EP0522475B1 - Inductive component and its manufacturing method - Google Patents

Inductive component and its manufacturing method Download PDF

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Publication number
EP0522475B1
EP0522475B1 EP92111382A EP92111382A EP0522475B1 EP 0522475 B1 EP0522475 B1 EP 0522475B1 EP 92111382 A EP92111382 A EP 92111382A EP 92111382 A EP92111382 A EP 92111382A EP 0522475 B1 EP0522475 B1 EP 0522475B1
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EP
European Patent Office
Prior art keywords
insulating material
layers
windings
stack
winding
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Expired - Lifetime
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EP92111382A
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German (de)
French (fr)
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EP0522475A1 (en
Inventor
Jürgen Pilniak
Hermann Struck
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ABB Patent GmbH
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ABB Patent GmbH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil

Definitions

  • the invention relates to an inductive component with at least two windings and a method for producing such a component.
  • Inductive components are, for example, transformers, transformers, converters or choke coils.
  • inductive components can be manufactured according to the prior art in that enamel-insulated round copper wires or insulated flat copper strips are wound on bobbins as winding carriers. For the insulation of windings against each other, insulation foils are wound or, for example, multi-chamber bobbins are used. In some cases, additional full cast resin or impregnation is required.
  • the known inductive components have a relatively large volume and require a large amount of material.
  • the manufacture requires complicated winding machines or labor-intensive manufacturing processes.
  • EP-A2-0 435 461 discloses an inductive component and a method for its production, multilayer stacks of insulating material layers and structured metal layers being used instead of conventional wire windings.
  • the height of the inductive component can thus be better matched to that of other components of a circuit.
  • a structured metal layer forms a turn of a coil. Multiple turns are made using metal pins can be produced by connecting individual turns in series.
  • the invention is based on the object of specifying such an inductive component which is embodied in a stacked construction and a method for its production which can meet increased requirements with regard to electrical insulation, compact and inexpensive windings and low power loss.
  • an inductive component in particular a transformer, with at least two windings, each of which can have one or more turns, insulation material layers and structured metal layers being stacked on top of one another, and electrical connections between structured metal layers to be contacted are made by means of metallic connecting pins.
  • the insulating material layers are made of a material that is deformable under the influence of pressure and temperature. Spirally structured metal layers are used to form windings with several turns.
  • the layered stack is baked by the action of pressure and temperature, the insulating material layers being somewhat larger than the metal layers, baked during the manufacturing process to form a common winding package that is electrically insulated on all sides.
  • Square or hexagonal pins are used as connecting pins for the production of electrical connections in the winding package, which are pressed into the winding package at selected points in bores perpendicular to the layer plane and cold-welded.
  • the components according to the invention are notable for a particularly small size and for saving material since, for example, no separate coil former is required.
  • the electrical insulation requirements can take up less space be met.
  • the inductive components can be produced inexpensively and have advantageous technical data, in particular a large main inductance, a low power loss and thus also a good efficiency.
  • FIG. 1a shows the front view
  • FIG. 1b shows the side view of a transformer 1 according to the invention.
  • the transformer 1 contains a core 2 and a winding package 3 with connections 4, which correspond to the connections shown in FIG. 2 with 4.11, 4.13, 4.21, 4.22 and 4.23 are specified.
  • bores 5 can also be seen, into which connecting pins 6 (see FIG. 5f) are inserted.
  • FIGS. 1a and 1b shows the electrical circuit diagram of the transformer 1 shown in FIGS. 1a and 1b.
  • the transformer 1 has two primary windings 7a and 7b and two secondary windings 8a and 8b.
  • the transformer 1 can have further windings, for example for auxiliary voltages contain.
  • the primary windings 7a and 7b are connected in series with the aid of a bridge 13, which is realized by means of connecting pins 6 in the upper row of bores 5 in FIG. 1a, as by comparison with Figures 5a and 5b can be understood.
  • the secondary windings 8a and 8b are electrically connected in series, but a metal part 11 and connecting pins 6 shown in FIG. 5e are used to implement a secondary-side connection point 14, which is led out as connection 4.22.
  • Fig. 3 the layered structure of the winding package 3 is shown schematically for the embodiment shown in the other figures.
  • the following are stacked one above the other: a first insulating material layer 9, the second primary winding 7b, a further insulating layer 9, the second secondary winding 8b, an insulating layer 9, the first secondary winding 8a, an insulating layer 9, the first primary winding 7a, an insulating layer 9, a metal part ( see Fig. 5e) for establishing the secondary connection to the winding ends 14.1 and 14.2 via (not shown in Fig. 3) connecting pins 6 and an upper insulating layer 9.
  • the insulating material layers 9, of the individual levels are dimensioned in terms of their thickness in accordance with the respective insulation requirements.
  • the insulating material layers are somewhat larger than the metal layers 11, so that baking of the insulating layers 9 in a manufacturing step in which deformation of the insulating material layers or melting of the resin contained therein is brought about by the action of temperature and pressure, also in an edge region 10 and in Spaces between the structured Metal layers 11 a closed electrically insulating layer is reached.
  • the meltable resin hardens on cooling and creates a permanent connection between the layers of the winding package.
  • the insulating material layers 9 can be designed as multi-layer glass fiber mats or plates, the respective insulation requirements being met by choosing an appropriate number of layers. For example, a smaller number of layers may be sufficient to insulate several secondary windings from one another than to insulate between primary and secondary windings.
  • insulating material layers 9 can also be considered as insulating material layers 9, such as, for example, ceramic plates, which can be connected, for example, to structured copper foils using the direct connection method.
  • FIG. 4 shows the winding package 3 of the transformer shown in FIG. 1.
  • FIGS. 5a to 5f show the metal parts of the winding package 3.
  • FIGS. 5a to 5d show structured metal layers 11 which are designed, for example, as 0.5 mm thick copper sheets.
  • the structuring into flat, for example 5 or 8 mm wide, spiral turns of a coil can be achieved by stamping, etching or other methods. Molded external connections 4.11, 4.13, 4.21 and 4.23 are produced at the same time.
  • To produce the primary winding with the connections 4.11 and 4.13 two partial windings 7a and 7b, each with three turns, are used.
  • the winding ends 13.1 and 13.2 inside the spirals are interconnected to produce the bridge 13 shown in FIG. 2.
  • the two partial windings 7a and 7b are placed one above the other with the interposition of an insulating material layer 9, as shown in FIG. 6.
  • the partial windings 7a and 7b are designed in the same way, but are superimposed on each other in a mirror image, so that the winding ends 13.1 and 13.2 lie one above the other and can be connected to one another by means of connecting pins 6, in order to implement the bridge 13.
  • the secondary windings 8a and 8b are designed and placed one above the other, but the bridge 14 is realized by connecting the winding ends 14.1 and 14.2 to the metal piece shown in FIG. 5e, again using connecting pins 6, one of which is shown in FIG. 5f is shown.
  • the arrangement of the piece of metal shown in Fig. 5e, which is also terminal 4.22, is indicated in Fig. 1 with dashed lines.
  • connection pins 6 Square pins made of a copper alloy are provided as connecting pins 6, which are dimensioned in relation to the bores 5 such that cold welding occurs when the pins are pressed into the bores 5. It goes without saying that the pins can also have a different shape and that the electrical and mechanical connection can also be produced in another way.
  • FIG. 7 shows a preferred embodiment of the insulating material layer 9, namely as a glass fiber fabric mat or plate which contains a meltable resin.
  • a cutout 15 for the core 2 is kept free in the insulating material layer 9.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulating Of Coils (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

The invention relates to an inductive component having at least two windings, and to a method for its production. In order to achieve a compact construction and a cost-effective production method, a winding stack (3) is proposed having an arrangement of insulating material layers (9) and layers of structured metal sheet (11) stacked one above the other. The structured metal sheets (11) represent flat, spiral windings (7,8) which are embedded between insulating layers (9) and are baked under the influence of temperature and pressure to form a winding stack (3). Electrical connections between the windings connections (13) and to external connections (4) are produced with the aid of connecting pins (6) which are pressed into holes (5) which are incorporated at right angles to the plane of the layer, and are in consequence cold-welded to the respective metal sheets (11). <IMAGE>

Description

Beschreibungdescription

Die Erfindung bezieht sich auf eine induktives Bauelement mit wenigstens zwei Wicklungen und ein Verfahren zur Herstellung eines solchen Bauelements.The invention relates to an inductive component with at least two windings and a method for producing such a component.

Induktive Bauelemente sind zum Beispiel Transformatoren, Übertrager, Wandler oder Drosselspulen.Inductive components are, for example, transformers, transformers, converters or choke coils.

Es ist allgemein bekannt, daß solche induktiven Bauelemente nach dem Stand der Technik dadurch hergestellt werden können, daß lackisolierte Kupferrunddrähte oder isolierte Flachkupferbänder auf Spulenkörper als Wickelträger gewickelt werden. Zur Isolierung von Wicklungen gegeneinander werden Isolationsfolien mitgewickelt oder es werden zum Beispiel Mehrkammerspulenkörper verwendet. In manchen Fällen ist ein zusätzlicher Gießharzvollverguß oder eine Imprägnierung erforderlich.It is generally known that such inductive components can be manufactured according to the prior art in that enamel-insulated round copper wires or insulated flat copper strips are wound on bobbins as winding carriers. For the insulation of windings against each other, insulation foils are wound or, for example, multi-chamber bobbins are used. In some cases, additional full cast resin or impregnation is required.

Die bekannten induktiven Bauelemente haben ein relativ großes Bauvolumen und erfordern einen hohen Materialeinsatz. Die Herstellung erfordert komplizierte Wickelmaschinen oder lohnintensive Herstellverfahren.The known inductive components have a relatively large volume and require a large amount of material. The manufacture requires complicated winding machines or labor-intensive manufacturing processes.

Aus der EP-A2-0 435 461 ist ein induktives Bauelement und ein Verfahren zu dessen Herstellung bekannt, wobei anstelle konventioneller Draht-Wicklungen mehrschichtige Stapel aus Isoliermaterialschichten und strukturierten Metallschichten verwendet werden. Damit läßt sich die Bauhöhe des induktiven Bauelements besser an diejenige anderer Bauelemente eines Schaltkreises anpassen. Eine strukturierte Metallschicht bildet dabei eine Windung einer Spule. Mehrere Windungen sind mit Hilfe von Metallstiften durch Serienschaltung von Einzel-Windungen herstellbar.EP-A2-0 435 461 discloses an inductive component and a method for its production, multilayer stacks of insulating material layers and structured metal layers being used instead of conventional wire windings. The height of the inductive component can thus be better matched to that of other components of a circuit. A structured metal layer forms a turn of a coil. Multiple turns are made using metal pins can be produced by connecting individual turns in series.

Davon ausgehend liegt der Erfindung die Aufgabe zugrunde, ein solches in Stapelbauweise ausgeführtes induktives Bauelement und ein Verfahren zu dessen Herstellung anzugeben, das erhöhten Anforderungen bezüglich elektrischer Isolierung, kompakter und kostengünstig herstellbarer Wicklungen und geringer Verlustleistung genügen kann.Proceeding from this, the invention is based on the object of specifying such an inductive component which is embodied in a stacked construction and a method for its production which can meet increased requirements with regard to electrical insulation, compact and inexpensive windings and low power loss.

Diese Aufgabe wird gelöst durch ein induktives Bauelement, insbesondere Transformator, mit wenigstens zwei Wicklungen, von denen jede eine oder mehrere Windungen aufweisen kann, wobei Isoliermaterialschichten und strukturierte Metallschichten übereinandergestapelt sind, und elektrische Verbindungen zwischen zu kontaktierenden, strukturierten Metallschichten mittels metallischen Verbindungsstiften hergestellt sind. Die Isoliermaterialschichten sind aus einem unter Druck- und Temperatureinwirkung verformbaren Material ausgeführt. Zur Bildung von Wicklungen mit mehreren Windungen sind spiralförmig strukturierte Metallschichten verwendet. Der geschichtete Stapel ist durch Druck- und Temperatureinwirkung wobei die Isoliermaterialschichten etwas großflächiger als die Metallschichten ausgeführt sind, wäh- rend des Herstellprozesses zu einem gemeinsamen, allseitig elektrisch isolierten Wicklungspaket verbacken. Als Verbindungsstifte sind zur Herstellung elektrischer Verbindungen im Wicklungspaket Vierkant- oder Sechskantstifte verwendet, die an ausgewählten Stellen in Bohrungen senkrecht zur Schichtenebene in das Wicklungspaket eingepreßt und kaltverschweißt sind.This object is achieved by an inductive component, in particular a transformer, with at least two windings, each of which can have one or more turns, insulation material layers and structured metal layers being stacked on top of one another, and electrical connections between structured metal layers to be contacted are made by means of metallic connecting pins. The insulating material layers are made of a material that is deformable under the influence of pressure and temperature. Spirally structured metal layers are used to form windings with several turns. The layered stack is baked by the action of pressure and temperature, the insulating material layers being somewhat larger than the metal layers, baked during the manufacturing process to form a common winding package that is electrically insulated on all sides. Square or hexagonal pins are used as connecting pins for the production of electrical connections in the winding package, which are pressed into the winding package at selected points in bores perpendicular to the layer plane and cold-welded.

Gemäß der Erfindung wird außerdem ein Verfahren zur Herstellung eines induktiven Bauelements gemäß Anspruch 4 vorgeschlagen.According to the invention, a method for producing an inductive component is also proposed.

Vorteilhafte Ausgestaltungen und ein bevorzugtes Verfahren zur Herstellung des erfindungsgemäßen induktiven Bauelements ergeben sich aus der untenstehenden Beschreibung eines Ausführungsbeispiels und den Patentansprüchen.Advantageous refinements and a preferred method for producing the inductive component according to the invention result from the description below of an exemplary embodiment and the patent claims.

Die erfindungsgemäßen Bauelemente zeichnen sich durch eine besonders kleine Baugröße und durch eine erzielte Materialeinsparung aus, da zum Beispiel kein gesonderter Spulenkörper benötigt wird. Den elektrischen Isolationsanforderungen kann bei kleinerem Raumbedarf entsprochen werden. Die induktiven Bauelemente können kostengünstig hergestellt werden und weisen vorteilhafte technische Daten insbesondere eine große Hauptinduktivität, eine geringe Verlustleistung und damit auch einen guten Wirkungsgrad auf.The components according to the invention are notable for a particularly small size and for saving material since, for example, no separate coil former is required. The electrical insulation requirements can take up less space be met. The inductive components can be produced inexpensively and have advantageous technical data, in particular a large main inductance, a low power loss and thus also a good efficiency.

Eine ausführliche Beschreibung der Erfindung erfolgt nachstehend anhand eines in der Zeichnung dargestellten Ausführungsbeispiels. Es zeigen:

Fig. 1a und b
Transformatoranordnung,
Fig. 2
Schaltbild zum Transformator,
Fig. 3
schematischer Aufbau des Wicklungspakets des Transformators,
Fig. 4
Wicklungspaket,
Fig. 5a bis f
Metallteile des Wicklungspakets,
Fig. 6
übereinander gelegte Metallteile, die in den Figuren 5a und 5b gezeigt sind,
Fig. 7
Isoliermaterialschicht.
A detailed description of the invention is given below with reference to an embodiment shown in the drawing. Show it:
1a and b
Transformer arrangement,
Fig. 2
Circuit diagram for transformer,
Fig. 3
schematic structure of the winding package of the transformer,
Fig. 4
Winding package,
5a to f
Metal parts of the winding package,
Fig. 6
superimposed metal parts shown in Figures 5a and 5b,
Fig. 7
Layer of insulating material.

Fig. 1a zeigt die Vorderansicht und Fig. 1b die Seitenansicht eines erfindungsgemäßen Transformators 1. Der Transformator 1 enthält einen Kern 2 und ein Wicklungspaket 3 mit Anschlüssen 4, die entsprechend den in Fig. 2 gezeigten Anschlüssen mit 4.11, 4.13, 4.21, 4.22 und 4.23 näher bezeichnet sind. In Fig. 1a sind außerdem Bohrungen 5 zu erkennen, in die Verbindungsstifte 6 (siehe Fig. 5f) eingesetzt sind.FIG. 1a shows the front view and FIG. 1b shows the side view of a transformer 1 according to the invention. The transformer 1 contains a core 2 and a winding package 3 with connections 4, which correspond to the connections shown in FIG. 2 with 4.11, 4.13, 4.21, 4.22 and 4.23 are specified. In FIG. 1a, bores 5 can also be seen, into which connecting pins 6 (see FIG. 5f) are inserted.

Fig. 2 zeigt das elektrische Schaltbild des in Fig. 1a und 1b gezeigten Transformators 1. Der Transformator 1 weist zwei Primärwicklungen 7a und 7b auf, sowie zwei Sekundärwicklungen 8a und 8b. Der Transformator 1 kann weitere Wicklungen, zum Beispiel für Hilfsspannungen enthalten. In dem in den Figuren 1a, 1b und 2 dargestellten Ausführungsbeispielen sind die Primärwicklungen 7a und 7b in Reihe geschaltet, mit Hilfe einer Brücke 13, die mittels Verbindungsstiften 6 in der in Fig. 1a oberen Reihe von Bohrungen 5 realisiert ist, wie durch Vergleich mit den Figuren 5a und 5b verständlich wird. Ebenso sind die Sekundärwicklungen 8a und 8b elektrisch in Reihe geschaltet, wobei jedoch ein in Fig. 5e dargestelltes Metallteil 11 und Verbindungsstifte 6 verwendet sind, zur Realisierung einer sekundärseitigen Verbindungsstelle 14, die als Anschluß 4.22 herausgeführt ist.2 shows the electrical circuit diagram of the transformer 1 shown in FIGS. 1a and 1b. The transformer 1 has two primary windings 7a and 7b and two secondary windings 8a and 8b. The transformer 1 can have further windings, for example for auxiliary voltages contain. In the exemplary embodiments shown in FIGS. 1a, 1b and 2, the primary windings 7a and 7b are connected in series with the aid of a bridge 13, which is realized by means of connecting pins 6 in the upper row of bores 5 in FIG. 1a, as by comparison with Figures 5a and 5b can be understood. Likewise, the secondary windings 8a and 8b are electrically connected in series, but a metal part 11 and connecting pins 6 shown in FIG. 5e are used to implement a secondary-side connection point 14, which is led out as connection 4.22.

In Fig. 3 ist der schichtenweise Aufbau des Wicklungspakets 3 schematisch für das in den übrigen Figuren dargestellte Ausführungsbeispiel gezeigt. Dabei sind übereinander gestapelt: eine erste Isoliermaterialschicht 9, die zweite Primärwicklung 7b, eine weitere Isolierschicht 9, die zweite Sekundärwicklung 8b, eine Isolierschicht 9, die erste Sekundärwicklung 8a, eine Isolierschicht 9, die erste Primärwicklung 7a, eine Isolierschicht 9, ein Metallteil (siehe Fig. 5e) zur Herstellung der sekundärseitigen Verbindung zu den Wicklungsenden 14.1 und 14.2 über (in Fig. 3 nicht dargestellte) Vebindungsstifte 6 und eine obere Isolierschicht 9. Die Isoliermaterialschichten 9, der einzelnen Ebenen sind bezüglich ihrer Dicke entsprechend den jeweiligen Isolationsanforderungen bemessen. Die Isoliermaterialschichten sind etwas großflächiger gestaltet als die Metallschichten 11, so daß durch Verbacken der Isolierschichten 9 in einem Herstellungsschritt bei dem durch Temperatur- und Druckeinwirkung eine Verformung der Isoliermaterialschichten bzw. ein Schmelzen des darin enthaltenen Harzes bewirkt wird, auch in einem Randbereich 10 sowie in Zwischenräumen der strukturierten Metallschichten 11 eine geschlossene elektrisch isolierende Schicht erreicht wird. Das schmelzbare Harz härtet beim Abkühlen aus und schafft eine nicht mehr lösbare Verbindung der Schichten des Wicklungspakets. Die Isoliermaterialschichten 9 können als mehrlagige Glasfasermatten oder -platten ausgeführt sein, wobei durch Wahl einer entsprechenden Lagenzahl den jeweiligen Isolationsforderungen entsprochen werden kann. Es kann zum Beispiel zur Isolierung von mehreren Sekundärwicklungen untereinander eine kleinere Lagenzahl ausreichend sein als zur Isolierung zwischen Primär- und Sekundärwicklungen.In Fig. 3 the layered structure of the winding package 3 is shown schematically for the embodiment shown in the other figures. The following are stacked one above the other: a first insulating material layer 9, the second primary winding 7b, a further insulating layer 9, the second secondary winding 8b, an insulating layer 9, the first secondary winding 8a, an insulating layer 9, the first primary winding 7a, an insulating layer 9, a metal part ( see Fig. 5e) for establishing the secondary connection to the winding ends 14.1 and 14.2 via (not shown in Fig. 3) connecting pins 6 and an upper insulating layer 9. The insulating material layers 9, of the individual levels are dimensioned in terms of their thickness in accordance with the respective insulation requirements. The insulating material layers are somewhat larger than the metal layers 11, so that baking of the insulating layers 9 in a manufacturing step in which deformation of the insulating material layers or melting of the resin contained therein is brought about by the action of temperature and pressure, also in an edge region 10 and in Spaces between the structured Metal layers 11 a closed electrically insulating layer is reached. The meltable resin hardens on cooling and creates a permanent connection between the layers of the winding package. The insulating material layers 9 can be designed as multi-layer glass fiber mats or plates, the respective insulation requirements being met by choosing an appropriate number of layers. For example, a smaller number of layers may be sufficient to insulate several secondary windings from one another than to insulate between primary and secondary windings.

Als Isoliermaterialschichten 9 kommen jedoch auch andere Isliermaterialien in Betracht, wie zum Beispiel Keramikplatten, die beispielsweise im Direktverbindungsverfahren mit strukturierten Kupferfolien verbunden werden können.However, other insulating materials can also be considered as insulating material layers 9, such as, for example, ceramic plates, which can be connected, for example, to structured copper foils using the direct connection method.

Fig. 4 zeigt das Wicklungspaket 3 des in Fig. 1 dargestellten Transformators.FIG. 4 shows the winding package 3 of the transformer shown in FIG. 1.

Die Figuren 5a bis 5f zeigen die Metallteile des Wicklungspakets 3. Die Figuren 5a bis 5d zeigen strukturierte Metallschichten 11, die als zum Beispiel 0,5 mm dicke Kupferbleche ausgeführt sind. Die Strukturierung zu flachen, zum Beispiel 5 oder 8 mm breiten, spiralförmigen Windungen einer Spule kann durch Stanzen, Ätzen oder andere Verfahren erreicht werden. Dabei werden zugleich angeformte äußere Anschlüsse 4.11, 4.13, 4.21 und 4.23 hergestellt. Zur Herstellung der Primärwicklung mit den Anschlüssn 4.11 und 4.13 werden zwei Teilwicklungen 7a und 7b mit je drei Windungen benutzt. Die in den Spiralen innenliegenden Wicklungsenden 13.1 und 13.2 werden miteinander verbunden zur Herstellung der in Fig. 2 gezeigten Brücke 13. Dazu werden die beiden Teilwicklungen 7a und 7b unter Zwischenfügung einer Isoliermaterialschicht 9 übereinander gelegt, wie in Fig. 6 gezeigt ist. Die Teilwicklungen 7a und 7b sind gleichartig gestaltet, sind jedoch spiegelbildlich zueinander übereinander gelegt, so daß die Wicklungsenden 13.1 und 13.2 übereinander liegen und mittels Verbindungsstiften 6 miteinander verbunden werden können, zur Realisierung der Brücke 13.FIGS. 5a to 5f show the metal parts of the winding package 3. FIGS. 5a to 5d show structured metal layers 11 which are designed, for example, as 0.5 mm thick copper sheets. The structuring into flat, for example 5 or 8 mm wide, spiral turns of a coil can be achieved by stamping, etching or other methods. Molded external connections 4.11, 4.13, 4.21 and 4.23 are produced at the same time. To produce the primary winding with the connections 4.11 and 4.13, two partial windings 7a and 7b, each with three turns, are used. The winding ends 13.1 and 13.2 inside the spirals are interconnected to produce the bridge 13 shown in FIG. 2. For this purpose, the two partial windings 7a and 7b are placed one above the other with the interposition of an insulating material layer 9, as shown in FIG. 6. The partial windings 7a and 7b are designed in the same way, but are superimposed on each other in a mirror image, so that the winding ends 13.1 and 13.2 lie one above the other and can be connected to one another by means of connecting pins 6, in order to implement the bridge 13.

In ähnlicher Weise sind die sekundären Wicklungen 8a und 8b ausgeführt und übereinander gelegt, wobei jedoch die Brücke 14 durch Verbindung der Wicklungsenden 14.1 und 14.2 mit dem in Fig. 5e gezeigten Metallstück realisiert wird, wiederum mittels Verbindungsstiften 6, von denen einer in Fig. 5f gezeigt ist. Die Anordnung des in Fig. 5e gezeigten Metallstücks, das zugleich Anschluß 4.22 ist, ist in Fig. 1 mit gestrichelten Linien angedeutet.Similarly, the secondary windings 8a and 8b are designed and placed one above the other, but the bridge 14 is realized by connecting the winding ends 14.1 and 14.2 to the metal piece shown in FIG. 5e, again using connecting pins 6, one of which is shown in FIG. 5f is shown. The arrangement of the piece of metal shown in Fig. 5e, which is also terminal 4.22, is indicated in Fig. 1 with dashed lines.

Als Verbindungsstifte 6 sind Vierkantstifte aus einer Kupferlegierung vorgesehen, die in Bezug auf die Bohrungen 5 so bemessen sind, daß beim Einpressen der Stifte in die Bohrungen 5 eine Kaltvverschweißung eintritt. Es versteht sich, daß die Stifte auch eine andere Form haben können und daß die elektrische und mechanische Verbindung auch auf andere Weise hergestellt werden kann.Square pins made of a copper alloy are provided as connecting pins 6, which are dimensioned in relation to the bores 5 such that cold welding occurs when the pins are pressed into the bores 5. It goes without saying that the pins can also have a different shape and that the electrical and mechanical connection can also be produced in another way.

Fig. 7 zeigt eine bevorzugte Ausführung der Isoliermaterialschicht 9, nämlich als Glasfasergewebematte oder -platte die ein schmelzbares Harz enthält. Es ist ebenso wie bei den strukturierten Metallschichten 11 in der Isoliermaterialschicht 9 ein Ausschnitt 15 für den Kern 2 freigehalten.FIG. 7 shows a preferred embodiment of the insulating material layer 9, namely as a glass fiber fabric mat or plate which contains a meltable resin. As with the structured metal layers 11, a cutout 15 for the core 2 is kept free in the insulating material layer 9.

Abschließend wird ein bevorzugtes Verfahren zur Herstellung des Wicklungspakets des erfindungsgemäßen induktiven Bauelements anhand des in den Figuren der Zeichnung dargestellten Ausführungsbeispiels im Zusammenhang beschrieben. Das Verfahren kann als eine Kombination von Verbacktechnik, Vergußtechnik, Kunststoffgehäusetechnik und Kunststoffolientechnik angesehen werden.Finally, a preferred method for producing the winding package of the inductive component according to the invention is described in connection with the exemplary embodiment shown in the figures of the drawing. The process can be viewed as a combination of baking technology, casting technology, plastic housing technology and plastic film technology.

Die Herstellung des Wicklungspakets erfolgt ausgehend von vorgefertigten gestanzten Kupferblechen und Isoliermaterialplatten in nachstehenden Schritten:

  • a) Es werden mehrere Schichten aus Isoliermaterial bzw. aus zu spiralförmigen Wicklungen und Anschlüssen strukturierten Metallblechen in einem Stapel abwechselnd übereinander geschichtet, wobei
    • der Stapel mit je einer Isoliermaterialschicht begonnen und abgeschlossen wird,
    • die Isoliermaterialschichten den jeweiligen Isolieranforderungen z.B. durch entsprechende Schichtdicke angepaßt sind,
    • die Isoliermaterialschichten aus einem nur bei sehr hoher Temperatur schmelzenden Material, z.B. einem Glasgewebe oder einer Keramikplatte, bestehen und mit einem dagegen niedrigschmelzenden Kleber, z.B. einem Harz, z.B. durch Einlagerung oder Beschichtung kombiniert sind, und
    • elektrisch zu verbindende Wicklungsenden und Anschlußbleche sich überlappend übereinanderliegen, jedoch durch Isoliermaterialschichten getrennt sind;
  • b) Der geschichtete Stapel wird unter Temperatur- und Druckeinwirkung verbacken, wobei die Isoliermaterialschichten und insbesondere der während dieses Prozesses schmelzende Kleber die strukturierten Metallbleche dicht umschließen und Zwischenräume im Stapel ausfüllen;
  • c) Zur Herstellung elektrischer Verbindungen zwischen einzelnen Wicklungen oder Wicklungsteilen, sowie zwischen Wicklungsenden und -anschlüssen werden Bohrungen senkrecht zur Schichtenebene an den Stellen an denen sich zu verbindende Metallschichten überdecken durchgeführt und Verbindungsstifte, vorzugsweise Vierkantstifte, eingepreßt und dabei mit den Blechen kaltverschweißt, wobei eine feste und gasdichte Verbindung entsteht.
The winding package is manufactured based on prefabricated stamped copper sheets and insulating material plates in the following steps:
  • a) Several layers of insulating material or of metal sheets structured into spiral windings and connections are alternately stacked in a stack, whereby
    • the stack is started and completed with one layer of insulation material,
    • the layers of insulation material are adapted to the respective insulation requirements, for example by appropriate layer thickness,
    • the insulating material layers consist of a material which melts only at a very high temperature, for example a glass fabric or a ceramic plate, and are combined with an on the other hand low-melting adhesive, for example a resin, for example by incorporation or coating, and
    • winding ends and connecting plates to be electrically connected overlap one another, but are separated by layers of insulating material;
  • b) The layered stack is baked under the action of temperature and pressure, the layers of insulating material and in particular during this Process melting glue tightly enclose the structured metal sheets and fill gaps in the stack;
  • c) For the production of electrical connections between individual windings or winding parts, and between winding ends and connections, bores are carried out perpendicular to the layer plane at the points at which metal layers to be connected overlap, and connecting pins, preferably square pins, are pressed in and thereby cold-welded to the sheets, one of which solid and gas-tight connection is created.

Claims (4)

  1. Inductive component, in particular transformer (1), having at least two windings (7a, 7b, 8a, 8b), each of which can have one or more turns,
    - insulating material layers (9) and structured metal layers (11) being stacked one above the other, and
    - electrical connections being established between structured metal layers (11), between which contact is to be made, by means of metallic connecting pins (6),
    characterized in that
    a) the insulating material layers (9) are made of a material which can be deformed under the action of pressure and temperature,
    b) spirally structured metal layers (11) are used to form windings (7a, 7b, 8a, 8b) having a plurality of turns,
    c) the layered stack (9, 11) are [sic] baked by the action of pressure and temperature, the insulating material layers (9) being designed to have a somewhat larger area than the metal layers (11), during the manufacturing process to form a common winding stack (3) which is electrically insulated on all sides, and
    d) the connecting pins (6) used for establishing electrical connections in the winding stack (3) are rectangular or hexagonal pins which are pressed into the winding stack (3), at selected points, in holes (5) perpendicularly with respect to the layer plane and are cold welded.
  2. Inductive component according to Claim 1, characterized in that the structured metal layers (11) for forming windings (7a, 7b, 8a, 8b) comprise copper or aluminium laminates and are embodied, for example by stamping, as a spiral laminate strip lying flat in one plane.
  3. Inductive component according to Claim 1 or 2, characterized in that the insulating material layers (9) comprise single- or multilayer glass-fibre fabric plates, interspaces in the fabric being filled with a fusible resin.
  4. Method for manufacturing an inductive component, for example a transformer, a plurality of windings of the component being arranged within a winding stack, characterized in that the winding stack is produced using the following steps:
    a) a plurality of layers of insulating material or of metal laminates structured to form spiral windings and connections are alternately layered one above the other in a stack,
    - the stack being started and finished in each case with an insulating material layer,
    - the insulating material layers being matched to the respective insulation requirements by an appropriate layer thickness, for example,
    - the insulating material layers comprising a material which melts only at a very high temperature, for example a glass fabric or a ceramic plate, and being combined, for example by inclusion or coating, with an adhesive which, in contrast, has a low melting point, for example a resin, and
    - winding ends and connection laminates which are to be electrically connected lying one above the other in an overlapping manner, but being separated by insulating material layers;
    b) the layered stack is baked under the action of temperature and pressure, the insulating material layers, and in particular the adhesive which melts during this process, tightly enclosing the structured metal laminates and filling interspaces in the stack;
    c) in order to establish electrical connections between individual windings or winding parts, and between winding ends and connections, holes are made perpendicularly with respect to the layer plane at the points where metal layers to be connected overlap, and connecting pins, preferably rectangular pins, are pressed in and cold welded to the laminates in the process, a permanent and gastight connection being produced.
EP92111382A 1991-07-10 1992-07-04 Inductive component and its manufacturing method Expired - Lifetime EP0522475B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4122796 1991-07-10
DE4122796A DE4122796A1 (en) 1991-07-10 1991-07-10 INDUCTIVE COMPONENT AND METHOD FOR THE PRODUCTION THEREOF

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EP0522475A1 EP0522475A1 (en) 1993-01-13
EP0522475B1 true EP0522475B1 (en) 1996-05-22

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US5652561A (en) * 1993-06-29 1997-07-29 Yokogawa Electric Corporation Laminating type molded coil
CA2147251C (en) * 1993-09-29 1999-03-30 Mitsuhiro Murata Field coil for motor
DE29522242U1 (en) 1995-10-24 2000-12-21 Abb Patent Gmbh, 68309 Mannheim Circuit arrangement for an AC / DC converter with electrical isolation and inductive component for use in such a circuit arrangement
DE19542357A1 (en) * 1995-10-24 1997-04-30 Abb Patent Gmbh Circuit arrangement for an AC / DC converter with electrical isolation and inductive component for use in such a circuit arrangement
BG62541B1 (en) * 1997-03-19 2000-01-31 "Изоматик Лаб." ООД Transformer winding for electric resistance welding
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DE19945013C5 (en) * 1999-09-20 2005-10-13 Epcos Ag Planar
DE10234081A1 (en) * 2002-07-26 2004-02-05 Philips Intellectual Property & Standards Gmbh Device with a circuit arrangement with an inductive element
EP3944271A1 (en) * 2016-12-22 2022-01-26 AT & S Austria Technologie & Systemtechnik Aktiengesellschaft Inductor made of component carrier material comprising electrically conductive plate structures
CN107578898B (en) * 2017-09-29 2024-08-02 东翔电子（东莞）有限公司 Transformer framework with built-in multilayer circuit and preparation method thereof
KR102424223B1 (en) * 2020-08-31 2022-07-25 (주) 트랜스온 Primary coil assembly for transformer and transformer comprising the primary coil assembly
DE102021203048A1 (en) * 2021-03-26 2022-09-29 Siemens Mobility GmbH Spiral device and method of making same
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DE4122796A1 (en) 1993-01-21
DE59206342D1 (en) 1996-06-27
EP0522475A1 (en) 1993-01-13
ATE138493T1 (en) 1996-06-15

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