EP2530688A1 - Enroulement de bande plate pour cýur dýinducteur - Google Patents

Enroulement de bande plate pour cýur dýinducteur Download PDF

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Publication number
EP2530688A1
EP2530688A1 EP12172102A EP12172102A EP2530688A1 EP 2530688 A1 EP2530688 A1 EP 2530688A1 EP 12172102 A EP12172102 A EP 12172102A EP 12172102 A EP12172102 A EP 12172102A EP 2530688 A1 EP2530688 A1 EP 2530688A1
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EP
European Patent Office
Prior art keywords
linear region
flat band
winding
insulated conductive
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.)
Withdrawn
Application number
EP12172102A
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German (de)
English (en)
Inventor
Franc Zajc
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Individual
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Individual
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Filing date
Publication date
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Publication of EP2530688A1 publication Critical patent/EP2530688A1/fr
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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
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/346—Preventing or reducing leakage fields
    • 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
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • 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
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation
    • 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
    • H01F2027/2857—Coil formed from wound foil conductor

Definitions

  • This invention relates to a flat band winding for an inductor core
  • Flat band windings for inductor cores are e.g. known from DE 100 40 415 C1 and WO 2007/136288 A1 .
  • US 7,573,362 B2 discloses a high-current, multiple air gap, conduction-cooled, stacked lamination inductor.
  • the magnetic core section of this known inductor includes substantially rectangular profiled magnetic laminations arranged in a stack.
  • converters are designed which use working frequencies that for small power converters up to 10 V have risen into the MHz range.
  • the research of middle power converters up to 200V and high power converters up to 500V is seeking to reach frequencies in the range of 300 kHz up to 1 MHz.
  • the inductor presents an important part regarding the losses and the size. Particularly, the inductor's size should be minimal, and if possible, the inductor shape should be square and the inductor should have the lowest possible AC/DC resistance ratio at the desired working frequency. In the existing inductors which are used in the high frequency area the skin effect, proximity effect and fringing effect are the reason for comparatively high losses and correspondingly required big size.
  • TC denotes a toroidal ferrite core with an air gap AG and having strand wire SW wound around the core TC.
  • the prior art inductors shown in Fig. 14 show a favourable AC/DC current resistance ratio, however, their field radiation is high, their size is big, and their shape is inconvenient to be fixed on a circuit board.
  • High-frequency current in circular or square-shape free wires is conducted only in the wire surface area which is called skin effect. That effects that the known inductors wound with such wires to have very low resistance and also high inductivity vary their resistance with increasing frequency very dramatically. Therefore, the high-frequency losses make the known inductors only useful for low alternating current frequencies.
  • the air gap also contributes to increase the high-frequency losses.
  • the magnetic flux exits the core in the area of the air gap and enters the winding causing heating of the winding. Even the replacement of a single air gap by plural air gaps does not reduce the effect of this heating phenomenon very much at high frequencies.
  • the permeability of a corresponding inductor depends very much on the magnetic density.
  • the composite ferrite material has a much lower saturation level than the sintered ferrite material. This effects that the inductivity of such composite ferrite material inductors varies drastically with current changes.
  • the invention provides a flat band winding as defined in independent claim 1 and 2, respectively.
  • the invention is well suited for high ripple current applications at high frequencies.
  • Fig. 1 shows a cross-section of a multi gap inductor core.
  • reference sign 1 denotes a multi gap inductor core according an embodiment of the present invention.
  • the core 1 includes a plurality of seven magnetic lamination sheets 2a-2g made of a ferrite material with lowest possible losses for the desired frequency range.
  • Reference sign HA denotes a length axis of the core 1, i.e. along the staggering direction of the laminations 2a-2g.
  • an appropriate ferrite material would be Ferrouxcube 3F45.
  • d1 minimum lamination thickness of about 0,2 mm can be reached, allowing the permeability to be low and to have a good gap distribution.
  • Each glue layer 3a-3f includes a spacer means 4 in form of spherical particles made of carbon, socalled glassy carbon spherical powder, which define a gap G having a predetermined thickness d2 between each corresponding pair of magnetic lamination sheets 2a-2g. Since a narrow size diameter distribution can be obtained by filtering such carbon material, the diameter d3 of the carbon particles 4 substantially equals the predetermined thickness d2 of the gap G. In other words, there is a monolayer of carbon particles included in the hardened glue layers 3a-3f acting as said mechnical spacer means.
  • the core 1 allows the production of an inductor having excellent performance and comparatively low losses in the desired frequency range, here 1 MHz.
  • the total gap of the core of Fig. 1 is the sum of all gaps G from where the magnetic field is dissipated only in a very small area causing no additional losses in the winding. The winding therefore can take the space very close to the core 1.
  • Fig. 2 shows a cross-section of a multi gap inductor core of Fig. 1 in order to explain a corresponding manufacturing method thereof.
  • the desired number of magnetic lamination sheets 2a-2g is stacked on top of each other, wherein between the pairs of adjacent magnetic lamination sheets the glue layers 3a-3f are dispensed by appropriate dispensing means.
  • the glue layer is a premix of glue and the spherical carbon particles 4.
  • the concentration of the particles in the glue is typically between 0,1 and 3 %, preferably 1 %. If the volume concentration is too high there would be the risk that the particles stick together making the gap thickness d2 inhomogeneous. On the other hand, if the volume concentration of the particles is too low, the particles could be not evenly distributed over the area between adjacent laminations and therefore also make the thickness d2 inhomogeneous. Despite of these lower and upper limitations which can normally be found very easily by experiments, the range of applicable concentrations still stays broad.
  • a pressure P is applied on the stack such that the spherical carbon particles 4 can exactly match and define the gap G with the predetermined thickness d2 according to their own diameters d3.
  • glue e.g. epoxy glue
  • the hardening can then be performed at room temperature or elevated temperatures, while the application of pressure P is continued until the stack is completely hardened.
  • Fig. 3, 4 are perspective views in order to explain the step of separating individual multi gap inductor cores from the hardened stack manufactured as explained in Fig. 2 .
  • the dimensions of the stack orthogonal to the length axis HA do not correspond to the dimensions of the finished core.
  • the dimensions of the hardened stack 100 are 80 mm width, 50 mm depth, and 25 mm length.
  • the hardened stack 100 is cut by means of a wafer saw (i.e. diamond saw) or wire saw into rows 100a and then into the cores 1', where the laminations are labelled 2a'-2m' and the glue/spacer layers 3a'-3l'.
  • a wafer saw i.e. diamond saw
  • wire saw i.e. wire saw
  • arbitrary core shapes may be obtained, for example, circular shapes as shown in Fig. 4 for the core 1" including laminations 2a"-2n" and glue/spacer layers 3a"-31".
  • This manufacturing method allows an accuracy of typically 5% of the inductance value and very small gaps.
  • 1,3 mm of gap were distributed among 65 ferrite sheets.
  • the tolerance accuracy can be improved by sorting out and assembling together two or more partial core stacks in order to provide air gaps with desired small tolerances.
  • Fig. 5a is a plain view of a first embodiment of an insulated conductive flat band (also sometimes denoted in the art as strip) used as a winding in connection with the multi gap inductor core; and Fig. 5b,c are perspective views of the insulated conductive flat band shown in Fig. 5a in order to illustrate a first winding procedure.
  • an insulated conductive flat band also sometimes denoted in the art as strip
  • Fig. 5b,c are perspective views of the insulated conductive flat band shown in Fig. 5a in order to illustrate a first winding procedure.
  • the insulated conductive flat band 5 shown in Fig. 5a-c is made of insulated conductive material such as copper or aluminum and includes a first linear region SR, a second linear region SL and a third linear region SM.
  • the width b1 of the first linear region SR is equal to the width b1 of the second linear region SL
  • the width b2 of the third linear region SM is 2 x b1 + S, where S is a given distance. This means that the first and second linear regions SR, SL are displaced by the distance S.
  • first and second linear regions SR, SL are orthogonally connected to the third linear region SM and run in anti-parallel directions as may be clearly obtained from Fig. 5a .
  • Virtual segments SR1-SR5 of the first linear region SR having a length l are denoted in order to show the folding lines when winding the insulated conductive flat band 5 around a core according to an embodiment of the present invention occurs.
  • Analogously SL1-SL5 denote virtual segments of the second linear region SL having all the length I which is a little bit larger than the diameter of the core to be used.
  • the first linear region SR and the second linear region SL are wound in opposite directions FU (clockwise) and FG (counter-clockwise) around the third linear region SM in order to form the winding around the core.
  • Fig. 6 is a perspective view of the first embodiment of insulated conductive flat band used as a winding in connection with the multi gap inductor core after the first winding procedure is finished.
  • a finished winding 5' made of an insulated conductive flat band as shown in Figs. 5a-c is shown in Fig. 6 .
  • the ends E1, E2 of the finished winding 5' are orthogonal to the length axis HA of the core to be inserted into the finished winding 5'.
  • Fig. 7 shows a cross-section of a multi gap inductor having the winding type of Fig. 6 .
  • the finished inductor of Fig. 7 includes a multi gap core 1'" having 20 laminations with intervening glue/spacer layers as explained in connection with Figs. 1 and 2 and having a surrounding winding 5" in analogy to the winding 5' described with reference to Fig. 6 , however, having a larger number of winding turns.
  • Fig. 7 the gap ⁇ between the core 1"' and the winding 5" can be made very small.
  • the section A of Fig. 7 is shown in enlarged form on the righthand side of Fig. 7 and also shows the space s which corresponds to the distance S between the first and second linear regions SR, SL.
  • Reference sign V finally denotes a magnetic shielding which surrounds the inductor according to this embodiment and closes the magnetic field of the coil.
  • Fig. 8 shows a cross-section of a multi gap inductor having a strand wire winding type.
  • Fig. 8 the laminated core 1"' is surrounded by a strand wire 50. All further details are the same as described above with respect to Fig. 7 .
  • Fig. 9a is a plain view of a second embodiment of an insulated conductive flat band used as a winding in connection with the multi gap inductor core; and Fig. 9b , c are perspective views of multiple parallel windings of the insulated conductive flat band shown in Fig. 9a in order to illustrate a second winding procedure.
  • the insulated conductive flat band 25 shown in Fig. 9a includes first linear region SU, a second linear region SO and a third linear region SM'.
  • the third linear region SM' is substantially orthogonally connected to the first linear region SU and to said second linear region SO, wherein the first linear region SU and the second linear region SO are displaced by a distance S, however, in contrast to the example in Fig. 5a run in parallel.
  • the distance S arises from the difference of the width b2 of the third linear region SM' and the sum of the width b1 of the first and second linear regions SU, SO.
  • virtual segments SU1-SU5 of the first linear region SU and virtual segments SO1-SO5 of the second linear region SO are depicted in order to clarify the folding lines when the insulated conductive flat band 25 of Fig. 9a is wound to form a winding around a core.
  • a plurality of insulated conductive flat bands of the 25, 25', 25", 25"' of the type shown in Fig. 9a is isolatedly stacked on top of each other.
  • the isolation can be achieved by using a foil, e.g. Kapton foil a resin or a native or artificial oxide on the surface of the insulated conductive flat bands 25, 25', 25", 25"'.
  • the stack of insulated conductive flat bands 25, 25', 25", 25'" shown in Fig. 9b is then wound in opposite directions FU (clockwise) and FG (anticlockwise) around the third linear regions of the insulated conductive flat bands 25, 25', 25", 25'" in order to form the winding around a core.
  • Fig. 10 is a perspective view of the second embodiment of multiple parallel windings of insulated conductive flat band used as a winding in connection with the multi gap inductor core after the second winding procedure is finished.
  • the final winding shape is shown in Fig. 10 , wherein the ends E1', E2' are also bend orthogonal to the length axis HA of the core in accordance with the embodiments of the present invention to be inserted into the wound winding.
  • the outer flat band 25 on one side becomes the inner flat band on the other side when wound in opposite directions FU, FG.
  • This contributes to counteract the proximity effect which otherwise would tend to shift the high-frequency current in the outermost flat band area.
  • the stack sequence change equalizes the induced voltage along the bands in order to avoid a current along the bands.
  • Fig. 11a,b are plain views of the first embodiment of insulated conductive flat band in form of a first and second specially stacked flat bands used as a winding in connection with the multi gap inductor core.
  • winding around a core in accordance with the embodiments described is made of two insulated conductive flat bands 5a, 5b of the type shown in Fig. 5a which are specially stacked on top of each other in an isolated manner.
  • SRa, SRb denote the corresponding first linear region of the first and second flat band 5a, 5b and SLa
  • SLb denote the corresponding second linear region of the flat bands 5a, 5b
  • SMa and SMb correspond to a respective third linear region connecting the first and second linear regions of the flat bands 5a, 5b.
  • the insulated conductive flat bands 5a, 5b shown in Fig. 11a are stacked isolatedly on each other such that there is a crossover such that on one side the first linear region SRa of the first insulated conductive flat band 5a lies above the first linear region SRb of the second insulated conductive flat band 5b, however, on the other side the second linear region SLa of the first insulated conductive flat band 5a lies below the second linear region SLb of the second insulated conductive flat band 5b.
  • the crossover region there is a small lateral gap S' x S between the insulated conductive flat bands 5a, 5b.
  • Fig. 12 shows a partial cross-section of another multi gap inductor core.
  • spacer means 4' includes a photolithgraphically structured Al 2 O 3 layer having a plurality of cube shape bumps 4' between which the hardended fixing layers 3f etc. are provided.
  • the fixing layer 3f is not made of glue but of adhesive wax.
  • Fig. 13 shows a schematic view of a transformer including a multi gap inductor core.
  • reference sign 1 denotes a multi gap inductor core according to the embodiment of the present invention shown in Fig. 1
  • W1, W2 denote a primary and secondary winding wound around the core so as to form a transformer T.
  • the spacer means is not restricted to the specified carbon particles or Al 2 O 3 bumps, but other materials, e.g. sand particles or quartz particles, or spacer foils or meshes may be used as well.
  • shape of the particles or bumps is not restricted to the circular or square cube shape, but can have various other shapes, such as polyedral shape, etc., however, it still is important that the diameter distribution is narrow enough to achieve the desired homogeneity of the gap thickness between the individual laminations.
  • various materials can be used for the laminations, the fixing material and the windings, and the invention is not restricted to the materials and dimensions mentioned hereinbefore.
  • the fixing material are Teflon, resist and grease which can be sufficiently hardenend.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Coils Or Transformers For Communication (AREA)
EP12172102A 2011-05-26 2011-05-26 Enroulement de bande plate pour cýur dýinducteur Withdrawn EP2530688A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP11167585.6A EP2528069B1 (fr) 2011-05-26 2011-05-26 Noyau d'inducteur à plusieurs espaces, inducteur à plusieurs espaces, transformateur et procédé de fabrication

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EP2530688A1 true EP2530688A1 (fr) 2012-12-05

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EP11167585.6A Not-in-force EP2528069B1 (fr) 2011-05-26 2011-05-26 Noyau d'inducteur à plusieurs espaces, inducteur à plusieurs espaces, transformateur et procédé de fabrication
EP12172102A Withdrawn EP2530688A1 (fr) 2011-05-26 2011-05-26 Enroulement de bande plate pour cýur dýinducteur

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11296572B1 (en) 2020-09-21 2022-04-05 Evr Motors Ltd Electric machine with variable cross-sectional area constant perimeter trapezoidal teeth

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140300440A1 (en) * 2013-04-05 2014-10-09 Hamilton Sundstrand Corporation Inductor gap spacer
CN108597801A (zh) * 2018-04-20 2018-09-28 江西特种变压器厂 一种可减小涡流损耗的浇注箔式线圈及其制造方法
CN113707443B (zh) * 2021-08-23 2023-03-31 横店集团东磁股份有限公司 一种纳米晶磁芯的制备方法及纳米晶磁芯

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GB2037089A (en) * 1978-11-22 1980-07-02 Philips Nv Ferromagnetic core having a gap
JPH08264342A (ja) * 1995-03-17 1996-10-11 Omron Corp コイル装置
US6011339A (en) * 1996-01-18 2000-01-04 Shibaura Engineering Works Co., Ltd. Motor mounted in a vehicle
DE10040415C1 (de) * 2000-08-18 2002-01-10 Robert Seuffer Gmbh & Co Kg Induktives Bauelement
EP1429352A1 (fr) * 2002-12-11 2004-06-16 Canon Kabushiki Kaisha Dispositif électrique et son procédé de fabrication
WO2007136288A1 (fr) * 2006-05-22 2007-11-29 Sergey Vasilievich Ivanov Procédé de bobinage de transformateur d'alimentation haute fréquence
DE102009008405A1 (de) * 2009-02-11 2010-08-19 Keiper Gmbh & Co. Kg Stellantrieb

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DE2718274A1 (de) * 1977-04-25 1978-10-26 Vogt Gmbh & Co Kg Verfahren zur herstellung definierter luftspalte in magnetischen kreisen
JP3127613B2 (ja) * 1992-10-13 2001-01-29 松下電器産業株式会社 磁気ヘッド及びその製造方法
US6660412B2 (en) * 2001-03-15 2003-12-09 Waseem A. Roshen Low loss, high frequency composite magnetic material and methods of making the same
US7573362B2 (en) 2005-10-11 2009-08-11 Hamilton Sunstrand Corporation High current, multiple air gap, conduction cooled, stacked lamination inductor
JP4539730B2 (ja) * 2008-02-18 2010-09-08 トヨタ自動車株式会社 リアクトルのコア
EP2209128B1 (fr) * 2009-01-20 2015-03-04 ABB Research Ltd. Culasse magnétique avec entrefers

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2037089A (en) * 1978-11-22 1980-07-02 Philips Nv Ferromagnetic core having a gap
JPH08264342A (ja) * 1995-03-17 1996-10-11 Omron Corp コイル装置
US6011339A (en) * 1996-01-18 2000-01-04 Shibaura Engineering Works Co., Ltd. Motor mounted in a vehicle
DE10040415C1 (de) * 2000-08-18 2002-01-10 Robert Seuffer Gmbh & Co Kg Induktives Bauelement
EP1429352A1 (fr) * 2002-12-11 2004-06-16 Canon Kabushiki Kaisha Dispositif électrique et son procédé de fabrication
WO2007136288A1 (fr) * 2006-05-22 2007-11-29 Sergey Vasilievich Ivanov Procédé de bobinage de transformateur d'alimentation haute fréquence
DE102009008405A1 (de) * 2009-02-11 2010-08-19 Keiper Gmbh & Co. Kg Stellantrieb

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11296572B1 (en) 2020-09-21 2022-04-05 Evr Motors Ltd Electric machine with variable cross-sectional area constant perimeter trapezoidal teeth
US11322994B2 (en) 2020-09-21 2022-05-03 Evr Motors Ltd Electric machine with multi-piece trapezoidal teeth
US11336132B2 (en) 2020-09-21 2022-05-17 Evr Motors Ltd Electric machine with liquid cooled coils and stator core
US11349359B2 (en) 2020-09-21 2022-05-31 Evr Motors Ltd Electric machine with SMC rotor core sandwiched between bandage and magnets
US11355985B2 (en) 2020-09-21 2022-06-07 Evr Motors Ltd Electric machine with stator base as common heat sink
US11374444B2 (en) 2020-09-21 2022-06-28 Evr Motors Ltd Method of forming irregular shaped coils of an electric machine
US11451099B2 (en) 2020-09-21 2022-09-20 Evr Motors Ltd Method of inserting multi-part tooth of an electric machine into a coil
US11489379B2 (en) 2020-09-21 2022-11-01 Evr Motors Ltd Electric machine with SMC stator core
US11489378B2 (en) 2020-09-21 2022-11-01 Evr Motors Ltd Electric machine with core piece of multi-piece teeth extending from an annular ring
US11594920B2 (en) 2020-09-21 2023-02-28 Evr Motors Ltd Electric machine with liquid-cooled stator core
US11831202B2 (en) 2020-09-21 2023-11-28 Evr Motors Ltd Electric machine with multi-part trapezoidal teeth

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EP2528069A1 (fr) 2012-11-28

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