the first component and the base part of the second component by the base part of the first component and the base part of the second component, the inductor coil according to Example 16 or 17.

[0384] Example 19. The first part of a conductor of a predetermined length is arranged surrounding a first part of the central axis and is at least partially compressed before being arranged surrounding a second part of the central axis, the inductor coil according to any one of Examples 16 to 18.

[0385] Example 20. Adjacent turns among a plurality of turns of the conductor are joined to each other, the inductor coil according to any one of Examples 16 to 19.

[0386] Example 21. Each turn of the conductor among a plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. The inner parts of the conductors of two or more turns of the conductor arranged surrounding a first part of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner parts of the conductors of one or more turns of the conductor arranged surrounding a second part of the central axis are spaced apart from the central axis by at least a predetermined second distance that is greater than at least the predetermined first distance, the inductor coil according to any one of Examples 16 to 20.

[0387] Example 22. An inductor coil according to any one of Examples 16 to 21, wherein a spacer 50 is disposed in a gap within the core so as to form a gap 42 surrounding the core, and an outer surface of a portion of the spacer is disposed at a distance from a central axis that is greater than a distance from the central axis of an outer surface of a second component forming the core.

[0388] Example 23. An inductor coil according to Example 22, wherein a dimension of a portion of the spacer adjacent to an outer surface of the second component in a direction of the central axis is greater than a dimension of a gap 24 within the core in the direction of the central axis.

[0389] Example 24. An inductor coil according to Example 22 or 23 when dependent on Example 21, wherein an outer surface of a portion of the spacer is configured to contact one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0390] Example 25. An inductor coil according to any one of Examples 22 to 24, wherein the spacer includes a non-conductive material.

[0391] Example 26. An inductor coil according to any one of Examples 22 to 25, wherein the spacer includes a central hole configured to be disposed surrounding the central axis.

[0392] Example 27. An inductor coil according to any one of Examples 1 to 26, wherein the first component includes a ferrite material.

[0393] Example 28. An inductor coil according to any one of Examples 16 to 27, wherein the second component includes a ferrite material.

[0394] Example 29. An inductor coil according to any one of Examples 16 to 28, wherein the conductor includes a multi-strand wire.

[0395] Example 30. An inductor coil according to any one of Examples 16 to 29, wherein the conductor includes a Litz wire.

[0396] Example 31. An inductor coil, comprising: a first component 12; a second component 14; a conductor 18 of a predetermined length; and the first component is arranged adjacent to the second component; a core 16 is formed from the first component and the second component; the core is arranged along a first portion of the central axis and a second portion of the central axis; along a third portion of the central axis, the first component is spaced apart from the second component to form gaps 20, 30 in the core, and the third portion of the central axis is between the first portion of the central axis and the second portion of the central axis; a first part of the conductor of the predetermined length is arranged to surround the first portion of the central axis, the second portion of the central axis, and the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps in the core; each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, and the inner portions of the conductors of two or more turns of the conductor arranged to surround the first portion of the central axis and / or the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner portions of the conductors of one or more turns of the conductor arranged to surround the third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than the predetermined first distance. The inductor coil.

[0397] Example 32. The inductor coil according to Example 31, wherein a spacer 30 is arranged in the gap in the core so as to form a gap 22 surrounding the core, and an outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distances from the central axis of the outer surfaces of the first component and the second component forming the core.

[0398] Example 33. The inductor coil according to Example 32, wherein the dimensions of a part of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are larger than the dimension 24 of the gap in the core in the direction of the central axis.

[0399] Example 34. The inductor coil according to Example 32 or 33, wherein a part of the outer surface of the spacer is configured to contact one or more turns of a conductor disposed surrounding a third part of the central axis.

[0400] Example 35. The inductor coil according to any one of Examples 32 to 34, wherein the spacer comprises a non-conductive material.

[0401] Example 36. The inductor coil according to any one of Examples 32 to 35, wherein the spacer comprises a central hole 32 configured to be disposed surrounding the central axis.

[0402] Example 37. The inductor coil according to any one of Examples 32 to 36, wherein at least one section of the first part of a conductor of a predetermined length is compressed in the direction of the central axis.

[0403] Example 38. The inductor coil according to Example 37, wherein at least one section of the first part of a conductor of a predetermined length that is compressed has a dimension in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0404] Example 39. The inductor coil according to Example 37 or 38, wherein at least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component is compressed between the base part of the first component and the base part of the second component by the base part of the first component and the base part of the second component.

[0405] Example 40. The first part of a conductor of a predetermined length is arranged to surround a first part of the central axis, arranged to surround a second part of the central axis, and at least partially compressed before being arranged to surround a third part of the central axis, the inductor coil according to any one of Examples 31 to 39.

[0406] Example 41. Adjacent turns among a plurality of turns of a conductor are joined to each other, the inductor coil according to any one of Examples 31 to 40.

[0407] Example 42. An inductor coil, a first component 12, a second component 14, a conductor 18 of a predetermined length, comprising, the first component is arranged adjacent to the second component, a core 16 is formed from the second component, the core is arranged along a first part of the central axis, along a second part of the central axis, the first component is spaced apart from the second component to form gaps 40, 50 in the core, and the second part of the central axis is between the first part of the central axis and the first component, the first part of the conductor of a predetermined length is arranged to surround the first part of the central axis, arranged to surround the second part of the central axis, and forms a plurality of turns of the conductor surrounding the core and the gaps in the core, each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, the inner parts of the conductor among two or more turns of the conductor arranged to surround the first part of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner parts of the conductor among one or more turns of the conductor arranged to surround the second part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance. An inductor coil.

[0408] Example 43. An inductor coil according to Example 42, wherein a spacer 50 is disposed in a gap within a core so as to form a gap 42 surrounding the core, and an outer surface of a part of the spacer is disposed at a distance from a central axis that is greater than a distance from the central axis of an outer surface of a second component forming the core.

[0409] Example 44. An inductor coil according to Example 43, wherein a dimension of a part of the spacer adjacent to an outer surface of the second component in the direction of the central axis is greater than a dimension 24 of the gap within the core in the direction of the central axis.

[0410] Example 45. An inductor coil according to Example 43 or 44, wherein an outer surface of a part of the spacer is configured to contact one or more turns of a conductor disposed surrounding a second part of the central axis.

[0411] Example 46. An inductor coil according to any one of Examples 43 to 45, wherein the spacer comprises a non-conductive material.

[0412] Example 47. An inductor coil according to any one of claims 43 to 46, wherein the spacer comprises a central hole configured to be disposed surrounding the central axis.

[0413] Example 48. An inductor coil according to any one of Examples 42 to 47, wherein at least one section of a first part of a conductor of a predetermined length is compressed in the direction of the central axis.

[0414] Example 49. An inductor coil according to Example 48, wherein at least one section of a first part of a compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0415] Example 50. At least one section of the first part of a conductor of a predetermined length between the base part of the first component and the base part of the second component is compressed by the base part of the first component and the base part of the second component between the base part of the first component and the base part of the second component. The inductor coil according to any one of Examples 42 to 49.

[0416] Example 51. The first part of a conductor of a predetermined length is arranged surrounding the first part of the central axis and is at least partially compressed before being arranged surrounding the second part of the central axis. The inductor coil according to any one of Examples 42 to 50.

[0417] Example 52. Adjacent turns among a plurality of turns of the conductor are joined to each other. The inductor coil according to any one of claims 42 to 51.

[0418] Example 53. The first component includes a ferrite material. The inductor coil according to any one of Examples 42 to 52.

[0419] Example 54. The second component includes a ferrite material. The inductor material according to any one of Examples 42 to 53.

[0420] Example 55. The conductor includes a multi-strand wire. The inductor coil according to any one of Examples 42 to 54.

[0421] Example 56. The conductor includes a litz wire. The inductor coil according to any one of Examples 42 to 55.

[0422] Example 57. A method of forming an inductor coil, To arrange the first component 12 adjacent to the second component 14, such that a core 16 is formed from the first and second components, the core being arranged along a first part of the central axis and a second part of the central axis, and along a third part of the central axis, the first component being spaced from the second component to form gaps 20, 30 within the core, the third part of the central axis being between the first part of the central axis and the second part of the central axis, the arranging; To arrange a first part of a conductor 18 of a predetermined length to surround the first part of the central axis, to surround the second part of the central axis, and to surround the third part of the central axis, to form a plurality of turns of the conductor surrounding the core and the gaps within the core; To compress at least one section of the first part of the conductor of the predetermined length in the direction of the central axis; A method comprising the above.

[0423] Example 58. The method according to Example 57, wherein at least one section of the first part of the compressed conductor of the predetermined length has a dimension in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0424] Example 59. The method according to Example 57 or 58, the method comprising compressing at least one section of the first part of the conductor of the predetermined length between the base part of the first component and the base part of the second component.

[0425] Example 60. The method according to any one of Examples 57 to 59, the method comprising at least partially compressing the first part of the conductor of the predetermined length before arranging it to surround the first part of the central axis, to surround the second part of the central axis, and to surround the third part of the central axis.

[0426] Example 61. The method according to any one of Examples 57 to 60, the method comprising joining adjacent turns of the plurality of turns of the conductor to each other.

[0427] Example 62. The method includes arranging a conductor of a predetermined length such that each turn of the conductor among a plurality of turns of the conductor has an inner portion of the conductor spaced apart from a central axis by at least a predetermined distance in a direction perpendicular to the central axis, and the inner portions of the conductor among two or more turns of the conductor arranged to surround a first portion of the central axis and / or the conductor arranged to surround a second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner portions of the conductor among one or more turns of the conductor arranged to surround a third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance, the method according to any one of Examples 57 to 61.

[0428] Example 63. The method includes arranging a spacer 30 in a gap within a core so as to form a gap 22 surrounding the core, and an outer surface of a portion of the spacer is arranged at a distance from a central axis greater than a distance from the central axis of an outer surface of a first component forming the core and an outer surface of a second component, the method according to any one of Examples 57 to 62.

[0429] Example 64. The dimensions of a portion of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are greater than the dimensions 24 of the gap within the core in the direction of the central axis, the method according to Example 63.

[0430] Example 65. The method includes bringing an outer surface of a portion of the spacer into contact with one or more turns of a conductor arranged to surround a third portion of the central axis, the method according to Example 63 or 64 when dependent on Example 62.

[0431] Example 66. The spacer includes a non-conductive material, the method according to any one of Examples 63 to 65.

[0432] Example 67. The spacer includes a central hole 32 configured to be arranged surrounding the central axis, the method according to any one of Examples 63 to 66.

[0433] Example 68. The first component is the method according to any one of Examples 57 to 67, including a ferrite material.

[0434] Example 69. The second component is the method according to any one of Examples 57 to 68, including a ferrite material.

[0435] Example 70. The conductor is the method according to any one of Examples 57 to 69, including a multi-strand wire.

[0436] Example 71. The conductor is the method according to any one of Examples 57 to 69, including a Litz wire.

[0437] Example 72. A method of forming an inductor coil, wherein the first component 12 is arranged adjacent to the second component 14, a core is formed from the second component, the core is arranged along a first part of the central axis, along a second part of the central axis, the first component is spaced from the second component to form gaps 40, 50 in the core, and the second part of the central axis is between the first part of the central axis and the first component; arranging, arranging a first part of a conductor 18 of a predetermined length to surround the first part of the central axis and to surround the second part of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps in the core; compressing at least one section of the first part of the conductor of the predetermined length in the direction of the central axis; comprising the method.

[0438] Example 73. The method according to Example 72, wherein at least one of the first parts of the compressed conductor of the predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than the dimension of the conductor in a direction perpendicular to the central axis.

[0439] Example 74. The method includes compressing at least one section of a first part of a conductor of a predetermined length between a base portion of a first component and a base portion of a second component, the method according to Example 72 or 73.

[0440] Example 75. The method includes at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of a central axis and to surround a second part of the central axis, the method according to any one of Examples 72 to 74.

[0441] Example 76. The method includes joining adjacent turns among a plurality of turns of a conductor, the method according to any one of Examples 72 to 75.

[0442] Example 77. The method includes arranging a conductor of a predetermined length such that each turn of the conductor among a plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, and the inner parts of the conductor among two or more turns of the conductor arranged to surround a first part of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner parts of the conductor among one or more turns of the conductor arranged to surround a second part of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance, the method according to any one of Examples 72 to 76.

[0443] Example 78. The method includes arranging a spacer 50 in a gap within a core so as to form a gap 42 surrounding the core, and an outer surface of a part of the spacer is arranged at a distance from the central axis greater than a distance from the central axis of an outer surface of a second component forming the core, the method according to any one of Examples 72 to 77.

[0444] Example 79. The dimension of a part of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension 24 of the gap within the core in the direction of the central axis, the method according to Example 78.

[0445] Example 80. The method is the method according to Example 78 or 79 when dependent on Example 7, including contacting an outer surface of a portion of the spacer with one or more turns of a conductor disposed surrounding a second portion of the central axis.

[0446] Example 81. The method according to any one of Examples 72 to 80, wherein the spacer comprises a non-conductive material.

[0447] Example 82. The method according to any one of Examples 72 to 81, wherein the spacer comprises a central hole configured to be disposed surrounding the central axis.

[0448] Example 83. The method according to any one of Claims 72 to 82, wherein the first component comprises a ferrite material.

[0449] Example 84. The method according to any one of Examples 72 to 83, wherein the second component comprises a ferrite material.

[0450] Example 85. The method according to any one of Examples 72 to 84, wherein the conductor comprises a multi-strand wire.

[0451] Example 86. The method according to any one of Examples 72 to 85, wherein the conductor comprises a litz wire.

[0452] Example 87. A method of forming an inductor coil, placing a first component 12 adjacent to a second component 14, wherein a core 16 is formed from the first component and the second component, the core being disposed along a first portion of the central axis and a second portion of the central axis, along a third portion of the central axis, the first component being spaced apart from the second component to form gaps 20, 30 in the core, the third portion of the central axis being between the first portion of the central axis and the second portion of the central axis; Arrange the first part of the conductor 18 of a predetermined length to surround the first part of the central axis, surround the second part of the central axis, and surround the third part of the central axis, to form a plurality of turns of the conductor surrounding the core and the gap within the core. Arrange the first part of the conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis. Among the two or more turns of the conductor arranged to surround the first part of the central axis and / or the conductor arranged to surround the second part of the central axis, the inner part of the conductor is spaced apart from the central axis by at least a predetermined first distance. Among the one or more turns of the conductor arranged to surround the third part of the central axis, the inner part of the conductor is spaced apart from the central axis by at least a predetermined second distance greater than at least the predetermined first distance. A method comprising.

[0453] Example 88. The method includes arranging a spacer 30 in the gap within the core so as to form a gap 22 surrounding the core. The outer surface of a part of the spacer is arranged at a distance from the central axis greater than the distance from the central axis of the outer surfaces of the first component and the second component forming the core. The method according to Example 87.

[0454] Example 89. The dimensions of a part of the spacer adjacent to the outer surfaces of the first component and the second component in the direction of the central axis are greater than the dimension 24 of the gap within the core in the direction of the central axis. The method according to Example 88.

[0455] Example 90. The method includes contacting the outer surface of a part of the spacer with one or more turns of the conductor arranged to surround the third part of the central axis. The method according to Example 88 or 89.

[0456] Example 91. The spacer includes a non-conductive material. The method according to any one of Examples 88 to 90.

[0457] Example 92. The method according to any one of Examples 88 to 91, wherein the spacer comprises a central hole 32 configured to be arranged surrounding a central axis.

[0458] Example 93. The method according to any one of claims 87 to 92, comprising compressing at least one section of a first part of a conductor of a predetermined length in a direction of the central axis.

[0459] Example 94. The method according to Example 93, wherein at least one of the first parts of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

[0460] Example 95. The method according to any one of Examples 87 to 94, comprising compressing at least one section of a first part of a conductor of a predetermined length between a base part of a first component and a base part of a second component.

[0461] Example 96. The method according to any one of Examples 87 to 95, comprising at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of the central axis, to surround a second part of the central axis, and to surround a third part of the central axis.

[0462] Example 97. The method according to any one of Examples 87 to 96, wherein adjacent turns among a plurality of turns of the conductor are joined to each other.

[0463] Example 98. A method of forming an inductor coil, Arranging a first component 12 adjacent to a second component 14, wherein a core 16 is formed from the second component, the core being arranged along a first portion of a central axis, and along a second portion of the central axis, the first component is spaced from the second component to form gaps 40, 50 within the core, and the second portion of the central axis is between the first portion of the central axis and the first component, and arranging; Arranging a first part of a conductor 18 of a predetermined length to surround the first portion of the central axis and to surround the second portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gaps within the core; Arranging a first part of a conductor of a predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner part of the conductor spaced from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, wherein the inner parts of the conductor of two or more turns of the conductor arranged to surround the first portion of the central axis are spaced from the central axis by at least a predetermined first distance, and the inner parts of the conductor of one or more turns of the conductor arranged to surround the second portion of the central axis are spaced from the central axis by at least a predetermined second distance greater than at least the predetermined first distance, and arranging; A method comprising.

[0464] Example 99. The method includes arranging a spacer 50 within the gap in the core to form a gap 42 surrounding the core, wherein an outer surface of a part of the spacer is arranged at a distance from the central axis greater than a distance from the central axis of the outer surface of the second component forming the core, the method according to Example 98.

[0465] Example 100. The dimension of a part of the spacer adjacent to the outer surface of the second component in the direction of the central axis is greater than the dimension 24 of the gap in the core in the direction of the central axis, the method according to Example 99.

[0466] Example 101. The method is the method according to Example 99 or 100, including contacting an outer surface of a part of the spacer with one or more turns of a conductor arranged to surround a second part of the central axis.

[0467] Example 102. The spacer includes a non-conductive material, and is the method according to any one of Examples 99 to 101.

[0468] Example 103. The spacer includes a central hole configured to be arranged to surround the central axis, and is the method according to any one of claims 99 to 102.

[0469] Example 104. The method includes compressing at least one section of a first part of a conductor of a predetermined length in a direction of the central axis, and is the method according to any one of Examples 98 to 103.

[0470] Example 105. At least one section of the first part of the compressed conductor of a predetermined length has a dimension of the conductor in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis, and is the method according to Example 104.

[0471] Example 106. The method includes compressing at least one section of a first part of a conductor of a predetermined length between a base part of a first component and a base part of a second component, and is the method according to any one of Examples 98 to 105.

[0472] Example 107. The method includes at least partially compressing a first part of a conductor of a predetermined length before arranging it to surround a first part of the central axis and also to surround a second part of the central axis, and is the method according to any one of Examples 98 to 105.

[0473] Example 108. The method includes joining adjacent turns among a plurality of turns of the conductor, and is the method according to any one of Examples 98 to 107.

[0474] Example 109. The first component is the method according to any one of Examples 98 to 108, which includes a ferrite material.

[0475] Example 110. The second component is the method according to any one of Examples 98 to 109, which includes a ferrite material.

[0476] Example 111. The conductor is the method according to any one of Examples 98 to 110, which includes a multi-strand wire.

[0477] Example 112. The conductor is the method according to any one of Examples 98 to 111, which includes a litz wire.

[0478] Note that the embodiments of the present invention are described with reference to different subjects. In particular, some embodiments are described with reference to method-type claims, and other embodiments are described with reference to device-type claims. However, those skilled in the art will presume that, unless otherwise notified, any combination of features belonging to one type of subject, in addition to any combination between features related to different subjects, is also considered to be disclosed together with this application from the above and below descriptions. However, it is not possible to combine all features to provide a synergistic effect that exceeds the simple sum of the features.

[0479] Although the present invention has been illustrated and described in detail in the drawings and the foregoing description, such illustrations and descriptions are exemplary or illustrative and should not be considered limiting. The present invention is not limited to the disclosed embodiments. Other modifications to the disclosed embodiments can be understood and achieved by those skilled in the art when implementing the invention described in the claims from the study of the drawings, the disclosure, and the dependent claims.

[0480] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. A single processor or other unit may perform the functions of a plurality of items recited in the claims. The mere fact that certain means are recited in mutually different dependent claims does not indicate that a combination of these means cannot be used advantageously. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. An inductor coil, comprising: a first component (12) having a first base portion and a first cylindrical core portion; a second component (14) having a second base portion and a second cylindrical core portion; a conductor (18) of a predetermined length; and the first cylindrical core portion is arranged adjacent to the second cylindrical core portion; a core (16) is formed from the first cylindrical core portion and the second cylindrical core portion; the core is arranged along a first portion of the central axis and a second portion of the central axis; along a third portion of the central axis, the first cylindrical core portion is spaced apart from the second cylindrical core portion to form a gap (20, 30) in the core, and the third portion of the central axis is between the first portion of the central axis and the second portion of the central axis; a spacer (30) is arranged in the gap within the core so as to form a gap (22) surrounding the core, and an outer surface of a part of the spacer (30) is arranged at a distance from the central axis greater than a distance from the central axis of the outer surface of the first cylindrical core portion and the outer surface of the second cylindrical core portion forming the core; a first part of the conductor of the predetermined length is arranged surrounding the first portion of the central axis, surrounding the second portion of the central axis, and surrounding the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core; at least one section of the first part of the conductor of the predetermined length is compressed in the direction of the central axis; at least one section of the first part of the conductor of the predetermined length between the base portion of the first component and the base portion of the second component is compressed between the first base portion and the second base portion by the first base portion and the second base portion. Each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, and the inner portion of the conductor among two or more turns of the conductor disposed surrounding the first portion of the central axis and the inner portion of the conductor among two or more turns of the conductor disposed surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner portion of the conductor among one or more turns of the conductor disposed surrounding the third portion of the central axis is spaced apart from the central axis by at least a predetermined second distance greater than the at least predetermined first distance. The outer surface of the part of the spacer (30) is configured to contact one or more turns of the conductor disposed surrounding the third portion of the central axis. Inductor coil.

2. The inductor coil according to claim 1, wherein at least one section of the first part of the conductor of the predetermined length in the compressed state has a dimension of the conductor in the direction of the central axis that is smaller than a dimension of the conductor in a direction perpendicular to the central axis.

3. The inductor coil according to claim 1 or 2, wherein the first part of the conductor of the predetermined length is at least partially compressed before being disposed surrounding the first portion of the central axis, disposed surrounding the second portion of the central axis, and disposed surrounding the third portion of the central axis.

4. The inductor coil according to any one of claims 1 to 3, wherein adjacent turns among the plurality of turns of the conductor are joined to each other.

5. The inductor coil according to claim 1, wherein the dimension of the part of the spacer adjacent to the outer surface of the first component and the outer surface of the second component in the direction of the central axis is larger than the dimension of the gap (24) in the core in the direction of the central axis.

6. The inductor coil according to any one of claims 1 to 5, wherein the spacer includes a non-conductive material.

7. The inductor coil according to any one of claims 1 to 6, wherein the spacer includes a central hole (32) configured to be disposed surrounding the central axis.

8. The first component is the inductor coil according to any one of claims 1 to 7, including a ferrite material.

9. The second component is the inductor material according to any one of claims 1 to 8, including a ferrite material.

10. The conductor is the inductor coil according to any one of claims 1 to 9, including a multi-strand wire.

11. The conductor is the inductor coil according to any one of claims 1 to 10, including a Litz wire.

12. A method of forming an inductor coil, placing a first cylindrical core portion of a first component (12) adjacent to a second cylindrical core portion of a second component (14), wherein the first component (12) has the first cylindrical core portion and a first base portion, the second component (14) has the second cylindrical core portion and a second base portion, a core (16) is formed from the first cylindrical core portion and the second cylindrical core portion, the core is arranged along a first portion of a central axis and a second portion of the central axis, along a third portion of the central axis, the first cylindrical core portion is spaced from the second cylindrical core portion to form gaps (20, 30) in the core, and the third portion of the central axis is between the first portion of the central axis and the second portion of the central axis; placing a spacer (30) in the gap within the core so as to form a gap (22) surrounding the core, and an outer surface of a part of the spacer (30) is arranged at a distance from the central axis greater than a distance from the central axis of an outer surface of the first component forming the core and an outer surface of the second component; arranging a first part of a conductor (18) of a predetermined length to surround the first portion of the central axis, surround the second portion of the central axis, and surround the third portion of the central axis to form a plurality of turns of the conductor surrounding the core and the gap within the core; compressing at least one section of the first part of the conductor of the predetermined length in a direction of the central axis. Compressing at least one section of the first part of the conductor of the predetermined length between the first base portion and the second base portion, so that in the formed inductor coil, at least one section of the first part of the conductor of the predetermined length between the first base portion and the second base portion is compressed between the first base portion and the second base portion and by the first base portion and the second base portion. Arranging the conductor of the predetermined length such that each turn of the conductor among the plurality of turns of the conductor has an inner portion of the conductor spaced apart from the central axis by at least a predetermined distance in a direction perpendicular to the central axis, wherein the inner portions of the conductor among two or more turns of the conductor arranged surrounding the first portion of the central axis and / or the conductor arranged surrounding the second portion of the central axis are spaced apart from the central axis by at least a predetermined first distance, and the inner portions of the conductor among one or more turns of the conductor arranged surrounding the third portion of the central axis are spaced apart from the central axis by at least a predetermined second distance greater than the at least predetermined first distance. Contacting the outer surface of the portion of the spacer (30) with the one or more turns of the conductor arranged surrounding the third portion of the central axis. Method.

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