DE8518437U1 - Toroidal transformer or reactor - Google Patents

Description

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The invention relates to a toroidal transformer or - throttle with an annular core winding, the toroidal core is arranged in an electrically insulating sheath.

Various types of transformers are known. Conventional transformers with transformer sheets in the middle Gaussian range of 10,000 to 14,000 Gauss per cm * are in themselves the cheapest solution. By using highly inductive, grain-oriented transformer steels, the power-to-weight ratio can be reduced by up to approx. * 50 % . We know coilformers with ME and I cross-sections (Armco, grain-oriented transformer steel), cut-band core transformers and, in particular, toroidal core transformers, which ultimately represent the cheapest solution in terms of price-performance-weight ratio.

Reducing the power-to-weight ratio of toroidal transformers even further is limited by the heat generated during operation of a toroidal transformer. The highest possible temperature rise for copper is approx. 218 ^° C. At higher permanent temperatures, copper oxidizes and no longer allows reliable electrical insulation. Known toroidal transformers sometimes have electrically insulating outer bandages, which are wrapped around the closed ring, or a plastic-like encapsulation around the ring as an electrically insulating sheathing, which, with reliable electrical insulation, is accompanied by a comparatively strong thermal insulation, i.e. the heat generated during operation of a toroidal transformer can only dissipate to a limited extent.

The object of the invention is to create a toroidal transformer s or a ring core pink of the entrance mentioned type, which or * which with a simple production-favorable structure an improved performance Gewiöht has, i.e. a transformer according to the invention or

a throttle according to the invention can be operated with great power compared to the structural weight ί *.

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The object on which the invention is based is achieved in that the toroidal core is embedded in electrically insulating, thermally conductive, fine-grained, consistent grit such as quartz sand or the like, which is accommodated together with the toroidal core in an aluminum housing, the aluminum housing comprising at least one inwardly protruding cone which extends at least partially centering the toroid through the central toroidal core opening.
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The aluminum housing preferably consists of a single, laterally open cast, including the toroidal core completely absorbing the consistent grit

Aluminum shell with an integrated base and an integrated aluminum cone as well as an essentially flat one non-thermally conductive end plate, which is connected to the adjacent webs of the aluminum ■ 5 shell and the flat end of the cone is connected, wherein

the end plate has line connections of the toroidal core winding.

At least the bottom of the aluminum shell expediently has integrated outer cooling fins.

An advantageous embodiment of a transformer according to the invention or a choke according to the invention provides before that the aluminum housing two preferably equal

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formed aluminum half-shells, each with an integrated Floor and each having an integrated cone, the adjacent two flat cone ends are in surface contact with each other and over the mutually facing webs of the aluminum half-shells Centering or dowel pins are connected to one another.

Between the web connection of the two aluminum half-shells can be at least partially received one or more electrically insulating plates, which the electrical Line connections of the toroidal core winding included. Similar to the aforementioned embodiment, here too the aluminum half-shells have outer cooling fins, in particular in the floor area.

Another useful embodiment is characterized in that the aluminum housing is open on both sides the toroidal core and the grit completely absorbing the round or polygonal tubular casing and two casing openings covering end cover, each with a central one Has aluminum cone, the jacket and cover being connected to one another via centering or dowel pins and an insulating plate with electrical line connections is interposed at at least one of the last-mentioned connection points. Advantageously, the Aluminum cone has a central, preferably cylindrical, through-hole through which cooling air during operation can flow. The through hole can also be equipped with (inner) cooling fins.

The wound toroidal core is used to extract the resulting induction heat from the toroidal core preferably from several winding segments evenly distributed on the circumference of the ring, which in turn are integrated into the consistent grit are completely embedded, with the adjacent winding segments in radial

ler arrangement in particular plate-like copper parts in flat Contact to the central aluminum cone and to the outer jacket of the aluminum housing.

The invention therefore provides a toroidal core transformer or a toroidal core choke with an external electrical equipped insulating attachment, which compared to the prior art significantly improved Allowing heat radiation during operation and beyond that targeted cooling can also be achieved without neglecting electrical insulation regulations Need to become.

This is achieved through:

- Embed the toroidal transformer with an appropriate insulation distance in a consistent grit such as quartz sand or in another highly thermally conductive, electrically insulating material, all in one aluminum (Half) shell with cooling fins, the end of which is cemented or knurled Printed circuit board is formed with the appropriate connection pins. This method is particularly suitable for the Use of transformers also in connection with a voltage-constant semiconductor for the construction Printed circuit boards.

Embed the toroidal transformer in two aluminum half-shells, where the electrically necessary insulating distance as in the aforementioned embodiment durr.h an intermediate, consistent, thermally conductive grit such as quartz sand is achieved. Such a one Variant of the invention is characterized by an even more favorable power-to-weight ratio. The two aluminum half-shells have here on their outer halves cooling fins and are through

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! Guide elements fit precisely to an in particular rectangular one Cubes or held together in another outer shape appropriate for the purpose. The latter can also.

be a cast aluminum housing, in which also "others

f active or passive components of the construction

& speaking of the individual case of an electrical component

arrangement are arranged. The most important feature are

here essentially the two central aluminum

cone formations, which in the remaining hole of the toroidal transformer s protrude from both shells and are connected to one another in the middle or at another point to ensure heat dissipation. The electrical connections for the transformer are made via an insulating plate, which is inserted between the half-shells in a corresponding recess and after contains soldered connections inside as well as outside, for example AMP connector tongues or screw terminals or strain-relieved ones Cable.

- Embed the toroidal transformer in an aluminum housing made of a rectangle with cooling fins or round pipe section with two open ends with intermediate arrangement of the aforementioned consistent spreading material, The connection covers for the open ends of the square or round tube each have a cone, which is adapted to the arc radius of the toroidal core and both conical surfaces directed towards one another in the middle or in another area with good heat conduction during operation. Through the Two cone formations that are flatly interconnected or the one through the remaining hole of the toroidal transformer leading pins can be designed with central, in particular cylindrical, through-bores with internal cooling fins,

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■ | so that an appropriate coolant, water, air or

Oil, forcibly by pumps or fans to dissipate heat can be used in operation. Such a transformer or choke design of the invention is suitable for particularly high performance.

'- Training of individuals on the circumference of the ring ver

divided winding segments, which in turn are in central aluminum tube housing with the interposition of the

\ the aforementioned grit are arranged and further

between adjacent winding segments in a radial direction

I arrangement plate copper parts are provided, which

f in flat contact with the central aluminum cone and

to the central outer aluminum jacket of the housing

I in order to avoid additional induction

tion heat from the inside of the toroid in the radial direction

deducted, which also results in an increased

; mator performance goes hand in hand.

• All of the above designs can be waterproof on the outside

f are executed, so that in particular a protection against

Splash or drip water occurs. It has been shown that the invention increases the power-to-weight ratio

I reduce conventional transformers by approx. 30%

leaves. In production, comparatively little copper and low-quality transformer steel are required.

1 The invention is explained below on the basis of exemplary embodiments with reference to the accompanying drawings explained in more detail; show it:

Fig. 1 shows a toroidal transformer in a schematic Cross-section,

. 2 a toroidal transformer in a different configuration in a schematic cross section,

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3 shows a third variant of a toroidal core transformer,

4 shows a further embodiment of a transformer in a schematic section perpendicular to the toroidal core axis, and

Fig. 5 shows a detail of Fig. 4 along the line I-1 of Fig. 4.

The illustrated in Fig. 1 toroidal transformer 1 comprises a toroidal core shown in section 3 with surrounding Toroidal core winding 2, which are completely accommodated in an aluminum housing 5, which consists of a (open at the bottom) aluminum shell 9 with an integrated (upper) bottom 8 and a central downwardly projecting integrated aluminum cone 6 and a lower flat one End plate 10 consists of cemented, cast or knurled printed circuit board with appropriate Line connections 13 is formed * The end plate consists of a non-heat-reflecting material, has furthermore on its upper side (not illustrated in the exemplary embodiment) centering or dowel pins for the purpose of Adaptation of the upper aluminum shell to the lateral webs 11 and to the central cone 6 in a centered manner fortified way.

The arrangement is made in particular so that between the aluminum shell 9 and the toroidal core winding 2 a consistent fine-grained, good heat-conducting, electrically insulating grit 4 is provided, for example Quartz sand. Thus, a toroidal core transformer is formed, which is characterized by a compact, lightweight Structure is characterized and has a solid inner toroidal core 3, the heat generated during operation through the consistent, thermally conductive grit 4 and through

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the aluminum material of the outer aluminum case 5 can be discharged to the outside, reinforced by the cooling effect of the cooling fins 14, which are integrated on the Bottom 8 of the aluminum shell 9 are provided.

For a production, the prefabricated individual parts are assembled in the reverse order. The (now the upper) open end of the aluminum half-shell 9 introduced some grit 4 until the annular inside of the bottom 8 is completely covered with grit 4. Then the prefabricated toroidal core 3 with winding 2 placed over the cone 6 and deposited on the grit 4 in the aluminum housing 5, whereupon the remaining grit 4 is introduced until the entire aluminum shell 9 with grit including the toroidal core Winding is filled covering. After the electrical lines have been aligned accordingly, the end plate 10 placed on the centering parts and firmly connected to the aluminum shell 9 in a waterproof manner.

The toroidal transformer 1 illustrated in FIG. 2 is characterized in particular by two aluminum half-shells 9 of an aluminum housing 5 »which essentially equally trained üind. The cone ends 12 of the two cone formations 6 »7, which are directed towards one another touch each other flat, preferably in the middle, for the purpose of good heat transfer during operation. On the outer one on top of the other to aligned aluminum webs 11 are in an integrated arrangement inner centering or dowel pins 15, so that both aluminum half-shells 9 can be firmly connected to one another in a centered manner, if necessary with an interposition of electrically insulating Isolation plates 16 in appropriate design

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Savings in the webs 11, in which the electrical line connections 13 run from the inside to the outside. Both aluminum halo cups 9 can also have outer cooling fins on the bottom side, as in the aforementioned exemplary embodiment.

The embodiment of a toroidal transformer 1 according to FIG. 3 sees a hollow round or corner tubular aluminum jacket 17 with two laterally open ends, the actual toroidal core 3 including core winding 2 and grit 4 is completely received in the tubular jacket 17. The two open ends of the pipe jacket 17 are laterally through Cover 18 made of aluminum, each with a central integrated aluminum cone 6 with flat Have conical ends 12. Both facing each other. Conical ends 12 touch flat for the purpose of good heat conduction operational. The fastening of the cover 18 to the tubular jacket 17 is carried out by means of centering or dowel pins 15, optionally with the interposition of insulating plates in which the electrical line connections 13 in run in an electrically insulating manner.

Both end covers 18 including the associated cone formations have a central cylindrical through hole in mutual axial alignment, with inner cooling fins are provided on the peripheral wall of the through hole. Through the through hole If such a transformer 1 is in operation, coolant, for example air, is conducted, if necessary by forced circulation through a fan 22 connected to the side Such a transformer dissipates the heat generated during operation well to the outside, so that this with high performance can be operated without damaging the material.

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Finally, another variant of a toroidal transformer looks 1 according to FIGS. 4 and 5 instead of a single toroidal core winding 2 closed on the circumference individual (in the exemplary embodiment four) winding segments 20, which in turn completely enclose "In grit 4 within the? circular in cross section Aluminum housing 5 are arranged. Between two adjacent winding segments 20 is located in a radial Extension in each case a substantially plate-like ifcupferteil 21 in flat contact with the central aluminum cone 6 and in flat contact with the central inner circumference of the outer jacket of the aluminum housing 5 »around the induction heat generated in the radial direction from the inside of the toroid during operation to be withdrawn to the outside. The plate-like copper parts 21 are divided into two parts for assembly of the arrangement according to FIG and are held by a central steel band core 23.

All of the new features mentioned in the description and / or shown in the drawing in themselves or in a more meaningful way Combinations are essential to the invention, even if they are not expressly claimed in the claims

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Claims (1)

1. Toroidal transformer or choke with an annular Core winding, the toroidal core being arranged in an electrically insulating sheath, thereby characterized in that the toroidal core (3) in electrically insulating, thermally conductive fine-grained consistent grit (4-) such as quartz sand or the like. Is embedded, which together with the toroidal core (3) is received in an aluminum housing (5), the aluminum housing (5) at least an inwardly projecting cone (6,7) which is at least partially centering the toroidal core extends through the central toroidal core opening. t ι t • * IN THE • - · ■ Toroidal core transformer according to Claim 1, characterized in that the aluminum housing (5) consists of a single cast, the toroidal core (3) including grit (4 ·) completely receiving open aluminum shell (9) with integrated base (8) and integrated cone (-6) and a flat, non-thermally conductive end plate (10), which via centering or dowel pins (15) and / or fastening means with the adjacent webs (11) the aluminum shell and the flat cone end (12) is connected, and that in the end plate (10) line connections (13) drr toroidal core winding (2) are included. Toroidal core transformer according to claim 2, characterized in that at least the bottom (8) of the aluminum shell (9) has integrated outer cooling ribs (14-) (Fig. 1), Toroidal transformer according to Claim 1, characterized in that the aluminum housing (5) is preferably two identically designed aluminum half-shells (9) each with an integrated base (8) and each has an integrated cone (6), the adjacent two flat cone ends (12) in one Surface contact with each other and the mutually facing webs (11) of the aluminum half-shells (9) over Centering or dowel pins (15) are connected to one another (Fig. 2). Toroidal core transformer according to Claim 4, characterized in that between the web connection of the two Aluminum half-shells (9) at least partially one or several electrically insulating plates (16) are added, which the electrical line & connections (13) of the Toroidal core winding (2) included. <· <■ »·· 4 · Il lit · I t B * «« tie »IC * ·> · · ·· · Il ill 6 * toroidal transformer according to claim 4 or 5 »thereby marked * that the bottoms (δ) of the aluminum half-shells (9) have cooling fins (14). 7. toroidal transformer according to claim 1, characterized that the aluminum housing (5) has a ring core (3) and the grit (4) which is open on both sides and which completely absorbs a round or polygonal ear jacket (iy) and two cover plates (18) covering the rianteiofiuUDgeij, each with a central one Aluminum cone (9) has »with casing (17) and cover (18) connected to one another via centering or dowel pins (15) are connected and an insulating plate at at least one of the last-mentioned connection points (16) with electrical line connections (13) interposed are (Fig. 3) 8. toroidal transformer according to one of claims 1 to 6, characterized in that the aluminum cone (9) has a central, preferably cylindrical Has through hole (19). 9. toroidal transformer according to claim 8, characterized in that the through hole contains inner cooling fins. 10. Toroidal transformer according to one of claims 1 to 9 » characterized in that the wound toroidal core (3) several preferably the same on the circumference of the ring contains distributed winding segments (20), which in turn are embedded in the grit (4), with adjacent Winding segments (20) in a radial arrangement, plate-like copper parts (21) in flat contact with the central one Aluminum cone (6) and to the outer aluminum jacket of the aluminum housing (5) are located (Fig. 4- and 5) - 5a - Λ a Λ Λ m Λ Λ ΑΛΛ * 11. toroidal transformer according to one of claims 1 to 10, characterized in that the aluminum housing (5) has recesses for receiving active and / or passive electrical components.