Inductor device, method of manufacturing same and antenna

A method of manufacturing an inductor device, comprising:

• producing an electrically insulating support by injection molding, being made of a single hollow part open on one of the faces thereof with a rectangular prismatic cavity, provided for completely housing a magnetic core, and being accessible through an opening surrounded by a frame having four sides arranged opposite one another in pairs, said support being provided with:
• two orthogonal winding up channels dimensioned to delimit respective two orthogonal windings (DX, DY), said winding up channels being defined by winding supporting outer faces (12X, 12Y and 12Z) each perpendicular to one axis X, Y or Z, winding limiting edges perpendicular to the winding supporting outer faces (12X, 12Y), four additional winding supporting outer faces (12X and 12Y) formed on said four sides of the frame and the winding limiting edges associated therewith;
• winding supporting outer faces (12Z) perpendicular to one of said axis X and Y and configured to support a third winding (DZ) orthogonal to the other two windings (DX, DY);
• and
• four lower corner protuberances including winding limiting edges perpendicular to the winding supporting outer faces (12X, 12Y and 12Z),
• providing, inside said rectangular prismatic cavity of the electrically insulating support, a rectangular prismatic magnetic core with eight vertexes and three pairs of opposite faces facing and parallel to one another, defining said three axes X, Y and Z orthogonal to one another each perpendicular to one of said pairs of faces and passing through the geometric center of the faces;
• providing three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wound around said magnetic core and supported on the winding supporting faces (12X, 12Y and 12Z), confined between the winding limiting edges;
• wherein the method includes:
• produce the electrically insulating support through a two-part mold lacking of upper corner protuberances in correspondence with the remaining four vertexes of the magnetic core, with said frame being arranged flush with or above the level of the magnetic core, and with the two orthogonal winding up channels being centered with respect to the orthogonal axes X, Y and Z,
• wound the third winding (DZ) on said winding supporting outer faces (12Z) delimited on one side by said limiting edges of the lower corner protuberances, centered with respect to the orthogonal axes X and Y, configured so that in combination with the dimensions of the magnetic core and with the other two orthogonal windings (DX, DY) define three isotropic orthogonal magnetic fields,
• wherein removable upper corner protuberances are furthermore provided before winding up the winding (DZ) around the axis Z and are removed when said winding up ends, such that the winding supporting faces (12Z) for supporting the winding (DZ) around the axis Z are demarcated between the electrically insulating support and said removable upper corner protuberances during the winding up step.

A transmitting or receiving antenna including an inductor device comprising:

• a rectangular prismatic magnetic core with eight vertexes and three pairs of opposite faces facing and parallel to one another defining an axis X, an axis Y, and an axis Z orthogonal to one another each perpendicular to one of said pairs of opposite faces and passing through the geometric center of the opposite faces,
• an electrically insulating support surrounding all but one of the opposite faces of the magnetic core and made of a single part with a rectangular prismatic cavity arranged around said magnetic core, said cavity completely housing the rectangular prismatic magnetic core and being accessible through an opening surrounded by a frame having four sides arranged opposite one another in pairs, said electrically insulating support being provided with:
• two orthogonal winding up channels dimensioned to delimit respective two orthogonal windings of conductive wire, said winding up channels being defined by winding supporting outer faces each perpendicular to one of said axis X, Y, winding limiting edges perpendicular to the winding supporting outer faces, four additional winding supporting outer faces formed on said four sides of the frame and the winding limiting edges associated therewith;
• winding supporting outer faces perpendicular to one of said axis X and Y and configured to support a third winding of conductive wire, orthogonal to the other two windings, and
• four lower corner protuberances arranged on four vertexes of the magnetic core, including winding limiting edges perpendicular to the winding supporting outer faces,
• said three windings being arranged orthogonal to one another wound around said magnetic core supported on said winding supporting faces, confined between the winding limiting edges such that when a current circulates through the mentioned windings, an electromagnetic field with electromagnetic field vectors coaxial with the axes of each of the windings is generated,
• wherein:
• said frame is arranged flush with or above the level of the magnetic core,
• said winding supporting outer faces define four pilasters projecting from the four corners protuberances of the electrical insulating support, wherein an end of each pilaster also project from the frame forming steps determining said winding limiting edges,
• said winding supporting outer faces extending from lower corner protuberances up to said pilaster end;
• and
• said winding supporting outer faces, where the third winding is wound, provide surfaces delimited on one side by said limiting edges of the lower corner protuberances, and
• said third winding is centered with respect to the orthogonal axes X and Y,
• wherein said two orthogonal windings and said third winding are configured to, in combination with the dimensions of the magnetic core, define three isotropic orthogonal magnetic fields.