EP2561520A1

EP2561520A1 - Inductive component having variable core characteristics and method for setting same

Info

Publication number: EP2561520A1
Application number: EP11718285A
Authority: EP
Inventors: Johann Weidinger; Karl-Heinz Vogl; Johann Winkler; Gerhard Karl
Original assignee: Sumida Components and Modules GmbH
Current assignee: Sumida Components and Modules GmbH
Priority date: 2010-04-19
Filing date: 2011-04-19
Publication date: 2013-02-27
Anticipated expiration: 2031-04-19
Also published as: DE102010015410A1; EP2561520B1; WO2011131341A1

Abstract

The invention relates to an inductive component, in particular a storage choke, which contains a core having variable characteristics, wherein in some aspects the magnetic permeability is laterally variable, whilst in other aspects the setting of the permeability takes place additionally or alternatively by means of different materials, the composition of which can be altered if required in a dynamic manner. The invention relates in particular to a storage choke, in which a separate centre limb is provided.

Description

Inductive component with variable core properties and method for their adjustment

In general, the present invention relates to inductive components used in electronic and electrical assemblies in which power flows in the range of a few hundred watts to several or many kilowatts have to be processed, generally caching energy in the form of magnetic energy in inductive components he follows.

The technical progress in the development of electronic switches, such as in the form of transistors, thyristors, and the like, in combination with the development of extremely powerful electronic controls leads to increasingly electronic components for the conversion or adjustment of electrical energy in small to very large Power range can be used. These include power supplies, which usually operate on the basis of a clocked mode of operation, so that a very good dynamic adaptation of the provided output power with relatively high efficiency is made possible. Also in many other areas, an efficient adaptation of electrical energy to given facilities or supply networks is required, so that in these areas increasingly circuit topologies are used in which fast-switching semiconductor elements provide high dynamics and high efficiency. For example, in the field of the automotive industry increasingly electrical energy is used in higher performance, such as for the supply of increasingly extensive peripheral components or for storage and provision of drive energy, so often an adaptation to rapidly changing load conditions by the electronic circuits, such as storage and / or providing drive energy is required. Also in the field of regenerative energy production must be a suitable adaptation of the electrical energy, such as in the form of solar power, electricity generated by wind generators, and the like, carried out in a suitable manner for storage and / or for feeding into corresponding networks. In this case, very different energy flows occur, which are adapted by the electronic components with the highest possible efficiency to the required output voltages and currents.

In such clocked electronic assemblies must, at least at higher powers, temporarily stored as magnetic energy in an inductive component, such as a storage inductor, temporarily to allow about an adjustment in current and voltage at high efficiency, since then the correspond chenden electronic switch in a non-linear manner, ie alternately in the open and closed state, can be operated. For this purpose, the inductive components for the required size of the magnetic energy to be stored are designed appropriately, which is accomplished by selecting a suitable magnetic core material and its size. Furthermore, the entire geometry of the inductive component is essential in order to minimize leakage losses and also to meet the thermal and electrical properties, such as in terms of heat dissipation, electrical creepage distances, etc. Also, the weight of the products plays a major role, such as in automotive applications, since with lower weight, a lower consumption can be achieved. In order to generally keep the required volume of the core material as small as possible, relatively high switching frequencies are typically used, for example, up to 100 kilohertz or more for powers in the range of a few kilowatts, so that a total compact volume of a corresponding electronic assembly is achieved, in particular the inductive components have a large volume of construction compared to other electronic components. By defining a certain clock frequency or a certain range of clock frequencies and the selection of a suitable inductive component, an adaptation to the expected load conditions in a certain range is therefore possible, but typically the dynamic range is limited and also the efficiency can vary relatively widely unless further elaborate precautions are taken to achieve high efficiency in the various different load ranges.

For example, very different input powers are to be processed, for example in the vehicle sector or alternatively in alternative energy generation, wherein in addition to a compact construction of the entire electronic component, the efficiency over the entire field of application is of crucial importance, since, for example, the economy in the alternative energy sector essentially depends on high energy conversion efficiency depends. Corresponding components, such as inverters, and the like, are sometimes subject to long-term, larger fluctuations in input energy due, for example, to solar module aging, especially for thin-film modules and amorphous modules, which in part initially deliver 15 to 20% more energy than those in the prior art This is the case in subsequent years when aging is significantly flatter. Similarly, there is a strong fluctuation, which is caused by the seasonal weather conditions, at least in our latitudes. Also, very high power fluctuations can occur during the day, so that the respective inverters are designed for a high dynamic input range, and it is then very difficult to maintain a desired high efficiency over the entire range. In particular the inductive components corresponding electronic components represent essential components that determine efficiency and cost, it is important to make the functional behavior of the inductive components, such as storage chokes, and the like, so that for a required maximum power high efficiency even at significantly lower input power , about one-tenth of the maximum power or less, achieving an overall compact design and good thermal performance for the maximum power range.

In view of the above object, the present invention provides inductive components, such as storage chokes, and methods for adjusting the magnetic properties of these inductors, wherein "variability" of the magnetic properties is provided so as to increase the efficiency in operation of the inductor achieved in the respective service areas. For this purpose, for example, the variability of the core characteristics of the core can be specified such that a smaller inductance results in a higher inductance of the component, which results in a higher overall efficiency of a corresponding electronic subassembly. For example, if necessary, due to the higher inductance at low currents, the clock frequency can be reduced accordingly, so that overall in the smaller power range lower switching losses and Ummagnetisierungsverluste contribute to higher efficiency. A desired adaptation of the magnetic properties can be effected, for example, by a suitable design of the magnetic permeability over the magnetic effective cross section of the core material at least in some core regions, so that different effective magnetic conductivities are effective at different magnetic field strengths and thus load currents Behavior revealed. This variability of the core behavior in the operation of the inductive component can be, for example, by the use of different magnetic core materials, by appropriately designed air gaps, by a suitable permanent bias or in a very dynamic manner by temporarily penetrating different materials into a core region or by a combination of any of these Possibilities are accomplished.

The aforementioned object is achieved inter alia by an inductive component having a winding and a magnetic core, which has a first core part and a second core part. The first core part encloses at least a part of the outside of the winding and is constructed of a first magnetic material type, while the second core part is enclosed by the winding at least along a part of its magnetic longitudinal direction and at least in the part enclosed by the winding of one or more second constructed of magnetic material types, which differ from the first magnetic material type.

As previously indicated, due to the different magnetic properties of the materials in the first and second core portions, a magnetic behavior corresponding to a "superposition" of the two different magnetic materials results, such that a desired overall magnetic behavior, such as a higher inductance at smaller current values , is achievable. For example, the second core member may be provided as a center leg or "center wear" of the magnetic core, wherein the first core member more or less encloses the inductor winding, thereby providing a very compact design with low EMI and good thermal properties becomes.

In one embodiment, the first magnetic material species has a smaller magnetic permeability compared to the one or more second magnetic material species. That is, in this embodiment, the magnetic conductivity of the first core member is lower, so that a corresponding larger volume, such as more or less complete enclosure of the winding, can be provided, but without the magnetic behavior at small magnetic field strengths and thus load currents unfavorable to influence. On the other hand, the higher magnetic resistance of the first core part can then be effective at higher magnetic field strengths, so that saturation of the second core part with the higher magnetic conductivity is effectively suppressed. In one embodiment, the magnetic material of the first core member is provided in the form of a ferrite material, which is generally more permeable than other low permeability materials, such as iron powder, nickel / iron powder composite materials, carbonylus materials, or other alloys, for example, under Use of cobalt, and the like. On the other hand, many ferrite materials have desirable properties, such as thermal conductivity and electrical conductivity, so that the first core member can be used as an efficient heat conductor for dissipating heat loss of the inductor to the outside. For this purpose, if necessary, the winding is arranged as close as possible to the ferrite material or brought into mechanical contact with it when relatively small voltages, for example less than about 500 volts, and the like occur during operation of the inductive component. This results in a very favorable thermal coupling of the winding to the first core part, which has a good thermal conductivity and a large outer surface, so that an efficient cooling can be achieved. If necessary, the outside of the second core part can have a suitably textured surface in order to further increase the cooling effect. In a further advantageous embodiment, at least one of the one or more second magnetic material types comprises a permanently magnetized material. In this case, the provision of a permanently magnetized material, a desired type of bias can be achieved, whereby a higher magnetization of the core material is achieved, for example, in applications in which a direct current of predetermined polarity with superimposed alternating current component, since a larger hub for the permissible magnetic induction of the core material in this mode of operation due to the bias is available. The permanently magnetized material may be introduced at any suitable position within the second core member, such as at a position external to the coil, to reduce corresponding magnetic losses in the permanently magnetized material. In other embodiments, the permanently magnetized material is distributed over an extended area of the second core portion, which also reduces losses incurred.

In a further embodiment, the permanently magnetized material is enclosed perpendicularly to the longitudinal direction of the second core part by a material which is not permanently magnetized. For this purpose, for example, a bore can be provided in the second core part, in which the permanently magnetized material is introduced in the form of a permanent magnet. Therefore, in some embodiments, a particular efficient manner of fabrication results because, for example, the second core member can be made together with the first core member during a common manufacturing operation, for example, pressed, and then the permanent magnet is inserted as a second magnetic material into a suitable bore. In this case, the desired magnetic behavior of the core can be suitably adjusted by the type of permanently magnetized material, by its effective cross section in cooperation with the entire effective cross section of the second core part and in conjunction with the first core part, wherein, as explained above, also a suitable bias is achieved.

In a further advantageous embodiment, the second core part has an end face and is placed with this end face on the first core part. Thus, the first core part and the second core part can be manufactured as separate components, so that two different materials can be used efficiently without requiring a complicated manufacturing process. The separately fabricated second core part also results in a very efficient assembly of the inductive component, for example because the winding can be arranged more efficiently with respect to the first core part, even in the presence of certain manufacturing tolerances for the winding, so that a desired minimum distance of the winding from the first Core part or a direct mechanical contact at least with some surface areas of first core part is possible. The second core part can then be easily inserted into the winding and placed on the first core part. The mechanical fixation can then be done by means of potting compound and the like.

In a further embodiment, the magnetic permeability varies in a cross section perpendicular to the magnetic longitudinal direction of the core. Thus, in this embodiment, in addition to the variable "series resistance" of the magnetic core, i. the first core part and the second core part, which are made of different materials, provided a further variability perpendicular to the magnetic propagation direction. This can be done, for example, as stated above with respect to the permanently magnetized material, by providing magnetic properties which vary in cross section over at least a partial length of the second core part. In particular, in embodiments in which the second core part is manufactured separately, there is a high degree of flexibility in the integration of various core materials in a variable manner perpendicular to the magnetic longitudinal direction. For example, initially suitable cavities or recesses may be provided, which are subsequently filled with a suitable material or with a plurality of materials. Also, a plurality of discrete portions of the second core portion may be provided, which are then interconnected by other pieces of material, these pieces of material, in conjunction with a suitable shape of the end faces of the respective core portions, leading to the desired variable critical permeability in the radial direction. In this case, the sections of material disposed between the individual core sections may be considered as "air gaps" containing, for example, a material with lower magnetic permeability or with a diamagnetic behavior and the like. In this way, the mechanical stability of the second core part is ensured and it is also possible to set a desired thermal behavior in addition to the suitable magnetic behavior. In other embodiments, for example, only a single "air gap" is provided by about at least one of the end faces of the second core part is formed so that adjusts a variable gap width in the radial direction.

In advantageous embodiments, the inductive component represents a storage choke, which can thus be designed for a desired maximum power and also shows a very efficient behavior with corresponding powers from zero to the desired maximum power. That is, with the above-mentioned technical measures, storage chokes with a construction volume of a few 10 cubic centimeters for a maximum power of a few hundred watts and more can be made up to arbitrarily larger construction volumes for powers of a few kilowatts and significantly higher, with frequencies for clocked circuit components in the range of a few hundred hertz to about one megahertz or more are applicable.

In another aspect of the present invention, there is provided an inductive device having a winding and a magnetic core partially enclosed by the winding. The magnetic core has a magnetic permeability that varies perpendicular to the magnetic longitudinal direction. The inductive component according to the invention thus has a locally different magnetic resistance, i. the magnetic permeability varies in a cross-sectional area which is perpendicular to the magnetic field propagation, so that a corresponding overall behavior of the component results depending on the magnetic field generated during operation and the induced induction in the core material. For example, at low currents and thus at small magnetic fields, a region within the cross section of the core is effective, which has the higher magnetic permeability, so that a desired higher inductance for the inductive component results in this operating region. As the magnetic field strength increases, the influence of the regions of lower permeability in the cross-section of the core becomes increasingly effective, so that the saturation behavior can be controlled in a targeted manner. Thus, the profile of the inductance of the device as a function of the load current can be adjusted so that even at lower power levels due to the larger inductance can achieve an overall higher efficiency.

In a further advantageous embodiment, the core has at least one core part in which magnetic materials with different magnetic permeability are provided. For this purpose, corresponding areas, for example in the form of recesses, bores and the like, can be provided in a suitable core material, which are then filled with one or more different materials in order to produce the permeability of the core that varies in the lateral direction. In some embodiments, the core has one or more gaps with variable gap width. The one or more gaps may be provided as "air gaps", ie, they may be filled with material having a very low relative permeability, or one or more of these gaps may be filled with low permeability material to thereby vary in the radial direction set magnetic resistance in the desired shape. If more than one column is provided, different materials may be used as needed to suitably adjust other properties such as thermal conductivity and the like if necessary. In a further advantageous embodiment, a core center part enclosed by the winding is provided with an end face which is placed on a second core part of the magnetic core. In this embodiment, there is thus a mechanical contact between the central core part and the second core part, without, however, that a continuous material is used for these two core parts. The central core part and the second core part can thus be produced as separate components, which results in the possibility, for example, of efficiently introducing suitable materials into the central core part in such a way that the desired variability of the magnetic permeability is achieved. For this purpose, measures may be provided, as also described above.

In a further embodiment, the core part has a cavity which can be filled with material for adjusting the magnetic properties. For this purpose, for example, suitable materials in powder form, as curable materials of suitable initial viscosity, and the like can be filled into the cavity, such as in the production of a separate core part, so that realize a variety of different magnetic properties of the core for an otherwise predetermined configuration of the core to let. In some embodiments, the core is designed so that the filling of a desired material into the cavity can also take place after the assembly of the inductive component. For example, suitable "connection areas" are provided, so that after assembly, for example after the casting of the individual component components, and the like, a further adaptation of the magnetic properties can take place. In this way, a suitable adaptation to an electronic module can be realized during any phase after the actual production of the inductive component, wherein in some embodiments, a corresponding adjustment can also take place within the electronic circuit, so that even a "dynamic" adaptation of the magnetic Properties is possible. The degree of dynamics for the adjustability of the magnetic properties depends on the given circuit periphery. For example, an initially desired lower inductance may be appropriately increased in the circuit by introducing a suitable magnetic material into the cavity. When providing a plurality of cavities and a stepwise adjustment of the inductance over time can be done. As stated in the introduction, there are many applications in which a change in the energy flows to be processed occurs over time, so that an appropriate adaptation may allow even higher efficiency for the future operation of the electronic component. For example, with inverters for solar systems, it may be advantageous to initially design the inductance to a higher maximum power and, once the aging begins, the inductance to a higher one or more times To set value, so as to take into account the decreasing maximum power of the solar modules.

In some illustrative embodiments, the one or more initial cavities are provided in the form of gaps having a nearly identical gap spacing over the entire cross-sectional area so that well-defined and low leakage inductance values are achieved. The adaptation of the inductance is then carried out by filling one or more of the cavities by a suitable material, wherein the favorable cross-sectional shape, ie about the constant gap width further contributes to very low leakage inductance values.

The provision of such "active" mechanisms for adapting the magnetic properties of the inductive component may be particularly advantageous in applications in which relatively high powers are to be processed, so that in particular the avoidance of additional inductive components as well as maintaining a high efficiency for the entire operating time electronic assembly significantly exceeds a corresponding cost of the peripheral components, which may be required for the active adjustment mechanism.

According to a further aspect of the present invention, a method for adjusting the inductance of an inductive component is provided. The method includes the step of providing a magnetic core of the inductor and generating a variable magnetic permeability in the magnetic core by providing at least two different magnetic core materials and / or by providing a gap having a varying gap width.

The method according to the invention thus makes it possible to vary the magnetic permeability, the variability occurring along the magnetic longitudinal direction and / or along the radial direction, that is to say perpendicular to the magnetic longitudinal direction. In other embodiments, the magnetic permeability is varied dynamically by changing the magnetic properties of at least a portion of the core during or after assembly.

In one embodiment, the provision of at least two different core materials includes placing an end surface of a first core member on a second core member, wherein the first and second core members are constructed of different types of magnetic materials. In this way, a high degree of flexibility can be achieved in the adjustment of the magnetic properties of the core, while still providing a moderately low wall in the production of the individual core parts is obtained. Thus, for example, as described above with respect to a center-core memory choke, a core member may be provided as a desired molding to provide the properties of noise immunity, dissipation heat dissipation, corrosion resistance, and the like, while the second core member may be made of suitable material and optionally is provided with desired additional materials in the form of inserts and the like, wherein the overall simpler configuration of this core part also enables efficient production. For example, almost closed cores may be provided in which the components for the "outer shell" are made of, for example, ferrite material, so that high corrosion resistance is achieved in addition to the aforementioned favorable magnetic shielding effects and good thermal conductivity, while an internal Core part is made of suitable iron materials, alloys, and the like, which would usually require a special corrosion protection when exposed to certain environmental conditions. For example, many electronic assemblies, such as inverters, and the like, designed for demanding environmental conditions, so that usually inductive components of iron powder and the like, an additional cost for the corrosion resistance is necessary.

Further advantageous embodiments will become apparent from the appended claims and from the following detailed description, in which reference is made to the following drawings, in which:

1 a and 1 b show schematically cross-sectional views of an inductive component during different assembly phases, wherein a central core part is provided as a separate component, which is constructed of a different magnetic material compared to other core parts,

1c to 1h schematically represent cross-sectional views of various core middle limbs or "middle jaws" of an inductive component of FIGS. 1a and 1b, wherein additional measures are taken to adjust the overall properties of the inductive component,

1 i and 1j is a plan view and a cross-sectional view of an inductive component in

In the form of a storage choke in which a free center leg is optionally provided in conjunction with one or more permanently energized magnetic materials, including a high current cantilevered winding, 1 k schematically shows a cross-sectional view of a part of a magnetic core in which a material is introduced in a middle limb, for instance in the form of a permanent magnet, and the like, in order to set the desired magnetic properties,

Fig. 11 schematically, e.g. a current waveform of a storage choke or the magnetic

Field in the inductive component, in which a bias is included for a better utilization of the core material,

Fig. 1 m and 1 n show a cross-sectional view and a plan view of a core part, wherein a

Cavity is provided, which can be filled with material during a suitable phase during assembly or after assembly for setting the desired magnetic properties,

Fig. 2a shows schematically a cross section of an inductive component, wherein in a

Core area one or more air gaps are provided with variable gap width, and

Fig. 2b and 2c show schematically the course of the inductance as a function of the current for different variants with chamfered distributed air gap.

FIG. 1a schematically shows an inductive component 100 which is provided, for example, in the form of a storage choke. The device 100 has in the assembly phase shown a winding 1 10, which is constructed according to the desired electrical and magnetic properties. In the illustrated embodiment, the winding 110 represents the winding of a storage choke designed for relatively high currents, so that a moderately large copper cross-section of the winding 110 is provided with a relatively small number of individual windings. In some embodiments, the winding 1 10 is formed in the form of a cantilevered winding, so that can be dispensed with about a bobbin. In this way, the number of required individual components of the device 100 can be reduced, wherein at the same time, if appropriate, can improve the electrical and thermal properties. The winding 110 is arranged in a core part 140 of a magnetic core 120 of the component 100, wherein this can be accomplished during assembly so that optionally one or more outer surfaces, such as an outer surface 1 11 of the winding 1 10 in close proximity to an inner surface of the Core part 140 is arranged. For example, a conductor piece having a relatively large area 1 1 1 serving as a lead to the turns of the winding 110 may be provided, which is adjacent to or in contact with a complementary surface in the core portion 140, so that when directly Tem contact or even with a corresponding thin Zwischenisolierschicht a good thermal connection of the winding 110 results in the core member 140. The core member 140 is constructed of a suitable magnetic material 141, such as a ferrite material, which, given the desired overall shape of the core member 140, provides the desired magnetic permeability and also has the desired magnetic behavior with respect to the required operating frequency range. In the embodiment shown, the core part 140 is designed such that the winding 10 is almost completely enclosed, so that the core part 140 also serves as a "housing" for accommodating the winding 110. With this measure it is possible not only to achieve the desired magnetic properties To also minimize magnetic interference outside the device 100. Also, using a field material results in efficient heat conduction from inside to outside, so that the outer surface of the core part 140 serves as an efficient cooling surface, with further passive and non-conductive features as needed For example, the outer surface of the core member 140 may be appropriately patterned as needed so that the resulting increased surface area allows for improved heat dissipation surface of the device 100 in the form of a ferrite may not require further measures in terms of corrosion resistance, even if the device 100 is used in electronic assemblies that are exposed to demanding environmental conditions, such as in the form of assemblies that are used outdoors. For example, many inverters are built for photovoltaic systems for outdoor use, so that a sufficient corrosion protection of appropriate inductive components must be guaranteed.

In the assembly phase shown, a further core part 130 is provided, which is constructed of a desired magnetic material 131, which differs from the material 141. For example, the core portion 130, or at least a portion thereof, may be constructed of a low permeability material, such as iron powder, an iron / nickel alloy, or other suitable materials that can thus be efficiently integrated into the core 120 to provide a desired match of overall core properties. In providing such materials, which are generally not corrosion resistant, as the center leg or "center piece" of the device 100, reliable corrosion protection is still provided because the core part 140 together with another core part, which is described below with reference to Fig. 1 b, serves as an efficient housing. The core parts 140 and 130 can therefore be efficiently manufactured by any suitable method, for example, be pressed, and be subsequently assembled during assembly, wherein the winding 110 can be arranged with better thermal contact with the core part 140, even if certain manufacturing tolerances occur, since the core part 130 is to be introduced into the winding 110 only subsequently or is introduced together with the winding. In particular, different versions of the core part 130 can be provided, as also shown below, so that various separate characteristics are available for a basic configuration of the inductive component 100, without the production of the other component components, such as the winding 110, of the core part 10, and other core parts, thereby being influenced. In this way, a high degree of flexibility results in the adaptation of the component 100 to various circuit topographies without, for example, changing the external dimensions of the device 100.

During assembly of the component 100, the core part 130 is then inserted into the winding 110 and thus placed with an end face 130s on a corresponding surface 140s of the core part 140. Thus, the two surfaces 130s and 140s are in mechanical contact, so that an efficient magnetic coupling of the parts 130 and 140 is achieved. It should be noted that the core portion 130 is not necessarily constructed entirely of the same material, but other materials may be provided locally to provide, for example, an "air gap" and / or to set certain magnetic properties, such as biasing. and the like, as explained below.

Fig. 1b schematically shows the inductive component 100 in a more advanced phase of the assembly process. As shown, the core member 130 is inserted into the coil 1 10 and rests on the core member 140, so that in the illustrated embodiment, a portion of the core member 130, designated as 132, in a longitudinal direction L, also referred to as the magnetic longitudinal direction is surrounded by the winding 1 10. Furthermore, a core part 150 is provided which serves approximately as a cover for the core part 140 and thus completes the magnetic circuit of the core 120. If necessary, an air gap 101 may be provided between the core member 130 and the core member 150 by making a dimension of the core member 130 smaller along the magnetic longitudinal direction L than a corresponding dimension of the core member 140. Further, in the shown embodiment, terminal portions 12 and 12 are 113 of the winding 1 10 led out "laterally", ie they are led out through recesses in the core part 140, wherein in other embodiments, one or both terminal portions 112, 113 may be led out through the core part 150. Furthermore, in the assembly phase shown, if appropriate, a potting material in Inside of the volume defined by the core parts 140 and 150, which is used for the mechanical fixing of the individual components. th of the device 100 and for integrity in terms of chemical and other influences.

1c schematically illustrates a cross-sectional view of the core member 130 according to an embodiment in which a plurality of gaps 132a, 132b are provided to define the magnetic properties of the core member 130 and thus the entire core 120 shown in FIG. 1b. In the embodiment shown, both the gap 132a and the gap 132b have a constant gap width, which may be different for the gaps 132a, 132b as needed. The gaps 132a, 132b are filled with a suitable material, such as a low permeability material, a material that is substantially non-magnetic, but has, for example, a high thermal conductivity, and the like. For this purpose, individual sections of the core part 130 may be provided in the form of material pieces of the material 131 which are mechanically connected to respective pieces of material corresponding to the gaps 132a, 132b. Optionally, the individual components of the core part 130 can be used during assembly in the core part 140 of Fig. 1 a and are then mechanically fixed accordingly during the pouring. In particular, since core member 130 can be manufactured independently of other core members, there is a high degree of flexibility in selecting suitable materials and in the geometric configuration of gaps 132a, 132b. If appropriate biasing is desired, one of the gaps 132a, 132b or both gaps may be filled with a permanently magnetized material. In the embodiment shown in Fig. 1c, the core member 130 thus has a substantially non-varying magnetic permeability perpendicular to the magnetic longitudinal direction L, since both the geometrical dimensions of the gaps 132a, 132b and their respective materials are uniform across the cross-section are.

Fig. 1d shows a similar arrangement of the middle limb 130, with the "slits" 132A, 132B realized at the respective end regions of the leg 30. In the example shown, the slits 132A, 132B are both geometrically and similar in material, so that the behavior results, as it has also been previously described with reference to Fig. 1 a.

1e schematically illustrates a cross-sectional view of the core member 130 according to an embodiment in which an air gap 132 is provided having a varying gap width in a transverse direction Q, as indicated by A and B. That is, in the illustrated embodiment, at least one end face 132s is provided as an oblique surface, so that upon subsequent assembly in cooperation with another core member, such as the core member 150 of FIG. 1b, the air gap 132 with the variable gap side is formed. Thus, the magnetic permeability, ie the magnetic conductivity for the given magnetic Lengthwise L across the cross-section Q variable, since due to the smaller gap width A, a much lower magnetic resistance is caused than by the gap width B. It should be noted, however, that a variable gap width can be produced by any configuration of the end face 132s if it has a conical shape, and the like. It should also be noted that, if necessary, a suitable piece of material may be provided to fill the gap 132 accordingly.

Fig. 1f schematically shows such an embodiment in which approximately both end portions of the leg lead to a variable gap width which is largest at the edges and minimum in the middle. Here, this configuration is shown as a truncated cone-like arrangement.

Fig. 1g shows schematically the core part 130 in an embodiment in which a plurality of gaps

132a, 132c are provided, wherein one or more of the gaps 132a, ..., 132c a in

Transverse direction Q have variable gap width. In this way, for example, an efficient distribution of an air gap within the core part 130 can take place, whereby also a desired lateral change of the magnetic permeability reaches, if for instance all gaps

132a 132c have a varying gap width. The gaps 132a, ..., 132c are filled with any suitable material having the required magnetic, thermal and mechanical properties. If necessary, different materials may be used so that a high degree of flexibility is achieved in the adjustment and adjustment of the desired final magnetic properties of the inductive component. In this case as well, the separate production of the core part 130 does not require any elaborate production methods, yet a large number of different parts 130 can be provided, so that also many different versions of the complete inductive component based on the same base components without high Production costs can be produced.

Fig. 1 h shows schematically further embodiments of the leg 130, wherein a mixture of different gap shapes is applied. That is, different gap geometries can be used in combination with identical or different filling materials in order to set the desired core properties efficiently. In the embodiment shown approximately the gap 132b is provided as a truncated cone, wherein a "Füllmateria is provided at the truncated cone center, which is different from the material 131. On the other hand, at the opposite end portion, a uniform gap 132a provided with a suitable material, so for example, the global magnetic resistance is dictated by the gaps 132b and 132a and the materials used therein, while achieving a desired modulation across the cross-section through the cone shape of the gap 132b. Other gaps 132c of suitable shape may also be provided so that flexibility in adjusting the overall magnetic properties may be further enhanced.

1 i schematically shows a top view of the inductive component 100 according to a further embodiment, in which the core 120 has a core part 140 a enclosing the winding 10 in conjunction with a separate core part 130 a. With regard to the components 140a and 120a, the same criteria apply as previously explained with reference to the core parts 140 and 130. In the embodiment shown, dimensions b, b2 of about 80 and 73 cm are used by way of example, while the winding 110 is designed for currents up to 150 amperes as a self-supporting coil. Corresponding dimensions of the winding 110 of the core part 130a are provided as d1 at 6.6 cm and d2 at 4.3 cm. However, these values are only exemplary values and can be adapted to other specifications at any time.

FIG. 1j schematically shows the component 100 in a cross-sectional view, wherein the core 20 has a further core part 140b, which completely encloses the winding 110 with the exception of the connection regions 112, 11 with the core part 140a, wherein in the core part 140b another separate core part 130b is used. That is, instead of a "housing" and a "lid", as shown in Fig. 1 b in the form of components 140 and 150, both the core portion 140a and the core portion 140b are formed as a "housing" in the illustrated embodiment Furthermore, in the embodiment shown, the middle leg of the core 120 is provided in the form of the two core parts 130a, 130b, in other versions also a single separate core part is used Columns 132a, 132b, which contain a permanently excited magnetic material, for example, so that a desired biasing of the core 120 is achieved The two gaps 132a, 132b lie outside the winding 110, so that corresponding losses in and through the magnet remain low ,

With regard to the production of the individual core parts and their assembly, the same criteria apply as stated above. Furthermore, it should be noted that if necessary, further materials, for example in the form of foils, and the like can be introduced during the assembly of the individual core parts of the winding in order to provide approximately required insulating distances. Also, other "air gaps", such as air gaps and the like, can be provided in a suitable manner, as also explained above.

For example, 1f and 1g goes for the inductor 100 in FIGS. At a height of 12 cm, a component volume of about 100 cm ^3, wherein a maximum current of 150 amps is used as a basis. With a number of turns of 1 1 results in a magnetic In production of about 600 mT, while the maximum field strength reaches 6000 amperes per meter. In this case, the materials of the core 130 are selected so that an inductance of about 65 μΗ sets at the maximum current.

FIG. 1 k schematically illustrates the inductor 100 according to further illustrative embodiments, wherein the core 120 includes the core portions 140 and 150 to enclose the coil 110. Furthermore, the central core part 130 is provided, which in one embodiment is designed as a separate and thus attached core part, as described above, while in other embodiments the core part 130, i. H. Areas 131 thereof, constitute a part of the core part 140 and are thus constructed of the same material. Furthermore, a material 135 is provided in the core part 130 serving as a magnetic core material and whose magnetic properties are different from those of the material 131. In one embodiment, the material 135 represents a permanent magnet, i. H. a permanent magnetic material, and thus to achieve a bias in the core 130. The inclusion of the material 35 in the material 131 of the core part 130 results in an efficient possibility of adjusting the overall properties of the core 120 by also selecting its dimension within the core part 130 in addition to the type of material.

11 schematically shows a current profile or the course of the field strength in the inductive component 100 when a clocked operation is present, wherein a DC component or a DC component of the magnetic field always has the same polarity or direction. Due to this DC magnetization, designated HO, the overlying AC component, i. H. the rising and falling edges of the current or the magnetic field so limited that the permissible magnetic induction in the core material is not exceeded. Therefore, with a high DC component occurring, only a small stroke results when passing through the respective hysteresis curve of the core material. By means of a corresponding biasing, as shown for example in the embodiments in Fig. 1g and in Fig. 1 h in the form of permanent magnets, can be with appropriate adjustment of the magnetic field direction of the permanent magnets, such as the column 132a, 132b in Fig. 1g or the material 135 in Figure 1k, achieve a reduction in the DC component or even a "pole reversal" of the HO component, so that a much larger range is available for the magnetization of the core by the AC component.

FIG. 1 m schematically illustrates a cross-sectional view of the core member 130 according to embodiments in which a cavity 136 is provided in the material 131 that is configured to collapse with a desired material at least partially during any assembly phase or can be refilled during operation. For this purpose, for example, at least one connection region 136a, 136b is provided, via which a material 137, for example in the form of a powder, a viscous material, and the like can be supplied. By way of example, the connection regions 136a, 136b are designed such that a coupling to a supply line can take place at least during assembly, so that the material 137 can be introduced into the cavity 136. For this purpose, appropriate projections may optionally be provided with corresponding lead pieces, which are still accessible during the desired assembly phase or continue to be accessible even after final assembly.

1 n schematically shows a plan view of the core part 130 in an embodiment in which the connection regions 136a, 136b are designed to receive the material 137 in a controllable manner and possibly to lead it out. In this way, for example, the cavity 136 in the region of the material 131 can be provided as a gap with a constant gap width, with a change in the total permeability of the magnetic core by introducing the material 137 in the desired manner. For example, fine tuning of the magnetic properties by introducing material 137 may be accomplished after final assembly. In other embodiments, the cavity 136 may also be accessible in the installed state, so that a "dynamic" adaptation of the magnetic properties can be achieved If, for example, a lower inductance is required in an operating phase of the inductive component, as generally higher load currents are to be expected can be carried out by removing material 137 from the cavity 136, which is contained there approximately in the form of powder material by introducing under suitable pressure, so that there is a reduction of the inductance.On the other hand, if a higher inductance is required, then material 137 The components required for this, for example a material reservoir in conjunction with a suitable supply, can be provided, for example, in the context of conventional electromechanical components, as are also required for forced cooling and the like ss too much effort arises. In particular, for inductive components for very high performance is a corresponding saving in terms of additional inductive components or the gain in efficiency by a targeted adjustment of the inductance during operation advantageous compared to the additional energy and component costs required for the introduction of the material 137 is. Mechanisms may also be provided in which the material 137 may be introduced only once, which may be done in the installed state using external or internal control pulses. For example, a plurality of cavities 136 may be provided which controllably be selectively sensed with the material 137, so that a stepwise increase in the inductance is achieved. For example, a suitable material can be selectively introduced into one of the cavities 136 by activation of a corresponding electromechanical component and optionally treated, so that the desired mechanical stability of the material 137 in the cavity 136 is achieved. For example, temporarily higher temperatures may be generated for this purpose, and the like. In this way, for example, the inductance of the "aging" of solar modules can be adjusted, so that first the electronic assembly is optimized for the initial maximum power and controlled in the chronological order of the corresponding state of the solar modules is adjusted.

By providing a suitably suitable periphery for the feeding of the material 137, the dynamic behavior in the adaptation of the inductance can be correspondingly improved, for example, by efficiently supplying the material 137 and also removing it efficiently, the respective setting time being in the region of a few seconds or significantly can lie underneath. In this case, a suitable controller can set the inductance in the desired manner "dynamically", so that always a favorable for the respective operating mode efficiency is achieved.

2a shows schematically a cross-sectional view of an inductor 200 having a winding 210 and a core 220. The core 220 has a core portion 230 in which a plurality of air gaps 232a, 232e are provided which distribute the reduced magnetic permeability throughout the portions provide magnetic longitudinal L away. Further, at least some of the gaps 232a, ..., 232e have a gap width varying along the transverse direction Q, as indicated by a and b. In this way, a magnetic permeability of the core 220 varying in the transverse direction Q is generated, which in turn leads to different inductance values as a function of the magnetic field or of the load current. For example, with a small magnetic field in the longitudinal direction L, the permeability of the core 220 is essentially determined by the lower magnetic resistance achieved by a smaller gap width a, so that overall the effective inductance of the device 200 is relatively high. With increasing magnetization of the core 220, the higher magnetic resistance caused by the increasing gap width b becomes increasingly effective, so that then results in a reduced inductance. In the embodiment shown, the material of the core part 230 is substantially equal to the remaining components of the core 220, which can be accomplished by making corresponding sections and arranging corresponding insert elements. In other embodiments, the part 230 may also be based on a other magnetic material, as also previously explained with reference to the device 100.

Fig. 2b shows schematically the course of the inductance as a function of the load current for a coil, which is operated up to several 100 watts. As shown, for a maximum load current of about 16 amps, an inductance of about 0.35 mH results, with the inductance then increasing nearly linearly with decreasing load current and decreasing at a load current of about 6 amps.

Fig. 2c shows schematically the corresponding dependence of the inductance of the load current for a further embodiment, wherein the ratio of the inductors is less pronounced at very low load current and at very high load current, however, for a total larger maximum load current, a higher inductance is achieved.

It should be noted that by means of the aforementioned mechanisms, a high degree of flexibility in the adjustment of the respective inductance can be achieved, so that an efficient adjustment of the efficiency of the inductance to the respective current circumstances is possible. In particular, the mechanisms described above can be suitably combined with one another, such as the provision of a bias in conjunction with a non-linear course of the inductance, and the like, so that there is a high degree of flexibility in the adjustment of the magnetic properties.

Claims

Patent claims

1. Inductive component, in particular storage inductor, with a winding (1 10) and a magnetic core (120), which has a first core part (140) and a second core part (130), the first core part (140) being at least part of the Encloses the outside (1 1 1) of the winding (110) and is constructed from a first type of magnetic material (141) and the second core part (130) is enclosed by the winding (110) at least along part of its magnetic longitudinal direction (L) and at least in the part enclosed by the winding (110) is made up of one or more second types of magnetic material (131), which differ from the first type of magnetic material (141).

2. Inductive component according to claim 1, wherein the first magnetic material type has a smaller magnetic permeability compared to at least one of the one or more second magnetic material types.

3. Inductive component according to claim 1, wherein the first magnetic material type has a greater magnetic permeability compared to at least one of the one or more second magnetic material types.

4. Inductive component according to one of the preceding claims, wherein the winding is in direct mechanical contact with the first core part.

5. Inductive component according to one of the preceding claims, wherein at least one of the one or more types of magnetic material has a permanently magnetized material.

6. Inductive component according to claim 5, wherein the permanently magnetized material is surrounded by a non-permanently magnetized material perpendicular to the longitudinal direction of the second core part.

7. Inductive component according to one of the preceding claims, wherein the second core part is placed on the first core part (140) by means of an end face (130S).

8. Inductive component according to one of the preceding claims, wherein the magnetic permeability varies perpendicular to the magnetic longitudinal direction (L).

9. Inductive component according to claim 8, wherein at least one air gap (132) is provided, the distance of which changes perpendicular to the magnetic longitudinal direction (L).

10. Inductive component with a winding (110, 210) and a magnetic core (120, 220) partially enclosed by the winding (1 10, 210), the magnetic core (120, 220) having a magnetic permeability that is vertical ( Q) varies to the magnetic longitudinal direction (L).

1 1. Inductive component according to claim 10, wherein the core has at least one core part (130, 230) in which magnetic materials with different magnetic permeabilities are provided.

12. Inductive component according to claim 10 or 11, wherein the core has one or more gaps (132, 232A - 232E) with variable gap width.

13. Inductive component according to claim 12, wherein the one or more gaps are filled with a substance to increase thermal conductivity.

1 . Inductive component according to one of claims 10 to 13, wherein a core middle part enclosed by the winding is provided with an end face (130S) which is placed on a second core part (1 0).

15. Inductive component according to one of claims 10 to 14, wherein the core has a cavity (136) which can be filled with material to adjust the magnetic properties.