Electrical component, method for manufacturing electrical component and vehicle

Abstract

This invention relates to an electrical component comprising at least one soft magnetic core element and at least one encapsulated electromagnetic coil assembly, each encapsulated electromagnetic coil assembly comprising: (i) a thermally conductive and electrically insulating retainer having at least one soft magnetic element held by the retainer; (ii) a coil formed of enameled wire and having a magnetic shaft and two ends, wherein the coil wire is wound around the retainer with at least one soft magnetic element, wherein the coil, the retainer, and the at least one soft magnetic element form a coil assembly; and (iii) a thermally conductive and electrically insulating cover comprising an inner side facing an internal space enclosed by the cover and an outer side facing an external space, and the coil assembly being disposed within the internal space. The invention also relates to a method for manufacturing the electrical component and to a vehicle.

Description

Technical Field

[0001] The present invention relates to an electrical component and a method for manufacturing the electrical component. Prior Technology

[0002] Electromagnetic coils are the basic building blocks of chokes (also known as inductors) and transformers.

[0003] For example, a changing current, especially alternating current, flowing through a choke coil generates a changing magnetic field, particularly an alternating magnetic field. This changing magnetic field induces an electromotive force (EMF) in the choke coil, and the induced EMF is opposite to the change in current. Similarly, a changing current, especially alternating current, flowing through the primary coil of a transformer generates a changing magnetic field, particularly an alternating magnetic field. When this changing magnetic field passes through the coupled secondary coil, it induces an EMF in the secondary coil.

[0004] In the prior art, electromagnetic coils used as part of a choke or transformer are typically wound around a ferromagnetic or ferrimagnetic core to increase the magnetic field due to the strong magnetization that may occur in ferromagnetic or ferrimagnetic materials. Preferably, the electromagnetic coil is wound around a ferromagnetic or ferrimagnetic core, providing a magnetic circuit with one or more closed-loop paths. When a magnetic field above a certain intensity is applied to both ferromagnetic and ferrimagnetic materials, they typically experience saturation characteristics. Saturation characteristics manifest as saturation magnetization in ferromagnetic or ferrimagnetic materials.

[0005] Once saturation is reached, inductors or transformers will exhibit undesirable nonlinear characteristics. To enable ferromagnetic or subferromagnetic cores to withstand high magnetic field strengths without saturation, air gaps are known to be used in the prior art.

[0006] For example, chokes typically incorporate an air gap in the magnetic circuit, where the central legs of two ferrimagnetic core elements meet, for instance, in a so-called "E"-shaped core. By varying the size of this air gap, the inductance of the choke can be controlled, and the strength of the magnetic field at which saturation occurs can be appropriately altered. Air gaps in ferromagnetic core elements often require extremely high precision manufacturing through grinding. While standard cores may be readily available, non-standard air gap distributions and core geometries often complicate the manufacturing process for ferromagnetic cores with air gaps. To reduce eddy currents, it may be preferable to provide multiple smaller air gaps rather than fewer larger ones, which can further complicate the manufacturing process.

[0007] For frequencies common in switch-mode power supplies, typically ranging from 10 to 200 kHz, the skin effect can become prominent in conductors such as chokes, which are part of the active power factor correction in switch-mode power supplies. To reduce the skin and proximity effects between parallel conductors near the choke, existing technologies typically employ coils wound around ferrite, a low-conductivity ferrimagnetic material, using Litz wire, usually triple-insulated Litz wire. As for the winding pattern, basket windings are commonly used, with the winding wires, particularly Litz wire, forming multiple layers around the ferrite core. However, Litz wire, especially triple-insulated Litz wire, is unsuitable for fully automated production of chokes or transformers. The multi-layered Litz wire used in the prior art often results in a large temperature gradient between the outermost and innermost layers of the winding around the ferrite core, potentially altering the characteristics of the choke or transformer due to heating of the ferrite core.

[0008] In existing technologies, flat-wound coils are also used instead of Litz wire wound in multiple layers around a ferrite core; flat-wound coils are particularly suitable for applications in power electronics, such as for use with switch-mode power supplies for vehicle charging solutions. Flat-wound coils typically consist only of enameled wire, without further insulation. To insulate the choke coil, which includes the flat-wound coil around the ferrite core, in existing technologies, the entire choke coil is encapsulated in, for example, an electrically insulating cover; however, this insulation method is detrimental to cooling because both the coil and the ferrite core are encapsulated by the insulating cover and encapsulation material.

[0009] Prior art document Japanese Patent JP2009246221A discloses a choke with the following structure: In the holding portion of the choke, soft magnetic inner cores are kept apart from each other by gap-limiting portions; a coil is wound around the holding portion; the holding portion and the coil wound thereon are contained between two frame-shaped members, which are arranged on opposite sides of the holding portion relative to the magnetic axis of the coil; on the side of each frame-shaped member facing away from the holding portion and the coil, a corresponding soft magnetic outer core is arranged at each frame-shaped member; the entire assembly is coated with resin for electrical insulation. Because the entire assembly of the choke in Japanese Patent JP2009246221A is coated with resin and may be further enclosed in a housing, the choke in Japanese Patent JP20092462212A is difficult to cool. When the choke in Japanese Patent JP2009246221A is placed in the cavity of a chassis, the electrical clearance and creepage distance are disadvantageously short, leading to potential insulation problems.

[0010] Chinese patent CN209515404U discloses a multi-air-gap high-current choke. The choke in CN209515404U includes two PQ magnetic cores, a flattened coil at both ends, an R-shaped rod core, an insulating pad, a sleeve, a base, a housing, a bottom shell, and two annular pads. The R-shaped rod cores are coaxially arranged between the middle columns of the two PQ magnetic cores. The insulating pads can be located, for example, between the middle column of each PQ magnetic core and the adjacent R-shaped rod core to form an air gap, or between adjacent R-shaped rod cores. The sleeve is located between the coil and the middle column of the PQ magnetic cores: the R-shaped rod cores and the insulating pads are located in the sleeve, and the coil is directly wound on the sleeve. Annular pads are provided on the upper and lower surfaces of the coil to prevent contact between the coil and the PQ magnetic cores. Chinese patent CN209515404U does not disclose any encapsulation or further protection of the coil to prevent intrusion, meaning the coil of the choke in Chinese patent CN209515404U can be accessed from the outside, which may lead to electrical insulation problems. When the choke in Chinese patent CN209515404U is placed in the chassis cavity, the electrical clearance and creepage distance are disadvantageously short, resulting in potential insulation problems.

[0011] Prior art document Chinese Patent CN218100935U discloses a choke coil comprising two PQ magnetic cores, two insulating sheets, a coil, a base, and a cylinder in which the magnetic sheets are placed. The cylinder includes grooves in which the magnetic sheets can be arranged. By appropriately positioning the magnetic sheets in different grooves, various sizes and numbers of air gaps can be obtained. The coil is located outside the cylinder. Chinese Patent CN218100935U does not disclose any encapsulation or further protection of the coil against ingress, meaning that the choke coil of Chinese Patent CN218100935U can be accessed from the outside, which may lead to electrical insulation problems. The choke coil of Chinese Patent CN218100935U results in unfavorably short electrical clearances and creepage distances when placed in the cavity of a chassis, thus leading to potential insulation problems. Summary of the Invention

[0012] The object of this invention is to provide an electrical component that overcomes at least some of the disadvantages of solutions known in the prior art.

[0013] This invention relates to an electrical component, particularly an electrical component for a switch-mode power supply, comprising (i) at least one soft magnetic core element and (ii) at least one encapsulated electromagnetic coil assembly, wherein each of the at least one encapsulated electromagnetic coil assemblies comprises: 1) at least one soft magnetic element; 2) a thermally conductive and electrically insulating retainer, wherein the at least one soft magnetic element is located within and held by the retainer, and wherein the retainer is made of a first diamagnetic material or a first paramagnetic material; 3) a coil formed of enameled wire and having a magnetic shaft and two ends, wherein the conductor of the coil is wound around the retainer with at least one soft magnetic element; wherein the coil, the retainer, and at least one soft magnetic core element are combined to form a coil. A soft magnetic element forms a coil assembly, wherein a retainer and a coil are arranged such that the magnetic axis of the coil passes through at least one air gap provided by the retainer, and 4) a thermally conductive and electrically insulating cover, the cover including an inner side facing an internal space enclosed by the cover and an outer side facing an external space, the internal space being accessible only through an opening in the cover, and the coil assembly being arranged in the internal space, wherein the cover and the coil assembly are arranged such that only the two ends of the coil's wires protrude through the opening, wherein the cover is made of a second diamagnetic material or a second paramagnetic material, and wherein the encapsulated electromagnetic coil assembly includes a thermally conductive and electrically insulating encapsulating material, the coil assembly being encapsulated in the internal space enclosed by the cover with the encapsulating material. Each of at least one soft magnetic core element is in direct contact with at least a portion of the outer side of the cover of at least one or more of the encapsulated electromagnetic coil assemblies. Each of at least one soft magnetic core element is in contact with the encapsulating material of at least one encapsulated electromagnetic coil assembly at most at the surface of the outer side of the cover of at least one or more of the encapsulated electromagnetic coil assemblies in which the corresponding soft magnetic core element is in direct contact with the corresponding soft magnetic core element.

[0014] At least one encapsulated electromagnetic coil assembly is combined with a soft magnetic core element to provide an electrical component, such as a choke or transformer. Soft magnetic materials are materials that are easily magnetized by an external magnetic field, and the magnetization of a soft magnetic material produces a magnetic flux density much stronger than that of an external magnetic field in air. Compared to hard magnetic materials, soft magnetic materials have lower hysteresis losses. As a soft magnetic material for such a soft magnetic core element, ferrite or other materials with high permeability can be used, for example. For example, cores such as ferrite cores, amorphous cores, nanocrystalline cores, or pressed powder cores known in the art are suitable. Similarly, for example, at least one soft magnetic element held by a retainer can be configured as at least one ferrite element, or at least one amorphous element, or at least one nanocrystalline element, or at least one pressed power element, or a suitable combination thereof. Preferably, for the soft magnetic core element and at least one soft magnetic element, the selected material has (i) low electrical conductivity to minimize eddy currents and (ii) good thermal conductivity to facilitate cooling. Soft magnetic ferrites are preferred as materials. Different soft magnetic materials can be used for the soft magnetic core element and at least one soft magnetic element.

[0015] The retainer of each packaged electromagnetic coil assembly in which the electrical components of the present invention, which are arranged with at least one soft magnetic element, is thermally conductive to facilitate cooling of at least one soft magnetic element. The retainer also has electrical insulation to prevent short circuits between the coil turns wound on the retainer. Furthermore, the retainer is diamagnetic or paramagnetic, i.e., it only weakly interacts with the magnetic field that the coil wound on the retainer may generate. The retainer can be made of plastic material and can be formed by molding. The retainer can also be made of ceramic material. The retainer is designed to hold at least one soft magnetic element. In the case where at least one soft magnetic element is implemented as at least one ferrite element, manganese-zinc ferrite or nickel-zinc ferrite can be used as the ferrite material, for example. At least one soft magnetic element can, in turn, be provided in standard sizes, for example, in the form of soft magnetic, particularly ferrite pellets. The retainer can be designed to include receiving slots into which at least one soft magnetic element can be inserted. By appropriately designing the number and spatial arrangement of such receiving slots in the retainer, a desired distribution of the air gap in the retainer between adjacent soft magnetic elements in the magnetic circuit can be obtained. Therefore, the retainer can advantageously provide the precise spatial range and position of the air gap required for a particular application, without the need to grind the air gap to the winding legs as is typically required in the prior art. Furthermore, for manufacturing the electrical components of the present invention, at least one soft magnetic element, particularly implemented as a ferrite pellet, can be advantageously and simply inserted into the receiving slot of the retainer. Retainers made of plastic materials can advantageously provide a high degree of design freedom with precise manufacturing tolerances.

[0016] When an electric current passes through, the coil formed by the enameled wire around the retainer generates a magnetic field. Enameled wire is a conductor, particularly made of copper or aluminum, coated with an enameled enamel for electrical insulation. For example, polyurethane enameled enamel, solderable polyimide enameled enamel, THEIC modified polyester enameled enamel, THEIC polyimide enameled enamel, polyimide enameled enamel, or polyvinyl alcohol formal enameled enamel can be used as the enameled enamel. At both ends of the enameled wire, the insulation layer is preferably completely removed. Enameled wire can also be called coated wire.

[0017] Preferably, the coil is formed as a flat-wound coil made of enameled flat wire, because the flat-wound coil advantageously simplifies the manufacture of the electrical components of the present invention.

[0018] The magnetic axis of a coil can be defined as the line of symmetry of the magnetic field pattern generated by the coil when current flows through it. For example, for a coil implemented as a solenoid, the magnetic axis can coincide with the axis passing through the geometric center of the solenoid. For a symmetrical coil, the magnetic axis can correspond to the coil's axis of symmetry. The magnetic axis can be oriented, for example, by the dominant direction of the magnetic field inside the coil when current flows through it. However, the magnetic axis does not need to provide a sense of direction.

[0019] A convex hull of a specific shape can be defined as the smallest set of convex hulls containing it. Since at least one soft magnetic element is located within the convex hull of the retainer, the coil wound on the retainer advantageously does not directly contact the at least one soft magnetic element, and through proper design of the retainer, it can advantageously have a defined geometric relationship with the at least one soft magnetic element, particularly a distance. Therefore, the retainer electrically insulates the coil from the at least one soft magnetic element. Consequently, the coil can be tightly wound on the retainer, which advantageously improves the mechanical stability and cooling of at least one encapsulated electromagnetic coil assembly of the electrical component.

[0020] Since the coils are made of enameled wire, for further electrical insulation, each encapsulated electromagnetic coil assembly of the electrical component of the present invention includes a thermally conductive and electrically insulating cover. Each cover is implemented to distinguish between an internal space and an external space enclosed by the respective cover, with the internal space facing the inside of the cover and the external space facing the outside of the cover. None of the covers completely encloses the corresponding internal space. Instead, an opening is provided in each cover, through which the corresponding internal and external spaces are connected. In manufacturing the electrical component of the present invention, the coil assembly of each encapsulated electromagnetic coil assembly moves into the internal space through the corresponding opening, where it is encapsulated with a thermally conductive and electrically insulating encapsulating material. Preferably, each cover is embodied as a single unit, i.e., the cover may not need to be assembled from sub-components but can be formed directly, for example, a cover made of plastic material formed during molding. The cover may also be made of ceramic material. Thus, the coil assembly of each encapsulated electromagnetic coil assembly is electrically insulated by the corresponding cover and encapsulating material. The cover does not include any other openings besides the opening for the coil assembly and encapsulating material to be inserted into the internal space to prevent leakage of the inserted encapsulating material before it has fully hardened.

[0021] The lid can preferably be implemented in a substantially cup-shaped manner. Therefore, the lid may include a portion identifiable as a bottom and a lateral portion extending away from the bottom, which together surround an interior space in which the coil assembly and encapsulation material can be housed; an opening may be located opposite the bottom. The lid and its opening are preferably shaped such that the coil assembly can be moved through the opening and placed directly into the interior space, thereby advantageously simplifying the manufacture of the electrical components. Thus, the lid and its opening are adapted to the coil assembly placed within the interior space enclosed by the lid.

[0022] The cover is preferably shaped in such a way that the shape and volume of the internal space enclosed by the cover match the shape and volume of the coil assembly. This allows all portions of the coil assembly facing the inside of the cover to be advantageously close to the inside of the cover, thereby improving coil cooling, where the encapsulation material secures the coil assembly within the internal space. To improve the electrical insulation of the electrical components, the portion of the coil assembly facing the opening and thus accessible from the external space is preferentially embedded in the encapsulation material. The cover and coil assembly of each encapsulated electromagnetic coil assembly are designed such that only the two ends of the coil's wires extend into the external space through the opening. The cover and coil assembly can preferably be designed such that the portion of the retainer without the coil is in direct contact with or close to the cover; that is, the cover can be designed to tightly seal certain portions of the coil assembly placed within the internal space enclosed by the cover.

[0023] The bulge of the cover can be essentially shaped like a cuboid surface, with one surface of the cuboid missing, allowing the coil assembly to be inserted into the cover through an opening. After the coil assembly and encapsulation material are inserted into the cover through the opening, the opening can be sealed by a substrate with slots through which the two ends of the coil can be guided, meaning the substrate and cover can completely enclose the internal space. Typically, the surface of the cover can deviate from the shape of the cuboid surface and can be specifically adapted to the shape of the coil assembly.

[0024] Before inserting the coil assembly, the encapsulating material can be inserted into the internal space surrounded by the cover, and after the encapsulating material has shifted following insertion, it can surround the coil assembly from all sides facing the inside of the cover and the opening. Alternatively, the coil assembly can be inserted first into the internal space surrounded by the cover, and then the encapsulating material can be inserted into the internal space where the coil assembly already exists. Preferably, an encapsulating material that interacts only weakly with the magnetic field generated by the coil is selected. As an encapsulating material, thermosetting plastics, silicone rubber gels, or epoxy resins can be used, for example, preferably in conjunction with a filler material to improve thermal conductivity. Polyurethane resin can be used as an encapsulating material, for example.

[0025] The cap is either diamagnetic or paramagnetic, meaning it only weakly interacts with the magnetic field generated by the coil wound around the retainer. The cap can be made of plastic and can be formed using molding processes. The cap can also be made of ceramic. The plastic or ceramic material of the cap can be different from or equivalent to the plastic or ceramic material of the retainer. Therefore, the cap can be easily adapted to the specific shape of the coil.

[0026] The magnetic axis of the coil wound on the retainer passes through at least one air gap, which, as described above, is provided by the arrangement of at least one soft magnetic element in the retainer's bulge. The retainer and at least one soft magnetic element are preferably arranged such that, at the intersection of the at least one soft magnetic element and the magnetic axis, the magnetic axis is orthogonal to the at least one soft magnetic element.

[0027] Each of at least one soft magnetic core element is arranged in the external space of at least one packaged electromagnetic coil assembly, i.e., the soft magnetic core elements are arranged such that they are in direct contact, i.e., immediately in contact with at least a portion of the outer side of the cover of one or more of the at least one packaged electromagnetic coil assembly. Each of the at least one soft magnetic core element contacts the packaging material of at least one packaged electromagnetic coil assembly at most on the outer surface of the cover of one or more of the at least one packaged electromagnetic coil assembly that is in direct contact with the corresponding soft magnetic core element. Specifically, when the coil assembly is packaged into the corresponding cover, some packaging material may flow out from the cover. This flowing packaging material can then contact the surface of at least one soft magnetic core element facing the corresponding packaged electromagnetic coil assembly from which the packaging material flows out. The soft magnetic core elements are preferably positioned around at least one packaged electromagnetic coil assembly, thereby providing a closed-loop path around at least one packaged electromagnetic coil assembly. Through at least partial direct contact between the soft magnetic core element and the cover, at least one packaged electromagnetic coil assembly can advantageously be cooled by the soft magnetic core element. Therefore, the soft magnetic core element is in direct contact with the encapsulation material included by the at least one encapsulated electromagnetic coil assembly at most on the surface of the soft magnetic core element facing the at least one encapsulated electromagnetic coil assembly; essentially, the soft magnetic core element is separated from the encapsulation material by the cover of the at least one encapsulated electromagnetic coil assembly. In some embodiments, the at least one soft magnetic core element may not be in contact with the encapsulation material of the at least one encapsulated electromagnetic coil assembly.

[0028] To improve cooling, the outer side of the packaged electromagnetic coil assembly is preferably formed so that there is extensive contact between the soft magnetic core element and the packaged electromagnetic coil assembly.

[0029] Because each encapsulated electromagnetic coil assembly is electrically insulated by its own cover and encapsulation material, the soft magnetic core element does not need to be encapsulated in an electrically insulating encapsulation material. For example, if the entire electrical component is to be encapsulated in the chassis of a vehicle's on-board charger, the electrical component can be encapsulated using an encapsulation material optimized primarily for high thermal conductivity; that is, a different encapsulation material can be used to encapsulate the entire electrical component compared to the encapsulation material used in at least one encapsulated electromagnetic coil assembly. Advantageously, when placed in the chassis cavity, the electrical component of the present invention has improved electrical clearance and creepage distance because the coil of each encapsulated electromagnetic coil assembly is at least shielded by its respective cover and encapsulation material. Therefore, the electrical component of the present invention provides a high degree of electrical insulation.

[0030] Therefore, the electrical components of the present invention are advantageously easy to manufacture and can be cooled in an improved manner, because only those parts of the electrical components that most require enhanced electrical insulation, namely the coils, are encapsulated with an electrically insulating encapsulating material. In contrast to solutions known in the prior art, for the purpose of electrical insulation, it is therefore advantageous not to encapsulate and cover the entire electrical component.

[0031] In an embodiment of the electrical component according to the invention, at least one of the coils in at least one encapsulated electromagnetic coil assembly is a flat-wound coil.

[0032] In another embodiment of the electrical component according to the invention, for at least one of the at least encapsulated electromagnetic coil assemblies, the coil assembly and the encapsulation material together fill the internal space surrounded by the lid, and / or, for at least one of the at least encapsulated electromagnetic coil assemblies, the coil assembly and the lid are configured such that the shape and volume of the internal space substantially match the shape and volume of the coil assembly, and / or, for at least one of the at least encapsulated electromagnetic coil assemblies, the lid is shaped in a substantially cup-like manner, wherein the substantially cup-shaped lid allows both the coil assembly and the encapsulation material to be inserted through openings into the internal space surrounded by the lid, and / or, for at least one of the at least one encapsulated electromagnetic coil assemblies, the lid is configured as an integral lid.

[0033] In another embodiment of the electrical component according to the invention, the retainer includes at least two receiving slots, wherein a soft magnetic element is inserted into each of the at least two receiving slots, and wherein the shapes of the at least two receiving slots and the at least two inserted soft magnetic elements are such that an air gap exists between any two inserted soft magnetic elements.

[0034] In another embodiment of the electrical component according to the invention, the electrical component further includes a substrate with a slot, wherein the end of the coil of each of at least one encapsulated electromagnetic coil assembly is guided through the slot, and the substrate is positioned at the opening of each of the at least one encapsulated electromagnetic coil assembly to prevent entry from the external space of the respective encapsulated electromagnetic coil assembly into the internal space of the respective encapsulated electromagnetic coil assembly.

[0035] In another embodiment of the electrical component according to the invention, the electrical component is implemented as a choke coil.

[0036] In conjunction with or already used alone, at least one soft magnetic core element, such as a manganese-zinc ferrite core element or a nickel-zinc ferrite core element, can provide a closed-loop path for the magnetic circuit. The at least one soft magnetic core element may preferably not include winding legs around which the coil is wound, wherein the coil of the choke is only disposed within the at least one encapsulated electromagnetic coil assembly. The at least one soft magnetic core element is preferably designed in such a way that it is in extensive direct contact with the outer side of the cover of the at least one encapsulated electromagnetic coil assembly. Since the at least one soft magnetic core element in the choke does not need to be encapsulated for electrical insulation as required in the prior art, it can, for example, be in direct contact with the chassis of an on-board charger, thereby advantageously allowing for improved cooling.

[0037] In another embodiment of the electrical component according to the invention, the electrical component is implemented as a transformer.

[0038] In addition to the choke coil, a transformer can be constructed using at least two encapsulated electromagnetic coil assemblies and at least one soft magnetic core element, wherein each of the at least one soft magnetic core element is in direct contact with at least a portion of the outer side of the cover of one or more of the at least two encapsulated electromagnetic coil assemblies. For constructing the transformer, the encapsulated electromagnetic coil assemblies and soft magnetic core elements are preferably positioned in a manner that provides strong coupling between the coils of the at least two electromagnetic coil assemblies.

[0039] The encapsulated electromagnetic coil assembly of the electrical component may also include another coil. This other coil may be formed of enameled wire. The other coil may also be wound around a retainer using at least one soft magnetic element of the encapsulated electromagnetic coil assembly. The magnetic axis of the other coil may coincide with the magnetic axis of the coil. The other coil may also have two ends. In this encapsulated electromagnetic coil assembly, the four ends of the coil and the other coil can thus protrude through the opening. The other coil may also be surrounded by encapsulation material. Electrical components including this encapsulated electromagnetic coil assembly can be used to construct transformers: thus, constructing a transformer may only require one such encapsulated electromagnetic coil assembly and at least one soft magnetic core element.

[0040] For example, chokes can be used as power factor correction chokes in switch-mode power supplies. Switch-mode power supplies typically include nonlinear components, such as rectifiers that distort the current. To combat this distortion, active power correction can be used, which typically operates at frequencies between 10 and 200 kHz. Chokes can also be used as part of a boost converter. For example, electrical components can be used in applications where voltages range from 200 to 800 V.

[0041] Due to its structure, the power factor correction choke, which includes at least one packaged electromagnetic coil assembly, can be advantageously cooled in an improved manner because the soft magnetic core element does not need to be covered to provide electrical insulation, and therefore can be directly connected to the cooling tank, for example.

[0042] In another embodiment of the electrical component according to the invention, the electrical component implemented as a choke includes an encapsulated electromagnetic coil assembly and two soft magnetic core elements, wherein the two soft magnetic core elements are in direct contact with each other and provide a closed-loop path around the encapsulated electromagnetic coil assembly.

[0043] The two soft magnetic core elements can have the same shape and size. Each of the two soft magnetic core elements can be implemented as follows: the soft magnetic core element includes two symmetrical planes passing through a circular portion of the soft magnetic core element, the diameter of which is smaller than the height of two outer legs of the soft magnetic core element, which form a flange. Two "V"-shaped portions are arranged between the circular portion and the two outer legs, connecting the circular portion and the two outer legs. When placed around the encapsulated electromagnetic coil assembly, the two soft magnetic core elements are in direct contact with each other at their respective two outer legs. The cover of the encapsulated electromagnetic coil assembly can include two recesses on opposite sides relative to the magnetic axis of the coil, these recesses being dimensionally matched to the circular portions of the two soft magnetic core elements. When the two soft magnetic core elements are arranged around the encapsulated electromagnetic coil assembly, their respective circular portions can be inserted into the corresponding recesses of the cover. After the circular portions are placed in the two recesses, the outer legs of the two soft magnetic core elements can extend along both sides of the cover parallel to the magnetic axis of the coil. Therefore, a closed-loop path around the encapsulated electromagnetic coil assembly can be provided by the four outer legs of the two soft magnetic core elements, the four "V"-shaped portions of the two soft magnetic core elements, and the two circular portions of the two soft magnetic core elements. Alternatively, a closed-loop path can be provided by the encapsulated electromagnetic coil assembly, the two circular portions of the two soft magnetic core elements, and the two outer legs of the two soft magnetic core elements arranged on one side of the cover. Similarly, another closed-loop path can be provided by the two outer legs of the two soft magnetic core elements arranged on the other side of the cover.

[0044] In another embodiment of the electrical component according to the invention, the electrical component implemented as a choke includes: a) two encapsulated electromagnetic coil assemblies, each having different magnetic axes and being parallel to each other, wherein the two encapsulated electromagnetic coil assemblies are arranged adjacent to each other; and b) two soft magnetic core elements, wherein the two soft magnetic core elements are arranged on opposite sides of the two encapsulated electromagnetic coil assemblies relative to the two parallel magnetic axes, wherein a first soft magnetic core element of the two soft magnetic core elements includes a soft magnetic core protrusion extending into the space between the two encapsulated electromagnetic coil assemblies, and wherein a second soft magnetic core element of the two soft magnetic core elements is directly connected to the soft magnetic core protrusion.

[0045] For example, the choke coil according to this embodiment can be used in an interleaved converter. Two packaged electromagnetic coil assemblies are separated from each other by a soft core protrusion of the first soft core element. Because the path through the soft core protrusion has lower magnetic reluctance than the path through the packaged electromagnetic coil assembly, in this embodiment, the two coils of the two packaged electromagnetic coil assemblies are only weakly coupled, since most of the magnetic field passing through one will bypass the other through the soft core protrusion. In this embodiment, the soft core protrusions extend in parallel to the two magnetic axes of the two packaged electromagnetic coil assemblies, and the second soft core element and the remainder of the first soft core element are orthogonal to these two magnetic axes.

[0046] In another embodiment of the electrical component according to the invention, the electrical component implemented as a choke includes: a) two encapsulated electromagnetic coil assemblies, each having a magnetic axis extending along a common line; and b) three soft magnetic core elements, wherein two of the three soft magnetic core elements are arranged on opposite sides of the two encapsulated electromagnetic coil assemblies relative to the common line, and wherein a third soft magnetic core element is arranged between the two encapsulated electromagnetic coil assemblies, wherein each of the two soft magnetic core elements is in direct contact with the third soft magnetic core element.

[0047] In this embodiment, the two packaged electromagnetic coil assemblies are separated from each other by a third soft magnetic core element. The first and second soft magnetic core elements of the three soft magnetic core elements can each be shaped as described above, including a circular portion, two "V"-shaped portions, and two outer supports. The cover of the first packaged electromagnetic coil assembly may include a matching first recess that allows the circular portion of the first soft magnetic core element to be placed therein, and the cover of the second packaged electromagnetic coil assembly may include a matching second recess that allows the circular portion of the second soft magnetic core element to be placed therein. The respective two outer supports of the first and second soft magnetic core elements can extend along the covers of the first and second packaged electromagnetic coil assemblies and indirectly contact each other via the third soft magnetic core element. The third soft magnetic core element may have a circular portion, two "V"-shaped portions, and two outer supports. The mutually facing sides of the cover can each include a recess that matches the circular portion of the third soft magnetic core element.

[0048] In another embodiment of the electrical component according to the invention, the electrical component implemented as a choke includes: a) three encapsulated electromagnetic coil assemblies, each having a different magnetic axis and being parallel to each other, wherein the three encapsulated electromagnetic coil assemblies are arranged adjacent to each other; and b) two soft magnetic core elements, wherein the two soft magnetic core elements are arranged on opposite sides of the three encapsulated electromagnetic coil assemblies relative to the three parallel magnetic axes, wherein each of the two soft magnetic core elements includes a corresponding soft magnetic core protrusion extending into a first space and a second space, wherein the first space is located between the first and second encapsulated electromagnetic coil assemblies of the three encapsulated electromagnetic coil assemblies, and wherein the second space is located between the second and third encapsulated electromagnetic coil assemblies of the three encapsulated electromagnetic coil assemblies, and wherein the first and second soft magnetic core elements are directly connected via their corresponding soft magnetic core protrusions in the first and second spaces.

[0049] In this embodiment, the first packaged electromagnetic coil assembly and the second packaged electromagnetic coil assembly, as well as the second packaged electromagnetic coil assembly and the third packaged electromagnetic coil assembly, are separated from each other by the soft core protrusions of two soft magnetic core elements. For example, the choke according to this embodiment can be used as a three-phase power factor correction choke.

[0050] In another embodiment of the electrical component according to the invention, the electrical component implemented as a choke coil includes: a) Six packaged electromagnetic coil assemblies, wherein a first packaged electromagnetic coil assembly, a second packaged electromagnetic coil assembly, and a third packaged electromagnetic coil assembly have magnetic axes extending along a first common line, and wherein a fourth packaged electromagnetic coil assembly, a fifth packaged electromagnetic coil assembly, and a sixth packaged electromagnetic coil assembly have magnetic axes extending along a second common line, wherein the first common line and the second common line are different and parallel to each other, wherein the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly are arranged adjacent to each other, wherein the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly are arranged adjacent to each other, and wherein the third packaged electromagnetic coil assembly and the sixth packaged electromagnetic coil assembly are arranged adjacent to each other. b) Four soft magnetic core elements, of which: a. The first soft magnetic core element of the four soft magnetic core elements is in direct contact with the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly. b. Of the four soft magnetic core elements, the second soft magnetic core element (i) is in direct contact with the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly, and (ii) through a second soft magnetic core protrusion extending into the first space between the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly, is in direct contact with the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly. c. The third soft magnetic core element of the four soft magnetic core elements (i) is in direct contact with the third packaged electromagnetic coil assembly and the sixth packaged electromagnetic coil assembly, and (ii) the protruding portion of the third soft magnetic core element protrudes into the second space between the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly, and is in direct contact with the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly. d. The fourth soft magnetic core element of the four soft magnetic core elements is in direct contact with the third packaged electromagnetic coil assembly and the sixth packaged electromagnetic coil assembly, wherein the fourth soft magnetic core element includes a fourth soft magnetic core protrusion that protrudes into the third space between the third packaged electromagnetic coil assembly and the sixth packaged electromagnetic coil assembly.

[0051] For example, the choke according to this embodiment can be used as a sixth switching power factor correction choke.

[0052] The present invention also relates to a method for manufacturing an electrical component according to the invention, the method comprising the steps of: a) for each of at least one packaged electromagnetic coil assembly: (i) providing a thermally conductive and electrically insulating retainer having at least one soft magnetic element; (ii) forming a coil assembly by placing a coil around the retainer; (iii) inserting the coil assembly through an opening in a cover into an internal space surrounded by a cover and a thermally conductive and electrically insulating encapsulating material; and b) arranging at least one soft magnetic core element in direct contact with at least a portion of the outer side of the cover of one or more of the at least one packaged electromagnetic coil assembly, and such that each of the at least one soft magnetic core element is in contact with at most the encapsulating material of the at least one packaged electromagnetic coil assembly on the surface of the respective soft magnetic core element facing the outer side of the cover of the at least one packaged electromagnetic coil assembly, while the at least one packaged electromagnetic coil assembly is in direct contact with the respective soft magnetic core element.

[0053] Advantageously, the electrical components according to the invention can be manufactured in a simple manner, and the manufacturing process is fully automated and precise.

[0054] In an embodiment of the method according to the invention, for at least one of at least one encapsulated electromagnetic coil assembly, the coil is implemented as a flat-wound coil surrounding a hollow interior, wherein both ends of the flat-wound coil point in the same direction and are located at the end sides of the coil, wherein the step of placing the coil around a retainer includes inserting the retainer into the hollow interior of the flat-wound coil, and wherein in the step of inserting the coil assembly into the interior space surrounded by a cover, the coil assembly is inserted into the interior space in such a way that one side of the coil relative to the end side is inserted into the interior space first, and after the coil assembly is inserted into the interior space, both ends of the coil protrude from the cover through the openings of the cover.

[0055] The end of the coil can correspond to the side of the substrate on which the coil can be arranged.

[0056] In another embodiment of the method according to the invention, the method further includes the step of guiding the end of the coil of each of at least one packaged electromagnetic coil assembly through a slot in the substrate.

[0057] In another aspect of the invention, the invention also relates to a vehicle, particularly an electric or hybrid vehicle, comprising an on-board charger having a chassis surrounding a cavity for receiving electrical components according to the invention, particularly implemented as a choke coil, wherein the electrical components are placed in the cavity, particularly encapsulated in the cavity with a thermally conductive chassis encapsulation material.

[0058] Electrical components can be directly connected to the chassis, which can therefore advantageously serve as a cooling tank for the soft magnetic core elements of the electrical components. Alternatively, the electrical components can be encapsulated within a chassis cavity using a chassis encapsulation material. This chassis encapsulation material can differ from the encapsulation material used for at least one encapsulated electromagnetic coil assembly. Thermosetting plastics, silicone rubber gels, or epoxy resins can be used as chassis encapsulation materials, preferably in conjunction with filler materials to improve thermal conductivity.

[0059] In addition to their use in vehicles, the electrical components according to the invention can also be used in conventional telecommunications fields, such as as electrical components for networks, particularly chokes or transformers, or in other industrial and vehicle applications.

[0060] Other advantageous embodiments and feature combinations are described in detail below. Simple Explanation of the Diagram

[0061] Figure 1 illustrates the steps involved in manufacturing a packaged electromagnetic coil assembly for an electrical component and an embodiment of the packaged electromagnetic coil assembly; Figure 2 illustrates the steps involved in manufacturing the first choke and the first choke itself; Figure 3 illustrates the steps for manufacturing the second choke and the second choke. Figure 4 illustrates the steps for manufacturing the third choke and the third choke itself; Figure 5 illustrates the steps for manufacturing the fourth choke and the fourth choke itself; and Figure 6 illustrates the steps for manufacturing the fifth choke and the fifth choke itself. In the figure, the same parts are given the same reference numerals. Implementation

[0062] Some typical embodiments that embody the features and advantages of this case will be described in detail in the following description. It should be understood that this case can have various variations in different forms, all of which do not depart from the scope of this case, and the descriptions and illustrations therein are essentially for illustrative purposes and not intended to limit this case.

[0063] Figure 1 illustrates the steps of an embodiment of manufacturing an encapsulated electromagnetic coil assembly 1 for an electrical component. Five ferrite elements 3 are inserted into receiving slots in a retainer 2. The retainer 2 is positioned such that the ferrite elements 3 inserted into the receiving slots are located within a bulge of the retainer 2. An air gap is formed between adjacent ferrite elements 3 in the retainer 2. In the embodiment of the encapsulated electromagnetic coil assembly 1 shown in Figure 1, the air gap is formed by the material of the retainer, which is magnetically similar to air.

[0064] After the ferrite element 3 is inserted into the retainer 2, the retainer 2 is inserted into the interior of the coil 4. The coil 4 is made of enameled wire and includes two ends 6 through which the coil 4 can make electrical contact / connection. The coil 4 can be implemented, for example, as a flat-wound coil. When current flows through the coil 4, a magnetic field is generated both inside and outside the coil, where all magnetic field lines are closed. The coil 4 includes a magnetic axis 5, which corresponds to the line of symmetry of the magnetic field pattern generated by the coil when current flows through it. In the symmetrical embodiment of the coil 4 in Figure 1, the magnetic axis 5 corresponds to the center line passing through the interior of the coil 4. The magnetic axis 5 can be oriented such that, when current flows through the coil 4, the direction of the magnetic axis 5 corresponds, for example, to the direction of the magnetic field inside the coil 4. However, the magnetic axis 5 does not need to be oriented. The interior of the coil 4 is such that it substantially corresponds to the bulge of the retainer 2, such that after the retainer 2 is inserted into the interior of the coil 4, the coil 4 tightly surrounds the retainer 2.

[0065] After the retainer 2 is inserted into the interior of the coil 4 to form coil assemblies 2, 3, and 4, the coil assemblies 2, 3, and 4 are inserted into the interior space surrounded by the cover 7 through the opening 8 in the cover 7. The coil 4 with the retainer 2 is encapsulated in the interior space surrounded by the cover 7 with encapsulating material. The coil 4 with the retainer 2 is inserted into the cover 7 in such a way that the end 6 of the coil 4 passes through the opening 8, that is, the end 6 of the coil 4 is not surrounded by encapsulating material.

[0066] In the embodiment of Figure 1, the lid 7 is shaped in a substantially cup-like manner, meaning that the lid 7 includes a bottom opposite the opening 8 and a transverse portion extending between the bottom and the opening 8. The interior space of the lid is the space contained between the opening, the transverse portion, and the bottom, and the exterior space of the lid 7 is the space outside the lid. The lid 7 is matched in shape and volume to the coil assemblies 2, 3, and 4 such that the coil assemblies 2, 3, and 4 are preferably located close to the inner side of the lid 7, which faces the interior space, to facilitate cooling of the coil assemblies 2, 3, and 4.

[0067] Figure 2 illustrates the steps of manufacturing the first choke 9' and the first choke 9' itself. Two ferrite core elements 11 are arranged around the encapsulated electromagnetic coil assembly 1. The two ferrite core elements 11 are identical: each includes a circular portion, two outer legs, and two "V"-shaped portions located between the circular portion and the two outer legs. The cover 7 of the encapsulated electromagnetic coil assembly 1 is designed such that, on its two opposite outer sides, the cover includes recesses that mate with the circular portions of the ferrite core elements 11, i.e., the circular portions fit into the recesses. After the circular portions of the ferrite core elements 11 are inserted into the recesses, the outer legs of the ferrite core elements 11 extend along the outer side of the cover 7, which is parallel to the magnetic axis of the coil 4. After the choke 9' is assembled, the outer legs of the ferrite core elements 11 are in direct contact. The end 6 of the coil 4 passes through a slot in the substrate 10, which also seals the passage through the opening 8 in the cover 7 into the internal space enclosed by the cover 7.

[0068] Each of the two ferrite core elements in Figure 2 can also be referred to as a double-legged single-flange ferrite U-shaped core element. The flange of the double-legged single-flange ferrite U-shaped core element is formed by a circular portion and two "V"-shaped portions. The soft magnetic element encapsulating the electromagnetic coil assembly 1 forms a central leg, which, together with the four outer legs of the two ferrite core elements 11, forms the three-legged EE core structure of the first choke 9'. Instead of the EE core structure, for example, an EI core structure can also be used to construct the first choke.

[0069] Figure 3 illustrates the steps for manufacturing the second choke 9'' and the second choke 9''. The second choke 9'' includes two packaged electromagnetic coil assemblies, each of which can be manufactured relative to Figure 1 as described above. The second choke 9'' also includes three ferrite core elements 11. Two of the three ferrite core elements 11 are implemented as double-legged single-flange ferrite U-shaped core elements, and the third ferrite core element 11 is implemented as an I-plate core element.

[0070] The two covers 7 of the two packaged electromagnetic coil assemblies in Figure 3 are connected to each other. The I-plate magnetic core element is inserted into the space between the two covers 7. The four ends of the two packaged electromagnetic coil assemblies are guided through four slots in the substrate 10.

[0071] The second choke coil 9'' is constructed using an EIE core structure. A soft magnetic element encapsulating the electromagnetic coil assembly provides the central support leg. Alternatively, an EEE core structure or other similarly modified core structures can be used instead of the EIE core structure.

[0072] Figure 4 illustrates the steps for manufacturing the third choke 9''' and the third choke 9'''. The third choke 9''' comprises two ferrite core elements 11 and two encapsulated electromagnetic coil assemblies 1', 1'' arranged adjacent to each other, with different magnetic axes and parallel to each other. A space is provided between the covers of the two encapsulated electromagnetic coil assemblies 1', into which the ferrite core protrusion of the first ferrite core element of the two ferrite core elements 11 is inserted. Thus, the first ferrite core element is implemented as a ferrite core element having one leg (i.e., the ferrite core protrusion) and two flanges. The second ferrite core element of the two ferrite core elements 11 is implemented as an I-plate core element. In the embodiment of Figure 4, when moving away from the opening side of the two encapsulated electromagnetic coil assemblies 1', 1'', the space between the two encapsulated electromagnetic coil assemblies 1', 1'' increases: the ferrite core protrusion matches the increased space between the two encapsulated electromagnetic coil assemblies, thereby filling the space between the two encapsulated electromagnetic coil assemblies.

[0073] The third choke coil 9''' is constructed using an EI core structure. The soft magnetic elements encapsulating the electromagnetic coil assemblies 1', 1'' form the outer legs. Alternatively, an EE core structure can be used, for example, in which two identical single-leg, double-flange ferrite core elements can be employed.

[0074] Figure 5 illustrates the steps for manufacturing the fourth choke 9'''' and the fourth choke 9''''. The fourth choke 9'''' comprises three encapsulated electromagnetic coil assemblies 1', 1'', 1''', with different magnetic axes and parallel to each other. A corresponding space is provided between two adjacent encapsulated electromagnetic coil assemblies, which increases with the distance from the open side of the encapsulated electromagnetic coil assemblies 1', 1'', 1'''.

[0075] The fourth choke 9'''' comprises two identical ferrite core elements 11, namely two double-legged, three-flange ferrite core elements. Each ferrite core element 11 includes two ferrite core protrusions that match the two spaces between adjacent packaged electromagnetic coil assemblies 1', 1'', 1''': thus, after assembling the fourth choke 9'''', the two ferrite core protrusions of each ferrite core element fill half the space between the packaged electromagnetic coil assemblies and are in direct contact with the two ferrite core protrusions of the other ferrite core element.

[0076] The fourth choke 9'''' is constructed using a WW core structure. Soft magnetic elements encapsulating the electromagnetic coil assemblies 1', 1'', and 1''' form the central and outer legs, and are fitted with two identical double-legged, three-flange ferrite core elements 11. Alternatively, a WI core structure can be used to construct the fourth choke, for example, using a double-legged, three-flange ferrite core element and an I-plate core element.

[0077] Figure 6 illustrates the steps involved in manufacturing the fifth choke 9'''' and the fifth choke 9'''''. The fifth choke 9''''' comprises six packaged electromagnetic coil assemblies 1'-1''''''', four ferrite core elements 11, and a substrate 10. The design of the ferrite core elements 11 in Figure 6 is similar to that of the ferrite core elements described above with reference to Figure 4, i.e., three of the four ferrite core elements 11 respectively fill the spaces between the first packaged electromagnetic coil assembly 1' and the fourth packaged electromagnetic coil assembly 1''', the second packaged electromagnetic coil assembly 1''' and the fifth packaged electromagnetic coil assembly 1'''', and the third packaged electromagnetic coil assembly 1'''' and the sixth packaged electromagnetic coil assembly 1'''''''.

[0078] The fifth choke 9'''' is constructed using an EEEI core structure. Soft magnetic elements encapsulating the electromagnetic coil assembly 1'-1'''''' form the outer legs. Alternatively, an EIEE or EEEE core structure can also be used to construct the fifth choke.

[0079] It should be noted that the above are merely preferred embodiments for illustrative purposes, and the scope of this application is not limited to the described embodiments. The scope of this application is determined by the claims of the appended patent application. Furthermore, this application may be modified in various ways by those skilled in the art, but all such modifications shall not depart from the protection sought by the claims of the appended patent application.

[0080] 1, 1', 1'', 1''', 1'''', 1'''', 1''''': Encapsulated electromagnetic coil assembly 2: Holder 3: Soft magnetic components 4: Coil 5: Magnetic shaft 6: End 7: Lid 8: Opening 9'、9''、9'''、9''''、9'''': Electrical components 10:Substrate 11: Soft magnetic core components

Claims

1. An electrical component for a switch-mode power supply, comprising (i) at least one soft magnetic core element and (ii) at least one packaged electromagnetic coil assembly, wherein, Each of the at least one encapsulated electromagnetic coil assembly includes: a. at least one soft magnetic element; b. a thermally conductive and electrically insulating retainer, wherein the at least one soft magnetic element is located within and held by the retainer's bulge, and wherein the retainer is made of a first diamagnetic material or a first paramagnetic material; c. a coil formed of enameled wire and having a magnetic axis and two ends, wherein the coil's conductor is wound around the retainer with the at least one soft magnetic element; wherein the coil, the retainer, and the at least one soft magnetic element form a coil assembly; wherein the retainer and the coil are such that the magnetic axis of the coil passes through at least one air gap provided by the retainer; and d. A thermally conductive and electrically insulating cover includes an inner side facing an internal space enclosed by the cover and an outer side facing an external space, the internal space being accessible only through an opening in the cover, and a coil assembly disposed within the internal space, wherein the cover and the coil assembly are arranged such that only the two ends of the wire of the coil protrude through the opening, wherein the cover is made of a second diamagnetic material or a second paramagnetic material, and wherein the encapsulated electromagnetic coil assembly includes a thermally conductive and electrically insulating encapsulating material, the coil assembly being encapsulated in the internal space enclosed by the cover with the encapsulating material, wherein each of the at least one soft magnetic core elements is in direct contact with at least a portion of the outer side of the cover of one or more of the at least one encapsulated electromagnetic coil assemblies, and wherein each of the at least one soft magnetic core elements is in contact with the encapsulating material of the at least one encapsulated electromagnetic coil assembly at most on the surface of the outer side of the cover of one or more of the at least one encapsulated electromagnetic coil assemblies in which the corresponding soft magnetic core element is in direct contact with the corresponding soft magnetic core element.

2. The electrical components as requested in item 1, wherein, The coil of at least one of the at least encapsulated electromagnetic coil assemblies is a flat-wound coil.

3. The electrical components as requested in item 1, wherein, For at least one of the at least encapsulated electromagnetic coil assemblies, the coil assembly and the encapsulation material together fill the internal space surrounded by the lid, and / or for at least one of the at least encapsulated electromagnetic coil assemblies, the coil assembly and the lid are configured such that the shape and volume of the internal space match the shape and volume of the coil assembly, and / or for at least one of the at least encapsulated electromagnetic coil assemblies, the lid is shaped in a generally cup-like manner, wherein the generally cup-shaped lid allows the coil assembly and the encapsulation material to be inserted into the internal space surrounded by the lid through the opening, and / or for at least one of the at least encapsulated electromagnetic coil assemblies, the lid is configured as an integral lid.

4. The electrical components as requested in item 1, wherein, The retainer includes at least two receiving slots, in which the soft magnetic element is inserted, and wherein the shapes of the at least two receiving slots and the at least two inserted soft magnetic elements are such that an air gap exists between any of the at least two inserted soft magnetic elements.

5. The electrical component as claimed in claim 1 further includes a substrate with grooves, wherein, The end of the coil of each of the at least one packaged electromagnetic coil assembly is guided through the slot, and wherein the substrate is positioned at the opening of each of the at least one packaged electromagnetic coil assembly to prevent entry from the external space of the respective packaged electromagnetic coil assembly into the internal space of the respective packaged electromagnetic coil assembly.

6. The electrical components as requested in item 1, wherein, The electrical component is implemented as a choke.

7. Electrical components as described in claim 6, including: The packaged electromagnetic coil assembly includes one soft magnetic core element and two soft magnetic core elements, wherein the two soft magnetic core elements are in direct contact with each other and provide a closed-loop path around the packaged electromagnetic coil assembly.

8. The electrical component as claimed in claim 6, used in an interleaving converter, comprising: a) two packaged electromagnetic coil assemblies, each having a different magnetic axis and being parallel to each other, wherein the two packaged electromagnetic coil assemblies are arranged adjacent to each other; and b) two soft magnetic core elements, wherein the two soft magnetic core elements are arranged on opposite sides of the two packaged electromagnetic coil assemblies relative to the two parallel magnetic axes, wherein the first soft magnetic core element of the two soft magnetic core elements includes a soft magnetic core protrusion extending into the space between the two packaged electromagnetic coil assemblies, and wherein the second soft magnetic core element of the two soft magnetic core elements is directly connected to the soft magnetic core protrusion.

9. Electrical components as described in claim 6, including: a) two of the packaged electromagnetic coil assemblies, each having a magnetic axis extending along a common line; and b) three of the soft magnetic core elements, wherein two of the three soft magnetic core elements are arranged on opposite sides of the two packaged electromagnetic coil assemblies relative to the common line, and wherein a third soft magnetic core element is arranged between the two packaged electromagnetic coil assemblies, wherein each of the two soft magnetic core elements is in direct contact with the third soft magnetic core element.

10. Electrical components as claimed in claim 6, including: a) three packaged electromagnetic coil assemblies, each having a different magnetic axis and being parallel to each other, wherein the three packaged electromagnetic coil assemblies are arranged adjacent to each other; and b) two soft magnetic core elements, wherein the two soft magnetic core elements are arranged on opposite sides of the three packaged electromagnetic coil assemblies relative to the three parallel magnetic axes, wherein each of the two soft magnetic core elements includes a corresponding soft magnetic core protrusion extending into a first space and a second space, wherein the first space is located between the first packaged electromagnetic coil assembly and the second packaged electromagnetic coil assembly of the three packaged electromagnetic coil assemblies, and wherein the second space is located between the second packaged electromagnetic coil assembly and the third packaged electromagnetic coil assembly of the three packaged electromagnetic coil assemblies, and wherein the first soft magnetic core element and the second soft magnetic core element are directly connected via their corresponding soft magnetic core protrusions in the first space and the second space.

11. Electrical components as claimed in claim 6, including: a) Six packaged electromagnetic coil assemblies, wherein the first, second, and third packaged electromagnetic coil assemblies have magnetic axes extending along a first common line, and wherein the fourth, fifth, and sixth packaged electromagnetic coil assemblies have magnetic axes extending along a second common line, wherein the first and second common lines are different and parallel to each other, wherein the first and fourth packaged electromagnetic coil assemblies are arranged adjacent to each other, wherein the second and fifth packaged electromagnetic coil assemblies are arranged adjacent to each other, and wherein the third and sixth packaged electromagnetic coil assemblies are arranged adjacent to each other; and b) Four soft magnetic core elements, wherein: a. the first soft magnetic core element of the four soft magnetic core elements is in direct contact with the first and fourth packaged electromagnetic coil assemblies; b. c. Of the four soft magnetic core elements, the second soft magnetic core element (i) is in direct contact with the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly, and (ii) is in direct contact with the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly via a second soft magnetic core protrusion protruding into a first space between the first packaged electromagnetic coil assembly and the fourth packaged electromagnetic coil assembly. d. Of the four soft magnetic core elements, the third soft magnetic core element (i) is in direct contact with the third packaged electromagnetic coil assembly and the sixth packaged electromagnetic coil assembly, and (ii) is in direct contact with the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly via a third soft magnetic core protrusion protruding into a second space between the second packaged electromagnetic coil assembly and the fifth packaged electromagnetic coil assembly.

12. A method for manufacturing an electrical component as claimed in any one of claims 1 to 11, comprising the steps of: a) for each of at least one packaged electromagnetic coil assembly: i. providing a thermally conductive and electrically insulating retainer having at least one soft magnetic element; ii. A coil assembly is formed by placing the coil around the retainer; iii. Inserting the coil assembly into the internal space surrounded by the cover and a thermally conductive and electrically insulating encapsulation material through an opening in the cover; and b) arranging at least one soft magnetic core element in direct contact with at least a portion of the outer side of the cover of one or more of the at least one encapsulated electromagnetic coil assemblies, and such that each of the at least one soft magnetic core element contacts at most the encapsulation material of the at least one encapsulated electromagnetic coil assembly at a surface facing the outer side of the cover of one or more of the at least one encapsulated electromagnetic coil assemblies in direct contact with the corresponding soft magnetic core element.

13. The method of claim 12, wherein for at least one of the at least encapsulated electromagnetic coil assemblies, the coil is implemented as a flat-wound coil surrounding a hollow interior, and wherein both ends of the flat-wound coil point in the same direction and are located at the end sides of the coil, wherein the step of placing the coil around the retainer includes inserting the retainer into the hollow interior of the flat-wound coil, and wherein in the step of inserting the coil assembly into the interior space surrounded by the cover, the coil assembly is inserted into the interior space in such a manner that the side of the coil relative to the end side is inserted into the interior space first, and after the coil assembly is inserted into the interior space, both ends of the coil protrude from the cover through the opening of the cover.

14. The method of claim 12 further includes the step of: c) guiding the end of the coil of each of the at least one packaged electromagnetic coil assembly through a slot in the substrate.

15. A vehicle including an on-board charger with a chassis having a cavity surrounding a housing for receiving electrical components, wherein, The electrical components according to any one of claims 1 to 11 are placed in the cavity, particularly encapsulated in the cavity with a thermally conductive chassis encapsulation material.

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