DE102018218860A1 - Holding device for a coupled throttle unit, current doubler arrangement with the holding device and the throttle unit, and method for mounting the throttle unit - Google Patents

Abstract

Usually two separate output chokes are used in conventional current doublers. In order to be able to save construction volume, it is therefore known to couple the two output chokes together and thus to integrate them in one component. For this purpose, a holding device 10 for a coupled choke unit 3 is a current doubler arrangement 1, the choke unit 3 being a core arrangement 9 with a coil core 16 and one comprises first and second coil windings 17, 18, the first and second coil windings 17, 18 being magnetically coupled to one another via the coil core, and wherein the choke unit 3 comprises at least one contacting rail 8a, b, c, d, with a core receptacle 23 for receiving of the core arrangement 9, the core receptacle 23 having a base section 23a for supporting the coil core 16 and a wall section 23b for the positive engagement of the coil core 16 in at least one horizontal direction H1, H2, with at least one rail receptacle 24a, b, c, d for receiving the contacting rail 8a, b, c, d, the rail receptacles 24a, b, c, d and the core receptacle 23 are arranged in such a way that the contact rail 8a, b, c, d accommodated therein as intended is held in a predetermined relative position to the core arrangement 9 receptacle accommodated in the core receptacle 23 during a joining process.

Description

The invention relates to a holding device for a coupled throttle unit of a current doubler arrangement. The invention further relates to a current doubler arrangement with the coupled throttle unit and the holding device, and to methods for assembling the throttle unit.

The current doubler topology, also known as the “current doubler topology”, represents a variant of realizing the high current side of an HV / LV DC / DC converter (high / low voltage, direct current), which means that the current load on one Secondary winding of a transformer can be kept low. Usually two separate output chokes are used in conventional current doublers. In order to be able to save construction volume, it is therefore known to couple the two output chokes together and thus to integrate them in one component.

The publication DE 20 2011 051 056 U1 , which probably forms the closest prior art, discloses an inductive component with at least two choke coils which are coupled to one another by a magnetic circuit and are arranged in a common core, the common core having at least one core intermediate element which can vary the coupling between the windings of the choke coils.

The invention has for its object to provide a holding device of the type mentioned, which is designed for a throttle unit and is characterized by a simple assembly.

This object is achieved according to the invention by a holding device with the features of claim 1, a current doubler arrangement with the features of claim 7 and by methods for mounting the throttle unit with the features of claims 14 and 15. Advantageous refinements result from the subclaims, the drawings and / or the description.

The invention relates to a holding device which is designed and / or suitable for a coupled throttle unit of a current doubler arrangement. The holding device is used, in particular, for positioning and / or fixing a plurality of components of the throttle unit to be contacted during a joining process. The current doubler arrangement is preferably designed as a current doubler rectifier. Preferably the holding device is in one piece, e.g. made of a plastic injection molded plastic component.

The choke unit has a core arrangement, the core arrangement having a coil core and a first and a second coil winding. The coil core preferably forms a common core for the two coil windings, the first and second coil windings being arranged together on the coil core and / or being magnetically coupled to one another via the coil core. For example, the coil core is designed as a ferrite core.

The two coil windings each have two winding ends. In particular, the winding ends are rectified to one another and / or staggered out of the coil core. The first and / or the second coil winding has at least one, preferably exactly two, windings. The two coil windings preferably have a rectangular and / or round and / or polygonal winding cross section. For example, the first and / or the second coil winding is designed as a copper bar.

The choke unit has at least or exactly one contacting rail which is designed and / or suitable for contacting the first and / or the second coil winding with a printed circuit board. Each coil winding is preferably assigned at least or exactly one separate contacting rail. The contacting rails are preferably contacted and / or contacted in an electrically conductive manner in a connection area with the associated coil winding. In particular, the connection area is the area of the choke unit in which the winding ends are electrically conductively contacted and / or contacted with the contacting rail (s). The contacting rails are particularly preferably designed as preformed sheet metal components. For example, the contacting rails can be U-shaped, L-shaped and / or I-shaped when viewed from above in a projection. For example, the contact rails are designed as copper sheets.

The holding device is preferably designed and / or set up to accommodate the intended or previously described throttle unit. For this purpose, the holding device has a core receptacle which is designed and / or suitable for receiving the core arrangement. The core receptacle preferably forms a negative of the core arrangement, in particular of the coil core, at least in sections, so that the core arrangement, in particular the coil core, can be inserted into the core receptacle with a precise fit. When viewed in a rough form, the coil core can have, for example, a cuboid and / or cube-shaped outer contour.

The core receptacle has a bottom section which is designed and / or suitable for supporting the coil core. The bottom section is preferably designed as a flat, preferably rectangular, bottom plate of the holding device. In particular, the bottom section defines a flat support surface, the coil core being able to rest in sections over the entire surface or over the entire area of the support surface. In particular, a horizontal plane is defined by the base section, in particular the support surface.

The core receptacle has a wall section which is designed and / or suitable for the form-fitting contact of the core arrangement, in particular the coil core, in at least or exactly one horizontal direction. In particular, the horizontal direction is to be understood in relation to the horizontal plane. In principle, the wall section can define two mutually opposite contact surfaces, so that the coil core is positively fixed between the two contact surfaces in exactly one horizontal direction. However, the wall section preferably defines four contact surfaces which delimit the bottom section in the horizontal plane in a first and a second horizontal direction perpendicular to the first, so that the coil core between the contact surfaces is completely positively fixed in the horizontal plane or in each horizontal direction. In particular, the four contact surfaces are arranged in a rectangle with respect to one another. Particularly preferably, each of the contact surfaces preferably extends in a separate vertical plane perpendicular to the horizontal plane.

The holding device has at least or exactly one rail receptacle, which is designed and / or suitable for receiving the contacting rail. In particular, the rail mount serves for the positive and / or non-positive mount of the contacting rail. In particular, the contacting rail can be held captively in the rail receptacle. The holding device can have a plurality of rail receptacles, with each rail receptacle preferably being assigned a separate contacting rail. The rail receptacles are preferably spaced apart and / or arranged parallel to one another and / or without crossing, so that the contacting rails are preferably accommodated in the respective rail receptacle without contact and / or in isolation from one another.

The rail receptacles and the core receptacle are arranged in such a way that the contacting rail accommodated therein as intended is held in a predetermined relative position to the core arrangement intended as housed in the core receptacle during a joining process. In particular, the at least one rail receptacle and the core receptacle are matched to one another in accordance with the predetermined relative position and / or are arranged on the holding device. In particular, the contacting rail and the core arrangement are held without play and / or firmly in the respective rail receptacle relative to one another during the entire joining process by the holding device. In particular, the first and / or the second coil winding can be pre-positioned relative to the coil core and / or the associated contact rail. For example, the first and / or the second coil winding can be mechanically and / or cohesively fixed to the coil core and / or the respective contact rail for prepositioning.

The advantage of the invention is that the mounting process of the coupled throttle unit can be simplified by the holding device, since the contacting rails are already positioned in the correct position relative to one another for the joining process by the holding device. This eliminates the need for complex alignment of the individual components during the joining process, so that the assembly time can be significantly reduced. In addition, the contacting rails and the core arrangement are still fixed in the holding device after the joining process, so that, for example, component distortion caused by the joining process is compensated for and / or damage to the contact points during the further assembly process is significantly reduced. Another advantage is, in particular, that damage to the components is prevented by accommodating the contacting rails or the core arrangement in the holding device.

In a preferred constructive embodiment, it is provided that the rail receptacle forms a negative contour of the contacting rail to be accommodated, at least in sections. Thus, the or each of the contacting rail (s) can be arranged and / or arranged with a precise fit in the associated rail receptacle. In particular, precisely fitting means an almost play-free mounting of the respective contacting rail in the associated rail mounting. The rail receptacle is particularly preferably designed such that the contacting rail is held in the rail receptacle in a self-retaining manner. For this purpose, the rail receptacle can be made with a slight oversize, so that the contacting rail is held in the rail receptacle by friction. During assembly, the contacting rail is inserted or pressed into the corresponding rail receptacle, for example, with a low pressure. Each of the rail receptacles is preferably designed such that an associated contact rail can only be arranged in the rail holder provided for this purpose. This can ensure that each of the contact rails is clearly assigned to the respective rail holder and incorrect assembly can be excluded. Furthermore, due to the precisely fitting receptacle, the connection area is clearly defined by the position of the contact rails.

In a further specification of the invention it is provided that at least or exactly one of the rail receptacles has a plug-in contour, the plug-in contour being arranged on an underside of the base section. In particular, the contacting rail can be inserted and / or inserted into the plug-in contour at least in sections. In principle, the plug-in contour can be molded into the base section. For this purpose, the plug-in contour can be designed, for example, as at least or exactly one groove made in the bottom section. Alternatively, the plug-in contour can be molded onto the underside of the base section. For this purpose, the plug-in contour can be formed, for example, by at least or exactly two webs arranged parallel to one another. In particular, the webs can be at least slightly resiliently deformable, so that the contacting rail between the two webs is held captive and / or clamped. The plug-in contour ensures simple and inexpensive mounting of the contact rails on the holding device.

An alternative or optional additional specification of the invention provides that at least or exactly one of the rail receptacles has a holding tab. The holding tab is arranged on an outside of the bottom section. Alternatively or optionally additionally, the retaining tab is arranged on an outside of the wall section. In particular, the at least one holding tab is molded onto the holding device in at least one of the horizontal directions. The holding tab can be opened at least on one side with respect to the horizontal plane in a vertical direction (a direction oriented orthogonally to the horizontal plane), so that the contacting rail is pushed into the holding tab and held in an opposite direction. Alternatively, the holding tab is open on both sides in the vertical direction, so that the contacting rail can be inserted and / or pushed in through the holding tab in the vertical direction. The at least one contacting rail is preferably received in the retaining tab in a frictionally locking manner at least in sections. In particular, the retaining tab can have a rib structure, which favors a frictional connection with the contacting rail. It can be provided that at least one of the rail receptacles is formed by the plug-in contour and the retaining tab. In particular, a defined end position of the contacting rail is defined in the vertical direction at least by the plug-in contour and in the horizontal direction at least by the holding tab and / or the plug-in contour. A rail mount is thus proposed which, in addition to the simple and inexpensive design, also enables the contacting rail to be fitted with a precise fit.

In a further development it is provided that the wall section is designed as a wall encircling the base section, the wall section being interrupted in a connection area for the implementation of the winding ends. For this purpose, the wall can have at least or exactly one opening or a recess, the winding ends being guided through the opening or the recess from the core receptacle in the connection area. The two winding ends of a coil winding are preferably arranged offset from one another in the vertical direction, the wall being interrupted accordingly. The position of the winding ends is thus clearly defined, as a result of which incorrect assembly of the first and / or the second coil winding can be prevented.

In a further embodiment of the invention it is provided that the holding device has a closure means which is designed and / or suitable for fixing the core arrangement in the core receptacle. In particular, the closure means is designed as a housing cover or a holding clip. After assembly of the core arrangement, the closure means is preferably placed on the core receptacle, so that the closure means closes the core receptacle at least in sections or completely. The closure means can be integrally and / or non-positively connected to the wall section. For example, the closure means can be releasably connected to the wall section via a snap connection. In particular, the core arrangement is positively fixed in the vertical direction between the bottom section and the closure means. The core arrangement is thus particularly preferably fixed in all three spatial directions in the holding device. A simple and quick final fixation of the core arrangement in the core receptacle can thus be implemented by the closure means.

Another object of the invention relates to a current doubler arrangement with the coupled throttle unit and with the holding device as described above. In particular, the current doubler arrangement comprises a transformer, preferably a planar transformer, with the coupled choke unit on a secondary side of the transformer is connected.

In a concrete constructive implementation it is provided that the throttle unit has a rail arrangement with at least or exactly four of the contacting rails. A first assignment rail is designed and / or suitable for contacting the first coil winding with a first transformer connection of the transformer. A second contacting rail is designed and / or suitable for contacting the second coil winding with a second transformer connection of the transformer. In particular, the first and / or the second contacting rail can have a connection contour and the associated transformer connection can have a corresponding counter contour, the connection contour preferably forming a contour partner to the counter contour.

A third contacting rail is designed and / or suitable as a first choke output for contacting the first and second coil windings. A fourth contact rail is designed and / or suitable as a second throttle output to form a ground connection. In particular, the third and fourth contacting rails, in particular the first and the second throttle output, can be electrically coupled to one another via a capacitor device. Alternatively or optionally in addition, the first and fourth contact rails and the second and fourth contact rails can each be electrically coupled to one another via a rectifier device.

The contact rails are each arranged in a separate rail holder and are held in the correct position relative to the core arrangement in the respective rail holder. In particular, the first and the second contacting rail are each held in a plug-in contour on the underside of the base section, the first contacting rail being guided into the connection region of the first coil winding via a first holding tab and the second contacting rail being guided into the connection region of the second coil winding via a second holding plate. The third contacting rail is held in a further retaining tab on one end face of the base section and is arranged in the connection region of the first and / or the second coil winding. The fourth contact rail is held on the underside of the base section, preferably between the first and the second contact rail, in a further separate plug-in contour. All contact rails can preferably be mounted in the respective rail receptacle by means of a plug-in movement, so that the contact rails can be installed particularly easily and quickly.

In a specific further development it is provided that the one winding end of the first coil winding is electrically conductively connected to the first contact rail and the other winding end of the first coil winding is connected to the third contact rail. Furthermore, one winding end of the second coil winding is electrically conductively connected to the second contact rail and the other winding end of the second coil winding is connected to the third contact rail. In particular, the transformer and the choke unit are arranged one behind the other, the first and the second contacting rails being contacted on the rear of the holding device with the respective transformer connection and on the front of the holding device being contacted with the respective winding end. The third contact rail is arranged on the front of the holding device parallel and / or offset in the horizontal direction to the first and the second contact rail. In particular, the winding ends of the first and second coil windings are of different lengths. The winding ends preferably lie flat against the respective contacting rail.

In a constructive implementation, at least or exactly one of the contact rails is integrally connected to the first and / or the second coil winding. In particular, the winding ends are each integrally connected to the associated contact rail by means of the joining process. For example, the joining process is a welding process or a soldering process. The contacting rails and the coil windings for the joining process are correctly positioned by the holding device and are fixed relative to one another for the duration of the entire joining process. This significantly simplifies the joining process, while at the same time increasing the assembly accuracy.

In a further constructive implementation it is provided that the current doubler arrangement has a printed circuit board. In particular, the circuit board is designed as a rectifier board. The throttle unit is arranged on the printed circuit board and contacted in an electrically conductive manner. The throttle unit, in particular the holding device, can be mounted on the printed circuit board via at least one fastening means. At least one of the contact rails is contacted with at least or exactly one conductor track of the circuit board, the contact rail being electrically conductively connected to at least or exactly one electronic component via the at least one conductor track. The electronic component is preferably an SMD component ("Surface mounted device"), which is mounted on the circuit board. The electronic component can be designed as the rectifier device or the capacitor device. For example, several of the electronic components are arranged on the circuit board and connected to one another via a plurality of conductor tracks with the plurality of contact rails in accordance with a current doubler topology.

In a specific implementation, it is provided that the at least one contacting rail has at least one contact pin for contacting the conductor track. The contacting rail is non-positively and / or cohesively connected to the printed circuit board via the contact pin. The circuit board preferably has corresponding pin receptacles for receiving the contact pins. The contact pin can be held non-positively in the pin receptacle via a press fit. Alternatively or optionally in addition, the contact pin can be held in a cohesive manner via a soldered connection in the pin receptacle. This enables the contact rail (s) to be fixed quickly and inexpensively on the printed circuit board.

In a further embodiment it is provided that the coil core has two inner core webs. In particular, the two inner core webs are arranged between two outer core webs, the core webs being connected to one another via a common base plate. In particular, the core holder can form a contour partner to the base plate. The coil core is preferably formed in two parts, the base plate forming a first core half with the core webs. A second core half can be designed, for example, as a plate-shaped cover plate, which is preferably arranged at a distance from the two outer and / or the two inner core webs. The two outer core webs are in particular spaced apart from the cover plate via an air gap. In particular, a leakage inductance can be realized and / or set via the air gap between the cover plate and the two outer core webs. The cover plate can in each case be supported on the two middle core webs by an insulator, so that the distance between the two middle core webs and the cover plate is defined by the insulator. The insulator can be arranged loosely or self-holding or tensioned between the two core halves. For example, the insulator can be in the form of a band or a plate. Specifically, the coil core can be designed in an EI design, the first core half being the E part and the second core half being the I part.

The first coil winding is arranged on one inner core web and the second coil winding is arranged on the other inner core web. In particular, a coil formed by the first coil winding forms a first output choke of the current doubler arrangement and a coil formed by the second coil winding forms a second output choke of the current doubler arrangement, the two output chokes being coupled to one another via the common coil core. The two output chokes can thus be implemented in a common component, resulting in a compact structural unit. The coupling has the result that a phase ripple at the throttle output can be minimized.

Another object of the invention relates to a method for assembling the throttle unit as described above. In particular, the method serves for pre-assembling the throttle unit with the aid of the holding device and the subsequent arrangement on the printed circuit board.

For this purpose, the at least one contacting rail is arranged in at least one of the rail receptacles in a positioning step. In particular, in the positioning step, all contact rails of the throttle unit are inserted into the corresponding rail receptacle of the holding device. The core arrangement can then be arranged in the core receptacle. Alternatively, however, it is also conceivable to first arrange the core arrangement in the core receptacle and then to insert the contacting rail (s) in the associated rail receptacle. The core receptacle and the rail receptacle (s) are arranged in relation to one another such that the core arrangement and the contacting rails are positioned in the correct position relative to one another by the holding device. In particular, the contacting rails and the core arrangement are positioned relative to one another by the holding device in such a way that the coil windings, in particular the winding ends, and the contacting rails abut one another in the correct manner in the connection region.

In a joining step, the first and / or the second coil winding are connected to the respectively associated contact rails by means of a joining process, so that the throttle unit is formed, in particular as a preassembled structural unit. In particular, the corresponding winding ends are welded or soldered to the associated contact rail. The contact rails and the core arrangement remain firmly fixed to each other during the entire joining step, so that process reliability can be permanently guaranteed during the entire joining process.

In a further positioning step, the throttle unit is arranged on the circuit board, wherein the contact rails and the circuit board are positioned in the correct position relative to one another by the holding device. In particular, the contacting rails are pre-positioned in the holding device in accordance with a conductor track arrangement applied to the printed circuit board. The throttle unit is aligned in accordance with the conductor arrangement and then placed on the circuit board. For this purpose, the contact rails are preferably inserted into the pin receptacles with the contact pins.

In a further joining step, the contacting rails are connected to the printed circuit board by means of a further joining process. In particular, the contact pins are soldered and / or pressed into the pin receptacle. The assembly of the throttle unit over the rectifier board results in a very compact structure, the assembly process being significantly simplified. In addition, the mounting accuracy during assembly steps can be significantly increased by the holding device.

Another object of the invention relates to an alternative method for assembling the throttle unit as described above. In particular, the method serves for preassembly of the contacting rails on the printed circuit board with the aid of the holding device and the subsequent assembly of the core arrangement in the preassembled holding device.

For this purpose, the at least one contacting rail is arranged in the at least one rail receptacle in a positioning step. In particular, in the positioning step, all contact rails of the throttle unit are inserted into the corresponding rail receptacle of the holding device. In particular, the contact rails can be arranged in advance in the corresponding rail receptacles of the holding device and the holding device can then be arranged together with the contact rails on the printed circuit board. Alternatively, the contact rails or at least some of the contact rails can be inserted on the circuit board, in particular into the pin receptacles, and the holding device can then be placed on the pre-assembled contact rails for final alignment. The contact rails and the printed circuit board are positioned in the correct position relative to one another by the holding device. In particular, the rail receptacles are arranged relative to one another such that the contacting rails are positioned on the printed circuit board in accordance with the predefined conductor track arrangement.

In a joining step, the contacting rails are connected to the circuit board by means of a joining process, so that in particular a pre-assembled structural unit is formed. In particular, the contact pins are soldered and / or pressed into the pin receptacle. The contact rails are held to one another during the entire joining step by the holding device on the circuit board so that the contact rails remain fixed in a predetermined end position in the connection area.

In a further positioning step, the core arrangement is arranged in the core receptacle of the holding device. In particular, the core arrangement is inserted into the core receptacle in the vertical direction. The winding ends are brought into contact with the respective contact rail. The contacting rails and the core arrangement are positioned in the correct position relative to one another by the holding device. In particular, the end position of the core arrangement is predetermined by the holding device in such a way that the coil windings, in particular the winding ends, and the contact rails in the connection region abut one another in the correct polarity.

In a further joining step, the first and / or the second coil winding of the core arrangement are connected to the contacting rail by means of a further joining process. In particular, the corresponding winding ends are welded or soldered to the associated contact rail. The contact rails and the core arrangement remain firmly fixed to each other during the entire joining step, so that process reliability can be permanently guaranteed during the entire joining process. The assembly of the throttle unit over the rectifier board results in a very compact structure, the assembly process being significantly simplified. In addition, the mounting accuracy during assembly steps can be significantly increased by the holding device.

• 1 eine perspektivische Darstellung einer Stromverdoppleranordnung mit einem Transformator und einer Drosseleinheit als ein Ausführungsbeispiel der Erfindung;
• 2 ein Schaltbild der Stromverdoppleranordnung;
• 3 schematische Darstellung einer Kernanordnung der Drosseleinheit aus 1 und Darstellung des Funktionsprinzips anhand der topologischen Darstellung der 2;
• 4 in einer dreidimensionalen Darstellung eine Haltevorrichtung mit der Kernanordnung der Drosseleinheit aus 1;
• 5 eine Unterseite der Haltevorrichtung mit einer Schienenanordnung der Drosseleinheit aus 1;
• 6 in einer dreidimensionalen Darstellung die Schienenanordnung auf einer Leiterplatte der Drosseleinheit aus 1;
• 7 in einer Draufsicht die Drosseleinheit aus 1 in einem montierten Zustand.

Further features, advantages and effects of the invention result from the following description of a preferred embodiment of the invention and the attached figures. These show:

• 1 a perspective view of a current doubler arrangement with a transformer and a choke unit as an embodiment of the invention;
• 2nd a circuit diagram of the current doubler arrangement;
• 3rd schematic representation of a core arrangement of the throttle unit 1 and Representation of the functional principle based on the topological representation of the 2nd ;
• 4th in a three-dimensional representation of a holding device with the core arrangement of the throttle unit 1 ;
• 5 an underside of the holding device with a rail arrangement of the throttle unit 1 ;
• 6 in a three-dimensional representation of the rail arrangement on a circuit board of the throttle unit 1 ;
• 7 in a plan view the throttle unit 1 in an assembled state.

1 shows a perspective view of a current doubler arrangement 1 , which is designed and / or suitable for power electronics of a motor vehicle, for example. The current doubler arrangement 1 assigns a transformer 2nd as well as a coupled throttle unit 3rd on. The transformer 2nd and the throttle unit 3rd are arranged one behind the other, the throttle unit 3rd on a secondary side of the transformer 2nd is arranged. The transformer 2nd is designed in the exemplary embodiment shown as a planar transformer, with a primary coil 4th as a circuit board and a secondary coil 5 formed as a metal rail. The primary coil 4th and the secondary coil 5 are at least in sections in a transformer core 6 arranged, being secondary coil 5 with the throttle unit 3rd is contacted electronically.

The throttle unit 3rd is on a circuit board 7 assembled and electrical with the circuit board 7 or with conductor tracks of the circuit board 7 contacted. For this purpose, the throttle unit 3rd a rail assembly 8th with several contact rails 8a to d on, the rail assembly 8th on the one hand, electrically conductive on the circuit board 7 contacted and on the other hand with the transformer 2nd and with the throttle unit 3rd are electrically connected. For this purpose, the secondary coil 5 of the transformer 2nd a first and a second transformer connection 5a, b on which each with a contact rail 8a, b the rail arrangement 8th is electrically connected. The throttle unit 3rd has a core arrangement 9 on, with the core assembly 9 as a coupled output choke of the current doubler arrangement 1 trained and over the rail assembly 8th with the transformer 2nd or the circuit board 7 is electrically connected.

The current doubler arrangement also includes 1 a holding device 10th , with the core assembly 9 and the rail assembly 8th via the holding device 10th are held in a predetermined relative position to each other. The holding device 10th also serves to fix and / or align the rail arrangement 8th and the core assembly 9 during a joining process.

2nd shows a circuit diagram or equivalent circuit diagram of the current doubler arrangement 1 out 1 . The current doubler arrangement 1 is preferably a component of a push-pull flux converter, with the current doubler arrangement 1 the high current side is realized. An advantage of the current doubler arrangement 1 is the lower current load of the secondary winding of the secondary coil compared to a midpoint rectifier 5 of the transformer 2nd . Another advantage is the simple contacting of the high current side since only a secondary winding is required compared to the midpoint rectifier.

In conventional current doublers, two separate output chokes are used, which require a comparatively large amount of space. The assembly and contacting of the current doubler or the two output chokes is comparatively complex. The in the 1 Coupled throttle unit shown 9 combines the two output chokes in a common component, which significantly improves efficiency, the use of materials and assembly. The coupling of the two output chokes has the result that the phase ripple of an output voltage is minimized. As a result, AC copper losses can also be minimized.

The core arrangement 9 or their first coil winding 17th and second coil winding 19th is modeled in the form of distributed and coupled inductors. The functionality of the coil output coil 18th is called a first inductor 9a and that of the coil winding 17th as a second inductor 9b shown. Here are the two coil windings 17th , 18th magnetically coupled together, which is in the form of coupling inductors 11 is shown, which together form a transformer.

The first transformer connection 5a the secondary coil 5 is over a first contact rail 8a the rail arrangement 8th on the input side with the first coupling inductance 11 the throttle unit 9 electrically connected. The second transformer connection 5b the secondary coil 5 is via a second contact rail 8b input side with the second coupling inductance 11 the throttle unit 9 electrically connected. The two inductors 9a , b are to form a first throttle output 12a on the output side together with a third contact rail 8c electrically connected.

A fourth contact rail 8d is to form a second throttle output 12b each via at least one rectifier component 13 , 14 , here a diode, as a rectifier device with the first and the second and the fourth contacting rail 8a, b , d electrically connected, the fourth contacting rail 8d a ground connection of the throttle unit 3rd forms. The first rectifier component 13 is between the first and fourth contact rails 8a , 8d arranged and electrically connected to them. The second rectifier component 14 is between the second and fourth contact rails 8b , 8d arranged and electrically connected to them.

Furthermore, the throttle unit 3rd a capacitor device 15 on, the capacitor device 15 serves for further smoothing. The capacitor device 15 is between the two throttle outputs 12a , b arranged and with the third and fourth contact rail 8c , d is electrically conductively contacted.

3rd shows the schematic arrangement of the core arrangement 9 the throttle unit 3rd out 1 . The core arrangement 9 has a coil core 16 and a first and a second coil winding 17th , 18th on, with the two coil windings 17th , 18th on the coil core 16 arranged together and magnetically coupled together. The coil core 16 has two inner core bars 19a, b and two outer core bars 20a, b on, with the first coil winding 17th on the one inner core bridge 19a and the second coil winding 18th on the other inner core bridge 19b is arranged. The two coil windings 17th , 18th each have two coil turns, the winding ends 17a, b , 18a, b of the two coil windings 17th , 18th rectified to each other from the core arrangement 16 are brought out. The two inner core bars 19a, b are between the two outer core bars 20a, b arranged, the core webs 19a, b ; 20a, b on a common base plate 21 are arranged vertically.

The coil core 16 has a cover plate 22 on, with the cover plate 22 spaced from the core bars 19a, b ; 20a, b is arranged. The coil core 22 is formed in two parts, with the base plate 21 with the core bars 19a, b ; 20a, b a first core half and the cover plate 22 forms a second core half. The coil core 16 is constructed similar to an EI construction, with the first core half forming an E part and the second core half forming an I part. The two outer core bars 20a, b are each over an air gap L to the cover plate 22 arranged, being through the air gap L a leakage inductance is realized or set. Between the two inner core bars 19a, b and the cover plate 22 an insulator, not shown, is arranged, the cover plate 22 via the insulator on the two inner core bars 19a, b rests and is spaced from them by a distance of, for example, more than 5 μm, preferably more than 10 μm, in particular more than 20 μm. For example, the insulator can be designed as a plastic film.

Below is the operating principle of the core arrangement 9 based on the circuit diagram of the 2nd explained. The first coil winding 17th forms through a magnetic flux ΦDC through cover plate 22 , inner core web 19a , Base plate 21 and outer core web 20a the choke inductance 9b . The second coil winding 18th forms through a magnetic flux ΦDC through cover plate 22 , inner core web 19b , Base plate 21 and outer core web 20b the choke inductance 9a . The magnetic coupling of the two coil windings 17th , 18th over cover plate 22 , inner core web 19a , Base plate 21 and outer inner core web 19a in the form of the flux ΦAC is in the form of coupled coupling inductors 11 shown.

4th shows the holding device in a three-dimensional representation 10th with the core arrangement 9 as an embodiment of the invention. The holding device 10th has a core image 23 on which to accommodate the core assembly 9 serves. The core shot 23 has a bottom portion 23a as well as a wall section 23b on, the wall section 23b the bottom section 23a in a horizontal plane passing through the bottom section 23a is defined, limited. The bottom section 23a is designed as a rectangular base plate, the core arrangement 9 in a vertical direction perpendicular to the horizontal plane V on the bottom plate 23a lies on. The wall section 23b is as the bottom section 23a circumferential wall formed so that the core receptacle 23 in a first horizontal direction H1 and a second horizontal direction perpendicular to the first H2 is limited. The first and the second horizontal direction H1 , H2 with respect to the horizontal plane as a planar direction vector and the vertical direction, respectively V to be understood as an orthogonal direction vector. The core arrangement 9 or the first core half of the coil core 16 lies in all horizontal directions H1 , H2 form-fitting on the wall section 23b so that a predetermined relative position of the core arrangement 9 through the core intake 23 is defined.

The wall section 23b is in a connection area A partly to carry out the winding ends 17a, b ; 18a, b interrupted in sections, the winding ends 17a, b ; 18a, b in the vertical direction V alternately offset and in the first horizontal direction H1 rectified to each other from the core receptacle 23 in the connection area A are led. The wall section 23b has several recesses for this purpose, which geometrically correspond to the position of the winding ends 17a, b ; 18a, b are adjusted. The connection area A is to be understood as the area in which the winding ends 17a, b ; 18a, b with the respective contact rail 8a, b, c, d , as in 1 shown, contacted.

To accommodate the contact rails 8a, b, c, d , has the holding device 10th several rail mounts 24th on, each contacting rail 8a, b, c, d a separate rail mount 24th assigned. The contact rails 8a, b, c, d are spaced apart or isolated from one another in the respective rail receptacle 24th added. In the view shown, several of the rail mounts 24th one holding tab each 25a, b, c on. The holding tabs 25a, b, c are in the first horizontal direction H1 to the bottom section 23a , in particular formed on the end face. A first retaining tab is used 25a to accommodate the first contact rail 8a and a second retaining tab 25b to accommodate the second contact rail 8b . The first and the second retaining tab 25a, b extend in a common vertical plane and are in the second horizontal direction H2 spaced from each other. A third tab 25c serves to accommodate the third contact rail 8c , the third retaining tab 25c in the first horizontal direction H1 to the other two retaining tabs 25a, b is arranged offset to the front and parallel to the first and the second retaining tab 25a, b extends.

The first and the second retaining tab 25a, b are continuously open in the vertical direction, so that the respective contact rail 8a, b through the associated retaining tab 25a, b through into the recording area A can be inserted. The third retaining tab 25c is in the vertical direction V formed closed on one side at least in sections, so that an insertion depth in the vertical direction V for the third contact rail 8c is formed. The holding tabs 25a, b, c are for the frictional connection of the respective contact rail 8a, b, c trained so that the contact rails 8a, b, c captive or self-retaining in the respective rail mount 24th are held. For this purpose, each of the holding tabs can be used 24a, b, c For example, have a rib structure, wherein when inserting the respective contact rail 8a, b, c a frictional connection is formed between the rib structure and the corresponding contact rail 8a, b, c is formed.

The holding device 10th also points to each corner of the floor section 23a an attachment portion 26 on which each to hold a fastener 27 serves. The holding device 10th can over the mounting sections 26 on the circuit board 7 , as in 1 shown, supported and on the fasteners 27 on the circuit board 7 be attached. The fasteners 27 are each designed as a screw, so that the holding device 10th via a screw connection on the circuit board 7 is held.

5 shows an underside of the holding device 10th with the rail arrangement 8th . The bottom section 23a has several plug-in contours 29 to accommodate the contact rails 8a , b, d on, the plug-in contour 29 at the bottom of the bottom section 23a are arranged. The plug contours 29 are each formed by two webs running parallel to each other, the contact rails 8a , b, d are held in sections between the two webs in a form-fitting and / or non-positive manner. The plug contours 29 are in the second horizontal direction H2 spaced apart and aligned parallel to each other.

The first and the second contact rail 8a, b are each U-shaped in a projection from below and face each other in one of the plug contours 29 arranged. The third contact rail 8b , shown partially hidden, is at least approximately I-shaped in a projection from below and on the front side in the third retaining tab 25c plugged in. The fourth contact rail 24b is L-shaped in a projection from below and between the first and the second contacting rail 8a, b at the bottom in one of the plug contours 29 arranged.

A first rail mount 24a to accommodate the first contact rail 8a is thus through one of the plug contours 29 and the first retaining tab 25a educated. A second rail mount 24b to accommodate the second contact rail 8a is through one of the plug contours 29 as well as the second retaining tab 25b educated. Thus, the first and the second contact rail 8a, b at the bottom of the bottom section 23a in the second horizontal direction H2 through the respective plug-in contour 29 and in the first horizontal direction H1 through the respective retaining tab 25a, b positively guided or precisely fitted.

A third rail mount 24c to accommodate the third contact rail 8c is only through the third retaining tab 25c formed, the third retaining tab 25c for contacting the third contact rail 8c with the circuit board 7 is recessed on the underside, so that the third contact rail 8c at least partially through the third retaining tab 25c through with the circuit board 7 is contactable. Here is the third contact rail 8c in the first and the second horizontal direction H1 , H2 through the third retaining tab 25a, b positively guided or precisely fitted.

A fourth rail mount 24d to accommodate the fourth contact rail 8d is only through one of the plug contours 29 educated. The plug-in contour 29 the fourth rail mount 24d is closed at the end, so that the fourth contact rail 8c in the first and second horizontal directions H1 , H2 is positively guided by the corresponding plug-in contour or is precisely fitted.

6 shows the circuit board in a three-dimensional representation 7 with the rail arrangement 8th . The contact rails 8a, b, c, d each have several contact pins 30th for contacting the circuit board 7 on, with the contact rails 8a, b, c, d via the contact pins 30th in corresponding pin receptacles 31 the circuit board 7 are plugged in. The contact pins 30th are, for example, cohesive via a solder connection or non-positive via a press connection to the printed circuit board 7 connected. On the circuit board 7 are three each of the first and second rectifier components 13 , 14 , for example semiconductor rectifiers, each arranged with a rectifier component 13 , 14 with a contact pin 30th the associated first or second contact rail 8a, b can be contacted via a conductor track.

To form the first throttle output 12a can the third contact rail 12a have a bent tab, which is in the first horizontal direction H1 extends. To form the second throttle output 12b is the fourth contact rail 8d below the third contact rail 8c passed through and then parallel to the third contact rail 8c arranged. For example, the transform gate device 15 , out 2nd , directly on the third and fourth contact rails 8c , d be soldered. Alternatively, the transform gate device 15 but also on the circuit board 7 arranged and via conductor tracks with the third and fourth contact rails 8c , d be contacted.

7 shows the top view of the throttle unit 3rd in an assembled state. Here is the first transformer connection 5a with the first contact rail 8a and the second transformer connection 5b with the second contact rail 8b cohesively connected, for example via a welded connection. The first and the second contact rail 8a , b has a connection contour 32a and the associated transformer connection has a corresponding counter contour 32b on, the connection contour 32a preferably a contour partner to the opposite contour 32b forms and serves as a positioning aid.

The first and the second contact rail 8a, b run like in 5 shown at the bottom of the bottom section 23a towards the connection area A , with the two contact rails 8a, b in the respective rail mount 24a , b a perfect fit and therefore in the right position for the core arrangement 9 are included. For this purpose, the first and the second contact rail 8a , b end, in particular in a common vertical plane through the respective retaining tab 25a, b in the recording area A guided. The first contact rail 8a is with one of the winding ends 17a the first coil winding 17th and the second contact rail 8b with one of the winding ends 18a the second coil winding 18th cohesively, for example via a welded or soldered connection.

The other two ends of the winding 17b , 18b the first and second coil windings 17, 18 are in the first horizontal direction H1 forward to the third contact rail 8c extended and each with the third contact rail 8c cohesively, for example via a welded or soldered connection.

In a first possible assembly process, everyone can Contact rails 8a, b, c, d in the holding device 10th be preassembled, with the precise fit of the contact rails 8a, b, c, d in the respective rail mount 24a, b, c, d , these are held in a predetermined relative position. Then the core assembly 9 in the core intake 23 used, the coil windings 17, 18 or the winding ends 17a, b , 18a, b in the connection area A with the respective contact rails 8a, b, c be contacted. Here are the core admission 23a and the rail mounts 24th arranged in such a way that the core arrangement 9 and the rail assembly 8th are held or positioned in the specified relative position during the entire assembly process. This can ensure that the rail arrangement during a subsequent joining process 8th and the core assembly 9 held in the correct position with respect to one another and ensuring assembly reliability or increasing assembly accuracy. Finally, the pre-assembled unit on the circuit board 7 put on and over the fasteners 26 be fixed. In a further joining process, the rail arrangement 8th with the circuit board 7 connected.

In an alternative assembly method, the contact rails can 8a, b, c, d in the holding device 10th be preassembled, with the precise fit of the contact rails 8a, b, c, d in the respective rail mount 24a, b, c, d these are held in a predetermined relative position. Then the holding device 10th together with the rail arrangement 8th on the circuit board 7 put on and over the fasteners 26 fixed. Here are the contact rails 8a, b, c, d such in the respective rail mount 24a, b, c, d recorded so that they are held or positioned in the specified relative position during the entire assembly process. In this way it can be ensured that the circuit board during a subsequent joining process 7 and the rail assembly 8th held in the correct position with respect to one another and ensuring assembly reliability or increasing assembly accuracy. Finally, the core arrangement 9 in the core intake 23 used, the coil windings 17th , 18th or the winding ends 17a, b , 18a, b in the connection area A with the respective contact rails 8a, b, c be contacted. In a further joining process, the rail arrangement 8th with the core arrangement 9 connected.

Reference list

1

Current doubler arrangement

2nd

transformer

3rd

Throttle unit

4th

Primary coil

5

Secondary coil

5a, b

Transformer connections

6

Transformer core

7

Circuit board

8th

Rail arrangement

8a, b, c, d

Contact rails

9

Core arrangement

9a, b

Inductor

10th

Holding device

11

Coupling inductance

12a, b

Throttle outputs

13

first rectifier components

14

second rectifier components

15

capacitor

16

Coil core

17th

first coil winding

17a, b

Winding ends

18th

second coil winding

18a, b

Winding ends

19a, b

inner core bars

20a, b

outer core bars

21

Base plate

22

Cover plate

23

Core intake

23a

Bottom section

23b

Wall section

24a, b, c, d

Rail mounts

25a, b, c

Retaining tabs

26

Fastening sections

27

Fasteners

28

empty

29

Plug contours

30th

Contact pins

31

Pin recordings

32a

Connection contour

32b

Counter contour

A

Connection area

H1

first horizontal direction

H2

second horizontal direction

V

Vertical direction

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for better information for the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 202011051056 U1 [0003]

Claims (15)

Holding device (10) for a coupled choke unit (3) of a current doubler arrangement (1), the choke unit (3) comprising a core arrangement (9) with a coil core (16) and a first and a second coil winding (17, 18), each with two winding ends (17a, b; 18a, b), the first and second coil windings (17, 18) being magnetically coupled to one another via the coil core, and the throttle unit (3) having at least one contacting rail (8a, b, c, d) for contacting the first and / or the second coil winding (17, 18) with a printed circuit board (7), with a core receptacle (23) for receiving the core arrangement (9), wherein the core receptacle (23) has a bottom section (23a) for supporting the coil core (16) and at least one wall section (23b) for positive engagement of the coil core (16) in at least one horizontal direction (H1, H2), with at least one rail receptacle (24a, b, c, d) for receiving the at least one contacting rail (8a, b, c, d), the rail receptacles (24a, b, c, d) and the core receptacle (23) being arranged in this way that the contacting rail (8a, b, c, d) accommodated therein is held in a predetermined relative position to the core arrangement (9) accommodated in the core receptacle (23) during a joining operation. Holding device (10) after Claim 1 , characterized in that at least one of the rail receptacles (24a, b, c, d) forms, at least in sections, a negative contour of the contacting rail (8a, b, c, d) to be accommodated, so that the contacting rail can be arranged precisely in the associated rail receptacle. Holding device (10) after Claim 1 or 2nd , characterized in that at least one of the rail receptacles (24a, b, c, d) has a plug-in contour (29), the plug-in contour (29) being arranged on an underside of the base section (23a). Holding device (10) according to one of the preceding claims, characterized in that at least one of the rail receptacles (24a, b, c, d) has a holding tab (25a, b, c), the holding tab (25a, b, c) on one Front side of the bottom section (23a) and / or on an outside of the wall section (23b) is arranged. Holding device (10) according to one of the preceding claims, characterized in that the wall section (23b) is designed as a wall surrounding the bottom section (23a), the wall section (23b) in a connection region (A) for the passage of the winding ends (17a, b; 18a, b) is interrupted. Holding device (10) according to one of the preceding claims, characterized in that the holding device (10) has a closure means for fixing the core arrangement (9) in the core receptacle (23), the closure means closing the core receptacle (23) at least in sections. Current doubler arrangement (1) with the holding device (10) according to one of the preceding claims and with the coupled throttle unit (3), characterized in that the at least one contacting rail (8a, b, c, d) in at least one of the rail receptacles (24a, b , c, d) is arranged, the contacting rail (8a, b, c, d) and the core arrangement (9) being held in the predetermined relative position to one another via the holding device (10). Current doubler arrangement (1) after Claim 7 , characterized in that the throttle unit (3) has a rail arrangement (8) with at least four of the contact rails (8a, b, c, d), the rail arrangement (8) having a first assignment rail (8a) for contacting the first coil winding (17 ) with a first transformer connection (5a), a second contact rail (8b) for contacting the second coil winding (18) with a second transformer connection (5b), a third contact rail (8c) for contacting the first and second coil windings (17, 18) as a first throttle output (12a) and a fourth contact rail (8c) to form a ground connection as a second throttle output (12b), the contact rails (8a, b, c, d) each in a separate rail mount (24a, b, c , d) are arranged and are held in the correct position relative to the core arrangement (9) in the respective rail receptacle (24a, b, c, d). Current doubler arrangement (1) after Claim 8 , characterized in that the one winding end (17a) of the first coil winding (17) is electrically conductively connected to the first contact rail (8a) and the other winding end (17b) of the first coil winding (17) is connected to the third contact rail (8c), and that one winding end (18a) of the second coil winding (18) is electrically conductively connected to the second contact rail (8b) and the other winding end (18b) of the second coil winding (18) is connected to the third contact rail (8c). Current doubler arrangement (1) according to one of the Claims 7 to 9 , characterized in that at least one of the contact rails (8a, b, c, d) is integrally connected to the first and / or the second coil winding (17, 18). Current doubler arrangement (1) according to one of the Claims 7 to 10th , characterized in that the current doubler arrangement (1) has a printed circuit board (7), at least one of the contact rails (8a, b, c, d) for contacting an electronic component (13, 14, 15) with at least one conductor track of the printed circuit board (7) is electrically conductively contacted. Current doubler arrangement (1) after Claim 11 , characterized in that the at least one contacting rail (8a, b, c, d) has at least one contact pin (30) for contacting the conductor track, the contact pin (30) being non-positively and / or materially connected to the printed circuit board (7). Current doubler arrangement (1) according to one of the Claims 7 to 12th , characterized in that the coil core (16) has two central core webs (19a, b), the first coil winding (17) being arranged on one core web (19a) and the second coil winding (18) on the other core web (19b) . Method for mounting the throttle unit (3) according to one of the Claims 1 to 13 , in which: in a positioning step the at least one contacting rail (8a, b, c, d) is arranged in at least one of the rail receptacles (24a, b, c, d) and the core arrangement (9) in the core receptacle (23), wherein the core arrangement (9) and the contacting rails (8a, b, c, d) are positioned in the correct position relative to one another by the holding device (10); - In a joining step, the first and / or the second coil winding (17, 18) is connected to at least one of the contact rails (8a, b, c, d) by means of a joining process, so that the throttle unit (3) is formed, - in another Positioning step, the throttle unit (3) is arranged on the printed circuit board (7), the contacting rails (8a, b, c, d) and the printed circuit board (7) being positioned in the correct position relative to one another by the holding device (10); - And in a further joining step, the contact rails (8a, b, c, d) are connected to the printed circuit board (7) by means of a further joining process. Method for mounting the throttle unit (3) according to one of the Claims 1 to 13 , in which: - in a positioning step the at least one contact rail (8a, b, c, d) is arranged in the at least one rail receptacle (24a, b, c, d), the contact rails (8a, b, c, d) and the circuit board (7) is positioned in the correct position relative to one another by the holding device (10); - In a joining step, the contact rails (8a, b, c, d) are connected to the circuit board (7) by means of a joining process, - in a further positioning step, the core arrangement (9) is arranged in the core receptacle (23) of the holding device (10) , wherein the contacting rails (8a, b, c, d) and the core arrangement (9) are positioned in the correct position relative to one another by the holding device (10); - And in a further joining step, the first and / or the second coil winding (17, 18) of the core arrangement (9) is connected to at least one of the contact rails (8a, b, c, d) by means of a further joining method.

Images