阅读说明：本技术 共模或差模电感器及其制造方法和电路系统 (Common mode or differential mode inductor and manufacturing method and circuit system thereof ) 是由 C·阿梅尔 H·哈夫诺 J·T·布拉斯塔德 K·哈根 于 2021-06-25 设计创作，主要内容包括：本发明提供一种共模或差模电感器、制造共模或差模电感器的方法和电路系统。共模或差模电感器包括：磁芯、第一线圈和支撑器件,第一线圈包括在磁芯周围缠绕多个匝的第一绝缘线,支撑器件用于支撑磁芯和第一线圈。支撑器件包括基座元件,其具有PCB接触面；以及第一对齐元件,其近端与基座元件相连,远端设置在与PCB接触面相隔距离处,其中远端界定对齐平面。磁芯具有第一端面和第二端面,其中第一端面面向对齐平面,第二端面面向基座元件。(The invention provides a common mode or differential mode inductor, a method for manufacturing the same and a circuit system. The common mode or differential mode inductor includes: the coil assembly includes a magnetic core, a first coil including a first insulated wire wound around the magnetic core by a plurality of turns, and a support device for supporting the magnetic core and the first coil. The support device comprises a base element having a PCB contact surface; and a first alignment element having a proximal end connected to the base element and a distal end disposed at a distance from the PCB contact surface, wherein the distal end defines an alignment plane. The magnetic core has a first end face facing the alignment plane and a second end face facing the base element.)

1. A common-mode or differential-mode inductor (100) comprising:

a magnetic core (102);

a first coil (104) comprising a first insulated wire (105) wound around the magnetic core (102) in a plurality of turns (a1, a 2.., aN); and

-a support means (110) for supporting the magnetic core (102) and the first coil (104);

wherein the support device (110) comprises:

a base element (112) having a Printed Circuit Board (PCB) contact face (113); and

a first alignment element (120) having a proximal end (120b) connected to the base element (112) and a distal end (120a) disposed at a distance (D) from the PCB contact surface (113), wherein the distal end (120a) defines an Alignment Plane (AP);

wherein the magnetic core (102) has a first end face (102a) and a second end face (102b), wherein the first end face (102a) faces the Alignment Plane (AP); the second end face (102b) faces the base element (112);

wherein each turn (a1, a 2.., aN) of the first insulating line (105) has a furthest point in the normal direction from the first end face (102a) to the Alignment Plane (AP) by a distance (Da1, Da 2.., DaN), wherein the turn furthest from the first end face (102a) is aligned with the Alignment Plane (AP).

2. Common mode or differential mode inductor (100) according to claim 1, wherein the base element (112) comprises a wire guide (114) for guiding an end portion (105a) of the first insulating wire (105) of the first coil (104) with respect to the base element (112).

3. The common mode or differential mode inductor (100) of claim 2 wherein the end (105a) of the first insulated wire (105) is slidingly engaged with the wire guide (114).

4. A common-mode or differential-mode inductor (100) according to any one of claims 1-3, wherein the inductor (100) comprises:

a second coil (106) comprising a second insulated wire (107) wound around the magnetic core (102) in a plurality of turns (b1, b 2.., bN);

wherein each turn (b1, b 2.., bN) of the second insulated wire (107) has a furthest point in the normal direction from the first end face (102a) to the Alignment Plane (AP) by a distance (Db1, Db 2.., DbN), wherein the turn furthest from the first end face (102a) is aligned with the Alignment Plane (AP).

5. The common mode or differential mode inductor (100) according to any one of claims 1-3, wherein the magnetic core (102), the first coil (104) and/or the second coil (106) are fixed to the support means (110) by an adhesive (200).

6. A common-mode or differential-mode inductor (100) according to any one of claims 1-3, wherein the supporting means (110) further comprises:

a second alignment element (125) having a proximal end (125b) coupled to the base element (112) and a distal end (125a) disposed at a second distance from the PCB contact surface (113), wherein the distal end (120a) of the first alignment element (120) and the distal end (125a) of the second alignment element (125) collectively define the Alignment Plane (AP).

7. A common-mode or differential-mode inductor (100) according to any one of claims 1-3, wherein the supporting means (110) comprises: a unitary first alignment element (120), wherein a distal end (120a) of the unitary first alignment element (120) comprises an end face (121) defining the Alignment Plane (AP).

8. The common mode or differential mode inductor (100) of claim 6, wherein the support device (110) further comprises:

a third alignment element (128) having a proximal end (128b) coupled to the base element (112) and a distal end (128a) disposed at a third distance from the PCB contact surface (113), wherein the distal end (120a) of the first alignment element (120), the distal end (125a) of the second alignment element (125), and the distal end (128a) of the third alignment element (128) collectively define the Alignment Plane (AP).

9. A method of manufacturing a common mode inductor or a differential mode inductor (100), comprising the steps of:

a) providing a support device (110), said support device (110) comprising a base element (112) having a PCB contact surface (113), and a first alignment element (120) having a proximal end (120b) connected to said base element (112) and a distal end (120a) arranged at a distance (D) from said base element (112), wherein said distal end (120a) defines an Alignment Plane (AP);

b) providing a magnetic core (102), wherein the magnetic core (102) has a first end face (102a) and a second end face (102 b);

c) winding a first insulated wire (105) around the magnetic core (102) in a plurality of turns (a1, a 2.., aN) to form a first coil (104) around the magnetic core (102);

d) supporting the magnetic core (102) and the first coil (104) on the support means (110) by positioning the first end face (102a) towards the Alignment Plane (AP) and the second end face (102b) towards the base element (112);

e) aligning the Alignment Plane (AP) with a flat surface (PS);

f) urging the magnetic core (102) and the first coil (104) towards the flat surface (PS) and abutting the magnetic core (102) and the first coil (104) with the flat surface (PS); and

g) -fixing the magnetic core (102) and the first coil (104) to the support means (110).

10. The method of claim 9, wherein the step of supporting the magnetic core (102) and the first coil (104) on the support means (110) comprises the steps of:

inserting an end (105a) of the first insulating wire (105) of the first coil (104) into a wire guide (114) of the support means (110).

11. The method according to claim 9 or 10, wherein the step of fixing the magnetic core (102) and the first coil (104) to the support means (110) comprises the steps of:

-gluing the magnetic core (102) and the first coil (104) to the support means (110) by means of an adhesive (200).

12. The method of claim 9 or 10, wherein the step of urging the magnetic core (102) and the first coil (104) towards the flat surface (PS) comprises:

-pushing the magnetic core (102) and the first coil (104) towards the flat surface (PS) with respect to the support means (110).

13. The method of claim 9 or 10, wherein each turn (a1, a 2.., aN) of the first insulating wire (105) has a furthest point in a normal direction from the first end face (102a) to the Alignment Plane (AP) by a distance (Da1, Da 2.., DaN), wherein the step of urging the magnetic core (102) and the first coil (104) towards the Planar Surface (PS) comprises:

aligning the turn most distant from the first end face (102a) with the Alignment Plane (AP).

14. The method of claim 9 or 10, wherein the step of urging the magnetic core (102) and the first coil (104) towards the flat surface (PS) comprises:

reducing a distance (Da1, Da 2.., DaN) of at least one turn (a1, a 2.., aN) of the first insulating line (105).

15. A circuit system, comprising:

a protective housing (31);

a Printed Circuit Board (PCB) mounted within the protective housing (31);

common mode or differential mode inductor (100) according to any of the preceding claims 1-8 or inductor (100) electrically connected to a Printed Circuit Board (PCB) manufactured according to any of the claims 9-14; and

a thermally conductive material (48) located in the Alignment Plane (AP) between the inductor (100) and the protective housing (31).

Technical Field

The present invention relates to a method of manufacturing a common mode or differential mode inductor. The invention also relates to such a common mode or differential mode inductor. The invention further relates to a circuit system having such a common mode or differential mode inductor.

Background

Outdoor power supply systems (power supply systems) are commonly used to supply power to outdoor electrical systems. An example of such an outdoor electrical system is a telecommunication device, such as a telecommunication base station. Such telecommunication base stations are typically supplied with a 48V Direct Current (DC) voltage, which is provided from a power supply system adjacent or near the base station.

The power supply system may include an Alternating Current (AC)/DC converter for converting an AC voltage from an AC mains (or an AC generator using fossil fuel, etc.).

Alternatively, the power supply system may also include a DC/DC converter for converting a DC voltage (from a solar panel system or other type of DC power source).

The power supply system may also include a rechargeable battery to provide Uninterruptible Power Supply (UPS) functionality.

Outdoor power supply systems also typically include a cabinet in which the electrical equipment is protected from the environment. The cabinet is protected from fine particles (dust, sand, etc.) and moisture (rain, snow, etc.). Fig. 1 shows a prior art cabinet, referred to as a type 4 outdoor cabinet, described in the data manual "outdoor telecommunications power cabinet (type 4)" issued by Eltek ASA. Such a cabinet has foreign object PROTECTION with an INGRESS PROTECTION (IP) code of 55 (PROTECTION level code defined in IEC standard 60529). Power cables, such as AC or DC input power cables and DC output power cables, are routed between the interior and exterior of the cabinet through the top or bottom of the cabinet.

Fig. 2a shows a prior art AC/DC converter module called an Eltek flexpack 2SHE converter, and in the brief text "SHE is so cool: efficiency improvement to the next level (SHE is so cool to the next level)'. There are now two versions that provide 2000W and 3000W, respectively. The power efficiency of this converter is about 98%. As shown in fig. 2a, the electrical and electronic components of the converter module are arranged in the cover body. The purpose of the cover is to provide protection against electrical shock and for EMI purposes. One or more such converters may be mounted in a rack within the cabinet shown in fig. 1.

When the converter and other parts of the power supply system generate heat, a cooling system is required to cool the air within the cabinet. The cooling system may be a heat exchanger, an air conditioner or a fan filter. The cooling system has several disadvantages: it reduces overall power efficiency, increases cabinet size, increases overall power supply system cost, and reduces overall system reliability. As shown in fig. 2a, the converter itself also has a fan on its front side to provide a cooling air flow through the converter.

Fig. 2b shows a prior art AC/DC converter in which the power converter module as shown in fig. 2a is arranged in a metal housing with heat sinks. This shell has an IP65 rating. This AC/DC converter is sold by Eltek ASA under the name Chameleon and described in the data manual Chameleon stand alone 48/650HE (Chameleon standard 48/650 HE). Such converters are passively cooled, which reduces costs due to the absence of an active cooling system. The housing is made of an extruded aluminum alloy, in which a Printed Circuit Board (PCB) and all its electrical components are inserted into the top or bottom opening of the housing. Then, the top end opening and the bottom end opening are closed by a top cover body and a bottom cover body, respectively, the bottom cover body including cable connectors for inputting/outputting power. Such an AC/DC converter increases manufacturing costs due to a cumbersome assembly process.

Fig. 2c shows a prior art AC/DC power system (power system) comprising two converters of fig. 2b connected together as a power core, the system further comprising a battery unit. This AC/DC Power System is sold by Eltek ASA and is described in the data Manual "Chameleon PS Systems-Compact-based Power Supply Systems". It is also susceptible to theft and vandalism. Such systems may provide limited power/electricity and may be relatively expensive to manufacture.

The converter modules of fig. 2a and 2b typically have three Common Mode (CM) inductors. A common mode inductor comprises at least two insulated copper wire coils wound on a single (usually toroidal) magnetic core. The purpose is to suppress electromagnetic interference (EMI) and noise. Today, such CM inductors are usually produced manually, since this is cheaper than using an automated production method. One reason for this is the wire size of the coil, which is typically 1.5 mm to 1.8 mm in diameter for the above power range. Therefore, the wire is relatively stiff and thus difficult to wind around the magnetic core. The manual production method results in high tolerances (i.e., the size of each CM inductor varies greatly), which makes the mounting and soldering process of the CM inductors to the printed circuit board difficult to mechanize.

Another inductor that may be used in such converters is a Differential Mode (DM) inductor. DM inductors typically have a coil of insulated copper wire wound on a single (usually toroidal) magnetic core. CM inductors typically have high permeability cores with low saturation capability, while DM cores have low permeability materials with higher saturation capability.

It is an object of the present invention to reduce tolerances in the manufacture of CM and DM inductors. This will reduce the amount of scrap, thereby reducing the production cost per CM and DM inductor available for manufacture. This will also make the mounting and welding process easier to mechanize. It is also an object of the present invention to improve the cooling of such CM and DM inductors.

Disclosure of Invention

The present disclosure relates to a common mode or differential mode inductor. In one embodiment of the present disclosure, a common mode or differential mode inductor is provided for connection to a Printed Circuit Board (PCB); wherein, the inductor includes:

a magnetic core;

a first coil comprising a first insulating wire wound around the magnetic core by a plurality of turns; and

a supporting device for supporting the magnetic core and the first coil;

wherein the support device comprises:

a base element having a PCB contact surface; and

a first alignment element having a proximal end connected to the base element and a distal end disposed at a distance from the PCB contact surface, wherein the distal end defines an alignment plane;

wherein the magnetic core has a first end face and a second end face, wherein the first end face faces the alignment plane; wherein the second end face faces the base element;

wherein each turn of the first insulated wire has a farthest point spaced apart from the first end face to the alignment plane in the normal direction, wherein the turn farthest from the first end face is aligned with the alignment plane.

In one embodiment, the core may be cylindrical or toroidal, and it may be rectangular or elliptical toroidal. It may also be a cube with an opening through the cube.

In an embodiment of the present case, the base element comprises a wire guide for guiding an end of the first insulated wire of the first coil relative to the support means.

In one embodiment, the end of the first insulated wire is slidingly engaged with the wire guide.

In an embodiment of the present invention, the end of the insulated wire of the first coil protrudes from the base element in a direction away from the alignment plane. The end portion is long enough to penetrate the opening of the printed circuit board and is soldered to a side of the printed circuit board opposite to the support device.

In one embodiment, the longitudinal central axis of the core is oriented perpendicular to the PCB contact surface.

In an embodiment of the present disclosure, the inductor further includes:

a second coil comprising a second insulated wire wound around the magnetic core in a plurality of turns;

wherein each turn of the second insulated wire has a farthest point spaced apart from the first end surface to the alignment plane in the normal direction, wherein the turn farthest from the first end surface is aligned with the alignment plane.

In one embodiment of the present invention, the end of the second insulated wire of the second coil is slidingly engaged with the wire guide.

In one embodiment, the inductor includes a coil separator separating the first coil from the second coil. The coil separator sets a separation distance between the turns of the first coil and the turns of the second coil.

In an embodiment of the present invention, the coil separator is at least partially disposed within the opening of the magnetic core. In an embodiment of the present invention, the entire coil separator is disposed between the alignment plane and the base member.

In one embodiment of the present disclosure, the coil separator includes an alignment face aligned with the alignment plane. In an embodiment of the present invention, the coil spacer is connected to the support device or is provided as a part of the support device.

In an embodiment of the present invention, the magnetic core, the first coil and/or the second coil are fixed to the support means by an adhesive.

The adhesive also secures the magnetic core to the support device when the one or more coils are wound around the magnetic core. The adhesive may also secure the coil separator to the coil and/or to the support device.

In an embodiment of the present disclosure, the supporting device further includes:

a second alignment element having a proximal end coupled to the base element and a distal end disposed a second distance from the PCB contact surface, wherein the distal end of the first alignment element and the distal end of the second alignment element together define an alignment plane.

In one embodiment of the present invention, the second distance between the PCB contact surface and the distal end of the second alignment element is equal to the distance between the PCB contact surface and the distal end of the first alignment element. In this case the alignment plane is parallel to the PCB contact face and thus to the plane of the printed circuit board.

The distal ends of the first and second alignment elements may be parallel lines. Alternatively, the distal end of the first alignment element may be a line and the distal end of the second alignment element may be a point that is not on the line, or vice versa.

In one embodiment, the support device comprises a single first alignment element, wherein a distal end of the single first alignment element comprises an end face defining an alignment plane.

In one embodiment, a single alignment element is provided through the opening of the core. In one embodiment of the present case, the end surfaces defining the alignment plane are substantially circular.

In an embodiment of the present disclosure, the supporting device further includes:

a third alignment element having a proximal end coupled to the base element and a distal end disposed a third distance from the PCB contact surface, wherein the distal end of the first alignment element, the distal end of the second alignment element, and the distal end of the third alignment element collectively define an alignment plane.

In one embodiment of the present invention, the third distance between the PCB contact surface and the distal end of the third alignment element is equal to the distance between the PCB contact surface and the distal end of the first alignment element and also equal to the distance between the PCB contact surface and the distal end of the second alignment element. Also in this case the alignment plane is parallel to the PCB contact face and thus to the plane of the printed circuit board.

In one embodiment, the support device is made as a single body. Alternatively, the base element and the alignment element are made as separate bodies fixed or fastened to each other.

In an embodiment of the present case, the support device is made of a plastic material.

In an embodiment of the present invention, one purpose of the support means is to support the core and the coil with respect to the printed circuit board. Another object is to support the core and the coil in a preferred position with respect to the printed circuit board and with respect to a cooling surface, which is located at a distance from the printed circuit board.

The invention also relates to a method of manufacturing a common mode or differential mode inductor; the method comprises the following steps:

a) providing a support device comprising a base element having a PCB contact surface, and a first alignment element having a proximal end connected to the base element and a distal end disposed at a distance from the base element, wherein the distal end defines an alignment plane;

b) providing a magnetic core, wherein the magnetic core has a first end face and a second end face;

c) winding a first insulated wire around the magnetic core by a plurality of turns to form a first coil around the magnetic core;

d) supporting the magnetic core and the first coil on the support means by positioning the first end face towards the alignment plane and the second end face towards the base element;

e) aligning the alignment plane with the planar surface;

f) urging the magnetic core and the first coil toward the flat surface and abutting the magnetic core and the first coil with the flat surface; and

the magnetic core and the first coil are fixed to the support device.

In an embodiment of the present invention, the step of supporting the magnetic core and the first coil on the supporting device comprises the steps of:

the end of the first insulated wire of the first coil is inserted into the wire guide of the support device.

In one embodiment, the end of the first insulated wire is slidingly engaged with the wire guide.

In an embodiment of the present disclosure, the step of fixing the magnetic core and the first coil to the supporting device includes the steps of:

the magnetic core and the first coil are bonded to the support device by an adhesive.

In one embodiment of the present case, the adhesive is in contact with the magnetic core, the first coil and the support means. However, since the wire of the first coil is wound around the magnetic core, it is sufficient that the adhesive is in contact between the first coil and the support means, since this indirectly causes the magnetic core to adhere to the support means.

In an embodiment of the present invention, the step of pushing the magnetic core and the first coil toward the flat surface includes:

the magnetic core and the first coil are urged against a flat surface relative to the support member.

In an embodiment of the present invention, each turn of the first insulated wire has a farthest point spaced apart in a normal direction from the first end surface to the alignment plane, wherein the step of urging the magnetic core and the first coil toward the flat surface includes:

aligning the turn most distant from the first end face with the alignment plane

In an embodiment of the present invention, the step of pushing the magnetic core and the first coil toward the flat surface includes:

the distance of at least one turn of the first insulated wire is reduced. .

According to the above inductor and the method of manufacturing such inductor it is achieved that no turns of the coil protrude from the first end face and further away by more than a distance protruding from the alignment plane and further away. Thus, all inductors will fit in the designated positions between the printed circuit board and the housing, making the mechanical manufacturing simpler.

In one embodiment, the housing is made of a thermally conductive material, so that the housing is capable of transferring heat away from the inductor. Typically, a thermally conductive material, such as a thermally conductive pad, thermally conductive gap filler, or cured liquid gap filler, is used between the inductor and the housing. The use of fewer and/or thinner shims is achieved due to the alignment of the coils with the alignment plane. Furthermore, the variation between different inductances is reduced, and therefore the variation in the required thickness of the liner is also reduced.

The common mode or differential mode inductor of an embodiment of the present invention further relates to a circuit system, comprising:

a protective housing;

a printed circuit board mounted within the protective housing;

the common mode or differential mode inductor described above, or an inductor manufactured according to the above method, the inductor being electrically connected to a printed circuit board; and

a thermally conductive material located substantially within the pair of flush faces between the inductor and the protective housing.

Drawings

Embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which:

fig. 1 shows a prior art housing of an outdoor power supply system, which housing is a cabinet;

fig. 2a shows a converter module for use in the power supply system of fig. 1;

fig. 2b shows a passively cooled converter module of the prior art;

fig. 2c shows a prior art power supply system with two such passively cooled converter modules;

FIG. 3a shows a front view of a first embodiment of the outdoor power supply system of the present disclosure;

FIG. 3b shows a rear view of a first embodiment of the outdoor power supply system of the present disclosure;

fig. 4a corresponds to fig. 3, wherein the upper part of the main housing and the upper part of each converter module housing have been removed;

fig. 4b shows an enlarged view of a converter module located within a converter module housing, wherein three common mode inductances are shown;

figure 5a shows a perspective view of a first embodiment of a common mode inductor;

fig. 5b shows a first side view of the inductor of fig. 5 a;

fig. 5c shows a second side view of the inductor of fig. 5 a;

FIG. 5d shows a perspective view of one embodiment of a magnetic core;

FIG. 5e shows a perspective view of another embodiment of the magnetic core;

FIG. 6a shows an enlarged side view of a first turn of a first winding wound on a core;

FIG. 6b shows an enlarged side view of a second turn of the first winding wound on the core;

figure 6c shows a photograph of a common mode inductor to illustrate the variation of different numbers of turns of the coil;

FIG. 6d shows an enlarged side view of a first turn of a second winding wound on the core;

FIG. 6e shows an enlarged side view of a second turn of a second winding wound on the core;

figure 7a shows a cross-sectional top view of a component of an embodiment two of the inductor along the line B-B shown in figure 7B;

figure 7b shows a cross-sectional top view of a component of embodiment two of the inductor along the line a-a shown in figure 7 a;

fig. 7c corresponds to fig. 7a, schematically showing a position in which the coil separator has been positioned;

fig. 7d corresponds to fig. 7b, schematically showing a position in which the coil separator has been positioned;

figures 8 a-8 c show the support device in the case of the inductor shown in figures 5 a-c;

FIG. 8d is a top view of the support device of FIGS. 8 a-c;

FIG. 9a shows a side view of another embodiment of a support device;

FIG. 9b shows a cross-sectional top view along line A-A of FIG. 9 a;

FIG. 10 shows a side view of another embodiment of a support device and a magnetic core;

FIG. 11 shows a cross-sectional top view of another embodiment of a support device and a magnetic core;

figures 12a-12e illustrate a method of manufacturing the common mode inductor of figures 5 a-c;

fig. 13 shows the common mode inductor and its position within the module housing.

Detailed Description

Embodiments of the present invention are described with reference to fig. 3a, 3b, 4a and 4 b. In fig. 3a and 3b, the front side FS and the rear side RS of the power supply system 1 are shown. The power supply system 1 includes a main unit 10 including a protective main casing 11 and a power distribution circuit 20 provided in the protective main casing 11. The power supply system 1 further comprises a converter module unit 30 comprising a protective module housing 31 and a converter module 40 arranged in the protective module housing 31. In the figure, the power supply system comprises four such converter module units 30a, 30b, 30c and 30d, each module comprising a respective module housing 31a, 31b, 31c, 31d and a converter module 40a, 40 b. However, the power supply system may comprise only one, two, three or four such units 30, depending on the intended load connected to the power supply system 1.

The power distribution circuit 20 includes cable connectors, circuit breakers/relays, controllers to control power through the converter, controllers to control output voltage, controllers for battery management, etc., while the converter modules 40 include AC/DC converters, DC/DC converters, and/or DC/AC converters, depending on the input power and load requirements. UPS functionality may also be achieved by connecting a rechargeable battery to the power distribution circuit 20.

In fig. 4b, the printed circuit board PCB of the converter module 40 is shown. It is also shown that the printed circuit board PCB comprises three inductors 100 according to an embodiment of the present case, which will be explained in detail below. In one embodiment, the three inductors 100 are common mode inductors.

When powered, the electronic components of the converter module 40, including the inductor 100, generate heat that must be removed from the interior of the housing 31 to prevent overheating.

The power supply system 1 thus comprises a passive cooling system 70, wherein the housing 31 is part of the cooling system, heat being dissipated from the housing 31 to the environment. Thus, the housing 31 is made of a thermally conductive material, such as metal. In one embodiment, the cooling system includes cooling fins 71 disposed on the outer surface of the housing 31.

In one embodiment of the present disclosure, the system 1 is designed for outdoor use. In this case, the housing 31 is a protective housing 31, protecting the interior of the housing 31 (i.e., the PCB and the electrical components) from the outdoor environment. For example, system 1 may have an IP65 rating.

In one embodiment, the housing 31 is made of aluminum or aluminum alloy. The cooling fins 71 of the passive cooling system 70 may be manufactured together with the converter module housing in a die-casting process or a machining process.

An embodiment of the common mode inductor 100 will be described in detail below.

Example one

Referring first to fig. 5a-5d, the inductor 100 has three main parts: a core 102, a coil 104, and a support device 110. These sections will be described in detail below.

The core 102, as shown in fig. 5d, is cylindrical in shape, having a first end face 102a and a second opposing end face 102b, and a longitudinal center axis I1 defined by an opening 102d through the core 102. The outer side surface between the first end surface and the second end surface is referred to as 102 c.

Fig. 5e shows another magnetic core 102, which is ring-shaped with an elliptical cross-section. The end faces 102a, 102b, the opening 102d, the outer side face 102c are also indicated in fig. 5 e.

In addition, the core 102 may be a cylinder with chamfered edges, or it may even be annular.

The coil 104 includes aN insulated wire 105 wound around the magnetic core 102 with a plurality of turns a1, a 2. The insulated wire 105 has two ends 105a for electrically conductive mounting to the printed circuit board PCB.

In the present embodiment, the inductor 100 is a common mode inductor having two coils. Thus, the coil 104 is referred to as a first coil 104 and the second coil is referred to as 106. The second coil 106 comprises a second insulated wire 107 wound around the magnetic core 102 with a plurality of turns b1, b2, …, bN. Likewise, both ends 107a of the second insulated wire 107 are used for conductive mounting onto the printed circuit board PCB.

The support device 110 of the present embodiment is shown in fig. 8a and 8 b. The support device 110 comprises a base element 112 having a PCB contact surface 113. In fig. 8b and 8c, the PCB contact surface 113 comprises four legs protruding from the base element 112 towards the dashed line representing the printed circuit board PCB.

The base element 112 further comprises a wire guide 114 for guiding an end 105a of the first insulated wire 105 of the first coil 104 and for guiding an end 107a of the second insulated wire 107 of the second coil 106 with respect to the base element 112. Wire guide 114 may be configured as an opening in base member 112, and may also be configured as an open U-shaped or V-shaped slot in base member 112. The ends 105a, 107a of the wires 105, 107 are slidably engaged with the wire guide 114.

The ends 105a, 107a of the insulated wires 105, 107 project from the base element 112 in a direction away from the alignment plane AP. The end portion 105a has a length sufficient to penetrate the opening of the printed circuit board PCB and is soldered to a side of the printed circuit board PCB opposite to the supporting device 110.

Support device 110 further includes a first alignment element 120 having a proximal end 120b coupled to base element 112 and a distal end 120a disposed a distance D from PCB contact surface 113.

The support device 110 further comprises a second alignment element 125 having a proximal end 125b connected to the base element 112 and a distal end 125a disposed at a second distance from the PCB contact surface 113.

In fig. 8b, the first alignment element 120 and the second alignment element 125 are shown oriented substantially parallel to each other. A dashed line La is drawn between the distal ends 120a, 125 a. The dashed line La is arranged parallel to the PCB plane. Also shown, the distal end 120a of the first alignment element 120 extends in a direction substantially perpendicular to the imaginary line La (indicated by the imaginary line L120 a), and similarly, the distal end 125a of the second alignment element 125 extends in a direction substantially perpendicular to the imaginary line La (indicated by the imaginary line L125 a).

Thus, the distal end 120a of the first alignment element 120 and the distal end 125a of the second alignment element 125 define parallel lines L120a, L125 a. The distal end 120a of the first alignment element 120 and the distal end 125a of the second alignment element 125 together define an alignment plane AP as indicated in fig. 8b and 8 c. This alignment plane AP is parallel to the printed circuit board PCB.

As shown in fig. 5a, 5b and 5c, the core 102 and the coils 104, 106 are located between the first alignment element 120 and the second alignment element 125.

It is also shown that the longitudinal central axis I1 of the magnetic core 102 is oriented parallel to the printed circuit board PCB.

In fig. 5a, it is further shown that the inductor 100 comprises a coil separator 140 for separating the first coil 104 from the second coil 106. Coil separator 140 sets the separation distance between turns a1, a2, ·, aN of first coil 104 and turns b1, b2,. and bN of second coil 106 to avoid electrical shorts between the first and second coils. In the present embodiment, the coil separator 140 is at least partially disposed within the opening of the magnetic core 102.

Further, the magnetic core 102, the first coil 104 and the second coil 106 may be fixed to the support device 110 by an adhesive (as shown in the adhesive container in fig. 12 e). Notably, the adhesive may only directly contact the coil and the support device 110. Since the coils 104, 106 are wound around the core 102, the adhesive also indirectly secures the core 102 to the support member 110. The coil spacers 140 may also be secured to the coil and/or the support device 110 using an adhesive 200.

EXAMPLE I production

The fabrication of the first embodiment of inductor 100 will now be described.

In a first step, a first insulated wire 105 is wound around a magnetic core 102 with a plurality of turns a1, a 2.

In the same manner, a second insulated wire 107 is wound around the magnetic core 102 by a plurality of turns b1, b 2.

It is noted that the coils 104, 106 shown in fig. 5a are illustrated by a three-dimensional (3D) computer program, where each turn is perfectly aligned with the other turns. In reality there will be variations between each turn, one of the reasons being that the insulated wires 105, 107 of the coils 104, 106 are relatively stiff. In fig. 6c, a picture of the inductor 100 is shown, wherein it is clear that the two adjacent turns a1, a2 are not perfectly aligned with each other.

Reference is now made to fig. 12 a. Here the support means 110 and the core 102 with the two coils 104, 106 are shown adjacent to each other (only coil 106 is shown). Notably, the end 107a of the insulated wire 107 is shown as being quite long.

Reference is now made to fig. 12 b. The core 102 and the coils 104, 106 are here supported on the support means 110 by orienting the first end plane 102a of the core 102 towards the alignment plane AP and the second end plane 102b towards the base element 112. The coils 104, 106 are located between two alignment elements 120, 125. The ends 105a, 107a of the first insulated wire 105 and the ends 105a, 107a of the second insulated wire 107 are inserted into the wire guide 114 of the support device 110.

Reference is now made to fig. 12 c. The inductor 100 here corresponds to the inductor shown in fig. 12b, but is inverted. The counter flush surface AP is aligned with a flat surface PS, such as the surface T of a table or the like. As shown in fig. 12c, the distance Dt1 between the turns of the coil and the alignment plane AP is greater than zero.

Reference is now made to fig. 12 d. Here, the core 102 and the coils 104, 106 are shown pushed together towards the flat surface PS until at least one turn of one of the coils abuts the flat surface PS. The distance Td1 is now zero. Notably, the core 102 and coils 104, 106 are urged together relative to the support device 110, as the distal ends 120a, 125a defining the alignment plane AP remain stationary relative to the plane. This relative movement is permitted because the insulated wires 105, 107 slidingly engage the wire guides 114.

In a final step, shown in fig. 12e, the core 102 is fixed to the support means 110 together with the coils 104, 106. As described above, this may be accomplished by bonding the core 102 and/or coils 104, 106 to the support device 110 with the adhesive 200. When the inductor 100 is in the position shown in fig. 12e, the adhesive will be allowed to cure.

Alternatively, as shown in fig. 12e, the ends 105a, 107a may be cut to a suitable length. Alternatively, this may also be done after the inductor 100 is soldered onto the printed circuit board PCB.

Reference is now made to fig. 6a and 6 b. Here two different turns a1, a2 of the magnetic core 102 are shown. Each turn a1, a 2.., aN of the first insulating line 105 has a farthest point from the first end surface 102a to the alignment plane AP by a distance Da1, Da 2.., DaN in a normal direction of the first end surface 102a and the alignment plane AP. When comparing fig. 6a and 6b, it is clear that the turn a1 is the farthest away from the first end face 102a, since the distance Da1 is greater than the distance Da 2.

As described above, with reference to fig. 12d, the coils 104, 106 (together with the magnetic core 102) are pushed towards the flat surface PS until at least one turn of one of the coils abuts the flat surface PS. In the case of fig. 6a and 6b, the first turn a1 will abut the planar surface PS, thus being aligned with the alignment plane AP, while the second turn a2 will not abut the planar surface PS. Thus, if the inductor has only one coil 104, the turn having the furthest distance Da1, Da2, a.

Reference is now made to fig. 6d and 6 e. Here two different numbers of turns b1, b2 of the magnetic core 102 are shown. Similar to fig. 6a and 6b described above, it is clear that the turn b1 is the farthest away from the first end face 102a, since the distance Db1 is greater than the distance Db 2.

Thus, if the inductor 100 has two coils 104, 106, the turn having the furthest distance Da1, Da2,. DaN, Db1, Db2,. dai, DbN from the first end face 102a will be aligned with the alignment plane AP.

In practice, some turns may have the same distance from the plane PS, and thus more than one turn of the same coil or of different coils may be aligned with the alignment plane AP.

It may also be the case that the step of pushing the magnetic core 102 and the first coil 104 will result in a decrease of the distance a1, a2,.. ann, aN 1, b2,. bN, of at least one of the turns Da1, Da2,. ann, DaN, Db1, Db2,. ann, DbN of the insulated wire 105, 107. This will typically require deformation of the insulated wires 105 and 107.

Example two

Reference is now made to fig. 7a-7 d. Only the support member 110 and the magnetic core 102 are shown here and the coil is not shown.

The support device 110 here comprises a base element 112 and a PCB contact surface 113. However, the support device 110 here comprises only a single alignment element 120. The single alignment element 120 here has to have a distal end 120a extending in two different directions, i.e. the distal end 120a itself has to define the alignment plane AP.

The single alignment element 120 is here disposed through the opening 102d of the core 102. The end face 121 defining the alignment plane AP is substantially circular. Also shown, the alignment element 120 includes a slot 122 at an end thereof, the slot 122 for receiving the separation element 140.

The coil spacer 140 includes an alignment surface 142 that will align with the alignment plane AP during the manufacturing step of pushing the coil (with the magnetic core) into abutment with the flat surface PS.

EXAMPLE III

Reference is now made to fig. 9a and 9 b. Here, the support device 110 further comprises a third alignment element 128, a proximal end 128b of which is connected to the base element 112 and a distal end 128a of which is arranged at a third distance from the PCB contact surface 113, wherein the distal end 120a of the first alignment element 120, the distal end 125a of the second alignment element 125 and the distal end 128a of the third alignment element 128 together define an alignment plane AP.

The third alignment element 128 is here arranged through the opening 102d of the core 102, similar to the embodiments described above. Therefore, this third embodiment can be regarded as a combination of the first and second embodiments described above.

Example four

Reference is now made to fig. 10. The support means 110 here comprises two alignment elements 120, 125, wherein one of the two alignment elements is arranged through the opening 102d of the core 102, similar to the second embodiment above.

The distal ends 120a, 125a of the first and second alignment elements 120, 125 together define an alignment plane AP.

EXAMPLE five

Referring now to fig. 11, the support device 110 includes three alignment elements 120, 125, 128, each located radially outward of the core 102 as shown in fig. 11.

The distal ends 120a, 125a, 128a of the first, second and third alignment elements 120, 125, 128 collectively define an alignment plane AP.

It is apparent from the above embodiments that there are a variety of ways to define such an alignment plane AP by one or more distal ends of one or more support elements.

In the above embodiment, the support device 110 is made single. It may be made of a non-conductive material, such as a plastic material. Alternatively, the base member 112 and the alignment member may be made as separate bodies that are fixed or fastened to each other.

As mentioned above, the purpose of the support means 110 is to support the core 102 and the coil with respect to the printed circuit board PCB. Another object is to support the core 102 and the coil in a preferred position for the printed circuit board PCB and the cooling surface, which is located at a distance from the printed circuit board PCB.

The circuitry implemented using inductor 100 is shown in fig. 13, where the cooling system provided by housing 31 is shown below and above inductor 100. Where the inductor 100 is conductively mounted on a printed circuit board PCB. As shown, the circuitry further includes a thermally conductive material 48 located in an Alignment Plane (AP) between the inductor 100 and the protective housing 31. In one embodiment, thermally conductive material 48 is a thermally conductive pad. A thermal pad 48 is disposed between the inductor 100 and the interior of the upper housing 31 to improve heat transfer from the inductor 100 to the upper housing 31.

According to the inductor and the method of manufacturing the same described above, it is achieved that no turns a1, a 2.., aN, b1, b 2.., bN protrude from the first end face 102a and further away, exceed the distance protruding from the alignment plane AP and further away. Thus, all of the inductors 100 will fit in the designated locations between the printed circuit board and the housing, and no inductor will interfere with the assembly of the circuit system.

The use of fewer or thinner shims is achieved due to the alignment of the coils with the alignment plane AP. Furthermore, the variation between different inductances is reduced.

Alternative embodiments

It is noted that the alignment plane AP may also be inclined with respect to the PCB plane if the interior of the housing is inclined, i.e. not parallel to the printed circuit board PCB.

The coil spacer 140 may be integrated with the support device 110, that is, the coil spacer 140 is provided as a part of the support device 110.

Notably, inductor 100 may have one, two, or more than two coils wound around magnetic core 102.