EP2933804B1 - Induction component - Google Patents

Description

The invention relates to an induction component, in particular a high-current throttle. Such components contain in a housing a coil whose winding ends are to be connected to solder pads of a circuit board. In the simplest case, the tinned winding ends are formed as an SMD soldering surface.

With loose wire ends, however, there is the problem that they do not always run exactly in a plane, which is required for an SMD assembly.

It is already known to bend the winding ends of a coil formed of flat wire around the bottom of a housing, so that the ends of the windings lie in one plane and can serve as a terminal contact ( US 6,922,130 B2 ).

It is likewise known to attach contact elements to a base of a housing and to connect the winding ends of the coil formed from flat wire with these contact elements in a form-fitting manner, each having a hole ( US 2013/0194061 A1 ).

Furthermore, it is known to arrange a rectangular plate in a housing constructed from two parts, which has angled contact elements at its opposite end faces, and to connect the coil ends via printed conductors of this plate with the angled contact elements ( JP 07-320961 A ).

An induction component having a housing, a coil wound from flat wire and a carrier for the coil is already known. The coil ends are led out of the housing flat and inserted into notches of connection formations ( JP 2011-159957 A ). JP 2011-159957 A discloses here an induction component according to the preamble of claim 1.

In another known induction component, the winding ends of the coils wound from round wire are wound around terminal formations ( US 5952907 ).

In a similar induction component, the coil ends of the round wire coils are also wound around terminal contacts ( US 2011/00503783 A1 ).

A housing for an induction component, which simultaneously forms the core, is also known (US Pat. EP 0026104 A1 ).

Also known is an induction component in which the tangentially led out ends of the coil wound from round wire are attached longitudinally to electrodes ( WO 2014/111172 A1 ).

In yet another known induction component, the coil ends are wound around terminal contacts of a carrier.

Furthermore, an induction component is known in which the coil is wound from flat wire, wherein the flat side of the flat wire runs parallel to the coil axis ( JP 7-3 20961 ).

JP 2010219473 and US 2003/0201859 A1 disclose further induction components with a flat coil.

The invention is based on the object to provide a particularly suitable for automatic assembly induction component.

To solve this problem, the invention proposes an induction component with the features mentioned in claim 1. Further developments of the invention are the subject of dependent claims.

The induction component proposed by the invention thus contains a housing, in particular of ferrite material or of pressed substrate powder, in which at least one coil is arranged. The coil is carried by a support member which is also disposed in the housing. The support member includes on the one hand terminal contacts to mechanically and functionally connect the induction member to a circuit board, and on the other hand terminal formations, which are attached to the coil ends of the coil and with which they are connected.

The planarity of the terminals thus no longer depends on the shape and nature of the coil ends of the coil and the coil ends of the coil can be reliably and reliably connected to the terminal training. For example, the terminal formations are designed as welding plates with which the coil ends are welded.

In a further development of the invention it can be provided that the carrier element consists of plastic and the connection contacts are injected or pressed into the plastic. This facilitates the production.

In a further development of the invention it can be provided that the connection formation for the connection of each winding end is formed integrally with the respective associated connection contact. There are therefore no additional connections between the coil ends and the metal parts required to form or have the connection contacts. These metal parts may be coated on their side forming the terminal contact, depending on the requirements of the case. Connection formations and connection contacts can then be injected in sections into the plastic of the carrier part.

In a further development of the invention can be provided that the carrier element is fixed immovably in the housing. This can preferably be done by a positive connection between the carrier element and the housing, wherein, optionally, an additional bonding may be provided.

In a further embodiment of the invention can be provided that the carrier element is centered in the housing through the housing. For example, the housing has a cylindrical spool core and the carrier element is centered with a tubular portion on the spool core.

It can also be provided that the carrier element has a centering for the coil. This centering makes it possible that the carrier element simultaneously forms an assembly aid for assembly during assembly of the induction component. Advantageously, the centering for the coil is formed as a tubular portion of the carrier element. With the outer periphery of the tubular portion of the coil is centered and with the inner circumference of the tubular portion, the support member is centered on the housing.

It can be provided in a development that the housing has a flat bottom and a plane parallel to this extending flat top, wherein the end faces may be formed on the short end faces as flat surfaces. Under the bottom is that side of the housing to understand, which is opposite to the mounting on a circuit board of the circuit board.

The coil of the induction component proposed by the invention is wound from flat wire whose flat side is perpendicular to the coil axes.

To further improve the mounting and the stability of the attachment, the support member may have a third surface which is constructed as a contact surface, so that it can be attached to the circuit board with the same technology with which the terminals are connected to the circuit board. However, this third pad does not make contact because it is not conductively connected to a coil. Instead of a third surface and several such surfaces may be provided to ensure a secure attachment to the circuit board. Alternatively, the third surface or other surfaces may also be made of plastic, for example at the end of a plastic pin or plastic pin, which is then pressed or hot-spliced with the circuit board.

This solution applies primarily to an induction component with only one coil.

It has already been mentioned that the carrier element also serves for centering and holding the coil. For this purpose, the carrier element may have a central annular portion or tubular portion, which serves both for centering the carrier element relative to the housing and for centering the carrier element relative to the coil or vice versa.

This central ring portion may be plate-shaped, so lie substantially in a plane. Both its outer edge and its inner edge can serve for centering with respect to the housing.

To center the coil can be attached to the inner edge of the ring portion individual perpendicular to the plane of the ring portion extending fingers.

The central ring portion may also be cylindrical. The cylindrical shape of the ring section can serve both for fixing the carrier element and for centering the coil.

In a further embodiment of the invention, the support element may have at least one leg that extends to the bottom of the housing of the induction component and is provided there with a foot. The underside of the foot is preferably located approximately in the plane of the underside of the housing.

In the bottom of the foot of the terminal contact can emerge, which is then also in a plane so that it is particularly well suited for SMD Ankontaktierung with the circuit board.

According to the invention, the connection formations for connecting the winding ends of the coil project at right angles out of a surface of the carrier element in the direction of the coil axis, preferably out of the upper side of the foot of the carrier element. As a result, a surface for connection between the coil ends and the connection formation is available, which allows for the assembly and the preparation of the compound free access, for example for a welded joint. The connection formation may for example also have a U-shaped bent sheet, wherein the coil end is pushed between the legs of the sheet and then connected thereto.

Further preferred features, details and advantages of the invention will become apparent from the dependent claims, the following description of preferred embodiments of the invention and from the drawing. Individual features of the different embodiments can be combined in any way, within the scope of the invention.

Fig. 1

eine isometrische Ansicht eines Induktionsbauteils gemäß einer ersten Ausführungsform der Erfindung von schräg oben;

Fig. 2

das Induktionsbauteil der Fig. 1 in auseinandergezogender Darstellung;

Fig. 3

das Trägerelement des Induktionsbauteils der Fig.en 1 und 2 von schräg unten;

Fig. 4

mehrere Stufen des Zusammenbaus eines erfindungsgemäßen Induktionsbauteils gemäß einer weiteren Ausführungsform der Erfindung;

Fig. 5

mehrere Stufen des Zusammenbaus eines Induktionsbauteils gemäß einer weiteren Ausführungsform der Erfindung;

Fig. 6

eine seitliche Ansicht einer Gehäusehälfte eines Induktionsbauteils gemäß einer weiteren Ausführungsform der Erfindung;

Fig. 7

eine Draufsicht auf die Gehäusehälfte der Fig. 6 on oben;

Fig. 8

eine Draufsicht auf eine Spule für ein erfindungsgemäßes Induktionsbauteil;

Fig. 9

eine seitliche Ansicht der Spule aus Fig. 8;

Fig. 10

eine seitliche Ansicht des fertig gestellten Induktionsbauteils mit zwei Gehäusehälften gemäß Fig. 6 und einer Spule gemäß Fig. 8;

Fig. 11

eine Ansicht des Induktionsbauteils der Fig. 10 aus einer um 90° versetzten Richtung;

Fig. 12

die Ansicht des Induktionsbauteils der Fig. 10 von unten;

Fig. 13

die Ansicht des Induktionsbauteils der Fig. 10 von oben;

Fig. 14

die Ansicht eines Trägerelements des Induktionsbauteils der Fig. 10 von unten;

Fig. 15

die Ansicht des Trägerelements der Fig. 14 von oben;

Fig. 16

die Ansicht des Trägerelements der Fig. 14 von der Seite;

Fig. 17

die Vorderansicht des Trägerelements der Fig. 14;

Fig. 18

die Ansicht eines Trägerelements einer weiteren Ausführungsform der Erfindung von unten;

Fig. 19

die Ansicht des Trägerelements der Fig. 18 von oben;

Fig. 20

die Ansicht des Trägerelements der Fig. 18 von der Seite;

Fig. 21

die Vorderansicht des Trägerelements der Fig. 18;

Fig. 22

eine perspektivische Ansicht eines von der Erfindung vorgeschlagenen Induktionsbauteils.

In the drawings show:

Fig. 1

an isometric view of an induction component according to a first embodiment of the invention obliquely from above;

Fig. 2

the induction component of Fig. 1 in a differentiated representation;

Fig. 3

the carrier element of the induction component of Figures 1 and 2 obliquely from below.

Fig. 4

several stages of assembly of an induction component according to the invention according to a further embodiment of the invention;

Fig. 5

a plurality of stages of assembling an induction component according to another embodiment of the invention;

Fig. 6

a side view of a housing half of an induction component according to another embodiment of the invention;

Fig. 7

a plan view of the housing half of Fig. 6 on top;

Fig. 8

a plan view of a coil for an inventive induction component;

Fig. 9

a side view of the coil Fig. 8 ;

Fig. 10

a side view of the completed induction component with two housing halves according to Fig. 6 and a coil according to Fig. 8 ;

Fig. 11

a view of the induction component of Fig. 10 from a 90 ° offset direction;

Fig. 12

the view of the induction component of Fig. 10 from underneath;

Fig. 13

the view of the induction component of Fig. 10 from above;

Fig. 14

the view of a support member of the induction component of Fig. 10 from underneath;

Fig. 15

the view of the support element of Fig. 14 from above;

Fig. 16

the view of the support element of Fig. 14 of the page;

Fig. 17

the front view of the support element of Fig. 14 ;

Fig. 18

the view of a support member of another embodiment of the invention from below;

Fig. 19

the view of the support element of Fig. 18 from above;

Fig. 20

the view of the support element of Fig. 18 of the page;

Fig. 21

the front view of the support element of Fig. 18 ;

Fig. 22

a perspective view of an induction component proposed by the invention.

Fig. 1 shows in a perspective view obliquely from above an inventive induction component according to a first embodiment. The induction component has a lower housing half 1a and an upper housing half 1b, which are formed identical to one another. Within the housing, a coil 7 is arranged. The coil is wound from flat material and has opposite the actual winding of the coil at right angles bent coil ends 8, 9 up. The winding ends 8, 9 are disposed within each U-shaped terminal formations 31 and welded to these terminal formations 31. The terminal formations are arranged on a support part 32, which also holds the coil 7, as will be explained below.

The presentation of the Fig. 2 shows the induction component of Fig. 1 in an exploded view. The coil 7 with the coil ends 8, 9 is placed on the support member 32 and held on a ring portion 16 of the support member 32 by means of three webs 26 which are arranged on the circumference of a central hole of the ring member 16 and follow the curvature of the hole. The webs 26 thereby define portions of a cylindrical surface, which is tuned to the inner diameter of the coil 7 and the coil 7 thereby centered on the support member 32. In the exploded view, the U-shaped configuration of the connection sections 31 can be seen, wherein the coil ends 8, 9 are inserted into the respective interior of the U-shaped connection sections 31. The coil ends 8, 9 can then be welded to the connection sections 31. Is in this way the coil 7 connected to the support member 32, the support member 32 is inserted into the lower housing half 1a. Finally, the upper housing half 1b can still be placed and the two housing halves can be connected to each other, for example, glued.

On a lower side of the carrier element connecting contacts 33 are provided, which are electrically conductively connected to the terminal formations 31 and in particular in each case a connection surface 33 and a connection formation 31 consists of a one-piece, bent sheet metal. These bent sheets are injected during the production of the support member 32 made of plastic in this. This can ensure that the connection contacts 33 lie in a common plane. It is thus easily possible to connect the induction component by means of the connection contacts 33 with solder pads 34 on a circuit board 35.

In the presentation of the Fig. 2 the circuit board 35 has a third solder pad 36. This solder pad 36 is provided with the underside of a leg 37 of the support member 32, see Fig. 3 to be connected, for example, to be soldered. In this way, the induction component at three points can be securely soldered to the circuit board 35. However, the solder pad 36 is preferably insulated and inoperative in electrical terms. Since the leg 37 is injected in the production of the support member 32 and contains at its bottom, for example, an injected, metallic surface, it can be ensured in the manufacture of the support member 32 that the terminal contacts 33 and the underside of the leg 37 are exactly in a plane and The induction component according to the invention can thus be reliably soldered to the circuit board 35.

The presentation of the Fig. 3 shows the support member 32 in a view from below.

The presentation of the Fig. 4 shows several stages in the assembly of an induction component according to the invention according to a further embodiment. In the Fig. 4 on the left a support member 15 is shown, which is based on the FIGS. 14 to 17 will be explained in detail. This support member 15 is inserted into the lower housing half 1a. In the next stage, the coil 7 is placed on the support member 15 and the coil ends 8, 9 are welded to the terminal formations on the carrier element 15. In the last stage, the upper housing half 1b is placed on the lower housing half 1a and the two housing halves are connected together, for example glued. Deviating from the Fig. 4 shown stages, the coil 7 can first be connected to the support member 15 and the unit of carrier element 15 and coil 7 is then inserted into the lower housing half 1a.

The presentation of the Fig. 5 shows various stages in the assembly of an induction component according to the invention according to a further embodiment. A carrier element 32 is here designed differently than the carrier element 15 and will be described below with reference to the Fig. 18 to 21 explained in detail. Incidentally, the assembly is done as in Fig. 4 indicated and again, the coil 7 can first be connected to the support member 32 and only then used in the lower housing half 1a.

The Fig. 6 shows one half of a housing of an induction component proposed by the invention. This half is shown as the lower half. The upper half is identical, but is just arranged in reverse and placed on the lower half shown. The housing half has two wings 1 shown on the right and left, each having a flat outer boundary surface 2. In the middle of the housing half a central core 3 is shown, which has a circular cylindrical shape. Between the two wings 1 floor sections 4 can be seen. These bottom portions 4 each form a flat bearing surface 5, which lies between the core 3 and the wings 1 and in Fig. 2 can be seen more clearly. The bearing surfaces 5 are for a in Fig. 6 Not shown provided coil.

The two housing halves need not necessarily be identical. For example, one half of the housing may be plate-shaped and the other half of the housing may be approximately E-shaped.

How to get the Fig. 2 can be seen, mutually facing boundary surfaces 6 of the two wings 1 are formed concentrically to the core 3 and each lie on a circular cylinder jacket. As a result, an annular channel is formed on the bottom sections 4, the downwards is limited by the bearing surfaces 5 of the bottom portions 4, while it is bounded inside and outside by the respective wall portions 6 of the two wings 1 and the outer surface of the core 3.

Seen from above, see Fig. 7 Above or below, the housing half is provided with notches, so that therefore the bearing surfaces 5 do not extend over the full circumference of the core 3 but cover on both sides in each case about 90 °.

The just mentioned annular channel serves to receive a coil 7, which in the 8 and 9 is shown. The coil 7 is a multi-layer coil whose individual turns are wound around a central circular opening. The coil 7 has two winding ends 8, 9, which in the illustration of Fig. 8 still lie in the respective level of the individual winding. At the two winding ends 8, 9, the insulation 10 of the winding is removed. The upper coil end 9 protrudes slightly further than the lower coil end 8. The two coil ends are compared to the plane of the Fig. 8 bent at a right angle down the line A, so that in the representation of the Fig. 9 can be seen in the front view. Because the upper coil end 9 is slightly longer than the lower coil end 8, the two coil ends end in the bent state of the Fig. 9 in the same plane.

The coil 7 is inserted by means of a support member to be described in the annular channel between the core 3 and the surfaces 6 of the lower half of the housing, and a second housing half, as already mentioned, placed in the reverse position on the lower half. This results in a shape of the housing, as in the Fig. 10 to 13 is shown.

Already from the side view of Fig. 6 It follows that the bottom 11 of the housing lies in a plane. From the side view shown in the same direction Fig. 10 It follows that the top 12 of the housing lies in a plane which is parallel to the bottom 11 of the housing. The Fig. 11 shows the case from a direction from the left in Fig. 10 , It follows that the back 13 and the front 14 of the housing, if one of the in Fig. 7 disregards notches, also lie in each case in a plane that run parallel to each other. Thus, with the exception of the notches, the housing has an approximately cuboid shape. The coil turns slightly protrude from the front 14 and rear 13 of the housing.

The Fig. 12 shows the induction component from below, and the Fig. 13 shows the induction component from above. On the other, in FIGS. 12 and 13 details to be seen below yet to be received. A perspective view of the induction component is in Fig. 22 shown.

The already mentioned support element is according to a first embodiment in the FIGS. 14 to 17 shown. The support member 15 includes a ring portion 16 surrounding a central circular hole 17. The diameter of this hole 17 corresponds to the outer diameter of the core 3 of the housing. The outer contour of the ring portion 16 corresponds over the largest part of the circumference also a circle whose diameter corresponds to the distance of the inner surfaces 6 of the wings 1 of the housing. At the two flattened sides of the ring portion 16, which face each other, the support member 15 includes means for connecting the support member to a circuit board.

This is now on the Fig. 16 referenced, which shows the support member 15 from the side. The ring portion 16 has the shape of a plate in this embodiment. On one side of the ring portion 16, which is associated with the front side 14 of the housing, the support member has a leg 18 which is angled perpendicular to the plane of the ring member 16 downwards. At its end, the leg 18 has a foot 19 whose underside 2O lies in a plane parallel to the plane of the ring element 16.

On the opposite side of the ring portion 16, which is associated with the back 13 of the housing, the support member 15 also has a leg 21, the bottom 22 is in the same plane as the bottom 20 of the foot 19. In the foot 19 of the support element 15, which is injection molded in one piece from plastic, two metallic angle elements 30 are injected, projecting the horizontal lower leg slightly opposite to the underside 20 of the foot 19 and there each form a terminal contact 23. These connection contacts 23 are in the Fig. 14 are shown, and are also in the housing from below Fig. 12 to see.

The second, upwardly directed legs of the angle elements 30 protrude from the top of the foot 19 at right angles from above and form there a connection formation 24 for each winding end 8, 9 of the coil. 7

In the bottom of the rear leg 21 is also a metallic planar element 25 is injected or pressed, but which forms no connection formation for a coil end. Since the induction component is to be soldered to solder pads of a circuit board, the rear leg 21 forms not only an alignment aid, but also a mounting option, since the metallic Element 25 can also be soldered to a non-functional solder pad at this point.

At the top of the ring member 16 are, see Fig. 15 , formed directly on the edge of the hole 17 three of the curvature of the edge of the hole 17 following fingers 26. The support member 15 serves to support and fix the coil 7 before it is inserted into the housing. The three fingers 26 hold the coil 7, so that the angled winding ends 8, 9 of the coil 7 come directly to the terminal formations 24 to the plant and can be welded there with these. The unit formed by carrier element 15 and coil 7 can then be inserted into the housing and glued to it. Even without the bond, the coil with the carrier element 15 is arranged in a form-fitting manner in the housing. For connection to solder pads of a printed circuit board then serve the connection contacts 23 on the underside of the feet 19, 21 of the support member 15. In the in the FIGS. 14 to 17 illustrated embodiment of the support member 15 serve the three fingers 26 for centering and the ring member 16 for supporting the coil. 7

The following ones Fig. 18 to 21 show a second embodiment of a support member 27. This support member 27 in turn includes a central ring member 28, which is now formed as a short, tubular sleeve. The inner diameter of the ring member 28 corresponds to the outer diameter of the core 3. At the bottom of the ring member 28, see Fig. 20 Again, a leg 18 is formed, which merges into a foot 19, which is formed in the same way as the foot 19 in the previous embodiment. From the top of the foot 19, the terminal formation 24 protrudes upward at right angles, and at the bottom of the foot 19, the terminal contact 23 exits.

At the back of the support member 27, left in Fig. 20 , a second leg 21 is formed, which is formed in this embodiment as an angle and has a metallic surface 25 on its underside. This metallic surface 25 has the same function as in the previous embodiment, so it is used for mounting on the circuit board.

The ring member 18 serves to center the coil 7, whose inner diameter is slightly larger than the outer diameter of the core 3 of the housing, so that it can be pushed onto the ring portion 28. To determine the position of the coil 7 in the axial direction, a web 29, which is integrally formed on the underside of the annular portion 28 and protrudes radially outward. On this web 28, the coil 7 is seated.

For assembling an induction component according to the invention, initially the coil 7 and the carrier element 15 or 27 are produced. The coil ends 8, 9 of the coil are stripped and in the in Fig. 9 Angled manner shown. Subsequently, the coil 7 is placed on the carrier element 15 or 27 and the winding ends 8, 9 are welded to the terminal formations 24. Thereafter, the respectively formed unit of coil and support member 15 and 27 are inserted into the lower half of the housing, in which this unit is fixed positively. The second, upper housing half can then be placed on the lower housing half and connected to this. This creates an induction component that is suitable for connection to a printed circuit board in SMT technology. The connection contacts 23 and the metal element 25 lie in a defined plane defined during the production of the carrier element.

The result, namely a finished induction component, is in Fig. 17 shown again in perspective view.

In the illustrated example, the coil ends 8, 9 of the coil 7 are welded to the front surfaces of the terminal formations 24. It is also conceivable that they are welded to the rear surfaces of the Anschlussausbildungen. It is also possible to form the connection formations in such a U-shape that the winding ends 8, 9 come to lie between the two legs of the U, see Fig. 1 to 3 ,

Claims (12)

1. Induction component, in particular high current inductor, having
   a housing (1a, 1b) that forms the core of the induction component,
   at least one coil (7) which is arranged in the housing,
   a carrier element (15, 27, 32) for the coil (7) which is arranged in the housing and comprises
   connection contacts (23, 33) which are accessible from an outside surface of the housing for connecting the coil (7) to a printed circuit board and
   connection realizations (24, 31) for connecting the winding ends (8, 9) of the coil (7), to which the winding ends are joined, in particular soldered, wherein the coil (7) is wound from flat wire, the flat side of which extends perpendicular to the coil axis,
   characterized in that
   the winding ends (8, 9) of the coil (7) are bent over at right angles in relation to the coil extending in the direction of the coil axis, and the connection realizations (24) project at right angles from a face of the carrier element extending in the direction of the coil axis for forming a connecting surface for the winding ends (8, 9).
2. Induction component according to Claim 1, characterized in that the connection contacts (23) are located at least in portions on a bottom side of the carrier element (15, 27, 32).
3. Induction component according to Claim 2, characterized in that the connection contacts project to a minor extent in relation to the bottom side of the carrier element (15, 27, 32).
4. Induction component according to Claim 2 or 3, characterized in that the connection contacts (23) at least in portions are accessible from one side of the carrier element (15, 27, 32).
5. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) is made of plastics material and the connection contacts (23) are injected or pressed into the plastics material.
6. Induction component according to any one of the preceding Claims, wherein the connection realization (24) for connecting each winding end (8, 9) is realized integrally with the respective connection contact (23).
7. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) is secured in a non-displaceable manner in the housing, preferably as a result of positive locking.
8. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) is centered in the housing by the housing and/or comprises a centering means for the coil (7).
9. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) comprises a third contact face (25) for connecting to the printed circuit board.
10. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) comprises a central ring portion (16, 28) for the centering thereof in relation to the housing and/or in relation to the coil (7).
11. Induction component according to any one of the preceding Claims, wherein the carrier element (15, 27) comprises at least one leg (18, 21) which reaches up to the bottom surface of the housing of the induction component and is there provided with a foot (19).
12. Induction component according to Claim 11, wherein the at least one foot (19) comprises a level bottom surface (20), which lies approximately in the plane of the bottom surface (11) of the housing and in which the connection contact (23) emerges.

Images