Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F3/00—Cores, Yokes, or armatures
  • H01F3/02—Cores, Yokes, or armatures made from sheets
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C24/00—Coating starting from inorganic powder
  • C23C24/02—Coating starting from inorganic powder by application of pressure only
  • C23C24/04—Impact or kinetic deposition of particles
• • 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
  • H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
• • 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
  • H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
  • H01F27/2455—Magnetic cores made from sheets, e.g. grain-oriented using bent laminations
• • 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
• • 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
  • H01F41/0206—Manufacturing of magnetic cores by mechanical means
  • H01F41/0233—Manufacturing of magnetic circuits made from sheets

Definitions

• the invention relates to a method having the features according to the preamble of patent claim 1.
• Transformer cores usually forms ge ⁇ with transformer plates . Due to the design, it is usually not possible for the sheet edges of the transformer sheets to be at impact, but the sheet edges tend to remain separated from each other by a small air gap. This air gap increases the magnetic resistance of the
• transformer sheets and thus the magnetic resistance of the resulting transformer core In order to reduce the influence of the air gaps, it is known to use the so-called step-lap layering of the transformer sheets, as can also be seen from the above cited document.
• the transformer plates are arranged relative to one another such that the air gaps between the plate edges do not lie directly above one another, but are offset from one another.
• a transformer plate located above or below dodge when he encounters an air gap, thus avoiding an immediate passage of the air gap.
• the resulting magnetic resistance is thereby reduced compared to air gaps lying one above the other.
• the invention has for its object to provide a method for producing a transformer core, which can achieve even better properties of the resulting transformer core and thus even better properties of the respective transformer.
• a significant advantage of the method according to the invention is the fact that the magnetic flux can remain within each transformer sheet, without having to change to a be ⁇ adjacent transformer sheet, because between adjacent sheet edges no air gap is no longer present; because according to the invention, the adjoining sheet metal edges are connected by means of cold gas spraying with a magnetizable material and so filled the still existing air gap. Since the magnetic flux in its jewei ⁇ time transformer sheet can remain and accordingly, not perpendicular to the transformer sheet metal flux component (normal component) occurs, planar electric WIR beiströme in the transformer sheets avoided and the overall electrical losses reduced. The core noise during operation of the transformer redu ⁇ graces, since magnetic forces between the transformer plates are reduced due to the omission of the normal component.
• the cold gas spraying method makes it possible to fill the gap area between the sheet edges in a very simple and cost-effective manner.
• the cold gas injection method can be used to produce connecting material with particularly good magnetic properties, which can not be achieved by other methods, for example welding, gluing, soldering or the like.
• the air gaps can be closed with connecting material which, in the case of a magnetic flux above a tesla, achieves relative permeability numbers in the range between 10 3 and 10 6 .
• bonding material on the Ba ⁇ sis of crystals, nanoparticles or nanocrystalline materials may be formed.
• thermal loads on the transformer plates for example in the form of mechanical stresses due to thermal material expansion, can also be avoided or at least minimized.
• the described method can be used as transformer cores, for example stack cores, cut cores or winding cores for stacked core transformers, cut core transformers or winding core transformers.
• a stack core is formed as a transformer core by stacking transformer plates on top of each other, it will regarded as advantageous when the adjacent sheet metal edges of the stacked transformer sheets are connected to each other by means of cold ⁇ gas spraying with a magnetizable material.
• a winding core is formed as the transformer core by bending at least one transformer sheet, then it is considered advantageous if adjacent sheet metal edges of the respective transformer sheet are connected to one another by means of cold gas spraying with a magnetizable material after bending over the at least one transformer sheet.
• a cold gas spraying system which has a gas heating device for heating a gas.
• a gas heating device for heating a gas.
• a Stagna ⁇ tion chamber is connected to the gas heater
• the output side with a convergent-divergent nozzle preferably a Laval nozzle is connected.
• Convergent-divergent nozzles have a ⁇ together men securedden part section and a section widening part, which are connected by a nozzle throat.
• the convergent-divergent nozzle produces the output side a powder jet in the form of a gas stream with particles therein at a high speed, so that the kinetic energy of the particles is sufficient so that they stick to the layer to be ⁇ surface.
• a powder jet with powders of soft magnetic material on the Interface between the adjacent sheet edges is directed and forms the powder when hitting the sheet edges a connecting the sheet edges soft magnetic material seam.
• a powder jet is directed with iron-containing powder on the adjacent sheet edges and it is an iron-containing material seam or connecting seam formed.
• a powder jet with powder particles of nanocrystalline material preferably with a crystal grain size ⁇ 100 nm, or of amorphous material is directed onto the interface.
• the powder particles preferably have a particle size Zvi ⁇ rule 10 ym and 40 ym and a grain size smaller than 15 nm.
• an electrically insulating insert is preferably inserted between the two transformer sheets.
• Such an insert may prevent at ⁇ game example, that the cold gas spraying beam in joining the two plate edges of the overlying sheet meet transformer to the underlying transformer sheet and / or the electrical insulation between the
• a powder jet with iron- and silicon-containing powder is directed onto the interface.
• the silicon content is less than 10%.
• phosphorus-containing iron or one or more phosphorus-containing iron alloys may be used to join the sheet edges.
• conditions for example in the form of amorphous alloys, are used, for example, amorphous Fe-P material having a Phos ⁇ phoranteil between 5% and 15%, preferably with a Phos ⁇ phoranteil of about 10%.
• a powder jet with powder of Dynamo ⁇ sheet material can be used;
• a powder ⁇ material is used, which is identical to the sheet material of the transformer plates to be connected.
• the transformer sheets form after the bonding of the adjacent plate edges in cross-section, preferably a self-contained contours, for example a ring ⁇ shaped contour.
• the self-contained contour may play in cross-section be oval, circular, round, quadratic table, rectangular or polygonal in ⁇ . If there are corners in the cross section, these are preferably rounded.
• the invention also relates to a transformer core with bent transformer plates. According to the invention, provision is made in this connection for adjacent ones to one another
• Sheet metal edges of at least one of the bent Transformatorble ⁇ che are connected to each other with a magnetizable material.
• the invention will be explained in more detail with reference toPhilhamspie ⁇ len. This show by way of example
• FIG. 12 shows a third exemplary embodiment of a method according OF INVENTION ⁇ dung, wherein the transformer core sheets of a stack by means of cold gas fuel ⁇ zen are joined together.
• FIG. 1 shows a sheet stack 10 which is formed by a multiplicity of transformer laminations, of which four are shown by way of example in FIG. 1 and are identified by the reference numerals 20, 30, 40 and 50.
• the Trans ⁇ formatorbleche for example, consist of a silicon-iron alloy with soft magnetic properties, ie, for example, from so-called Dynamo plate material.
• the thickness of the sheet metal plates is for example in loading ⁇ ranging between 200 and 600 ym. In order to achieve an electrical insulation between the transformer plates, these are preferably provided with thin electrical insulation layers, for example, a thickness in the range between 1 and 5 ym.
• the electrical insulation layers are not shown wei ⁇ ter for reasons of clarity in the figure 1.
• the sheet stack 10 after the
• Transformer plates 20, 30, 40 and 50 have each been twice umgebo ⁇ gen.
• the bending points are identified in FIG. 2 by reference numerals 60 and 70.
• two coils 80 and 90 which have been pushed onto the sheet stack 10.
• the on ⁇ push the coils 80 and 90 on the sheet stack 10 can be done before or after the bending of the stack of sheets.
• FIG. 3 shows the sheet stack 10 after the uppermost one
• Transformer sheet 20 according to Figure 1 has two times umo ⁇ gen conditions.
• the bending points are identified by reference numerals 100 and 110.
• an air gap 23 has remained between the mutually adjoining or opposite sheet metal edges 21 and 22 of the transformer sheet 20.
• the air gap 23 is created on ⁇ basic manufacturing tolerances matorbleche when bending the transformer and can be technical reasons never fully avoid.
• the sheet stack 10 is shown after the air gap 23 between the sheet edges 21 and 22 has been closed by means of a cold gas spraying process.
• a material seam or seam 24 is formed, which - seen in cross-section - previously open contour of the transformer plate 20 closes and generates a closed contour 25.
• the transformer sheet 30 is also bent along the bending points 100 and 110 so that the structure shown in FIG. 5 results - as seen in cross section.
• the transfor ⁇ matorblech 30 thus forms, after bending an open contour, which is marked in Figure 5 by the reference numeral 34th
• Sheet metal edges 31 and 32 by means of cold gas spraying of a magnetizable material to form a connecting seam 35 connected to each other; This shows an example of the figure 6.
• the now seen in cross section of the closed contour Trans ⁇ formatorbleches 30 is denoted in Figure 6 by the reference numeral 36th
• FIG. 7 shows how the third transformer sheet 40 has been bent over. Again, between the adjacent plate edges 41 and 42 initially an air gap present, which is identified by the reference numeral 43.
• the air gap 43 is also closed by means of cold gas spraying of a magnetizable material.
• the connecting seam formed in this case is identified in FIG. 8 by the reference numeral 44.
• FIGS. 9 and 10 show also the finished means of cold gas spraying ⁇ transformer core, which is marked with the reference numeral 200th It can be seen that the connecting seams 24, 35, 44 and 54 preferably do not lie directly above one another, but are preferably offset laterally relative to one another.
• a further exemplary embodiment for producing a transformer core will now be shown with reference to FIG.
• the insert 300 can be positioned before, during or even after the bending of the sheets in the area of the later or already existing air gaps.
• the jewei ⁇ celled air gap is closed with a magnetizable material in the context of a cold gas spraying process.
• the transformer ⁇ sheets 20 to 50 are preferably provided with a thin electrical Insulation layer provided in order to achieve an electrical insulation between the transformer plates. It is this electrical insulation layer could be spraying affected during the cold gas, which is, however, in the embodiment shown in Figure 11 prevented by the provided before each ⁇ IER cold spraying step introduction of the electrically insulating insert 300th
• FIG. 12 shows an exemplary embodiment for producing a stack core for a stacked core transformer.
• the stack core is formed by stacking not bent or unbent transformer sheets, Ge of de ⁇ nen in the figure 12 shows for the sake of clarity, only two and are marked by reference numerals 350 and 360th It can be seen that the adjacent sheet edges of the stacked transformer sheets 350 and 360 extend obliquely at an angle of 45 °, so that interim ⁇ rule the edges of an air gap 370, which is also inclined at an angle of 45 ° in the Figure 12 goes up.
• the air gaps 370 are each closed with a magnetizable material 380 as part of a cold gas spraying process, as has already been explained above in connection with FIGS. 1 to 11 by way of example.
• inserts can be used in addition as they are exemplified in FIG. 11

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• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Soft Magnetic Materials (AREA)
• Transformers For Measuring Instruments (AREA)
• Manufacturing Cores, Coils, And Magnets (AREA)

Applications Claiming Priority (2)

Publications (1)

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ID=43530142

Family Applications (1)

Country Status (7)

Families Citing this family (4)

Family Cites Families (10)

• 2009
  • 2009-09-29 DE DE102009048659A patent/DE102009048659B3/de not_active Expired - Fee Related
• 2010
  • 2010-08-25 BR BR112012007571A patent/BR112012007571A2/pt not_active IP Right Cessation
  • 2010-08-25 EP EP10747202A patent/EP2483897A1/de not_active Withdrawn
  • 2010-08-25 MX MX2012003763A patent/MX2012003763A/es active IP Right Grant
  • 2010-08-25 WO PCT/EP2010/062399 patent/WO2011039003A1/de active Application Filing
  • 2010-08-25 KR KR1020127010822A patent/KR101373974B1/ko not_active IP Right Cessation
  • 2010-08-25 CN CN201080043497.5A patent/CN102549681B/zh not_active Expired - Fee Related

Non-Patent Citations (2)

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