Inductive component

Abstract

The invention relates to an inductive component (1), which comprises a base (2) and a top (3). The inductive component (1) further comprises at least two winding legs (4). The winding legs (4) comprise a first material. Each of the winding legs (4) is connected to the base (2) and the top (3). Each of the winding legs (4) is arranged between the base (2) and the top (3). The inductive component (1) further comprises at least one center leg (5). The center leg (5) comprises a second material. The center leg (5) is positioned between the winding legs (4). A first gap (6) is provided between the center leg (5) and the base (2). Further, a second gap (7) is provided between the center leg (5) and the top (3). The first material has a first magnetic flux density, which is lower than a second magnetic flux density of the second material.

Description

[0001] Description

[0002] Inductive component

[0003] The present disclosure relates to an inductive component , in particular a coupled inductor .

[0004] Inductive components such as coupled inductors are used, for example , in voltage converters such as DC-DC converters . DC- DC converters may be used to convert a first DC voltage level to a second DC voltage level . The second DC voltage level can be lower or higher than the first DC voltage level .

[0005] Coupled inductors are known, for example , from document WO 2022 / 078769 Al .

[0006] Preferably, inductive components such as coupled inductors or DC-DC voltage converters are required to have high power ef ficiency, high power density and small spatial dimensions . In particular, in many applications , requirements regarding power density have increased in recent years . Thus , there is a desire to reduce spatial dimensions .

[0007] One obj ect to be achieved, inter alia, is to speci fy an improved inductive component , which in particular has comparably small spatial dimensions .

[0008] This obj ect is achieved, inter alia, by an inductive component comprising the features of independent claim 1 . Advantageous embodiments and further developments are the subj ect of the dependent patent claims . An inductive component is specified that comprises a base and a top. The inductive component further comprises at least two winding legs. The winding legs comprise a first material. Each of the winding legs is connected to the base and the top. Each of the winding legs is arranged between the base and the top. The inductive component further comprises at least one center leg. The center leg comprises a second material. The center leg is positioned between the winding legs. A first gap is provided between the center leg and the base. Further, a second gap is provided between the center leg and the top. The first material has a first magnetic flux density, which is lower than a second magnetic flux density of the second material.

[0009] The first material is, for example, a magnetic material. For example, the first material includes a ferrite or iron. The second material is, for example, based on iron. This means in particular, that the second material comprises an iron material system. For example, the second material is an iron powder .

[0010] For example, the second material comprises a sintered material. This means in particular, the at least one center leg comprises a sintered center leg.

[0011] Alternatively, the second material may comprise a soft magnetic composite, also referred to as SMC for short. For example, the second material comprises a soft magnetic composite (SMC) paste. It is possible, that the second material is arranged in an intermediate space between two winding legs. For example, the second material fills the intermediate space at least partially. Advantageously, it may be possible to reduce the size of the inductive component by using a soft magnetic composite for the second material , while preferably achieving similar performance when using a sintered material .

[0012] Preferably, the base and / or the top comprise the first material or another material with high permeability for coupling . In particular, the first material and the second material are di f ferent . This means in particular that at least one material component of the first and second materials is di f ferent i f the first and second materials comprise a mixture of material components .

[0013] It is thus possible that the second material comprises all material components of the first material with a further material component being added, and vice versa . It is further possible that the first and second materials comprise identical or essentially identical material components , wherein a mixing ratio of the di f ferent material components is di f ferent in the first and second materials .

[0014] The winding legs are each configured to receive a coil . The coils are in particular inductively coupled to one another by the winding legs and the base and the top . The winding legs , the base and the top together may thus form a core of the inductive component . The base and the top may also be referred to as yokes . For example , the base may be referred to as base yoke and the top may be referred to as top yoke .

[0015] During operation of the inductive component , the coils may be supplied with current . As a result , a coupling magnetic flux conduction path is generated in the core , coupling the coils of di f ferent winding legs . The center leg is configured to provide a leakage magnetic flux conduction path for a leakage flux of the inductive component emerging during operation . In particular, the leakage flux determines a leakage inductance of the inductive component .

[0016] The center leg may also be referred to as a " shared leg" .

[0017] During operation of the inductive component the center leg or shared leg establishes the leakage magnetic flux conduction path that is available for flux associated with di f ferent coils . Thus , the corresponding conductance path is " shared" by di f ferent coils .

[0018] The winding legs are in particular positioned between the base and the top in a first direction . The first direction is in particular perpendicular to a main extension plane of the base and / or the top . The winding legs have a main extension direction parallel to the first direction .

[0019] The center leg is in particular positioned between the winding legs in a second direction perpendicular to the first direction . The second direction may be parallel to the main extension plane of the base and / or the top . Preferably, the center leg is arranged between the base and the top in the first direction .

[0020] The first gap is preferably a vertical gap . This means in particular that the first gap is provided along the first direction . For example , the first gap has a width between 0 . 2 mm and 1 mm inclusive , measured parallel to the first direction . The second gap is preferably a vertical gap . This means in particular that the second gap is provided along the first direction . For example , the second gap has a width between 0 . 2 mm and 1 mm inclusive , measured parallel to the first direction .

[0021] Advantageously, the first gap and the second gap allow to trans fer a magnetic flux such as the leakage flux from the base or the top to the center leg . Furthermore , by the first and second gap di f ferent contrasts and expansions of the first and second materials can be balanced .

[0022] The inductive component described here , which is in particular a coupled inductor, is based on the following technical considerations . Commonly known coupled inductors typically comprise a leakage magnetic flux path mainly along the top and the base and shared legs . Therefore , a leakage flux of the coupled inductors is not suf ficiently balanced, and a comparably thick wall of the top and the base is needed to achieve a suf ficient application-dependent performance .

[0023] The inductive component described here makes use of the idea of providing a center leg that comprises a second material di f ferent from the first material of the winding legs or the core . The core is in particular formed by the base , the top and the winding legs . The second material is adapted such that it comprises a higher magnetic flux density than the first material . It is therefore possible to improve the leakage magnetic flux conduction path for the leakage inductance , i . e . the leakage flux of the inductive component . As a result , a thickness of the center leg can be reduced . For example , i f the magnetic flux density of the second material is approximately twice the magnetic flux density of the first material, a thickness of the center leg can be approximately halved, compared to a case where the center leg and the winding leg comprises the same material such as the first material.

[0024] Furthermore, it is possible to adjust the leakage inductance by, for example, adapting the second material or spatial dimensions of the center leg. Moreover, the leakage inductance can be adjusted by the first and second gaps. Thus, the leakage inductance can be adapted to specific applications .

[0025] According to at least one embodiment, the base and at least a part of each winding leg are formed in one piece. Preferably, also the top and at least a part of each winding leg are formed in one piece. "Formed in one piece" in particular means that the base and / or the top and the winding legs are made of the same material, i.e. the first material, and are, for example, formed in a common production process. In particular, the base, the top and the winding legs form a core of the inductive component.

[0026] According to a at least one embodiment, a third gap is provided in each of the winding legs. Preferably, the third gap is a vertical gap. This means in particular that the third gap is provided along the first direction.

[0027] Preferably, the third gap is smaller than a total of the first and second gap. In particular, the third gap has a smaller width than sum of the widths of the first and second gap. For example, the third gap has a width of about 0.2 mm, measured parallel to the first direction. It is in particular possible that the third gap is smaller than the first and / or the second gap. In particular, the third gap has a smaller width than the first and / or second gap. For example, the third gap has a width of about 0.2 mm, measured parallel to the first direction.

[0028] By the third gap, the mutual inductance of the inductive component can be mainly adjusted.

[0029] According to at least one embodiment, the first gap and the second gap have identical widths or essentially identical widths. This means in particular that the widths are identical within a manufacturing tolerance. The width is in particular measured along the first direction. The width is, for example, between 0.2 mm and 1 mm inclusive. For example, the width is 0.6 mm or 0.65 mm.

[0030] According to at least one embodiment, the inductive component comprises N winding legs, wherein N is a natural number greater than 2. Preferably, the inductive component further M center legs, each positioned between adjacent winding legs. In particular, M is a natural number. If N is an even number, M is at least (N / 2)-l and at most N-l. Alternatively, if N is an odd number, M is at least (N+l) / 2-l and at most N-l. In other words, M is in particular a natural number between ceil (N / 2)-l to N-l, wherein ceil is the ceiling function. In the present embodiment, the inductive component is in particular an N-phase coupled inductor.

[0031] According to at least one preferred embodiment, the inductive component comprises up to two side legs. The side legs are arranged between the base and the top in the first direction. In particular, a main extension direction of the side legs is parallel to main extension directions of the winding legs and / or the center leg.

[0032] Preferably, the M center legs are positioned such that each of the N winding legs is adjacent to at least one of the M center legs or one optional side leg.

[0033] In particular, each side leg comprises a third material having a third magnetic flux density larger than the first magnetic flux density.

[0034] In particular, if the inductive component comprises two side legs, the winding legs are positioned between the side legs.

[0035] Preferably, a fourth gap is provided between each side leg and the base. Further preferably, a fifth gap is provided between each side leg and the top. The fourth and fifth gaps preferably are each vertical gaps. This means in particular that the fourth and fifth gaps are each provided along the first direction. For example, the fourth and fifth gaps each have a width between 0.2 mm and 2 mm inclusive, measured parallel to the first direction.

[0036] Advantageously, the fourth gap and the fifth gap allow to transfer a magnetic flux such as the leakage flux from the base or the top to the side leg. Furthermore, by the fourth and fifth gaps different contrasts and expansions of the first and third materials can be balanced. Moreover, the leakage inductance can be further adjusted by the fourth and fifth gaps.

[0037] For example, the third material is similar or identical to the second material, and the third magnetic flux density is similar or identical or essentially identical to the second magnetic flux density .

[0038] By providing the side legs it is advantageously possible to balance the leakage flux, i . e . the leakage inductance associated with a coil of a winding leg, since the leakage flux can, in particular, form two closed loops . One of the closed loops runs through the winding leg, the top, a side leg, the base , and back to the winding leg . The other closed loop runs through the winding leg, the top, the center leg and the base back to the winding leg . Hence , improved balancing of the leakage flux in the base and the top is possible . Therefore , thicknesses of the base and top can be reduced . For example , the thicknesses of the base and the top can each be reduced by approximately a factor of up to 2 , compared to commonly known coupled inductors . Thus , the spatial dimensions of the inductive component can be reduced .

[0039] According to at least one embodiment , the fourth gap and the fi fth gap are vertical gaps extending along the first direction . Furthermore , a sixth gap and a seventh gap are provided between the base and each side leg, and between the top and each side leg, respectively . The sixth and seventh gaps are hori zontal gaps extending along the second direction . This means that , in a lateral direction parallel to the first direction, the side legs protrude from the base and the top .

[0040] According to an alternative embodiment , the side legs are flush with the base and the top in lateral directions , i . e . directions parallel to the main extension plane of the base and / or the top . According to another embodiment , the fourth gap has the same width as the first and / or the second gap or is bigger than the first and / or second gap . Alternatively or additionally, the fi fth gap has the same width as the first and / or the second gap or is bigger than the first and / or second gap . Here and in the following, the widths of the fourth and fi fth gaps are measured in particular along the first direction . The fourth gap and / or the fi fth gap thus may have a width between 0 . 2 mm and 1 mm inclusive .

[0041] Preferably, the fourth gap has the same width as the fi fth gap .

[0042] According to a preferred embodiment , a total cross-sectional area of all center legs is less than hal f a total cross- sectional area of all winding legs . A sectional plane corresponding to the cross-sectional area is , for example , parallel to the main extension direction of the base and / or the top . The total cross-sectional area of all center legs is in particular a sum of the cross-sectional areas of all center legs . I f , for example , only one center leg is present , the total cross-sectional area is in particular the cross- sectional area of the one center leg . The total cross- sectional area of all winding legs is in particular a sum of the cross-sectional areas of all winding legs .

[0043] According to at least one embodiment , the inductive component further comprises at least two coils . Each of the coils is wound around one winding leg . Preferably, all coils are identical . " Identical" means here in particular that all coils may comprise the same material and / or the same number of windings . For example , the coils comprise copper . For example , the number of windings of each coil is between 1 and 10 , inclusive .

[0044] During operation of the inductive component , the coils are supplied with current . Since the coils are wound, from either base to top, around the winding legs , which are part of the core , the coils are in particular coupled to one another . Thus , the inductive component is in particular a coupled inductor .

[0045] By providing identical coils on the winding legs , the same direct current resistance ( DCR) and the same current direction can be established in each of the coils . Therefore , a relatively balanced current can be achieved on each winding leg .

[0046] According to at least one embodiment , main extension planes and / or main extension directions of the winding legs , the center leg and the side legs are parallel to one another .

[0047] According to at least one embodiment , a cross-sectional area of each side leg is smaller than a cross-sectional area of the center leg .

[0048] For example , the inductive component comprises two winding legs and one central leg . The inductive component may have a height , measured parallel to the first direction, of about 11 mm, for example . Additionally, the inductive component may have a length, measured parallel to the second direction, of about 25 mm, for example . Furthermore , the inductive component may have a depth, measured parallel to a direction perpendicular to the first and second directions , of about 14 mm . According to at least one embodiment, a total cross-sectional area of all side legs and center legs, or the center leg, is less than half a cross-sectional area of all winding legs. The total cross-sectional area of all side legs and center legs is in particular a sum of the cross-sectional areas of all side legs and center legs. The total cross-sectional area of all winding legs is in particular a sum of the cross- sectional areas of all winding legs.

[0049] According to at least one embodiment, each winding leg is directly adjacent to at least one center leg or at least one side leg. "Directly adjacent" in particular means that no other leg, i.e. no other winding leg is positioned between the adjacent center leg / side leg. Advantageously, by such a configuration for each leakage flux emerging from each of the coils during operation a leakage magnetic flux conduction path is provided by the adjacent center leg or side leg. Thus, the leakage inductance can be efficiently adjusted.

[0050] According to a preferred embodiment, the inductive component comprises two winding legs, at least one center leg positioned between the winding legs and up to two side legs. The winding legs are in particular positioned between the side legs. In this case, the inductive component is in particular a 2-phase coupled inductor.

[0051] According to another preferred embodiment, the inductive component comprises four winding legs, at least one center leg, positioned between two of the winding legs, and two side legs. The winding legs are positioned between the side legs. In this case, the inductive component is in particular a 4- phase coupled inductor. It is preferably possible that the inductive component comprises a center leg between each pair of adj acent winding legs .

[0052] According to at least one embodiment of the inductive component , the second material comprises a soft magnetic composite . For example , the second material comprises a soft magnetic composite ( SMC ) paste . It is possible , that the second material is arranged in an intermediate space between two winding legs . For example , the second material fills the intermediate space at least partially . Advantageously, it may be possible to reduce the si ze of the inductive component by using a soft magnetic composite for the second material , while preferably achieving similar performance when using a sintered material .

[0053] It is alternatively possible that the second material comprises a sintered material . This means in particular, the at least one center leg comprises a sintered center leg . For example , the second material is based on iron . This means in particular, that the second material comprises an iron material system . For example , the second material is an iron powder .

[0054] Further advantages and advantageous embodiments and further developments of the inductive component described herein will become apparent from the following exemplary embodiments shown in connection with schematic drawings . Identical elements , elements of the same kind or elements having the same ef fect are provided with the same reference signs in the figures . The figures and the proportions of the elements shown in the figures are not to be regarded as true to scale . Rather, individual elements may be shown exaggeratedly large for better representability and / or for better comprehensibility .

[0055] In the figures :

[0056] Figure 1 shows an inductive component described herein according to a first exemplary embodiment in a schematic front view;

[0057] Figure 2 shows an inductive component described herein according to a second exemplary embodiment in a schematic front view;

[0058] Figure 3 shows an inductive component described herein according to a third exemplary embodiment in a schematic perspective view;

[0059] Figures 4 and 5 shows an inductive component described herein according to a fourth exemplary embodiment in di f ferent views ;

[0060] Figure 6 shows inductive components described herein according to a fi fth exemplary embodiment in a schematic front view;

[0061] Figure 7 shows inductive components described herein according to a sixth exemplary embodiment in a schematic front view;

[0062] Figure 8 shows inductive components described herein according to a seventh exemplary embodiment in a schematic front view; Figure 9 shows an inductive component described herein according to an eighth exemplary embodiment in a schematic front view;

[0063] Figure 10 shows an inductive component described herein according to a ninth exemplary embodiment in a schematic front view;

[0064] Figure 11 illustrates the gaps present in the ninth exemplary embodiment ;

[0065] Figure 12 illustrates cross-sectional areas of elements of the inductive components according to the ninth exemplary embodiment ;

[0066] Figures 13 and 14 illustrates an inductive component described herein according to exemplary embodiments in a schematic perspective view .

[0067] The inductive component 1 according to the first exemplary embodiment as shown in Figure 1 comprises a base 2 and a top 3 . Winding legs 4 of the inductive component 1 are connected to the base 2 and the top 3 . The winding legs 4 are arranged between the base 2 and the top 3 . In particular, the winding legs 4 are arranged between the base 2 and the top 3 in a first direction 100 . The first direction 100 is perpendicular to a main extension plane of the base 2 and the top 3 . The main extension plane of the base 2 is parallel to the main extension plane of the top 3 . A main extension plane of the winding legs 4 is perpendicular to the main extension plane of the base 2 . On each of the winding legs 4 a coil 40 is arranged . In the present exemplary embodiment , each of the coils 40 comprises four windings . The coils 40 preferably comprise copper . The windings may be flat-type windings that in particular may follow a contour of the winding legs .

[0068] The inductive component 1 in particular forms a coupled inductor, wherein the base 2 , the top 3 and the winding legs 4 form a core of the coupled inductor . Via the core the coils 40 are magnetically coupled .

[0069] The inductive component 1 comprises a center leg 5 . The center leg 5 is positioned between the winding legs 4 . In particular, the center leg 5 is positioned between the winding legs 4 in a second direction 200 . The second direction 200 is perpendicular to the first direction 100 .

[0070] The core formed by the base 2 , the top 3 and the winding legs 4 comprises a first material . The first material comprises a ferrite . The center leg 5 comprises a second material . The second material comprises an iron powder . The first material has a first magnetic flux density, which is lower than a second magnetic flux density of the second material .

[0071] During operation of the inductive component , currents are applied to the coils 40 from either the top 3 to the base 2 . Thereby, the coils 40 are magnetically coupled via the core .

[0072] Furthermore , a leakage flux is established that mainly runs through the center leg 5 . The leakage flux determines a leakage inductance of the inductive component 1 . Since the center leg 5 has a higher magnetic flux density than the core , the leakage inductance can be ef ficiently balanced and a geometrical dimension of the center leg 5 along the second direction 200 can be reduced. Thus, spatial dimensions of the inductive component 1 can be reduced compared to commonly known coupled inductors.

[0073] At the same time, a similar performance can be achieved with the inductive component 1 as with commonly known coupled inductors. Thus, a power density can be increased.

[0074] Between the center leg 5 and the base 2, a first gap 6 is provided. Between the center leg 5 and the top 3 a second gap 7 is provided. The first gap 6 and the second gap 7 are each vertical gaps along the first direction 100. A width of each of the gaps 6, 7 is between 0.2 mm and 2 mm inclusive, for example .

[0075] By the first and second gaps 6, 7 it is advantageously possible to adjust the leakage inductance. Furthermore, it is possible to efficiently transfer magnetic flux from the core to the center leg 5.

[0076] In contrast to the first exemplary embodiment, the inductive component 1 according to the second exemplary embodiment, shown in Figure 2, comprises side legs 9. The side legs 9 comprise a third material that is similar to the second material. Thus, a third magnetic flux density of the third material is similar to the second magnetic flux density. Hence, the third magnetic flux density is higher than the first magnetic flux density.

[0077] By providing the side legs 9 it is advantageously possible to balance the leakage flux on the base 2 and the top 3 since the leakage flux can form two closed loops (cf . Figure 10) . Hence, a thickness of the base 2 and top 3 can be reduced compared to commonly known coupled inductors. For example, the thicknesses of the base 2 and the top 3 can each be reduced by approximately a factor of up to 2. Thus, the spatial dimensions of the inductive component can be reduced.

[0078] Between each of the side legs 9 and the base 2, a fourth gap 10 is provided. Between each of the side legs 9 and the top 3 a fifth gap 11 is provided. The fourth gap 10 and the fifth gap 11 are each vertical gaps along the first direction 100. A width of each of the gaps 10, 11 is, for example, between 0.2 mm and 2 mm inclusive. In particular the width of the fourth and fifth gaps 10, 11 is the same as the width of the first and second gap 6, 7.

[0079] In other aspects the inductive component 1 according to the second exemplary embodiment may comprise similar features, technical effects and benefits as the inductive component 1 according to the first exemplary embodiment.

[0080] In contrast to the second exemplary embodiment, the inductive component 1 according to the third exemplary embodiment illustrated in Figure 3, the windings of the coils 40 are circular. Hence, the coils 40 may be cylinder coils. Thus, an intermediate space may be present between the coils 40 and the winding legs 4 associated to the coils 40.

[0081] In other aspects the inductive component 1 according to the third exemplary embodiment may comprise similar features, technical effects and benefits as the inductive component 1 according to the second exemplary embodiment. In contrast to the second exemplary embodiment , the inductive component 1 according to the fourth exemplary embodiment comprises four winding legs 4 , on which four coils 40 are arranged, as shown in Figures 4 and 5 . The inductive component 1 according to Figure 4 is a 4-phase coupled inductor, wherein the inductive components 1 according to Figures 1 to 3 are 2-phase coupled inductors .

[0082] Between each pair of adj acent winding legs 4 , a center leg 5 is positioned . Each center leg 5 comprises the same features , in particular the same second material and thickness . Furthermore , the first gaps 6 between each center leg 5 and the base 2 as well as the second gaps 7 between each center leg 5 and the top 3 are similar . By the center legs 5 leakage magnetic flux conduction paths for the coils 40 are provided .

[0083] In other aspects the inductive component 1 according to the fourth exemplary embodiment may comprise similar features , technical ef fects and benefits as the inductive component 1 according to the second exemplary embodiment .

[0084] Figures 6 to 8 illustrate di f ferent possibilities for positioning the center legs 5 and the side legs 9 .

[0085] Figure 6 illustrates that in contrast to Figures 4 and 5 , only one center leg 5 is provided between a certain pair of winding legs 4 .

[0086] Figures 7 illustrates that in contrast to Figures 4 and 5 , no side legs 9 are provided . Figures 8 illustrates that in contrast to Figures 4 and 5 , no side legs 9 are provided and that two center legs 5 are provided .

[0087] Figures 6 to 8 have in common that each winding leg 4 and hence each coil 40 is adj acent to at least one center leg 5 or side leg 9 . As a result , for each leakage flux emerging from each of the coils 40 during operation a leakage magnetic flux conduction path is provided by the adj acent center leg 5 or side leg 9 . Thus , the leakage inductance can be ef ficiently adj usted and balanced or at least partially balanced .

[0088] Figure 9 shows an inductive component 1 described herein according to an eighth exemplary embodiment . In contrast to the inductive component 1 shown in Figure 4 , the inductive component according to Figure 10 comprises three winding legs 4 , around each a coil 40 is wound . Between each winding leg 4 a central leg 5 is positioned . Furthermore , the inductance component 1 according to Figure 10 comprises side legs 9 , between which, in the first direction 100 the winding legs 4 and the center legs 5 are arranged .

[0089] In other aspects the inductive component 1 according to the eighth exemplary embodiment may comprise similar features , technical ef fects and benefits as the inductive component 1 according to the fourth exemplary embodiment .

[0090] Figure 11 shows an inductive component 1 according to a ninth exemplary embodiment . The inductive component 1 according to the ninth exemplary embodiment essentially comprises the same features as the inductive component 1 according to Figure 2 , wherein in contrast to Figure 2 , the side legs 9 are not flush with the base 2 and the top 3 in the second direction 200 .

[0091] A sixth gap 12 is provided between each of the side legs 9 and the base 2 . Furthermore , a seventh gap 13 is provided between each of the side legs 9 and the top 3 . The sixth gap 12 and the seventh gap 13 are hori zontal gaps along the second direction 200 .

[0092] Furthermore , Figure 10 illustrates a distribution of the leakage flux 15 in the inductive component 1 . The leakage flux 15 comprises two loops per winding leg 4 . Each of the loops extends from the corresponding winding leg 4 to the top 3 , further to a side leg 9 or the center leg 4 , further to the base 2 and back to the winding leg 4 , closing the loop . Since two loops can be established in the inductive component 1 for each winding leg 4 , the leakage inductance can be balanced ef ficiently .

[0093] A similar leakage flux distribution can be present in all other exemplary embodiments , in particular all other exemplary embodiments comprising side legs 9 . Furthermore , the leakage flux may be established in a corresponding way in all exemplary embodiment with a plurality of center legs 5 .

[0094] Figure 11 illustrates the vertical gaps present in the inductive component 1 according to the ninth exemplary embodiment . In Figure 11 the coils 40 are not shown for sake of illustration .

[0095] The winding legs 4 comprise a third gap 8 , which is a vertical gap along the first direction 100 . The third gap 8 has a smaller width than the first , second, fourth and fi fth gaps 6 , 7 , 10 , 11 . For example , the third gap 8 has a width of about 0 . 1 mm .

[0096] By the third gap 8 the mutual inductance can be further adj usted .

[0097] Such third gaps 8 can be present in all other exemplary embodiments without restricting other features of these exemplary embodiments .

[0098] Figure 12 illustrates the dimensions of the winding legs 4 , the center leg 5 and the side legs 9 . Figure 12 shows a sectional view of Figure 11 along the line A-A parallel to the main extension direction of the top 3 .

[0099] Each of the winding legs 4 comprises a width 20 . Each of the center leg 5 and the side legs 9 comprises a same width 24 . The widths 20 , 24 are measured along a direction perpendicular to the first direction 100 and the second direction 200 . The width 4 of the winding legs 4 is about 14 mm, for example . Preferably, the width 24 of the center leg 5 and the side legs 9 is bigger than the width 20 of the winding legs 4 .

[0100] The center leg 5 comprises a thickness 22 that is less than hal f of a thickness 21 of the winding legs 4 . Thus , a cross- sectional area of the center leg 5 is less than hal f of a cross-sectional area of each of the winding legs 4 .

[0101] The side legs 9 each comprise a thickness 23 that is less than the thickness 22 of the center leg 5 . A cross-sectional area of each side leg 9 is less than the cross-sectional area of the center leg 5 . A total cross-sectional area of all center legs 5 and side legs 9, that is, the sum of the cross-sectional areas of the center legs 5 and side legs 9, is less than half of the total cross-sectional area of all winding legs 4, that is, the sum of the cross-sectional areas of the winding legs 4.

[0102] For example, the thickness 21 of each winding leg 4 is 6 mm, the thickness 22 of the center leg 5 is 3 mm and the thickness 23 of the side leg 9 is 1.5 mm.

[0103] It is possible that the winding legs 4, center legs 5 and side legs 9 of all other exemplary embodiments have a similar relation among each other and / or similar dimensions without limiting other features of these exemplary embodiments.

[0104] For example, the inductive component 1 according to the first, second and / or seventh exemplary embodiments has a height, measured parallel to the first direction 100, of about 11 mm. Additionally, the inductive component 1 may have a length, measured parallel to the second direction 200, of about 25 mm, for example. Furthermore, the inductive component 1 may have a depth, measured parallel to a direction perpendicular to the first direction 100 and second direction 200, of about 14 mm.

[0105] A thickness of the base 2 and a thickness of the top 3 may be the same. The thickness of the base 2 and the top 3 is, for example, below 2 mm, for example 1.6 mm. The thickness of the base 2 and the top 3 is measured in the first direction 100. Figure 13 shows the inductive component 1 described herein in a schematic perspective view according to a further exemplary embodiment .

[0106] The inductive component 1 according to Figure 13 comprises a center leg 5 comprising a second material . The second material in the present exemplary embodiment comprises a sintered material . For example , the center leg 5 is a sintered center leg 5 . For example , the second material is based on iron . This means in particular, that the second material comprises an iron material system . For example , the second material is an iron powder .

[0107] It is possible that the second material of all other exemplary embodiments comprises a sintered material as the second material in the present exemplary embodiment without further restricting other features of these exemplary embodiments .

[0108] In other aspects the inductive component 1 according to the present exemplary embodiment may comprise similar features , technical ef fects and benefits as the inductive component 1 according to the first exemplary embodiment .

[0109] The exemplary embodiment shown in Figure 14 di f fers from the exemplary embodiment of Figure 13 in that the second material of the center leg 5 comprises a soft magnetic composite , SMC for short . For example , the second material comprises a soft magnetic composite ( SMC ) paste . The second material is arranged in an intermediate space between two winding legs 4 and between the coils 40 . For example , the second material fills the intermediate space at least partially . Advantageously, it may be possible to reduce the si ze of the inductive component 1 by using a soft magnetic composite for the second material , while preferably achieving similar performance when using a sintered material .

[0110] It is possible that the second material of all other exemplary embodiments comprises a soft magnetic composite as the second material in the present exemplary embodiment without further restricting other features of these exemplary embodiments .

[0111] In other aspects the inductive component 1 according to the present exemplary embodiment may comprise similar features , technical ef fects and benefits as the inductive component 1 according to the first exemplary embodiment .

[0112] The invention is not restricted to the exemplary embodiments by the description on the basis of said exemplary embodiments . Rather, the invention encompasses any new feature and also any combination of features , which in particular comprises any combination of features in the patent claims and any combination of features in the exemplary embodiments , even i f this feature or this combination itsel f is not explicitly speci fied in the patent claims or exemplary embodiments .

[0113] References

[0114] 1 inductive component

[0115] 2 base

[0116] 3 top

[0117] 4 winding leg

[0118] 5 center leg

[0119] 6 first gap

[0120] 7 second gap

[0121] 8 third gap

[0122] 9 side leg

[0123] 10 fourth gap

[0124] 11 fi fth gap

[0125] 12 sixth gap

[0126] 13 seventh gap

[0127] 15 leakage flux

[0128] 20 width of winding leg

[0129] 21 thickness of winding leg

[0130] 22 thickness of center leg

[0131] 23 thickness of side leg

[0132] 24 width of center leg, side leg

[0133] 40 coil

[0134] 100 first direction

[0135] 200 second direction

[0136] A-A section line

Claims

Claims1. Inductive component (1) comprising a base (2) and a top (3) , at least two winding legs (4) comprising a first material, and each being connected to and arranged between the base (2) and the top (3) , and at least one center leg (5) comprising a second material and being positioned between the winding legs (4) , wherein a first gap (6) is provided between the center leg (5) and the base ( 2 ) , a second gap (7) is provided between the center leg (5) and the top ( 3 ) , and the first material has a first flux density, which is lower than a second flux density of the second material.

2. Inductive component (1) according to claim 1, wherein the base (2) and at least a part of each winding leg (4) are formed in one piece, and the top (3) and at least a part of each winding leg (4) are formed in one piece.

3. Inductive component (1) according to one of the preceding claims, wherein a third gap (8) is provided in each of the winding legs (4) .

4. Inductive component (1) according to claim 3, wherein the third gap (8) is smaller than a total of the first and second gap (6, 7 ) .

5. Inductive component (1) according to one of the preceding claims, wherein the first gap (6) and the second gap (7) have essentially identical widths.

6. Inductive component (1) according to one of the preceding claims, further comprising at least two coils (40) , wherein each coil (40) is wound around one winding leg (4) , and all coils (40) are identical.

7. Inductive component (1) according to one of the preceding claims, comprising N winding legs (4) and M center legs (5) , each positioned between two adjacent winding legs (4) , wherein N is a natural number greater than 2, wherein M is a natural number and if N is an even number, M is at least (N / 2)-l and at most N-l, or if N is an odd number, M is at least (N+l) / 2-l and at most N-l.

8. Inductive component (1) according to one of the preceding claims, further comprising up to two side legs (9) , wherein each side leg (9) comprises a third material having a third magnetic flux density larger than the first magnetic flux density.

9. Inductive component (1) according to claim 8, wherein the inductive component (1) comprises two side legs (9) and the winding legs (4) are positioned between the side legs (9) .

10. Inductive component (1) according to one of the preceding claims, further comprising up to two side legs (9) , (9) , a fourth gap (10) is provided between each side leg (9) and the base ( 2 ) , a fifth gap (11) is provided between each side leg (9) and the top ( 3 ) , andeach side leg (9) comprises a third material having a third magnetic flux density larger than the first magnetic flux density .

11. Inductive component (1) according to one of claims 8 to10, wherein the third material is similar to the second material, and the third magnetic flux density is similar to the second magnetic flux density.

12. Inductive component (1) according to claim 10, wherein the fourth gap (10) and the fifth gap (11) extend along a first direction (100) perpendicular to a main extension plane of the base ( 2 ) , a sixth gap (12) along a second direction (200) , perpendicular to the first direction (200) , is provided between the base (2) and each side leg (9) , and a seventh gap (13) along the second direction (200) is provided between the top (3) and each side leg (9) .

13. Inductive component (1) according to one of claims 8 to12, wherein the side legs (9) are flush with the base (2) and the top (3) in directions parallel to a main extension plane of the base ( 2 ) .

14. Inductive component (1) according to one of claims 10 or 12, wherein the fourth gap (10) has the same width as the first and / or second gap (6, 7) or is bigger than the first and / or second gap (6, 7) , and the fifth gap (11) has the same width as the first and / or second gap (6, 7) or is bigger than the first and / or second gap (6, 7 ) .

15. Inductive component (1) according to one of claims 10 or12 or 14, wherein the fourth gap (10) has the same width as the fifth gap (11) .

16. Inductive component (1) according to one of claims 8 to15, wherein main extension planes of the winding legs (4) , the center leg (5) and the side legs (9) are parallel to one another .

17. Inductive component (1) according to one of claims 8 to16, wherein a cross-sectional area of each side leg (9) is smaller than a cross-sectional area of the center leg (5) .

18. Inductive component (1) according to one of claims 8 to 17, wherein a total cross-sectional area of all side legs (9) and center legs (5) is less than half a cross-sectional area of all winding legs (4) .

19. Inductive component (1) according to one of the preceding claims, wherein each winding leg (4) is directly adjacent to at least one center leg (5) or at least one side leg ( 9 ) .

20. Inductive component (1) according to one of the preceding claims, wherein the second material comprises a soft magnetic composite.

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