Inductive component

Abstract

An inductive component (1) is specified which comprises a core element (2) and at least two wires (31, 32) twisted together and wound around the core element (2) in at least two winding blocks (41, 42). Each winding block (41, 42) has an inner winding section (411, 421) in which at least one turn of the wires (31, 32) is directly wound around the core element (2) and an outer winding section (412, 422) in which at least one turn of the wires (31, 32) is directly wound around the corresponding inner winding section (411, 421). The outer winding section (412, 422) of one winding block (41, 42) is connected to the inner winding section (411, 421) of a directly adjacent winding block (41, 42).

Description

[0001] P2024, 1107 WO N November 12, 2025

[0002] 1

[0003] Description

[0004] Inductive component

[0005] The present disclosure relates to an inductive component .

[0006] Inductive components such as common mode chokes are used in a variety of applications for signal filtering. Usually, in applications where several bus systems operate in parallel, individual common mode chokes have to be provided for each bus system. For example, in modern implementations automotive ethernet high-speed bus systems may reach up to 25 gigabits per second. On the other hand, low-speed bus systems are commonly used for low-speed communications such as sensors or actuators . For example, low-speed bus systems show a transfer rate of 10 megabits per second, mid-speed bus systems show a transfer rate of 100 megabits per second, and high-speed bus systems show a transfer rate of 1000 megabits per second. Typically, common mode chokes are provided to cover a wide frequency range but are limited to either the high-speed bus system or mid-speed bus systems or low-speed bus system. Such common mode chokes, for example, maintain international standards like either IEEE 802. 3cg or IEEE 802. 3bp . However, the need for an individual common choke mode for every bus system particularly limits the consolidation of semiconductor designs to cover different speed levels .

[0007] Thus, one obj ect to be achieved, inter alia, is to specify an improved inductive component that is in particular usable as a common mode choke for low-speed bus systems up to highspeed bus systems . P2024, 1107 WO N November 12, 2025

[0008] 2

[0009] 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 .

[0010] An inductive component is specified which comprises a core element and at least two wires twisted together and wound around the core element in at least two winding blocks . Each winding block has an inner winding section in which at least one turn of the wires is directly wound around the core element and an outer winding section in which at least one turn of the wires is directly wound around the corresponding inner winding section. The outer winding section of one winding block is connected to the inner winding section of a directly adj acent winding block.

[0011] "Directly wound" in particular means that no further element is located between the wires and the element around which the turns are wound. In particular, the turns are in direct contact to the element around which the turns are wound. For example, the turns of the inner winding section are in direct contact with the core element and the turns of the outer winding section are in direct contact with the turns of the inner winding section.

[0012] In particular, during manufacturing of the inductive component, the wires are twisted during a winding procedure . For example, in each winding block, the twisted wires are first wound around the core in the inner winding section. Subsequently, the twisted wires are wound around the inner winding section in the outer winding section. Next, the wires may be guided back to the core element so as to directly adjoin the core element . Next, in particular, the following P2024, 1107 WO N November 12, 2025

[0013] 3

[0014] winding block is produced by winding the twisted wires around the core in the inner winding section of the following winding block. Thus, the inductive component comprises a plurality of winding blocks . In particular, the turns of the outer winding section of a specific winding block are connected to the turns of the following winding block as the wires are guided from the outer winding section of the specific winding block to the core and thus to the inner winding section of the following winding block.

[0015] For example, at least two or at least three turns are arranged in the inner winding section. In particular, the number of turns in the outer winding section is equal to or lower than the number of turns in the inner winding section. For example, the outer winding section comprises at least two or at least three turns .

[0016] The wires each comprise, for example, a conductive core and an insulating coating. For example, the conductive core comprises a metal such as copper .

[0017] The core element is preferably formed with a magnetic material . In particular, the material of the core element has a high permeability. For example, the core element comprises a ferrite such as NiZn.

[0018] In a specific example, the inductive component comprises nine winding blocks .

[0019] According to a preferred embodiment of the inductive component, the wires are wound around the core element in a winding region of the core element . A length of the winding region is preferably at least three times bigger than a width P2024, 1107 WO N November 12, 2025

[0020] 4

[0021] of the winding region. In particular, the winding region has an elongated shape . The length of the winding region is measured, in particular along a longitudinal direction. In particular, the longitudinal direction is parallel to a main extension direction of the core element . The longitudinal direction may be parallel to a winding axe around which the wires are wound. The width of the winding region is measured, in particular, in a direction perpendicular to the longitudinal direction.

[0022] For example, a fraction between the cross-sectional area of the winding region and the length of the winding region is at most 0.3 mm. A sectional plane of the cross-sectional area is in particular perpendicular to the longitudinal direction.

[0023] In the specific example mentioned above, the winding region comprises a length of 3.15 mm and the cross-sectional area is 0.9 mm times 0.9 mm. In particular, the width of the winding region is 0.9 mm. Furthermore, the depth of the winding region, measured perpendicular to the length and the width, is in particular 0.9 mm.

[0024] According to a further preferred embodiment of the inductive component, each of the wires comprises a conductive core and an insulating coating. The thickness of the insulating coating is in particular half a diameter of the core .

[0025] For example, the conductive core comprises a metal such as copper and the insulating coating comprises a polymer .

[0026] The inductive component described here is based on the following technical considerations . In order to provide a common mode choke which can be used for a plurality of bus P2024, 1107 WO N November 12, 2025

[0027] 5

[0028] systems that differ in transfer rate, for example the low-speed bus system, transfer rate 10 megabits per second; the mid-speed bus system, transfer rate 100 megabits per second; and the high-speed bus system, transfer rate 1000 megabits per second, and which fulfills the requirements of the relevant international standards, the following properties, inter alia, are required for the inductive component at all data transfer rates . The inductive component has a comparably high common mode rej ection, a low parasitic capacitance, a low mode conversion and matching return losses and insertion losses . Furthermore, an impedance matches a predefined value of, for example, 100 Q. Applications that require such a common mode choke capable of multi speed wideband filtering are, for example, automotive ethernet applications .

[0029] The inductive component described herein makes use of the idea of twisting the wires and winding the twisted wires around the core in winding blocks . By this winding technique, a comparably good symmetry of the inductive component when used as a common mode choke can be achieved. In other words, a low mode conversion can be achieved. That is, a comparably low portion of the differential mode signal passing the choke is transferred in a common mode signal . Thus, with a low mode conversion, the quality of the common mode choke is increased .

[0030] A low parasitic capacitance can be achieved by winding the wires in winding blocks . In particular, a distance between the wires, positioning of the wires and a material of the wire determine the parasitic capacitance . If, for example, the wires comprise an insulating coating, the parasitic capacitance is in particular direct proportional to a dielectric constant s of the insulating coating and indirect P2024, 1107 WO N November 12, 2025

[0031] 6

[0032] proportional to the distance between each wire . By arranging the wires in winding blocks, the distance between the windings assigned to different winding blocks can be on average increased, since windings in different winding blocks comprise a certain distance from each other that is advantageously bigger than a distance in a winding structure without winding blocks . Thus, the parasitic capacitance can be reduced.

[0033] Moreover, in order to achieve the requirements mentioned above, a relatively high inductance value of at least 200 pH is desired for the inductive component, in particular to fulfill requirements for the mid-speed bus system and the high-speed bus system. Commonly, such high inductance values can be achieved by increasing the number of turns of the wires wound around the core element . However, this typically increases the stray capacitance or parasitic capacitance of the inductive component . Since, the parasitic capacitance in particular has a direct influence on other properties of the inductive component such as return losses, insertion losses and common mode rej ection, adjusting the parasitic capacitance is necessary to fulfill the above-mentioned requirements .

[0034] Advantageously, by winding the wires in winding blocks around the core element, the parasitic capacitance can be influenced, and a low parasitic capacitance can be achieved as discussed above .

[0035] Furthermore, in the case that the inductive component comprises a winding region with an elongated shape, in particular in accordance with the preferred embodiment mentioned above, a coupling between the windings and the core P2024, 1107 WO N November 12, 2025

[0036] 7

[0037] can be increased, because more windings are spread in the winding region compared to comparably and commonly used common mode chokes . Moreover, the comparably small cross-sectional area allows for a comparably low DC resistance, which in particular results in relatively low return losses . Furthermore, since the cross-sectional area of the winding region is proportional to an impedance of the common mode rej ection, the elongated shape of the core element can allow requirements to be fulfilled with respect to common mode rej ection for a multi speed wideband filtering for applications comprising, for example, the low-speed bus system, the mid-speed bus system and the high-speed bus system.

[0038] In addition, the impedance of the inductive component can be adjusted by adjusting dimensions and materials of the wires . Furthermore, since the parasitic capacitance is, inter alia, determined by a distance between the wires, the parasitic capacitance can be further influenced by the dimensions and materials of the wires . In particular, the impedance of the inductive component is approximately given by the following equation :

[0039] r- / 2a

[0040] Z « 120 lVe In I — r

[0041] \ a

[0042] wherein a is a center-to-center distance between adj acent wires, d is an inner wire diameter, and s is the dielectric constant of a material between the wires, for example an insulating coating.

[0043] In the case that the wires of the inductive component comprise an insulating coating, which has a thickness, i . e . (a-d) / 2, that is half of the diameter of the conductive core, i . e . d, in particular in accordance with the further preferred embodiment mentioned above, the impedance of the P2024, 1107 WO N November 12, 2025

[0044] 8

[0045] inductive component can be adjusted as required. For example, the impedance can be adjusted to have 100 Q.

[0046] In particular with the inductive component described herein, a common mode choke with multi speed filter characteristics having a high common mode rej ection, a low parasitic capacitance, a low mode conversion and matching return losses and insertion losses can be achieved. Furthermore, a common mode choke fulfilling international standards like 10BASE-T1 ( IEEE 802. 3cg) up to 1000BASE-T1 ( IEEE802 . 3bp) can be provided in a single device .

[0047] According to at least one embodiment the inductive component comprises a magnetic shell that partially surrounds the core element in directions perpendicular to the main extension direction of the core element . For example, the magnetic shell covers the inductive component when seen in a top view and in side views . This means, in particular, that the magnetic shell may cover the inductive component on three sides . In particular, directions perpendicular to the main extension direction of the core element are directions perpendicular to the longitudinal direction.

[0048] For example, the magnetic shell comprises a magnetic material such as a ferrite .

[0049] Advantageously, the magnetic shell provides lateral magnetic shielding and mechanical protection to the wires in the winding region. Furthermore, stray inductance of the inductive component can be reduced, resulting in an increased overall inductance or mutual inductance of the inductive component . P2024, 1107 WO N November 12, 2025

[0050] 9

[0051] Preferably, the magnetic shell is formed in one piece and comprises a top portion and two side portions . The side portions extend perpendicular to the top portion, for example at two opposing sides of the top portion. Further preferably, at least one corner region at which the top portion adjoins the side portions is rounded. In a front view of the magnetic shell, the magnetic shell has a U-shape, for example . In particular, in a sectional view, where a sectional plane is perpendicular to the longitudinal direction, the magnetic shell has a U-shape .

[0052] The magnetic shell being formed in one piece means in particular that the top portion and the side portions are formed in one process step comprising the same material .

[0053] For example, the top portion merges into the side portions at the corner regions . In particular, rounded corner regions are free of a corner angle .

[0054] Advantageously, forming the magnetic shell with rounded corner regions increases the mechanical stability of the magnetic shell .

[0055] For example, the magnetic shell is attached to the core element by an adhesive . The adhesive is in particular applied to at least two flat surfaces of the magnetic shell facing the core element .

[0056] Gluing the magnetic shell to the core element on two sides in particular increases the mechanical stability of the connection between the core element and the magnetic shell . Furthermore, a gap between the two sides provided with the P2024, 1107 WO N November 12, 2025

[0057] 10

[0058] adhesive and the core element can be minimized to the thickness of the adhesive .

[0059] In general, it is advantageous if a gap between the core element and the magnetic shell is as small as possible to reduce the stray inductance of the inductive component .

[0060] In particular, the flat surfaces of the magnetic shell to which the adhesive is applied are grinded. Grinding the surfaces of the magnetic shell can advantageously improve a contact area between the core element and the magnetic shell . This allows for a higher inductance of the inductive component .

[0061] For example, the adhesive is applied to the top portion and a first side portion of the two side portions . Preferably, a surface of each of the top plate and the first side plate facing the core element is grinded.

[0062] Preferably, the adhesive comprises at least one magnetic filler . For example, the adhesive comprises ferrite particles or ferrite powder as fillers . Adding magnetic fillers to the adhesive allows for increasing the inductance of the inductive component .

[0063] According to at least one embodiment, the core element comprises two flange portions, between which the wires are wound around the core element in the winding region. For example, the flange portions confine the winding region in lateral direction.

[0064] Preferably, the flange portions comprise a bigger cross-sectional area than the winding region, wherein a sectional P2024, 1107 WO N November 12, 2025

[0065] 11

[0066] plane is perpendicular to the longitudinal direction. In particular, the flange portions each proj ect beyond the winding region in directions perpendicular to the longitudinal direction.

[0067] Further preferably, the flange portion and the winding region are formed in one piece and comprise the same material .

[0068] Each flange portion may comprise a top surface, a bottom surface, two side surfaces, and a front surface . The front surface is a surface of the flange portion that is opposite to a surface where the winding region is arranged. The bottom surface is a surface that faces away from the magnetic shell . The top surface is a surface that is opposite to the bottom surface . The side surfaces connect the top and bottom surface without being the front surface or the surface where the winding region is arranged.

[0069] According to at least one embodiment of the inductive component comprising a magnetic shell and a core element having flange regions, the magnetic shell is attached to the flange portions . In particular, in view of each of the flange portions, a gap between the core element and the magnetic shell is only present at a surface of the magnetic shell facing the core element that is free of the adhesive . In particular, the gap mentioned here is an air gap .

[0070] For example, if the adhesive is applied to the top portion and the first side portion of the magnetic shell, the gap is present between the core element, i . e . the flange portions and a second side portion of the two side portions of the magnetic shell . P2024, 1107 WO N November 12, 2025

[0071] 12

[0072] Thus, a total gap, i . e . a total air gap, between the magnetic shell and the core element can be comparably small . For example, the air gap between the magnetic shell and the core element is below 0.5 mm or below 0.4 mm or below 0.3 mm or below 0.1 mm or below 0.01 mm. Preferably, the gap is as small as possible . As a result, the stray inductance can be relatively small .

[0073] If corner regions of the magnetic shell facing the flange portions are rounded, the magnetic shell can advantageously be relatively easily mounted to flange portions comprising sharp edges .

[0074] According to at least one embodiment of the inductive component comprising a core element having flange portions, each of the flange portions comprises a recess through which the wires are guided from the winding region to connection terminals of the inductive component . For example, the recess is arranged in a center of each flange portion in a direction perpendicular to the longitudinal direction. The recess in particular penetrates the corresponding flange portion in the longitudinal direction.

[0075] For example, the recess is arranged at a bottom surface of each flange portion. The bottom surface is in particular a surface facing away from the magnetic shell . In a front view and / or a cross-sectional view of the flange portion, wherein the sectional plane is perpendicular to the longitudinal direction, the recess is arranged in the center of the bottom surface . The front view of the flange portion is in particular a view on a side of the flange portion that is opposite to a side where the winding region is arranged. P2024, 1107 WO N November 12, 2025

[0076] 13

[0077] For example, the connection terminals are part of a lead frame .

[0078] According to at least one embodiment of the inductive component, the core element is attached to a lead frame comprising connection terminals for the inductive component . For example, the lead frame is attached to flange portions of the core element at bottom surfaces and front surfaces of the flange portions . For example, the core element is electrically separated from the lead frame .

[0079] For example, the lead frame is attached to the flange portions at least partially using a glue . For example, the glue is electrically insulating. In case that the core element comprises ferrite, it is not necessarily required to use an electrically insulating glue .

[0080] For example, the inductive component can be electrically contacted via the connection terminals . During operation of the inductive component, a current, a voltage or a signal may be applied to the wires via the connection terminals . To achieve this, the wires are electrically conductively connected to the lead frame . For example, each connection terminal may comprise at least one connection surface, which can be externally electrically contacted. For example, the connection surfaces are configured to be connected to an electrical system or the like via a solder connection. This means in particular that the connection surfaces may be solder pads .

[0081] In particular, each connection terminal comprises fixation means for the wires . For example, each connection terminal may comprise a fixation flap and / or a welding region. The P2024, 1107 WO N November 12, 2025

[0082] 14

[0083] fixation flap is configured to fix a position of the corresponding wire at the connection terminal . The wire may be uncoated at the welding region and electrically and mechanically connected to the connection terminal by a welding connection. The welding connection is produced, for example, by laser welding.

[0084] According to at least one embodiment of the inductive component comprising a lead frame and a core element having flange portions, two of the connection terminals are associated with each flange portion. Referring to one certain flange portion, the two connection terminals associated with this flange portion are preferably arranged symmetrically with respect to the recess of the corresponding flange portion. For example, the distance between each of the connection terminals and the recess is essentially identical .

[0085] In particular, end sections of each wire are associated with one connection terminal . For example, a first connection terminal and a second connection terminal are arranged at a first flange portion. The first connection terminal is in particular connected to a first wire and the second connection terminal is in particular connected to a second wire . That is, a first end section of the first wire is associated with the first connection terminal and a second end section of the second wire is associated with the second connection terminal .

[0086] Furthermore, a third connection terminal and a fourth connection terminal may be arranged at a second flange portion opposite to the first flange portion. The third connection terminal may be connected to the first wire and the fourth terminal may be connected to the second wire . That P2024, 1107 WO N November 12, 2025

[0087] 15

[0088] is, a third end section of the first wire, opposite to the first end section, may be associated with the third connection terminal and a fourth end section of the second wire, opposite to the second end section, may be associated with the fourth connection terminal .

[0089] In particular, the first and second connection terminals are arranged at an input side of the inductive component and the third and fourth connection terminals are arranged at an output side of the inductive component . This means in particular that a signal to be filtered is applied to the inductive component via the first and second connection terminal, for example if the inductive component is used as a common mode choke .

[0090] According to at least one embodiment of an inductive component comprising connection terminals and a core element having flange portions, the path length of each wire between the recess and an associated connection terminal is essentially identical . In particular, this is achieved by arranging the connection terminals associated with a certain flange portion in a symmetric manner with respect to the corresponding recess .

[0091] According to at least one embodiment of an inductive component comprising connection terminals and a core element having flange portions, the wires are untwisted between the recess and associated connection terminals . This means in particular that the wires are only twisted in the winding region .

[0092] According to at least one embodiment, the core element comprises a rectangular cross-section with rounded corners . P2024, 1107 WO N November 12, 2025

[0093] 16

[0094] In particular, the winding region comprises a rectangular cross-section with rounded corners . For example, the crosssection has a contour of a square . In particular, the crosssection is determined along a sectional plane perpendicular to the longitudinal direction.

[0095] Damage to the wires can be prevented by rounded corners in the winding region.

[0096] It is possible that the flange portions of the core element comprise sharp corners and / or edges, for example in regions where the top surface and side surfaces or the top surface and the front surface merge .

[0097] Preferably, the recess in each flange portion comprises round corners and edges to reduce the risk of damaging the wires .

[0098] According to at least one embodiment, the inductive component is configured to be used as a common mode choke . In particular, the inductive component is configured as a common mode choke for multi-speed broadband filtering in applications comprising bus systems with different transfer rates such as the low-speed bus system, the mid-speed bus system and the high-speed bus system.

[0099] 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 effect are provided with the same reference signs in the figures . The figures and the proportions of the elements P2024, 1107 WO N November 12, 2025

[0100] 17

[0101] 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 .

[0102] In the figures :

[0103] Figures 1 and 2 show perspective views of an inductive component described here according to an exemplary embodiment ;

[0104] Figures 3 and 4 show perspective views of a core element of the inductive component according to the exemplary embodiment ;

[0105] Figure 5 shows a perspective view of a core element including connection terminals and a winding of the inductive component according to the exemplary embodiment ;

[0106] Figure 6 shows a view of a bottom side of the inductive component according to the exemplary embodiment;

[0107] Figure 7A illustrates a winding structure of the inductive component according to the exemplary embodiment;

[0108] Figure 7B illustrates parasitic capacitances between wires of the winding structure of Figure 7A;

[0109] Figure 8 illustrates a structure of wires of the inductive component according to the exemplary embodiment; P2024, 1107 WO N November 12, 2025

[0110] 18

[0111] Figures 9 and 10 show perspective views of a magnetic shell of the inductive component according to the exemplary embodiment;

[0112] Figure 11 shows a front view of the inductive component according to the exemplary embodiment;

[0113] Figure 12 shows a perspective view of a core element including connection terminals of the inductive component according to the exemplary embodiment;

[0114] Figure 13 is a diagram illustrating a comparison of the inductive component according to the exemplary embodiment with comparison examples with respect to return losses as a function of frequency;

[0115] Figure 14 is a diagram illustrating a comparison of the inductive component according to the exemplary embodiment with comparison examples with respect to insertion losses as a function of frequency;

[0116] Figure 15 is a diagram illustrating a comparison of the inductive component according to the exemplary embodiment with comparison examples with respect to common mode rej ection as a function of frequency;

[0117] Figure 16 is a diagram illustrating a comparison of the inductive component according to the exemplary embodiment with comparison examples with respect to mode conversion as a function of frequency. P2024, 1107 WO N November 12, 2025

[0118] 19

[0119] The inductive component according to the exemplary embodiment as shown in Figures 1 and 2 comprises core element 2 around which wires 31, 32 are wound in a winding region 20.

[0120] Referring to Figures 3 and 4, the core element 2 comprises a first flange portion 21 and a second flange portion 22 that confine the winding region 20 in longitudinal direction. The winding region 20 has a length 23 in longitudinal direction and a width 24 in a direction perpendicular to the longitudinal direction. The length 23 is at least three times bigger than the width 24. For example, the length 23 is 3.15 mm and the width 24 is 0.9 mm. A cross-sectional area 25 of the winding region 20 is, for example, 0.9 mm times 0.9 mm. The winding region 20 thus comprises an elongated shape . A result of the elongated shape is that a comparably large inductance of, for example, 200 pH can be achieved while at the same time the parasitic capacitance of the inductive component 1 can be kept advantageously small .

[0121] The flange portions 21, 22 and the winding region 20 are formed in one piece . A material of the core element 2 is a magnetic material with a high permeability. For example, the material of the core element 2 is a ferrite such as NiZn.

[0122] The first flange portion 21 comprises a top surface 211 facing a magnetic shell 5 of the inductive component 1 (cf . Figure 1 ) . The first flange portion 21 further comprises a front surface 212 opposite to a surface on which the winding region 20 is arranged. The first flange portion 21 further comprises a bottom surface 214 opposite to the top surface 211. The first flange portion 21 comprises side surfaces 213 connecting the top surface 211 and the bottom surface 214. P2024, 1107 WO N November 12, 2025

[0123] 20

[0124] The second flange portion 22 comprises a top surface 221 facing a magnetic shell 5 of the inductive component 1 (cf . Figure 1 ) . The second flange portion 22 further comprises a front surface opposite to a surface on which the winding region 20 is arranged (not visible in Figures 3 and 4 ) . The second flange portion 22 further comprises a bottom surface 224 opposite to the top surface 221. The second flange portion 22 comprises side surfaces 223 connecting the top surface 221 and the bottom surface 224.

[0125] Furthermore, each of the flange portions 21, 22 comprises a recess 3 penetrating the flange portions 21, 22 in longitudinal direction at the bottom surfaces 214, 224. The recess 3 is arranged in a center region of the corresponding flange portion 21, 22.

[0126] The wires 31, 32 are wound around the core element 2 (cf . Figures 2, 5, 6) . The wires 31, 32 are twisted in the winding region 20. Furthermore, the twisted wires 31, 32 are wound around the core element 2 in a plurality of winding blocks 41, 42, ..., 4N. In the present exemplary embodiment nine winding blocks 41, 42, ..., 4N are present . That is, N=9.

[0127] As illustrated in Figure 7A, each winding block 41, 42, ..., 4N comprises an inner winding section 411, 421, ..., 4N1 and an outer winding section 412, 422, ..., 4N2 . In the inner winding sections 411, 421, ..., 4N1 the wires 31, 32 are directly wound around the core element 2 in three turns . That is, the wires 31, 32 touch the core element 2 in the inner winding section 411, 421, ..., 4N1. P2024, 1107 WO N November 12, 2025

[0128] 21

[0129] In the outer winding sections 412, 422, ..., 4N2 the wires 31, 32 are directly wound around the corresponding inner winding section 411, 421, ..., 4N1 in two turns .

[0130] The turns of the outer winding section 412, 422, ..., 4N2 of a specific winding block 41, 42, ..., 4N are directly connected to the inner winding section 411, 421, ..., 4N1 of an directly adj acent winding block 41, 42, ..., 4N such as the following winding block 41, 42, ..., 4N, as illustrated by the dashed lines in Figure 7A.

[0131] A particularly low parasitic capacitance can be achieved for the inductive component by the winding structure comprising twisted wires 31, 32 and a plurality of winding blocks 41, 42, ..., 4N. Thus, a comparably low insertion loss and return loss can be achieved. In particular, a distance between the wires, positioning of the wires 31, 32 and a material of the wire determine the parasitic capacitance . If, for example, the wires 31, 32 comprise an insulating coating 34, the parasitic capacitance is in particular direct proportional to a dielectric constant s of the insulating coating 34 and indirect proportional to the distance between each wire 31, 32 .

[0132] As illustrated in Figure 7B showing a detailed view of Figure 7A, the parasitic capacitance has a part determined by first capacitances 81 emerging from the windings of the wires 31, 32 being arranged in a common winding block 41, 42, ..., 4N and second capacitances 82 between adj acent winding blocks 41, 42, ..., 4N.

[0133] By arranging the wires 31, 32 in winding blocks41, 42, ..., 4N, the distance between the windings of the wires 31, 32 can be P2024, 1107 WO N November 12, 2025

[0134] 22

[0135] on average increased, since windings assigned to different winding blocks 41, 42, ..., 4N comprise a certain distance from each other that is advantageously bigger than a distance in a winding structure without winding blocks 41, 42, ..., 4N.

[0136] Each of the wires 31, 32 comprises a conductive core 33 and an insulating coating 34, as illustrated in Figure 8. The conductive core 33 comprises, for example, copper . The insulating coating 34 comprises, for example, a polymer . The conductive core 33 has a diameter 33 that is approximately twice the thickness 36 of the insulating coating 34. For example, the conductive core 33 has a diameter 35 of 30 pm and the thickness 36 of the insulating coating 34 is approximately 15 pm.

[0137] By adapting materials and dimensions of the core 33 and the coating 34 of each of the wires 31, 32, the parasitic capacitance can be further influenced to achieve low insertion and return losses for the inductive component 1. Furthermore, by adapting the core 33 to have a diameter 35 of twice the thickness 36 of the coating 34, the desired impedance of 100 Q can be achieved for the inductive component 1 .

[0138] The winding region 20 has rounded corners to reduce the risk of damaging the wires 31, 32.

[0139] Referring to Figures 5 and 6, the wires 31, 32 are guided through the recesses 3 at the flange portions 21, 22 at both ends of the winding region 20. The wires 31, 32 are guided to connection terminals 61, 62, 63, 64 of a lead frame 6 attached to the core element 2. The recess 3 comprises a P2024, 1107 WO N November 12, 2025

[0140] 23

[0141] rounded edge 67 in order to reduce the risk of damaging the wires 31, 32 (cf . Figure 12 ) .

[0142] The lead frame 6 is attached to the bottom surfaces 214, 225 and front surface 212 of the flange portions 21, 22. The lead frame 6 is attached to the core element 2 by a glue . In particular, the glue is electrically insulating. Thus the lead frame 6 is electrically separated from the core element 2 .

[0143] The lead frame 6 comprises a first connection terminal 61 and a second connection terminal 62 arranged at the first flange portion 21. The first and second terminal 61, 62 are separated by the recess 3 (cf . Figure 6) . The first connection terminal 61 comprises first electrical contact surfaces 71 at the bottom surface 214 and the front surface 212. The second connection terminal 62 comprises second electrical contact surfaces 72 at the bottom surface 214 and the front surface 212.

[0144] The lead frame comprises 6 a third connection terminal 63 and a fourth connection terminal 64 arranged at the second flange portion 22. The third and fourth terminal 63, 64 are separated by the recess 3 (cf . Figure 6) . The third connection terminal 63 comprises third electrical contact surfaces 73 at the bottom surface 224 and the front surface . The fourth connection terminal 64 comprises fourth electrical contact surfaces 74 at the bottom surface 224.

[0145] The inductive component 1 can be integrated in a circuit configuration, for example of an electric system by the connection terminals 61, 62, 63, 64, in particular by the corresponding connection surfaces 71, 72, 73, 74. The first P2024, 1107 WO N November 12, 2025

[0146] 24

[0147] and second connection terminals 61, 62 preferably form an input side of the inductive component 1 and the third and fourth connection terminals 63, 64 form an output side of the inductive component 1 .

[0148] Each of the connection terminals 61, 62, 63, 64 further comprises a fixation flap 65 and a welding region 66 for mechanical and electrical connection to the wires 31, 32 (cf . Figure 2, 5, 6) . At the fixation flap 65 the corresponding wire 31, 32 is mechanically fixed for welding in the welding region 66. At least at the welding region 66 the insulating coating 34 of the corresponding wire 31, 32 is removed and the wire 31, 32 is connected to the lead frame 6 by laser welding .

[0149] The wires 31, 32 are untwisted (cf . Figure 6) between the recesses 3 and the connection terminals 61, 62, 63, 64. At the first flange portion 21, the first wire 31 is connected to the first connection terminal 61 and the second wire 32 is connected to the second connection terminal 62 . At the second flange portion 22, the first wire 31 is connected to the third connection terminal 63 and the second wire 32 is connected to the fourth connection terminal 64 .

[0150] The path length of each wire 31, 32 between the recess 3 and the corresponding connection terminals 61, 62, 63, 64 is essentially identical . Thus, a symmetric wire guidance can be achieved .

[0151] The inductive component 1 further comprises a magnetic shell 5. The magnetic shell 5 is arranged at top surfaces 211, 221 of the core element 2 (cf . Figure 1 ) . As shown in Figures 9 and 10, the magnetic shell 5 comprises a top portion 50 and P2024, 1107 WO N November 12, 2025

[0152] 25

[0153] side portions 51, 52 extending perpendicular to the top portion 50. In a sectional view the magnetic shell 5 has a shape of a U.

[0154] The magnetic shell 5 is in particular formed in one piece . Preferably, the magnetic shell 5 comprises a high permeability ferrite material such as NiZn. Stray inductance can be advantageously reduced by the magnetic shell 5.

[0155] Furthermore, the magnetic shell 5 may act as a magnetic and mechanical protection for the inductive component 1 .

[0156] Corner regions 53, 54, 55, 56, at which the top portion 50 merges in the side portions 51, 52, are rounded.

[0157] As illustrated by the front view of Figure 11, i . e . a view on the front surface 211 of the first flange portion 21, the magnetic shell 5 is attached to a side surface 213 of the flange portion 21 and the top surface 211 of the first flange portion 21. An adhesive is arranged between a first side portion 51 of the magnetic shell and the side surface 213 of the first flange portions 21 facing the first side portion 51 as well as between the top portion 50 and the top surface 211. The adhesive preferably comprises a magnetic filler .

[0158] A gap 57, which is in particular an air gap, is present between the second side portion 52 of the magnetic shell 5 and the core element 2. The gap 57 is as small as possible to increase the reduction of the stray inductance .

[0159] By attaching the magnetic shell 5 on two sides of the core element 2, the magnetic shell 5 can be mechanically fixedly connected to the core element 2. Furthermore, the gap 57 can P2024, 1107 WO N November 12, 2025

[0160] 26

[0161] be formed particularly small and only at one side portion 52 of the magnetic shell 5.

[0162] Furthermore, since the corner regions 53, 54, 55, 56 are rounded, the mechanical stability of the magnetic shell 5 can be increased. Moreover, the magnetic shell 5 can be easily applied to the flange portions 21, 22 that comprise sharp edges between the top surfaces 211, 221 and the side surfaces 213, 223 as illustrated in Figure 11.

[0163] Preferably, the inductive component 1 according to the exemplary embodiment is used as a common mode choke . In particular, the inductive component 1 comprises physical and electrical properties that make it particularly suitable for a common mode choke for electrical systems comprising a plurality of bus systems with different data transfer rates . Examples for such applications are automotive ethernet applications where, for example, a low-speed bus system with a transfer rate of 10 megabits per second, a mid-speed bus system with a transfer rate of 100 megabits per second and a high-speed bus system with a transfer rate of 1000 megabits per second are operated in parallel . Typically, common mode chokes for such applications are required to fulfil international standards such as 10BASE-T1 ( IEEE 802. 3cg) , 100BASE-T1 ( IEEE 802. 3bw) and 1000BASE-T1 ( IEEE 802. 3bp) . In particular, the inductive component 1 is capable of fulfilling the required standards for a plurality of data transfer rates .

[0164] In the diagrams of Figures 13 to 16, electrical properties of the inductive component 1 are compared to comparison examples of commonly used common mode chokes 7, 8, 9. A first comparison example 7 represents a common mode choke that is P2024, 1107 WO N November 12, 2025

[0165] 27

[0166] commonly used in applications with a transfer rate of 10 megabits per second. A second comparison example 8 represents a common mode choke that is commonly used in applications with a transfer rate of 100 megabits per second. A third comparison example 9 represents a common mode choke that is commonly used in applications with a transfer rate of 1000 megabits per second.

[0167] Figure 13 illustrates the return loss 101 as a function of frequency 100 for the inductive component 1 and the three comparison examples 7, 8, 9. The frequency 100 is given in MHz and the return loss 101 is given in dB . In particular, for the return loss the amplitude of an input signal is divided by the amplitude of a reflected signal .

[0168] The inductive component 1 described herein shows a low level of reflection up to a frequency 100 of around 10 MHz as well as a flattened response towards higher frequencies 100 due to its well-balanced geometrical design. Furthermore, the inductive component 1 shows a comparable performance with the comparison examples 7, 8, 9 for lower frequencies 100 up to around 10 MHz and a superior performance at higher frequencies 101 of about 10 MHz in the case of the first and second comparison examples 7, 8 and at higher frequencies of about 100 MHz in the case of the third comparison example 9.

[0169] Figure 14 illustrates the insertion loss 102 as a function of frequency 100 for the inductive component 1 and the three comparison examples 7, 8, 9. The frequency 100 is given in MHz and the insertion loss 102 is given in dB . In particular, for the insertion loss the amplitude of an input signal is divided by the amplitude of an output signal . P2024, 1107 WO N November 12, 2025

[0170] 28

[0171] The inductive component 1 described herein shows a high transmission level and keeps this level towards higher frequencies 100 of, for example, above 100 MHz due to its well-balanced geometrical design. The inductive component 1 shows a comparable performance with the comparison examples 7, 8, 9 at lower frequencies 100 up to a range between 10 MHz and 100 MHz and a superior comparable performance at higher frequencies 100.

[0172] Figure 15 illustrates the common mode rej ection 103 as a function of frequency 100 for the inductive component 1 and the three comparison examples 7, 8, 9. The frequency 100 is given in MHz and the common mode rej ection 103 is given in dB . In particular, the common mode rej ection 103 gives the efficiency for suppressing a common mode signal . For example, the common mode rej ection 103 is given by an amplitude on an input common mode signal divided by the amplitude of an output common mode signal .

[0173] The inductive component 1 described herein achieves both a good response in the inductive domain at lower frequencies up to about 50 MHz due to the elongated winding region 20, wherein the required number of turns of the wires 31, 32 can be arranged, and a good response in the capacitive domain at higher frequencies of more than 100 MHz due to the winding structure comprising twisted wires 31, 32 and a plurality of winding blocks 41, 42, ..., 4N as well as the chosen materials and dimensions for the conductive core 33 and the insulating coating 34 of the wires 31, 32. The inductive component 1 shows a comparable performance with the comparison examples 7, 8, 9. P2024, 1107 WO N November 12, 2025

[0174] 29

[0175] Figure 16 illustrates the mode conversion 104 as a function of frequency 100 for the inductive component 1 and the three comparison examples 7, 8, 9. The frequency 100 is given in MHz and the mode conversion 104 is given in dB . In particular, the mode conversion 104 is determined by an undesired effect, wherein a part of the differential mode signal is converted into a common mode signal . For example, the mode conversion 104 is given by an amplitude on an input differential mode signal divided by the amplitude of an output common mode signal .

[0176] The inductive component 1 described herein achieves a superior response over the complete frequency range 100 due to its well-balanced geometrical design which is combined with a highly symmetrical twisted winding structure, winding distribution and routing. The comparison examples 7, 8, 9 show weak points at frequencies 100 higher than 100 MHz .

[0177] In summary of Figures 13 to 16, the inductive component 1 shows a comparable or superior performance to the comparison examples 7, 8, 9, which are designed as common mode chokes for low-speed bus systems with a transfer rate of around 10 megabits per second, mid-speed bus systems with a transfer rate of around 100 megabits per second, and high-speed bus systems with a transfer rate of around 1000 megabits per second. Thus, the inductive component 1 may replace each or all of the comparison examples 7, 8, 9. Thus in an application where multiple transfer rates are present, the inductive component 1 may be used as a single multispeed broadband filtering component for a plurality of bus systems . Therefore, complexity and costs can be reduced. Examples of such applications include automotive ethernet . Furthermore, P2024, 1107 WO N November 12, 2025

[0178] 30

[0179] by using the inductive component 1 as a common mode choke for such applications, international standards can be fulfilled.

[0180] The invention is not restricted to the exemplary embodiment by the description on the basis of said exemplary embodiment . 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 embodiment, even if this feature or this combination itself is not explicitly specified in the patent claims or exemplary embodiment . P2024, 1107 WO N November 12, 2025

[0181] - 31 -

[0182] References

[0183] 1 inductive component

[0184] 2 core element

[0185] 3 recess

[0186] magnetic shell

[0187] lead frame

[0188] 7, 8, 9 comparison example

[0189] 20 winding region

[0190] 21, 22 first, second flange portion

[0191] 23 length of winding region

[0192] 24 width of winding region

[0193] 25 cross-sectional area of winding region 31, 32 wires

[0194] 33 conductive core of wire

[0195] 34 insulating coating of wire

[0196] 35 diameter of conductive core

[0197] 36 thickness of insulating coating

[0198] 41, 42, ..., 4N winding blocks

[0199] 50 top portion of magnetic shell

[0200] 51, 52 first, second side portion of magnetic shell

[0201] 53, 54, 55, 56 corner regions of magnetic shell

[0202] 57 gap

[0203] 61, 62, 63, 64 connection terminals

[0204] 65 fixation flap

[0205] 66 welding region

[0206] 67 rounded edge

[0207] 71, 72, 73, 74 connection surfaces of connection terminals

[0208] 81 first capacitance between windings in one winding block

[0209] 82 second capacitance between winding blocks P2024, 1107 WO N November 12, 2025

[0210] 100 frequency in MHz

[0211] 101 return loss in dB

[0212] 102 insertion loss in dB

[0213] 103 common mode rej ection in dB

[0214] 104 mode conversion in dB

[0215] 211 top surface of first flange portion 212 front surface of first flange portion 213 side surface of first flange portion 214 bottom surface of first flange portion 221 top surface of second flange portion 223 side surface of second flange portion 224 bottom surface of second flange portion 411, 421, ..., 4N1 inner winding section

[0216] 412, 422, ..., 4N2 outer winding section

Claims

1. P2024 , 1107 WO N November 12 , 20252.- 33 -3.Claims4.1 . Inductive component ( 1 ) comprising5.a core element ( 2 ) and at least two wires ( 31 , 32 ) twisted together and wound around the core element ( 1 ) in at least two winding blocks ( 41 , 42 ) , each block having6.an inner winding section ( 411 , 421 ) in which at least one turn of the wires ( 31 , 32 ) is directly wound around the core element ( 2 ) and7.an outer winding section ( 412 , 422 ) in which at least one turn of the wires ( 31 , 32 ) is directly wound around the corresponding inner winding section ( 411 , 421 ) ,8.wherein the outer winding section ( 421 , 422 ) of one winding block ( 41 , 42 ) is connected to the inner winding section ( 411 , 412 ) of a directly adj acent winding block ( 41 , 42 ) .9.2 . Inductive component ( 1 ) according to claim 1 , wherein the wires ( 31 , 32 ) are wound around a winding region ( 20 ) of the core element ( 2 ) ,10.wherein a length ( 23 ) of the winding region ( 20 ) is at least three times bigger than a width ( 24 ) of the winding region ( 20 ) .11.3 . Inductive component ( 1 ) according to claim 2 , wherein a fraction between a cross-sectional area of the winding region ( 20 ) and the length ( 23 ) of the winding region ( 20 ) at most 0 . 3 mm .12.4 . Inductive component ( 1 ) according to one of the preceding claims ,13.wherein each of the wires ( 31 , 32 ) comprises a conductive core ( 33 ) and an insulating coating ( 34 ) , and P2024, 1107 WO N November 12, 202514.3415.wherein a thickness (36) of the coating (34 ) is half a diameter (35) of the core (33) .

5. Inductive component ( 1 ) according to one of the preceding claims, further comprising a magnetic shell (5) , wherein the magnetic shell (5) partially surrounds the core element (2 ) in directions perpendicular to a main extension direction of the core element (2 ) .

6. Inductive component ( 1 ) according to claim 5, wherein the magnetic shell (5) is formed in one piece and comprises a top portion (50) and two side portions (51, 52 ) extending perpendicular to the top portion (50) , and wherein at least one corner region (53, 54, 55, 56) at which the top portions (50) adjoins the side portions (51, 52 ) is rounded .

7. Inductive component ( 1 ) according to claim 5 or 6, wherein the magnetic shell (5) is attached to the core element (2 ) by an adhesive, wherein the adhesive is applied to at least two flat surfaces of the magnetic shell (5) facing the core element (2 ) .

8. Inductive component ( 1 ) according to claims 6 and 7, wherein the adhesive is applied to the top portion (50) and a first side portion (51 ) of the two side portions (51, 52 ) , and20.wherein a surface of each of the top portion (50) and the first side portion (51 ) facing the core element (2 ) is grinded .

9. Inductive component ( 1 ) according to claim 7 or 8, wherein the adhesive comprises at least one magnetic filler .P2024 , 1107 WO N November 12 , 202522.10 . Inductive component ( 1 ) according to one of claims 7 to 9 , wherein23.the core element ( 2 ) comprises two flange portions ( 21 , 22 ) , between which the wires ( 31 , 32 ) are wound around the core element ( 2 ) ,24.wherein the magnetic shell ( 5 ) is attached to the flange portions ( 21 , 22 ) , and25.wherein in view of each of the flange portions ( 21 , 22 ) , a gap ( 57 ) between the core element ( 2 ) and the magnetic shell ( 5 ) is only present at a surface of the magnetic shell ( 5 ) facing the core element ( 2 ) that is free of the adhesive .26.11 . Inductive component ( 1 ) according to one of the preceding claims ,27.wherein the core element ( 2 ) comprises two flange portions ( 21 , 22 ) , between which the wires ( 31 , 32 ) are wound around the core element ( 2 ) in a winding region ( 20 ) ,28.each of the flange portions ( 21 , 22 ) comprises a recess ( 3 ) through which the wires ( 31 , 32 ) are guided from the winding region ( 20 ) to connection terminals ( 61 , 62 , 63 , 64 ) of the inductive component ( 1 ) .29.12 . Inductive component ( 1 ) according to one of the preceding claims ,30.wherein the core element ( 2 ) is attached to a lead frame ( 6 ) , comprising connection terminals ( 61 , 62 , 63 , 64 ) for the inductive component ( 1 ) .31.13 . Inductive component ( 1 ) according to claim 11 and 12 , wherein the lead frame ( 6 ) is attached to the flange portions ( 21 , 22 ) of the core element ( 2 ) using a glue . P2024 , 1107 WO N November 12 , 202532.3633.14 . Inductive component according to claim 11 and 12 or claim 13 , wherein two of the connection terminals ( 61 , 62 , 63 , 64 ) are associated with each flange portion ( 21 , 22 ) , wherein said two connection terminals ( 61 , 62 , 63 , 64 ) are arranged symmetrically with respect to the recess ( 3 ) of the corresponding flange portion ( 21 , 22 ) , and34.wherein each wire ( 31 , 32 ) is associated with one connection terminal ( 61 , 62 , 63 , 64 ) .35.15 . Inductive component ( 1 ) according to one of claims 11 to 14 , wherein the path length of each wire ( 31 , 32 ) between the recess ( 3 ) and an associated connection terminal ( 61 , 62 , 63 , 64 ) is essentially identical .36.16 . Inductive component ( 1 ) according to one of claims 11 to 15 , wherein the wires ( 31 , 32 ) are untwisted between the recess ( 3 ) and associated connection terminals ( 61 , 62 , 63 , 64 ) .37.17 . Inductive component ( 1 ) according to one of the preceding claims , wherein the core element ( 2 ) comprises a rectangular cross-section with rounded corners .38.18 . Usage of the inductive component ( 1 ) according to one of the preceding claims as a common mode choke .

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