EP1631973B1 - Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung - Google Patents

Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung Download PDF

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Publication number
EP1631973B1
EP1631973B1 EP04741775A EP04741775A EP1631973B1 EP 1631973 B1 EP1631973 B1 EP 1631973B1 EP 04741775 A EP04741775 A EP 04741775A EP 04741775 A EP04741775 A EP 04741775A EP 1631973 B1 EP1631973 B1 EP 1631973B1
Authority
EP
European Patent Office
Prior art keywords
core
heat
powder
magnetic
magnetic core
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.)
Expired - Lifetime
Application number
EP04741775A
Other languages
English (en)
French (fr)
Other versions
EP1631973A1 (de
Inventor
Peter Kull
Mika Matti Sippola
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.)
Schaffner EMV AG
Original Assignee
Schaffner EMV 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 Schaffner EMV AG filed Critical Schaffner EMV AG
Priority to EP04741775A priority Critical patent/EP1631973B1/de
Publication of EP1631973A1 publication Critical patent/EP1631973A1/de
Application granted granted Critical
Publication of EP1631973B1 publication Critical patent/EP1631973B1/de
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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • H01F27/085—Cooling by ambient air
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F13/00—Apparatus or processes for magnetising or demagnetising
    • H01F13/003—Methods and devices for magnetising permanent magnets
    • 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
    • H01F27/08—Cooling; Ventilating
    • H01F27/22—Cooling by heat conduction through solid or powdered fillings
    • 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
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • 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
    • H01F17/043—Fixed inductances of the signal type with magnetic core with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00

Definitions

  • the present invention relates to magnetic cores having enhanced self-cooling capabilities and, in particular to magnetic cores comprising special elements for dissipating the heat internally produced.
  • Magnetic cores as component of impedances, coils and transformers, are used in a number of electrical and electronic applications.
  • magnetic cores are used in the manufacturing of impedances, chokes, and transformers in many power or signal processing circuits for the purposes of impedance matching, frequency filtering, as energy tanks in voltage converters, for power factor correction and in numberless other cases.
  • US-A-5,768,113 discloses a high power and high voltage power supply is capable of charging one or more capacitors to high voltage.
  • the power supply includes a current rectifier circuit for connecting to an AC source, a voltage step-up circuit including at least one controllable electronic switch and a voltage step-up transformer including a primary winding electrically connected to the electronic switch, and a control device for controlling the electronic switch.
  • the power supply is organized to chop the current flowing through the primary winding in such a manner as to enable a high voltage to be taken from across the terminal to at least one secondary winding of the transformer.
  • the step-up circuit is of a non-resonant type.
  • the transformer core has heat dissipation features permanently fixed to its outer surface.
  • Magnetic coils and the associated cores are generally present in EMC filters, and in most noise-suppression filters. Due to their comparative bulk, Magnetic component contribute heavily to the size and cost of such filtering devices.
  • magnetic cores In many cases, and in particular in medium and high frequency applications with moderate or high core losses, it is customary to produce magnetic cores from magnetic metallic powders, typically iron or permalloy powders, or other magnetic powders, by a process of pressing a mixture of magnetic powder and an adequate binding and insulating phase, into a die of the desired form. The powder and the binding phase are compacted together by the action of heat and pressure into a solid core having the desired shape.
  • magnetic metallic powders typically iron or permalloy powders, or other magnetic powders
  • magnetic cores can be produced by magnetic powder alone, by a sintering process.
  • magnetic cores are cast at lower temperature and pressure, by adopting an appropriate resin binder, for example a two-component hardening compound, another chemically curable resin, or a low-temperature curing resin.
  • an appropriate resin binder for example a two-component hardening compound, another chemically curable resin, or a low-temperature curing resin.
  • Other magnetic core types comprise laminated cores, mostly employed for applications at mains frequency, and ceramic ferrite cores.
  • the internally produced heat must however be transferred to the outside to avoid that the temperature exceeds the thermal limit of the coil insulation or the Curie point of the magnetic material. Due to the finite core heat-transfer capability, core losses are often a major limiting factor in the power rating of a magnetic component.
  • Magnetic cores 10 are usually manufactured in a variety of shapes, some of which are represented on figure 1. Core shapes are generally designed with the aim of simplifying coil winding and/or of using the magnetic material in the most efficient way. The designer tries therefore to place the magnetic material in high flux zones, and regards regions of magnetic material in which the flux is sensibly lower then average as an unnecessary waste.
  • the known cores 10 represented on figure 1 are an example of this way of designing. While these cores use a minimal amount of magnetic material, the outer surface available for the heat exchange is necessarily very low. These cores are therefore easily overheated, because the heat dissipation of the core losses is very inefficient in this design. As a consequence, in many applications where core losses are moderate or high, the core dimensioning factor will be the power dissipation rather than the maximum available magnetic flux.
  • An object of the present invention is to provide a magnetic core in which the heat losses are efficiently transferred to the outside, and therefore a magnetic core allowing the construction of more compact, more powerful coils and magnetic components.
  • a further object of the present invention is to provide a filter, and a coil therefore, exhibiting smaller size and lower cost.
  • the shape of the core is chosen in order to enhance heat dissipation.
  • the outer surface of the core 10 is equipped with fin-like structures in order to increase heat dissipation.
  • Figures 2a and 2b represent an example of an E-core 10 provided with a series of heat fins 40 on the other surface.
  • the heat fins 40 are integrally realized together with the core 10, by appropriately shaping the die or the mould in which the metal powder is pressed or cast.
  • the magnetic material in the heat fins 40 may play little or no role as far as the magnetic circuit is concerned, yet the fins 40 significantly improve heat convection and radiation from the core 10 to the outside.
  • the cores of figure 2a will often lead, in presence of core losses, to a more compact and economical construction than the known cores 10 of the figure 1.
  • This invention is limited to powder cores, but the fins 40 could equally be added to ferrite cores, or to laminated cores, or to magnetic elements of other magnetic materials with which radiating fins can be integrally realized.
  • the same heat-dissipating fins 40 are realized on the outer surface of a pot-shaped core 10. It is clear that similar variant embodiments are also possible for any other usual core shape, for example for C-cores, ring, flat, drum or rod cores, and for all variations and combinations thereof.
  • the present invention should not be limited to the provision of parallel fins as described in the above non-limitative examples, but comprises as well other geometrical structures like ribs, slots, protrusions, nooks, combs, fingers, and in general any shape providing cavities and protrusions for increasing the available external surface of the core and the heat dissipation therefrom.
  • the magnetic core according to the invention comprises heat-conductive inserts 50, permanently attached to or inserted in the core 10, for conducting and dissipating the heat generated in the core 10 as a consequence of the magnetic losses therein.
  • heat conductive inserts 50 can for example be realized from pre-punched metal sheets, inserted in the die or in the mould before the magnetic powder is added and which become then permanently incorporated in the powder core.
  • the protruding part of the metal inserts 50 acts as radiating fins, thus increasing the heat dissipation from the core 10.
  • the metal inserts 50 can be inserted and integrated in the core 10 after the constitution of the core 10, for example by gluing, pressing, screwing, or by any other assembly technique.
  • the shape of the sheets will be chosen in order to achieve a large contact area with the core material, and the sheet orientation and thickness will be adapted in order to minimize the induced eddy currents.
  • the sheets may be realized of high thermal conductivity material, like aluminium or copper.
  • thermoelectric insert 50 consists of metal rods or of metal wires or of a metallic mesh.
  • Figures 6a and 6b represent an alternative embodiment of the present invention according to which a ring core 10 comprises metallic bushes 90 for fixing the wound core 10 to a heat sink.
  • the metallic bushes 90 are permanently inserted in the core 10, and produce three ear pads, by which the core 10 can conveniently be mounted on the heat sink. The internally generated heat flows therefore from the core 10 through the bushes 90 to the heat sink, by thermal conduction.
  • This embodiment of the present invention lends itself to several variants, in which the cylindrical bushes 90 are replaced by other mounting and heat-conduction inserts, like for example metallic profiles or fixation plaques.
  • a pot core 10, on which a winding 20 is realized has permanently inserted a heat pipe 80.
  • the heat pipe 80 is in thermal contact with the core 10, and comprises an internal conduit (not represented) partially filled with a volatile liquid, for example water in a low-pressure tight chamber.
  • the heat contact between the heat pipe 80 and the core 10 can be enhanced for example by providing a series of ribs on the former (not represented).
  • the volatile liquid continuously evaporates in the part of the heat pipe 80 in contact with the hot core 10 and condensates in the cold outer part thermally connected with the large radiator 81. From the cold end of the pipe 80 the liquid drips back to the core in a continuous cycle.
  • the heat transfer along the heat pipe 80 comprises the four following processes, all taking place in a continuous cycle:
  • the heat pipe 80 can be permanently integrated in the core 10 during its fabrication, or permanently mounted to it in a further fabrication phase.
  • the radiator 81 could be substituted by a heat sink.
  • the heat pipe 80 provides efficient conduction of the heat to the heat sink.
  • one or more conductors are wound around one of the magnetic cores described above, and the resulting coil is incorporated in a filter circuit, for example a power filter for electromagnetic compatibility, or another sort of filter or noise-suppression circuit.
  • a filter circuit for example a power filter for electromagnetic compatibility, or another sort of filter or noise-suppression circuit.
  • the coil so produced thanks to its small size and high loss tolerance is particularly suitable for such filtering applications, particularly for EMC filters at mains voltage.
  • the coil thus fashioned may comprise multiple windings, for example in the case of a filter for a multiphase power system.
  • the present invention also provides longitudinal coils and current-compensated coils with improved cooling capability.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Soft Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)

Claims (10)

  1. Magnetischer Kern (10) für einen leistungselektromagnetischen Kompatibilitätsfilter, in welchem besagter Kern (10) aus einem metallischen Pulver besteht,
    dadurch gekennzeichnet, dass
    der Kern (10) eine äussere Oberfläche umfasst und
    Wärmedissipationsmerkmale (40, 80, 81, 90) hat, die integral mit besagtem Pulverkern (10) geformt sind, oder wärmeleitende Einsätze (50) hat, die permanent in besagtem Pulverkern (10) inkorporiert sind, um die Wärmedissipation davon zu erhöhen.
  2. Magnetischer Kern (10) gemäss Anspruch 1, in welchem besagte Wärmedissipationsmerkmale besagte äussere Oberfläche des Kerns (10) vergrössern und mindestens eine der folgende Formen umfassen: Rippen, Vorsprünge, Flossen (40), Finger, Schlitze, Ecken und Waben oder in irgendeiner anderen Form, die Hohlräume oder Vorsprünge bereitstellt.
  3. Magnetischer Kern (10) gemäss Anspruch 1, in welchem besagte wäremeleitende Einsätze (50) vorgestanztes Material, Metallstangen, Metalldrähte, oder ein metallisches Netz umfassen.
  4. Magnetischer Kern (10) gemäss Anspruch 1, in welchem besagte Wärmedissipationsmerkmale aus der Aussenseite des besagten Kerns (10) herausstehen, um Wärme durch Konvektion und Strahlung zu abzugeben.
  5. Eine induktive elektrische Komponente, umfassend mindestens einen magnetischen Kern (10) gemäss einem der vorhergehenden Ansprüche.
  6. Einen Leistungsfilter für eine elektromagnetische Kompatibilität, umfassend eine induktive Komponente gemäss Anspruch 5.
  7. Der Leistungsfilter gemäss Anspruch 6, in welchem besagter Filter angepasst ist, um eine Störung, die in einer Hauptversorgungsleitung überlagert ist, zu filtern.
  8. Verfahren zur Herstellung eines magnetischen Kerns (10) für einen elektromagnetischen Kompatibilitätsfilter gemäss einem der Ansprüche 1 bis 4, in welchem besagter Kern (10) aus einem metallischen Pulver besteht, das Verfahren umfasst die folgenden Schritte
    • Bereitstellen einer Gussform oder Pressform;
    • Hinzufügen von metallischen Pulver und
    • Pressen oder Giessen des metallischen Pulvers, wobei das Verfahren durch die Schritte gekennzeichnet ist
    • Formen der Gussform oder Pressform in der Form von Wärmedissipationsmerkmalen (40, 50, 80, 81, 90) oder Einfügen von wärmeleitenden Einsätzen (50) in die Gussform oder Pressform und
    • integriertes Formen besagter Wärmedissipationsmerkmale (40, 50, 80, 81, 90) mit besagtem Pulverkern (10) oder permanentes Einfügen besagter Wärme leitender Einsätze (50) in dem Schritt von Pressen oder Giessen des metallischen Pulvers.
  9. Verfahren gemäss Anspruch 8, umfassend das Formen der Gussform oder Pressform in der Form von Rippen, Vorsprüngen, Flossen (40), Finger, Schlitze, Ecken und Waben oder in irgendeiner anderen Form, die Hohlräume oder Vorsprünge bereitstellt.
  10. Verfahren gemäss Anspruch 8, umfassend den Schritt Verwirklichen besagter Wärme leitender Einsätze (50) aus vorgestanztem Material, aus Metallstangen, aus Metalldrähten, oder aus einem metallischen Netz.
EP04741775A 2003-06-10 2004-06-10 Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung Expired - Lifetime EP1631973B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04741775A EP1631973B1 (de) 2003-06-10 2004-06-10 Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP03101688 2003-06-10
EP04741775A EP1631973B1 (de) 2003-06-10 2004-06-10 Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung
PCT/EP2004/051085 WO2004112064A1 (en) 2003-06-10 2004-06-10 Magnetic core and device with cooling capabilities

Publications (2)

Publication Number Publication Date
EP1631973A1 EP1631973A1 (de) 2006-03-08
EP1631973B1 true EP1631973B1 (de) 2007-11-07

Family

ID=33547698

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04741775A Expired - Lifetime EP1631973B1 (de) 2003-06-10 2004-06-10 Magnetkern mit kühlfähigkeiten und verfahren zur dessen herstellung

Country Status (4)

Country Link
EP (1) EP1631973B1 (de)
AT (1) ATE377834T1 (de)
DE (1) DE602004009924T2 (de)
WO (1) WO2004112064A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4390989A4 (de) * 2021-09-29 2024-12-04 Mitsubishi Heavy Industries Thermal Systems, Ltd. Reaktor

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2463871B1 (de) * 2010-12-07 2017-06-14 ABB Schweiz AG Amorpher Transformatorkern
EP2490231B1 (de) * 2011-02-16 2014-11-26 ABB Technology AG Kühlsystem für Trockenwandler
JP6460329B2 (ja) * 2015-02-27 2019-01-30 株式会社オートネットワーク技術研究所 リアクトル
FR3045921B1 (fr) * 2015-12-17 2019-07-12 Commissariat A L'energie Atomique Et Aux Energies Alternatives Circuit a inductance integrant une fonction de gestion thermique passive
FR3045923B1 (fr) * 2015-12-17 2021-05-07 Commissariat Energie Atomique Noyaux d'inductance monolithique integrant un drain thermique

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6194310A (ja) * 1984-10-15 1986-05-13 Kansai Electric Power Co Inc:The 電気機器用鉄心冷却装置
FR2740631B1 (fr) * 1995-10-31 1998-01-16 Eurofeedback Sa Alimentation a haute tension et de forte puissance
JPH10163022A (ja) * 1996-12-03 1998-06-19 Minebea Co Ltd 放熱面積を拡大した積層組立体
DE50014291D1 (de) * 1999-10-29 2007-06-14 Schaffner Emv Ag Verwendung eines drei-Phasen-Filters mit Nullleiter

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4390989A4 (de) * 2021-09-29 2024-12-04 Mitsubishi Heavy Industries Thermal Systems, Ltd. Reaktor

Also Published As

Publication number Publication date
DE602004009924D1 (de) 2007-12-20
EP1631973A1 (de) 2006-03-08
WO2004112064A1 (en) 2004-12-23
DE602004009924T2 (de) 2008-08-28
ATE377834T1 (de) 2007-11-15

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