EP1597739A1 - Insulating element, toroidal core, toroidal core choke, and method for producing said toroidal core choke - Google Patents

Insulating element, toroidal core, toroidal core choke, and method for producing said toroidal core choke

Info

Publication number
EP1597739A1
EP1597739A1 EP04707487A EP04707487A EP1597739A1 EP 1597739 A1 EP1597739 A1 EP 1597739A1 EP 04707487 A EP04707487 A EP 04707487A EP 04707487 A EP04707487 A EP 04707487A EP 1597739 A1 EP1597739 A1 EP 1597739A1
Authority
EP
European Patent Office
Prior art keywords
insulating part
core
toroidal core
toroidal
webs
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP04707487A
Other languages
German (de)
French (fr)
Other versions
EP1597739B1 (en
Inventor
Josef Feth
Jürgen STABENOW
Günter FEIST
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TDK Electronics AG
Original Assignee
Epcos AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Epcos AG filed Critical Epcos AG
Publication of EP1597739A1 publication Critical patent/EP1597739A1/en
Application granted granted Critical
Publication of EP1597739B1 publication Critical patent/EP1597739B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/06—Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • H01F17/062—Toroidal core with turns of coil around it
    • 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
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/16—Toroidal transformers
    • 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
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores

Definitions

  • Insulating part Insulating part, toroidal core, toroidal core choke and method for producing the toroidal core choke
  • the invention relates to an insulating part for installation in the interior of a ring core.
  • the invention further relates to a toroidal core with an insulating part.
  • the invention relates to a toroidal choke.
  • the invention relates to a method for producing the toroidal core choke.
  • winding space located in the interior of the toroidal core is preferably divided into a plurality of winding spaces of the same size.
  • the sintered cores are sintered with insulation during manufacture, the sintered cores have relatively large deviations from one another with regard to their inner diameter. Electrical isolation should be able to compensate for these tolerances as far as possible.
  • toroidal cores in plastic troughs or cores overmolded with plastic with molded grooves for receiving rigid plastic insulating webs or plastic insulating crosses.
  • the tolerances of the inner core diameter are absorbed by the plastic sleeve.
  • Such an arrangement has the disadvantage that valuable winding space is lost due to the plastic covering.
  • the casing is costly to manufacture due to its complex geometric shape.
  • an insulating part according to claim 1.
  • Advantageous embodiments of the insulating part, a ring core for a ring core choke, a ring core choke and a method for winding a ring core are specified in the further patent claims.
  • An insulating part is specified for installation in the core hole of a ring core, which has a number n ⁇ 2 radially outwards contains extending webs. At least one web has an elastically deformable spring element.
  • the insulating part has the advantage that it can be adapted to different core hole diameters of toroidal cores due to the spring element which is preferably deformable by a radial force.
  • the insulating part has the advantage that, due to its simple construction, it can be manufactured simply and inexpensively, for example by means of injection molding.
  • elastic tongues are arranged at the outer end of a web. These elastic tongues then at least partially take over the function of the deformable spring elements. For example, for one or more webs, they can be arranged in pairs at their outer ends and each deviate from the radial direction.
  • adjacent webs are connected to one another by elastic carrier elements.
  • These carrier elements can simultaneously be used for the insulating subdivision of the core hole into winding rooms. For example, they form an inner boundary complementary to the section of the ring core lying between two webs.
  • the webs are essentially offset from one another by an angle of 360 ° / n. This makes it easy and advantageous to divide the core hole into winding spaces of the same size.
  • this has an n-fold axis of symmetry. This means that the insulating part rotates around the axis of symmetry is mapped onto itself by an angle of 360 ° / n.
  • the insulating part is made in one piece.
  • it can advantageously be produced, for example, by an injection molding technique.
  • this can be a thermoplastic, e.g. B. contain polycarbonate.
  • polycarbonate is that it is electrically very well insulated on the one hand and has very good fire behavior on the other hand, namely only very low flammability in accordance with the UL 94 V-0 standard.
  • Lexan or Macrolon come into consideration as polycarbonate, for example.
  • a toroidal core is also specified which contains one of the insulating parts just described in its core hole.
  • Such a ring core has the advantage that it can be used very advantageously for producing a ring core choke.
  • Such a manufacturing process is given below:
  • a ring core is used, in the core hole of which an insulating part is arranged.
  • the insulating part is designed so that it projects beyond the ring core in the axial direction.
  • the insulating part can protrude over the ring core on the top and on the bottom or only on one side. While the toroidal core is being wrapped, it is held on the insulating part.
  • This procedure has the advantage that the mechanically very sensitive and, for example, sintered toroidal core is not mechanically stressed by a holding device during winding.
  • a toroidal choke is also specified which contains a toroid just described. In addition, each section of the ring core lying between two webs is wound with a winding.
  • Such a toroidal core choke can be used in a simple manner to implement a multiple choke with a plurality of windings which are insulated from one another and which, moreover, can also contain the same number of turns.
  • Figure 1 shows an exemplary insulating part in a plan view.
  • Figure 2 shows the insulating part of Figure 1 in a side view.
  • FIG. 3 shows an exemplary toroidal core choke containing an insulating part according to FIG. 1 in a side view.
  • Figure 4 shows the toroidal choke from Figure 3 in a plan view.
  • Figure 1 shows an insulating part 1 in a plan view. It has webs 31, 32, 33 which are connected to one another by support elements 421, 422, 423.
  • the webs 31, 32, 33 extend in the radial direction away from an imaginary center of the insulating part.
  • the axis of symmetry 5 runs through the imaginary center of the insulating part 1 (cf. FIG. 2).
  • the carrier elements 421, 422, 423 are made very thin-walled and have a relatively large outer or inner radius of curvature R1, R2.
  • the inner radius of curvature R1 can be 16.5 mm and the outer radius of curvature R2 can be 16 mm. This results in a wall thickness of the support elements of 0.5 mm.
  • Such support elements 421, 422, 423 are characterized by a high elasticity, which means that they can be deformed in the radial direction by pressing the rigid webs 31, 32, 33 compared to the support elements, and thus the adaptability of the insulating part to different core hole diameters demonstrate.
  • the webs 31, 32, 33 have a wall thickness W of 2 mm.
  • the carrier elements 421, 422, 423 have a wall thickness w of 0.5 mm.
  • tongues 411a, 411b; 412a, 412b and 413a, 413b are designed with respect to their wall thickness so that they correspond to the wall thickness of the carrier elements 421, 422, 423.
  • the tongues 411a, 411b, 412a, 412b, 413a, 413b fulfill the function of the spring elements 4.
  • the insulating part 1 has in its center an approximately triangular-shaped cavity that runs straight through the entire height (see FIG. 2), as a result of which the insulating part 1 can be produced very easily using an injection molding technique. Because of the support elements 421, 422, 423, which each connect two webs 31, 32, 33 to one another, the insulating part also has a high mechanical stability, which allows the insulating part to be inserted as a one-piece element into the core hole before winding the ring core , In the case of three webs 31, 32, 33, these are offset from one another by an angle oi of 120 °.
  • the present invention is not limited to three webs. Rather, it is possible to use two or four or five or a larger whole number of webs instead of three in order to subdivide the core hole of the ring core into the same size or simply into a multiplicity of winding spaces.
  • the insulating part extends radially so far that it can be circumscribed by a circle with a diameter D of 32.4 mm.
  • the center point of the circumscribing circle also forms the center point of the insulating part, which must be taken into account in the term “radial”.
  • the insulating part can be fastened mechanically very firmly in the core hole of a ring core, which has the advantage that the webs of the insulating part 1 do not push away during the winding to let.
  • a pressure surface 12 is also provided, by means of which the insulating part 1 can be pressed out of the injection mold.
  • FIG. 2 shows a side view of the insulating part 1 from FIG. 1, from which the height h of 24 mm emerges.
  • the symmetry axis 5 is shown in Figure 2, which runs through the center of the insulating part 1, shown in Figure 1 as the center of the outer circle.
  • bevels 13 are provided on the sides on the top and on the bottom of the insulating part can, in which the outer edges are inclined at an angle ⁇ relative to the axis of symmetry 5.
  • the angle ⁇ can be 45 °, for example.
  • the bevels 13 facilitate the insertion of the insulating part into the core hole of a ring core, since an automatic self-centering is thus achieved.
  • Figure 3 shows a toroidal choke in a side view.
  • a toroidal core 2 is shown, to which a winding 8 is applied.
  • An insulating part 1 according to FIG. 1 is inserted into the core hole of the ring core 2.
  • the height h of the insulating part 1, as well as the height hR of the toroidal core and the height hW of the winding 8 are chosen such that a projection 7 of the insulating part 1 results on both sides on the upper and on the lower side of the toroidal core 2.
  • This projection 7 can be present on one or on both sides of the ring core. It is used to hold the toroidal core 2 while the windings 8 are being wound.
  • FIG. 4 shows a plan view of the toroidal core choke from FIG. 3. It can be seen that the core hole 6 is divided into three winding rooms 111, 112, 113 of equal size by the insulating part 1. Each section 91, 92, 93 of the toroidal core 2 lying between two webs is wound with a wire 10, as a result of which three windings 8 which are well insulated from one another have arisen.
  • the present invention is not limited to the exemplary embodiments shown here. Rather, it is conceivable that instead of three, fewer or more webs are used to divide the core hole into winding spaces.
  • the design of the spring elements is not limited to support elements or tongues. Rather, all possible suitable devices are considered in order to achieve a suspension of the preferably rigid webs in the radial direction. LIST OF REFERENCE NUMBERS

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Insulating Of Coils (AREA)

Abstract

The invention relates to an insulating element for integrating into the hole of a toiroidal core (2), said element consisting of a number n = 2 of radially outwardly extending sections (31, 32, 33), at least one section (31, 32, 33) comprising a spring element (4) which can be elastically deformed in the radial direction. The invention also relates to a toroidal core (2), a method for applying windings to said toroidal core (2), and a toroidal choke core. Tolerances in the diameter of the core hole can be compensated by means of the inventive insulating element (1).

Description

Beschreibung description
Isolierteil, Ringkern, Ringkerndrossel und Verfahren zur Herstellung der RingkerndrosselInsulating part, toroidal core, toroidal core choke and method for producing the toroidal core choke
Die Erfindung betrifft ein Isolierteil zum Einbau in den Innenraum eines Ringkerns. Ferner betrifft die Erfindung einen Ringkern mit einem Isolierteil . Darüber hinaus betrifft die Erfindung eine Ringkerndrossel. Darüber hinaus betrifft die Erfindung ein Verfahren zur Herstellung der Ringkerndrossel .The invention relates to an insulating part for installation in the interior of a ring core. The invention further relates to a toroidal core with an insulating part. In addition, the invention relates to a toroidal choke. In addition, the invention relates to a method for producing the toroidal core choke.
Zur Herstellung von Mehrfachdrosseln werden auf Ringkerne entlang eines Umfangs mehrere voneinander isolierte Wicklungen aufgebracht. Um die elektrische Isolierung zwischen den Wicklungen zu gewährleisten, werden im Innenraum des Ringkerns eine oder mehrere Potentialtrennungen vorgesehen. Dadurch wird der im Innern des Ringkerns befindliche Wickelraum vorzugsweise in mehrere gleich große Wickelräume unterteilt.To produce multiple chokes, several mutually insulated windings are applied to ring cores along a circumference. In order to ensure the electrical insulation between the windings, one or more potential separations are provided in the interior of the toroid. As a result, the winding space located in the interior of the toroidal core is preferably divided into a plurality of winding spaces of the same size.
Da die Ringkerne bei der Herstellung mit einer Isolierung umsintert werden, weisen die umsinterten Kerne bezüglich ihres Innendurchmessers relativ starke Abweichungen voneinander auf. Eine Potentialtrennung sollte diese Toleranzen möglichst ausgleichen können.Since the toroidal cores are sintered with insulation during manufacture, the sintered cores have relatively large deviations from one another with regard to their inner diameter. Electrical isolation should be able to compensate for these tolerances as far as possible.
Es ist bekannt, den Ringkern auf eine Halterung mit angespritzten Isolierstegen aufzusetzen. Dies hat den Nachteil, daß die Potentialtrennung erst nach dem Bewickeln eingebaut werden kann. Daher bleibt bei Drosseln mit einer hohen Anzahl von Windungen, die in zwei oder sogar noch mehr Lagen auf dem Ringkern angeordnet werden müssen, kein oder nur sehr wenig Platz zum nachträglichen Einbau der angespritzten Isolierstege.It is known to place the toroid on a holder with molded insulating webs. This has the disadvantage that the electrical isolation can only be installed after winding. Therefore, in the case of chokes with a large number of turns, which have to be arranged in two or even more layers on the toroid, there is little or no space for retrofitting the molded insulating webs.
Des weiteren ist es bekannt, zwei Preßspanplättchen ineinander zu stecken und anschließend in den Ringkern einzubauen. Dies hat den Nachteil, daß sich die Plättchen beim Bewickeln durch den Wickelzug leicht verschieben lassen. Dies hätte zur Folge, daß die Wickelräume in ihrer Größe voneinander abweichen würden. Dadurch wäre es nicht möglich, unter optimaler Ausnutzung des vorhandenen Platzes mehrere gleich große Wicklungen auf der Drossel anzuordnen.Furthermore, it is known to insert two chipboard plates into one another and then to install them in the ring core. This has the disadvantage that the platelets become tangled when wrapped can be easily moved by the winding pull. As a result, the changing rooms would differ in size. As a result, it would not be possible to arrange several windings of the same size on the choke with optimal use of the available space.
Gemäß einer anderen bekannten Technik zur Herstellung der Potentialtrennung werden mehrere Kunststoffplättchen gegeneinander im Kernloch, also im Innenraum des Ringkerns verklemmt. Dies hat den Nachteil, daß die Anordnung von Kunststoffplättchen erst nach dem Einbau des letzten Plättchens richtig stabil ist. Darüber hinaus hat dies den Nachteil, daß für den Einbau ein relativ hoher Aufwand erforderlich ist.According to another known technique for producing the potential separation, a plurality of plastic plates are clamped against one another in the core hole, that is to say in the interior of the ring core. This has the disadvantage that the arrangement of plastic plates is only really stable after the last plate has been installed. In addition, this has the disadvantage that a relatively high effort is required for installation.
Es ist ferner bekannt, Ringkerne in Kunststofftrögen oder mit Kunststoff umspritzte Kerne mit angeformten Nuten zur Aufnahme von starren Kunststoffisolierstegen bzw. Kunststoffisolierkreuzen zu verwenden. Durch die Kunststoffhülle werden die Toleranzen des Kerninnendurchmessers aufgenommen. Eine solche Anordnung hat den Nachteil, daß durch die Kunststoff- umhüllung wertvoller Wickelraum verloren geht. Ferner ergibt sich der Nachteil, daß die Umhüllung aufgrund ihrer komplexen geometrischen Gestalt kostenintensiv in der Herstellung ist.It is also known to use toroidal cores in plastic troughs or cores overmolded with plastic with molded grooves for receiving rigid plastic insulating webs or plastic insulating crosses. The tolerances of the inner core diameter are absorbed by the plastic sleeve. Such an arrangement has the disadvantage that valuable winding space is lost due to the plastic covering. There is also the disadvantage that the casing is costly to manufacture due to its complex geometric shape.
Es ist daher Aufgabe der vorliegenden Erfindung, ein Isolierteil für einen Ringkern anzugeben, das einfach montiert werden kann und das Toleranzen von Kernlochdurchmessern ausgleichen kann.It is therefore an object of the present invention to provide an insulating part for a toroidal core which can be easily installed and which can compensate for tolerances in core hole diameters.
Diese Aufgabe wird gelöst durch ein Isolierteil nach Patentanspruch 1. In den weiteren Patentansprüchen sind vorteilhafte Ausgestaltungen des Isolierteils, ein Ringkern für eine Ringkerndrossel, eine Ringkerndrossel sowie ein Verfahren zum Bewickeln eines Ringkerns angegeben.This object is achieved by an insulating part according to claim 1. Advantageous embodiments of the insulating part, a ring core for a ring core choke, a ring core choke and a method for winding a ring core are specified in the further patent claims.
Es wird ein Isolierteil zum Einbau in das Kernloch eines Ringkerns angegeben, das eine Anzahl n ≥ 2 radial nach außen verlaufender Stege enthält . Dabei weist wenigstens ein Steg ein elastisch verformbares Federelement auf.An insulating part is specified for installation in the core hole of a ring core, which has a number n ≥ 2 radially outwards contains extending webs. At least one web has an elastically deformable spring element.
Das Isolierteil hat den Vorteil, daß es aufgrund des vorzugsweise durch eine radiale Kraft verformbaren Federelements an verschiedene Kernlochdurchmesser von Ringkernen angepaßt werden kann. Darüber hinaus hat das Isolierteil den Vorteil, daß es aufgrund seines einfachen Aufbaus einfach und preisgünstig, beispielsweise mittels Spritzguß hergestellt werden kann.The insulating part has the advantage that it can be adapted to different core hole diameters of toroidal cores due to the spring element which is preferably deformable by a radial force. In addition, the insulating part has the advantage that, due to its simple construction, it can be manufactured simply and inexpensively, for example by means of injection molding.
In einer Ausführungsform des Isolierteils sind am äußeren Ende eines Stegs elastische Zungen angeordnet. Diese elastischen Zungen übernehmen dann zumindest teilweise die Funktion der verformbaren Federelemente. Sie können beispielsweise für einen oder mehrere Stege paarweise an deren äußeren Enden angeordnet sein und jeweils abweichend von der radialen Richtung verlaufen.In one embodiment of the insulating part, elastic tongues are arranged at the outer end of a web. These elastic tongues then at least partially take over the function of the deformable spring elements. For example, for one or more webs, they can be arranged in pairs at their outer ends and each deviate from the radial direction.
In einer anderen Ausführungsform des Isolierteils sind benachbarte Stege durch elastische Trägerelemente miteinander verbunden .In another embodiment of the insulating part, adjacent webs are connected to one another by elastic carrier elements.
Diese Trägerelemente können gleichzeitig zur isolierenden Unterteilung des Kernlochs in Wickelräume verwendet werden. Sie bilden beispielsweise komplementär zum zwischen zwei Stegen liegenden Abschnitt des Ringkerns eine innere Begrenzung.These carrier elements can simultaneously be used for the insulating subdivision of the core hole into winding rooms. For example, they form an inner boundary complementary to the section of the ring core lying between two webs.
In einer anderen Ausführungsform des Isolierteils sind die Stege im wesentlichen um einen Winkel von 360°/n gegeneinander versetzt. Dadurch gelingt es einfach und in vorteilhafter Weise, das Kernloch in gleich große Wickelräume zu unterteilen.In another embodiment of the insulating part, the webs are essentially offset from one another by an angle of 360 ° / n. This makes it easy and advantageous to divide the core hole into winding spaces of the same size.
In einer anderen Ausführungsform des Isolierteils weist dieses eine n-zählige Symmetrieachse auf. Darunter ist zu verstehen, daß das Isolierteil bei Drehung um die Symmetrieachse um einen Winkel von 360°/n auf sich selbst abgebildet wird.In another embodiment of the insulating part, this has an n-fold axis of symmetry. This means that the insulating part rotates around the axis of symmetry is mapped onto itself by an angle of 360 ° / n.
Eine solche Symmetrie hat den Vorteil, daß die Herstellung wesentlich vereinfacht werden kann, da eine möglichst geringe Formenvielfalt zu beachten ist.Such a symmetry has the advantage that the production can be significantly simplified since the smallest possible variety of shapes has to be observed.
In einer anderen Ausführungsform ist das Isolierteil einstückig ausgebildet. Dadurch kann es beispielsweise vorteilhaft durch eine Spritzgußtechnik hergestellt werden.In another embodiment, the insulating part is made in one piece. As a result, it can advantageously be produced, for example, by an injection molding technique.
In einer anderen Ausführungsform des Isolierteils kann dieses einen Thermoplasten, z. B. Polycarbonat enthalten. Das Material Polycarbonat hat den Vorteil, daß es einerseits elektrisch sehr gut isoliert und andererseits ein sehr gutes Brandverhalten, nämlich eine nur sehr geringe Brennbarkeit entsprechend der Norm UL 94 V-0 aufweist.In another embodiment of the insulating part, this can be a thermoplastic, e.g. B. contain polycarbonate. The advantage of polycarbonate is that it is electrically very well insulated on the one hand and has very good fire behavior on the other hand, namely only very low flammability in accordance with the UL 94 V-0 standard.
Als Polycarbonat kommen beispielsweise die Materialien Lexan oder auch Macrolon in Betracht .The materials Lexan or Macrolon come into consideration as polycarbonate, for example.
Es wird darüber hinaus ein Ringkern angegeben, der eines der soeben beschriebenen Isolierteile in seinem Kernloch enthält. Ein solcher Ringkern hat den Vorteil, daß er sehr vorteilhaft zum Herstellen einer Ringkerndrossel verwendet werden kann. Ein solches Herstellungsverfahren wird im folgenden angegeben:A toroidal core is also specified which contains one of the insulating parts just described in its core hole. Such a ring core has the advantage that it can be used very advantageously for producing a ring core choke. Such a manufacturing process is given below:
Es wird ein Ringkern verwendet, in dessen Kernloch ein Isolierteil angeordnet ist. Das Isolierteil ist so ausgebildet, daß es den Ringkern in axialer Richtung überragt. Das Isolierteil kann auf der Oberseite und auf der Unterseite den Ringkern überragen oder auch nur auf einer Seite. Während des Bewickeins des Ringkerns wird dieser am Isolierteil gehalten. Diese Vorgehensweise hat den Vorteil, daß der mechanisch sehr empfindliche und beispielsweise umsinterte Ringkern während des Wickeins nicht durch eine Haltevorrichtung mechanisch belastet wird. Es wird darüber hinaus eine Ringkerndrossel angegeben, die einen soeben beschriebenen Ringkern enthält . Darüber hinaus ist jeder zwischen zwei Stegen liegende Abschnitt des Ringkerns mit einer Wicklung bewickelt .A ring core is used, in the core hole of which an insulating part is arranged. The insulating part is designed so that it projects beyond the ring core in the axial direction. The insulating part can protrude over the ring core on the top and on the bottom or only on one side. While the toroidal core is being wrapped, it is held on the insulating part. This procedure has the advantage that the mechanically very sensitive and, for example, sintered toroidal core is not mechanically stressed by a holding device during winding. A toroidal choke is also specified which contains a toroid just described. In addition, each section of the ring core lying between two webs is wound with a winding.
Durch eine solche Ringkerndrossel läßt sich auf einfache Art und Weise eine Mehrfachdrossel mit mehreren von gegeneinander isolierten Wicklungen, die noch dazu auch die gleiche Anzahl von Windungen enthalten können, realisieren.Such a toroidal core choke can be used in a simple manner to implement a multiple choke with a plurality of windings which are insulated from one another and which, moreover, can also contain the same number of turns.
Im folgenden wird die Erfindung anhand von Ausführungsbei- spielen und den dazugehörigen Figuren näher erläutert :The invention is explained in more detail below on the basis of exemplary embodiments and the associated figures:
Figur 1 zeigt ein beispielhaftes Isolierteil in einer Draufsicht .Figure 1 shows an exemplary insulating part in a plan view.
Figur 2 zeigt das Isolierteil aus Figur 1 in einer Seitenansicht .Figure 2 shows the insulating part of Figure 1 in a side view.
Figur 3 zeigt eine beispielhafte Ringkerndrossel enthaltend ein Isolierteil nach Figur 1 in einer Seitenansicht .FIG. 3 shows an exemplary toroidal core choke containing an insulating part according to FIG. 1 in a side view.
Figur 4 zeigt die Ringkerndrossel aus Figur 3 in einer Draufsicht .Figure 4 shows the toroidal choke from Figure 3 in a plan view.
Es wird darauf hingewiesen, daß mit gleichen Bezugszeichen bezeichnete Elemente einander gleichen oder wenigstens hinsichtlich ihrer Funktion gleich sind.It is pointed out that elements denoted by the same reference symbols are identical to one another or at least the same in terms of their function.
Figur 1 zeigt ein Isolierteil 1 in einer Draufsicht. Es weist Stege 31, 32, 33 auf, die durch Trägerelemente 421, 422, 423 miteinander verbunden sind. Die Stege 31, 32, 33 erstrecken sich in radiale Richtung von einem gedachten Mittelpunkt des Isolierteils weg. Durch den gedachten Mittelpunkt des Isolierteils 1 läuft die Symmetrieachse 5 (vgl. Figur 2) . Die Trägerelemente 421, 422, 423 sind dabei sehr dünnwandig ausgeführt und weisen einen relativ großen äußeren bzw. inneren Krümmungsradius Rl, R2 auf. Beispielsweise kann der innere Krümmungsradius Rl 16,5 mm und der äußere Krümmungsradius R2 16 mm betragen. Daraus ergibt sich eine Wandstärke der Trägerelemente von 0,5 mm. Solche Trägerelemente 421, 422, 423 zeichnen sich durch eine hohe Elastizität aus, was bedeutet, daß sie durch Drücken der verglichen mit den Trägerelementen starren Stege 31, 32, 33 in radiale Richtung verformt werden können, und somit die Anpaßbarkeit des Isolierteils an verschiedene Kernlochdurchmesser demonstrieren.Figure 1 shows an insulating part 1 in a plan view. It has webs 31, 32, 33 which are connected to one another by support elements 421, 422, 423. The webs 31, 32, 33 extend in the radial direction away from an imaginary center of the insulating part. The axis of symmetry 5 runs through the imaginary center of the insulating part 1 (cf. FIG. 2). The carrier elements 421, 422, 423 are made very thin-walled and have a relatively large outer or inner radius of curvature R1, R2. For example, the inner radius of curvature R1 can be 16.5 mm and the outer radius of curvature R2 can be 16 mm. This results in a wall thickness of the support elements of 0.5 mm. Such support elements 421, 422, 423 are characterized by a high elasticity, which means that they can be deformed in the radial direction by pressing the rigid webs 31, 32, 33 compared to the support elements, and thus the adaptability of the insulating part to different core hole diameters demonstrate.
Die Stege 31, 32, 33 weisen eine Wandstärke W von 2 mm auf. Die Trägerelemente 421, 422, 423 weisen eine Wandstärke w von 0 , 5 mm auf .The webs 31, 32, 33 have a wall thickness W of 2 mm. The carrier elements 421, 422, 423 have a wall thickness w of 0.5 mm.
An den äußeren Enden der Stege 31, 32, 33 sind jeweils paarweise Zungen 411a, 411b; 412a, 412b und 413a, 413b angeordnet . Diese Zungen erstrecken sich in eine von der radialen Richtung abweichende Richtung und sind hinsichtlich ihrer Wandstärke so ausgeführt, daß sie der Wandstärke der die Trägerelemente 421, 422, 423 gleichen. Die Zungen 411a, 411b, 412a, 412b, 413a, 413b erfüllen hierbei mit die Funktion der Federelemente 4. Durch ausüben eines Drucks in radiale Richtung können die Zungen sowie die Trägerelemente des Isolierteils zur Seite gebogen werden, und eine Anpassung des Isolierteils an kleinere Kernlochdurchmesser kann stattfinden.At the outer ends of the webs 31, 32, 33 tongues 411a, 411b; 412a, 412b and 413a, 413b. These tongues extend in a direction deviating from the radial direction and are designed with respect to their wall thickness so that they correspond to the wall thickness of the carrier elements 421, 422, 423. The tongues 411a, 411b, 412a, 412b, 413a, 413b fulfill the function of the spring elements 4. By exerting a pressure in the radial direction, the tongues and the support elements of the insulating part can be bent to the side, and the insulating part can be adapted to smaller core hole diameters can take place.
Das Isolierteil 1 weist in seiner Mitte einen in etwa drei- eckförmigen, geradlinig durch die gesamte Höhe (vgl. Figur 2) laufenden Hohlraum auf, wodurch das Isolierteil 1 sehr einfach in einer Spritzgußtechnik hergestellt werden kann. Aufgrund der Trägerelemente 421, 422, 423, die jeweils zwei Stege 31, 32, 33 miteinander verbinden, weist das Isolierteil auch eine hohe mechanische Stabilität auf, die es erlaubt, das Isolierteil als einstückiges Element bereits vor dem Bewickeln des Ringkerns in dessen Kernloch einzuschieben. Im Fall von drei Stegen 31, 32, 33 sind diese um einen Winkel oi von 120° gegeneinander versetzt.The insulating part 1 has in its center an approximately triangular-shaped cavity that runs straight through the entire height (see FIG. 2), as a result of which the insulating part 1 can be produced very easily using an injection molding technique. Because of the support elements 421, 422, 423, which each connect two webs 31, 32, 33 to one another, the insulating part also has a high mechanical stability, which allows the insulating part to be inserted as a one-piece element into the core hole before winding the ring core , In the case of three webs 31, 32, 33, these are offset from one another by an angle oi of 120 °.
Es ist jedoch zu beachten, daß die vorliegende Erfindung nicht auf drei Stege beschränkt ist. Vielmehr kommt es in Betracht, anstelle von drei auch zwei oder vier oder fünf oder eine größere ganze Anzahl von Stegen zu verwenden, um das Kernloch des Ringkerns in gleich große oder in einfach in eine Vielzahl von Wickelräumen zu unterteilen.However, it should be noted that the present invention is not limited to three webs. Rather, it is possible to use two or four or five or a larger whole number of webs instead of three in order to subdivide the core hole of the ring core into the same size or simply into a multiplicity of winding spaces.
Es ist in Figur 1 noch angegeben, daß sich das Isolierteil radial so weit erstreckt, daß es von einem Kreis mit einem Durchmesser D von 32,4 mm umschrieben werden kann.It is also indicated in Figure 1 that the insulating part extends radially so far that it can be circumscribed by a circle with a diameter D of 32.4 mm.
Der Mittelpunkt des umschreibenden Kreises bildet gleichzeitig den Mittelpunkt des Isolierteils, was bei der Bezeichnung „radial" jeweils zu berücksichtigen ist.The center point of the circumscribing circle also forms the center point of the insulating part, which must be taken into account in the term “radial”.
Aufgrund der mit den starren Stegen zusammenwirkenden Federelemente 4, die in dem Isolierteil gemäß Figur 1 enthalten sind, kann das Isolierteil mechanisch sehr fest im Kernloch eines Ringkerns befestigt werden, was den Vorteil hat, daß sich die Stege des Isolierteils 1 nicht während des Bewickeins wegdrücken lassen.Due to the spring elements 4 which cooperate with the rigid webs and which are contained in the insulating part according to FIG. 1, the insulating part can be fastened mechanically very firmly in the core hole of a ring core, which has the advantage that the webs of the insulating part 1 do not push away during the winding to let.
Für die Zwecke der Herstellung mittels Spritzgußtechnik ist noch eine Andrückfläche 12 vorgesehen, mittels derer das Isolierteil 1 aus der Spritzgußform herausgedrückt werden kann.For the purposes of production by means of injection molding technology, a pressure surface 12 is also provided, by means of which the insulating part 1 can be pressed out of the injection mold.
Figur 2 zeigt eine Seitenansicht des Isolierteils 1 aus Figur 1, aus der die Höhe h von 24 mm hervorgeht. Darüber hinaus ist in Figur 2 die Symmetrieachse 5 gezeigt, die durch das Zentrum des Isolierteils 1, gezeigt in Figur 1 als Mittelpunkt des äußeren Kreises, verläuft. Aus Figur 2 geht ferner hervor, daß an den Seiten an der Oberseite und an der Unterseite des Isolierteils 1 Anschrägungen 13 vorgesehen sein können, bei denen die Außenkanten gegenüber der Symmetrieachse 5 um einen Winkel ß geneigt sind. Der Winkel ß kann beispielsweise 45° betragen. Die Anschrägungen 13 erleichtern das Einführen des Isolierteils in das Kernloch eines Ringkerns, da somit eine automatische SelbstZentrierung erreicht wird.FIG. 2 shows a side view of the insulating part 1 from FIG. 1, from which the height h of 24 mm emerges. In addition, the symmetry axis 5 is shown in Figure 2, which runs through the center of the insulating part 1, shown in Figure 1 as the center of the outer circle. From Figure 2 it also shows that bevels 13 are provided on the sides on the top and on the bottom of the insulating part can, in which the outer edges are inclined at an angle β relative to the axis of symmetry 5. The angle β can be 45 °, for example. The bevels 13 facilitate the insertion of the insulating part into the core hole of a ring core, since an automatic self-centering is thus achieved.
Figur 3 zeigt eine Ringkerndrossel in einer Seitenansicht . Es ist dabei ein Ringkern 2 dargestellt, auf den eine Wicklung 8 aufgebracht ist. In das Kernloch des Ringkerns 2 ist ein Isolierteil 1 gemäß Figur 1 eingeschoben. Die Höhe h des Isolierteils 1, sowie die Höhe hR des Ringkerns und die Höhe hW der Wicklung 8 sind so gewählt, daß auf beiden Seiten also auf der oberen und auf der unteren Seite des Ringkerns 2 ein Überstand 7 des Isolierteils 1 resultiert. Dieser Überstand 7 kann auf einer oder auf beiden Seiten des Ringkerns vorhanden sein. Er wird dazu benutzt, den Ringkern 2 während des Wickeins der Wicklungen 8 zu halten.Figure 3 shows a toroidal choke in a side view. A toroidal core 2 is shown, to which a winding 8 is applied. An insulating part 1 according to FIG. 1 is inserted into the core hole of the ring core 2. The height h of the insulating part 1, as well as the height hR of the toroidal core and the height hW of the winding 8 are chosen such that a projection 7 of the insulating part 1 results on both sides on the upper and on the lower side of the toroidal core 2. This projection 7 can be present on one or on both sides of the ring core. It is used to hold the toroidal core 2 while the windings 8 are being wound.
Figur 4 zeigt eine Draufsicht auf die Ringkerndrossel aus Figur 3. Es ist zu erkennen, daß das Kernloch 6 durch das Isolierteil 1 in drei gleich große Wickelräume 111, 112, 113 unterteil ist. Jeder zwischen zwei Stegen liegende Abschnitt 91, 92, 93 des Ringkerns 2 ist mit einem Draht 10 bewickelt, wodurch drei voneinander gut isolierte Wicklungen 8 entstanden sind.FIG. 4 shows a plan view of the toroidal core choke from FIG. 3. It can be seen that the core hole 6 is divided into three winding rooms 111, 112, 113 of equal size by the insulating part 1. Each section 91, 92, 93 of the toroidal core 2 lying between two webs is wound with a wire 10, as a result of which three windings 8 which are well insulated from one another have arisen.
Es wird darauf hingewiesen, daß sich die vorliegende Erfindung nicht auf die hier dargestellten Ausführungsbeispiele beschränkt. Es ist vielmehr denkbar, daß anstelle von drei auch weniger oder mehr Stege zur Unterteilung des Kernlochs in Wickelräume verwendet werden. Darüber hinaus ist die Ausbildung der Federelemente nicht auf Trägerelemente oder Zungen beschränkt. Es kommen vielmehr alle möglichen geeigneten Vorrichtungen in Betracht, um eine Federung der vorzugsweise starren Stege in radialer Richtung zu erreichen. BezugszeichenlisteIt is pointed out that the present invention is not limited to the exemplary embodiments shown here. Rather, it is conceivable that instead of three, fewer or more webs are used to divide the core hole into winding spaces. In addition, the design of the spring elements is not limited to support elements or tongues. Rather, all possible suitable devices are considered in order to achieve a suspension of the preferably rigid webs in the radial direction. LIST OF REFERENCE NUMBERS
1 Isolierteil1 insulating part
2 Ringkern2 toroid
31, 32, 33 Steg31, 32, 33 footbridge
4 Federelement4 spring element
411a, 411b, 412a, 412b, 413a, 413b Zunge411a, 411b, 412a, 412b, 413a, 413b tongue
421, 422, 423 Trägerelement421, 422, 423 carrier element
5 Symmetrieachse5 axis of symmetry
6 Kernloch6 core hole
7 Überstand7 supernatant
8 Wicklung8 winding
91, 92, 93 Abschnitt91, 92, 93 section
10 Draht10 wire
111, 112, 113 Wickelraum111, 112, 113 changing room
12 Andrückfläche12 pressing surface
13 Anschrägung a, ß Winkel13 chamfer a, ß angle
D DurchmesserD diameter
W Wandstärke w Wandstärke h, hR, hW Höhe W wall thickness w wall thickness h, hR, hW height

Claims

Patentansprüche claims
1. Isolierteil zum Einbau in das Kernloch eines Ringkerns (2),1. insulating part for installation in the core hole of a ring core (2),
- enthaltend eine Anzahl n ≥ 2 radial nach außen verlaufender Stege (31, 32, 33), wobei wenigstens ein Steg (31, 32, 33) ein elastisch verformbares Federelement (4) aufweist,- Containing a number n ≥ 2 radially outwardly extending webs (31, 32, 33), at least one web (31, 32, 33) having an elastically deformable spring element (4),
- bei dem am Ende eines Stegs (31, 32, 33) elastische Zungen- At the end of a web (31, 32, 33) elastic tongues
(411a, 411b, 412a, 412b, 413a, 413b) angeordnet sind.(411a, 411b, 412a, 412b, 413a, 413b) are arranged.
2. Isolierteil nach Anspruch 1, bei dem zwei benachbarte Stege (31, 32, 33) durch elastische Trägerelemente (421, 422, 423) verbunden sind.2. Insulating part according to claim 1, in which two adjacent webs (31, 32, 33) are connected by elastic carrier elements (421, 422, 423).
3. Isolierteil nach einem der Ansprüche 1 bis 2, bei dem die Stege (31, 32, 33) im wesentlichen um einen Winkel (a) von 360°/n gegeneinander versetzt sind.3. Insulating part according to one of claims 1 to 2, in which the webs (31, 32, 33) are offset from one another essentially by an angle (a) of 360 ° / n.
4. Isolierteil nach einem der Ansprüche 1 bis 3, das eine n-zählige Symmetrieachse (5) aufweist.4. Insulating part according to one of claims 1 to 3, which has an n-fold axis of symmetry (5).
5. Isolierteil nach einem der Ansprüche 1 bis 4, das einstückig ausgebildet ist .5. Insulating part according to one of claims 1 to 4, which is integrally formed.
6. Isolierteil nach einem der Ansprüche 1 bis 5, das ein Spritzgußteil ist.6. Insulating part according to one of claims 1 to 5, which is an injection molded part.
7. Isolierteil nach einem der Ansprüche 1 bis 6, das einen Thermoplasten enthält .7. Insulating part according to one of claims 1 to 6, which contains a thermoplastic.
8. Ringkern enthaltend ein Isolierteil (1) nach einem der Ansprüche 1 bis 7 in seinem Kernloch (6) .8. toroidal core containing an insulating part (1) according to one of claims 1 to 7 in its core hole (6).
9. Verfahren zum Bewickeln eines Ringkerns (2),9. method for winding a toroidal core (2),
- wobei ein Ringkern (2) nach Anspruch 9 verwendet wird, bei dem das Isolierteil (1) in axialer Richtung übersteht, - und wobei der Ringkern (2) während des Wickeins am Isolierteil (1) gehalten wird.- wherein an annular core (2) according to claim 9 is used, in which the insulating part (1) protrudes in the axial direction, - And wherein the toroidal core (2) is held on the insulating part (1) during winding.
10. Ringkerndrossel, enthaltend einen Ringkern (2) nach Anspruch 8, bei der jeder zwischen zwei Stegen (31, 32, 33) liegende Abschnitt (91, 92, 93) des Ringkerns (2) mit einer Wicklung (8) bewickelt ist. 10. toroidal choke containing a toroidal core (2) according to claim 8, wherein each between two webs (31, 32, 33) lying section (91, 92, 93) of the toroidal core (2) is wound with a winding (8).
EP04707487A 2003-02-25 2004-02-03 Insulating element, toroidal core, toroidal core choke, and method for producing said toroidal core choke Expired - Lifetime EP1597739B1 (en)

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DE10308010A DE10308010A1 (en) 2003-02-25 2003-02-25 Insulating part, toroidal core, toroidal core choke and method for producing the toroidal core choke
DE10308010 2003-02-25
PCT/DE2004/000171 WO2004077459A1 (en) 2003-02-25 2004-02-03 Insulating element, toroidal core, toroidal core choke, and method for producing said toroidal core choke

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JP4582656B2 (en) 2010-11-17
JP2006518933A (en) 2006-08-17
EP1597739B1 (en) 2007-07-11
CN1754232A (en) 2006-03-29
US20060192649A1 (en) 2006-08-31
DE502004004289D1 (en) 2007-08-23
WO2004077459A1 (en) 2004-09-10
CN1754232B (en) 2011-12-14
DE10308010A1 (en) 2004-09-09
US7280027B2 (en) 2007-10-09

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