EP2751814A1 - Transformer and associated production method - Google Patents

Transformer and associated production method

Info

Publication number
EP2751814A1
EP2751814A1 EP12751490.9A EP12751490A EP2751814A1 EP 2751814 A1 EP2751814 A1 EP 2751814A1 EP 12751490 A EP12751490 A EP 12751490A EP 2751814 A1 EP2751814 A1 EP 2751814A1
Authority
EP
European Patent Office
Prior art keywords
secondary winding
conductor
winding
transformer according
transformer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP12751490.9A
Other languages
German (de)
French (fr)
Other versions
EP2751814B1 (en
Inventor
Dirk Schekulin
Silvia GROSS-KÄUFLER
Chriss HÄRTSCH
Thomas Bisig
Alex Itten
Piere CAVIN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schmidhauser AG
Original Assignee
Schmidhauser AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schmidhauser AG filed Critical Schmidhauser AG
Publication of EP2751814A1 publication Critical patent/EP2751814A1/en
Application granted granted Critical
Publication of EP2751814B1 publication Critical patent/EP2751814B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • H01F27/085—Cooling by ambient air
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2876—Cooling
    • 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
    • H01F27/2823—Wires
    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor

Definitions

  • the invention relates to a transformer and an associated manufacturing method.
  • High-frequency transformers for high output currents are predominantly planar designs with stamped sheets for the secondary winding.
  • the primary winding is usually also laminated or realized with stranded wire.
  • Another problem is the implementation of the required isolation distances without an excessive increase of the leakage inductances. - -
  • the invention has for its object to provide a transformer and an associated manufacturing method available that allow efficient cooling of the transformer with the least possible effort.
  • the invention achieves this object by a transformer according to claim 1 and a manufacturing method according to claim 12.
  • Preferred embodiments are the subject of the subclaims, the wording of which is hereby made part of the description.
  • the transformer is preferably suitable or provided for clocked power supplies and comprises: a magnetic or magnetizable core, in particular a ferrite core, which defines a winding axis or has a winding axis, at least one primary winding, which is formed by a primary winding conductor, in particular in the form of multi-insulated high-frequency strand, which at least partially surrounds the winding axis of the core or a leg of the core through which the winding axis passes, and at least one secondary winding which is formed by a secondary winding conductor.
  • a magnetic or magnetizable core in particular a ferrite core, which defines a winding axis or has a winding axis
  • at least one primary winding which is formed by a primary winding conductor, in particular in the form of multi-insulated high-frequency strand, which at least partially surrounds the winding axis of the core or a leg of the core through which the winding axis passes
  • secondary winding which is formed by
  • the secondary winding conductor encloses the primary winding conductor, ie the secondary winding conductor and the primary winding conductor form different winding layers over the winding axis, the secondary winding is formed in one layer and a cross section of the secondary winding conductor is rectangular, in particular square. Due to the cross section and the consequent outer contour, the secondary winding can be coupled very easily and with low thermal resistance, for example to a cooling surface.
  • the cross section of the particular massive winding or the solid conductor is deliberately oversized, so that an efficient heat flow within the winding is possible.
  • the secondary winding conductor is massive, i. the complete cross-section of the conductor is filled with conductor material or the conductor is completely filled within its outer dimension with conductor material.
  • the conductor is not constructed by interwoven strands, a plurality of combined individual conductors, as a waveguide or the like.
  • the at least one secondary winding is formed from a solid block of material which is structured to form the secondary winding conductor, in particular by drilling, sawing and / or milling is structured.
  • the at least one secondary winding is formed from a die-cast molding.
  • the transformer has a rated power, wherein the (minimum) cross section of the secondary winding conductor is dimensioned such that a current carrying capacity of the secondary winding conductor is greater than required for the nominal power, i. the cross-section of the conductor is oversized relative to the rated power
  • the secondary winding conductor made of copper or titanium, particularly preferably made of aluminum.
  • a planar cooling element is provided, which is thermally coupled to the secondary winding, in particular to the side of the secondary winding facing away from the winding axis of the core.
  • a heat-conducting electrical insulator is provided, which is arranged between the cooling element and the secondary winding.
  • the electrical insulator is preferably an electrically insulating heat-conducting foil.
  • the secondary winding or the secondary winding conductor forms a thermal bridge to the planar cooling element.
  • Losses and losses of the primary winding (s) go first on the secondary winding (s), in order then to be dissipated, for example, over the flat cooling element in the form of a water-cooled cooling plate can.
  • the secondary winding forms a heat sink.
  • a distance between the primary winding and the core and a distance between the secondary winding and the primary winding are selected such that leakage losses are minimized.
  • the primary winding is as close as possible above the core and the secondary winding is as close as possible to the primary winding, so that there are minimal loss components due to stray fields and a good thermal coupling of the system.
  • the secondary winding is formed from a solid block of material which is patterned to form the conductor, in particular by material-removing machining in the form of drilling, sawing and / or milling.
  • FIG. 1 is an illustration of a transformer according to the invention
  • Fig. 2 is an exploded view of the transformer shown in Fig. 1 and
  • FIG. 3 is an electrical equivalent circuit diagram of that shown in FIGS. 1 and 2
  • a switched-mode power supply transformer 1 having a magnetizable ferrite core 2 with a leg defining a winding axis 3, a first primary winding 4a (see FIG. 2) formed by a first primary winding conductor of multi-insulated high-frequency stranded wire.
  • a second primary winding 4b formed by a second primary winding conductor of multi-insulated high-frequency strand immediately surrounding the winding axis 3 of the core 2, the first primary winding 4a and the second primary winding 4b being axially adjacent the leg are arranged, a first solid secondary winding 5a made of aluminum, which is formed by a first secondary winding conductor 6a, and a second solid secondary winding 5b made of aluminum, which is formed by a second secondary winding conductor 6b
  • bores 9a and 9b are provided as terminals for the first and second secondary winding 5a and 5b, respectively.
  • Isolation elements 10 serve for electrically insulating between the primary and secondary circuits.
  • the secondary winding conductors 6a and 6b enclose their associated primary winding conductor so as to be axially adjacent to the leg.
  • the secondary winding conductors 6a and 6b are each formed in one layer and each have a rectangular cross-section in the winding direction, which is variable in the winding direction.
  • the transformer has a specific rated power, wherein the cross section of the secondary winding conductors 6a and 6b is dimensioned such that their current carrying capacity is greater than required for the nominal power.
  • a flat cooling element 7 is further provided, which is thermally coupled to the side facing away from the winding axis 3 of the core 2 side or surface of the secondary windings 5a and 5b, wherein between the cooling element 7 and the secondary windings 5a and 5b, a heat-conducting electrical Insulator in the form of an electrically insulating heat conducting foil 8 is provided.
  • Corresponding cooling elements may be provided on the upper side and / or the lower side of the secondary windings 5a and 5b.
  • the secondary windings 5a and 5b are each formed from a solid aluminum block of material, which is suitably structured by drilling, sawing, spark erosion and / or milling.
  • the cross-section of the secondary winding conductors 6a and 6b or their minimal cross-section over the entire winding is dimensioned such that at a given operating frequency effective by current displacement replacement surface (skin depth) is significantly smaller than the geometric cross-section of the massive secondary winding conductors 6a and 6b.
  • skin depth current displacement replacement surface
  • Fig. 2 shows for clarity an exploded view of the transformer shown in Fig. 1.
  • Fig. 3 shows an equivalent electrical circuit diagram of the transformer 1 shown in Figs. 1 and 2 with the primary windings 4a and 4b and the secondary windings 5a and 5b.
  • the embodiments shown have massive secondary-side windings 5a and 5b, which are directly above the primary windings 4a - - or 4b are made of multi-insulated high-frequency stranded wire.
  • the primary windings 4a and 4b are arranged at a minimum distance above the ferrite core 2.
  • the (minimum) cross section of the massive secondary windings 5a and 5b is deliberately oversized, so as to achieve an efficient heat flow within the secondary windings 5a and 5b.
  • the insulation of the windings 5a and 5b against the cooling surface 7 takes place with a thin heat-conducting foil 8 or ceramic material.
  • the embodiments shown allow a simple cooling of the transformer 1 via the thermally well connectable massive secondary windings 5a and 5b.
  • the transformer core 2 can also be easily thermally coupled, so that optimal cooling of the entire component is possible. Furthermore, due to the large cross section of the secondary windings 5a and 5b aluminum can be used, which saves weight and costs.
  • the transformer 1 for clocked power supplies has at least one massive (secondary) winding whose cross-section is chosen such that a transport of heat generated during operation loss is possible to a flat heat sink without additional coolant is required. - -

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Of Transformers For General Uses (AREA)

Abstract

The invention relates to a transformer (1) for switched current supplies, comprising a magnetizable core (2) that has a winding axis (3), and comprising at least one primary winding (4a, 4b) formed by a primary winding conductor which at least partly surrounds the winding axis of the core, and at least one secondary winding (5a, 5b) formed by a secondary winding conductor (6a, 6b). In said transformer, the secondary winding conductor surrounds the primary winding conductor, the secondary winding has a single-layer structure and a cross-section of the secondary winding conductor is rectangular and in particular square.

Description

Transformator und zugehöriges Herstellungsverfahren  Transformer and related manufacturing process
Die Erfindung betrifft einen Transformator und ein zugehöriges Herstellungsverfahren. The invention relates to a transformer and an associated manufacturing method.
Hochfrequenztransformatoren für hohe Ausgangsströme sind überwiegend planare Konstruktionen mit gestanzten Blechen für die Sekundärwicklung. Die Primärwicklung wird meistens ebenfalls geblecht oder auch mit Litze realisiert. High-frequency transformers for high output currents are predominantly planar designs with stamped sheets for the secondary winding. The primary winding is usually also laminated or realized with stranded wire.
Die korrekte elektrische Verbindung der Bleche untereinander ist mit hohem Aufwand verbunden. The correct electrical connection of the sheets with each other is associated with great expense.
Ein weiteres Problem ist die Kühlung des Bauteils, da die Verlustwärme der Wicklungen überwiegend durch einen umschließenden Ferritkern abgeleitet werden muss. Ferrit-Material ist jedoch ein schlechter Wärmeleiter und eine vollflächige beidseitige thermische Anbindung an einen Kühlkörper ist schwer zu realisieren. Another problem is the cooling of the component, since the heat loss of the windings must be derived predominantly by an enclosing ferrite core. However, ferrite material is a poor conductor of heat and a full-surface two-sided thermal connection to a heat sink is difficult to realize.
Problematisch ist zudem die Implementierung der erforderlichen Isolati- onsabstände ohne eine übermäßige Vergrößerung der Streuinduktivitäten. - - Another problem is the implementation of the required isolation distances without an excessive increase of the leakage inductances. - -
Der Erfindung liegt die Aufgabe zugrunde, einen Transformator und ein zugehöriges Herstellungsverfahren zur Verfügung zu stellen, die eine effiziente Kühlung des Transformators mit möglichst geringem Aufwand ermöglichen. The invention has for its object to provide a transformer and an associated manufacturing method available that allow efficient cooling of the transformer with the least possible effort.
Die Erfindung löst diese Aufgabe durch einen Transformator nach Anspruch 1 und ein Herstellungsverfahren nach Anspruch 12. Bevorzugte Ausführungsformen sind Gegenstand der Unteransprüche, deren Wortlaut hiermit zum Inhalt der Beschreibung gemacht wird. The invention achieves this object by a transformer according to claim 1 and a manufacturing method according to claim 12. Preferred embodiments are the subject of the subclaims, the wording of which is hereby made part of the description.
Der Transformator ist bevorzugt für getaktete Stromversorgungen geeignet oder vorgesehen und weist auf: einen magnetischen bzw. magne- tisierbaren Kern, insbesondere einen Ferrit-Kern, der eine Wicklungsachse definiert bzw. eine Wicklungsachse aufweist, mindestens eine Primärwicklung, die durch einen Primärwicklungsleiter gebildet ist, insbesondere in Form von mehrfach isolierter Hochfrequenzlitze, der die Wicklungsachse des Kerns bzw. einen Schenkel des Kerns, durch den die Wicklungsachse verläuft, zumindest teilweise umschließt, und mindestens eine Sekundärwicklung, die durch einen Sekundärwicklungsleiter gebildet ist. Der Sekundärwicklungsleiter umschließt den Primärwicklungsleiter, d.h. der Sekundärwicklungsleiter und der Primärwicklungsleiter bilden unterschiedliche Wicklungslagen über der Wicklungsachse, die Sekundärwicklung ist einlagig gebildet und ein Querschnitt des Sekundärwicklungsleiters ist rechteckförmig, insbesondere quadratisch. Aufgrund des Querschnitts und der dadurch bedingten Außenkontur kann die Sekundärwicklung sehr einfach und mit geringem thermischem Widerstand beispielsweise an eine kühlende Fläche angekoppelt werden. Der Querschnitt der insbesondere massiven Wicklung bzw. des massiven Leiters wird dabei bewusst überdimensioniert, so dass ein effizienter Wärmefluss innerhalb der Wicklung möglich ist. - - The transformer is preferably suitable or provided for clocked power supplies and comprises: a magnetic or magnetizable core, in particular a ferrite core, which defines a winding axis or has a winding axis, at least one primary winding, which is formed by a primary winding conductor, in particular in the form of multi-insulated high-frequency strand, which at least partially surrounds the winding axis of the core or a leg of the core through which the winding axis passes, and at least one secondary winding which is formed by a secondary winding conductor. The secondary winding conductor encloses the primary winding conductor, ie the secondary winding conductor and the primary winding conductor form different winding layers over the winding axis, the secondary winding is formed in one layer and a cross section of the secondary winding conductor is rectangular, in particular square. Due to the cross section and the consequent outer contour, the secondary winding can be coupled very easily and with low thermal resistance, for example to a cooling surface. The cross section of the particular massive winding or the solid conductor is deliberately oversized, so that an efficient heat flow within the winding is possible. - -
In einer Weiterbildung ist der Sekundärwicklungsleiter massiv, d.h. der vollständige Querschnitt des Leiters ist mit Leitermaterial ausgefüllt bzw. der Leiter ist innerhalb seiner Außenabmessung vollständig mit Leitermaterial ausgefüllt. Der Leiter ist insbesondere nicht durch miteinander verflochtene Litzen, mehrere kombinierte Einzelleiter, als Hohlleiter oder dergleichen aufgebaut. In a further development, the secondary winding conductor is massive, i. the complete cross-section of the conductor is filled with conductor material or the conductor is completely filled within its outer dimension with conductor material. In particular, the conductor is not constructed by interwoven strands, a plurality of combined individual conductors, as a waveguide or the like.
In einer Weiterbildung ist die mindestens eine Sekundärwicklung aus einem massiven Materialblock gebildet, welcher zur Bildung des Sekundärwicklungsleiters strukturiert ist, insbesondere durch Bohren, Sägen und/oder Fräsen strukturiert ist. Alternativ ist die mindestens eine Sekundärwicklung aus einem Druckgussformteil gebildet. In a development, the at least one secondary winding is formed from a solid block of material which is structured to form the secondary winding conductor, in particular by drilling, sawing and / or milling is structured. Alternatively, the at least one secondary winding is formed from a die-cast molding.
In einer Weiterbildung weist der Transformator eine Nenn-Leistung auf, wobei der (minimale) Querschnitt des Sekundärwicklungsleiters derart dimensioniert ist, dass eine Strombelastbarkeit des Sekundärwicklungsleiters größer ist als für die Nenn-Leistung erforderlich, d.h. der Querschnitt des Leiters ist bezogen auf die Nenn-Leistung überdimensioniert In a further development, the transformer has a rated power, wherein the (minimum) cross section of the secondary winding conductor is dimensioned such that a current carrying capacity of the secondary winding conductor is greater than required for the nominal power, i. the cross-section of the conductor is oversized relative to the rated power
In einer Weiterbildung besteht der Sekundärwicklungsleiter aus Kupfer oder Titan, besonders bevorzugt aus Aluminium. In a development, the secondary winding conductor made of copper or titanium, particularly preferably made of aluminum.
In einer Weiterbildung ist ein flächiges Kühlelement vorgesehen, welches thermisch mit der Sekundärwicklung, insbesondere mit der von der Wicklungsachse des Kerns abgewandten Seite der Sekundärwicklung, gekoppelt ist. Bevorzugt ist ein wärmeleitender elektrischer Isolator vorgesehen, der zwischen dem Kühlelement und der Sekundärwicklung angeordnet ist. Bevorzugt ist der elektrische Isolator eine elektrisch isolierende Wärmeleitfolie. In a further development, a planar cooling element is provided, which is thermally coupled to the secondary winding, in particular to the side of the secondary winding facing away from the winding axis of the core. Preferably, a heat-conducting electrical insulator is provided, which is arranged between the cooling element and the secondary winding. The electrical insulator is preferably an electrically insulating heat-conducting foil.
Erfindungsgemäß bildet die Sekundärwicklung bzw. der Sekundärwicklungsleiter eine thermische Brücke zu dem flächigen Kühlelement. Kern- - - According to the invention, the secondary winding or the secondary winding conductor forms a thermal bridge to the planar cooling element. Core- - -
Verluste und Verluste der Primärwicklung(en) gehen zunächst auf die Sekundärwicklung(en) über, um dann beispielsweise über das flächige Kühlelement in Form einer wassergekühlten Kühlplatte abgeführt werden zu können. Losses and losses of the primary winding (s) go first on the secondary winding (s), in order then to be dissipated, for example, over the flat cooling element in the form of a water-cooled cooling plate can.
In einer Weiterbildung bildet die Sekundärwicklung einen Kühlkörper. In a development, the secondary winding forms a heat sink.
In einer Weiterbildung sind ein Abstand zwischen der Primärwicklung und dem Kern und ein Abstand zwischen der Sekundärwicklung und der Primärwicklung derart gewählt, dass Streuverluste minimiert sind. Mit anderen Worten liegt die Primärwicklung möglichst dicht über dem Kern und die Sekundärwicklung liegt möglichst dicht über der Primärwicklung, so dass sich minimale Verlustanteile durch Streufelder sowie eine gute thermische Kopplung des Systems ergeben. In a further development, a distance between the primary winding and the core and a distance between the secondary winding and the primary winding are selected such that leakage losses are minimized. In other words, the primary winding is as close as possible above the core and the secondary winding is as close as possible to the primary winding, so that there are minimal loss components due to stray fields and a good thermal coupling of the system.
Bei dem Verfahren zur Herstellung des oben genannten Transformators wird die Sekundärwicklung aus einem massiven Materialblock gebildet, welcher zur Bildung des Leiters strukturiert wird, insbesondere durch materialabtragendes Bearbeiten in Form von Bohren, Sägen und/oder Fräsen. In the method for producing the above-mentioned transformer, the secondary winding is formed from a solid block of material which is patterned to form the conductor, in particular by material-removing machining in the form of drilling, sawing and / or milling.
Die Erfindung wird nachfolgend unter Bezugnahme auf die Zeichnungen beschrieben, die bevorzugte Ausführungsformen der Erfindung darstellen. Hierbei zeigt schematisch: The invention will now be described with reference to the drawings which illustrate preferred embodiments of the invention. This shows schematically:
Fig. 1 eine Darstellung eines erfindungsgemäßen Transformators, 1 is an illustration of a transformer according to the invention,
Fig. 2 eine Explosionsdarstellung des in Fig. 1 gezeigten Transformators und Fig. 2 is an exploded view of the transformer shown in Fig. 1 and
Fig. 3 ein elektrisches Ersatzschaltbild des in Fig. 1 und 2 gezeigten FIG. 3 is an electrical equivalent circuit diagram of that shown in FIGS. 1 and 2
Transformators. - - Transformer. - -
Fig. 1 zeigt einen Transformator 1 für getaktete Stromversorgungen mit einem magnetisierbaren Ferrit-Kern 2 mit einem Schenkel, der eine Wicklungsachse 3 definiert, einer ersten Primärwicklung 4a (siehe Fig. 2), die durch einen ersten Primärwicklungsleiter aus mehrfach isolierter Hochfrequenzlitze gebildet ist, die die Wicklungsachse 3 des Kerns 2 unmittelbar umschließt, einer zweiten Primärwicklung 4b, die durch einen zweiten Primärwicklungsleiter aus mehrfach isolierter Hochfrequenzlitze gebildet ist, die die Wicklungsachse 3 des Kerns 2 unmittelbar umschließt, wobei die erste Primärwicklung 4a und die zweite Primärwicklung 4b axial benachbart auf dem Schenkel angeordnet sind, einer ersten massiven Sekundärwicklung 5a aus Aluminium, die durch einen ersten Sekundärwicklungsleiter 6a gebildet ist, und einer zweiten massiven Sekundärwicklung 5b aus Aluminium, die durch einen zweiten Sekundärwicklungsleiter 6b gebildet ist 1 shows a switched-mode power supply transformer 1 having a magnetizable ferrite core 2 with a leg defining a winding axis 3, a first primary winding 4a (see FIG. 2) formed by a first primary winding conductor of multi-insulated high-frequency stranded wire. which directly surrounds the winding axis 3 of the core 2, a second primary winding 4b formed by a second primary winding conductor of multi-insulated high-frequency strand immediately surrounding the winding axis 3 of the core 2, the first primary winding 4a and the second primary winding 4b being axially adjacent the leg are arranged, a first solid secondary winding 5a made of aluminum, which is formed by a first secondary winding conductor 6a, and a second solid secondary winding 5b made of aluminum, which is formed by a second secondary winding conductor 6b
Weiter sind Bohrungen 9a und 9b als Anschlüsse für die erste bzw. zweite Sekundärwicklung 5a bzw. 5b vorgesehen. Further, bores 9a and 9b are provided as terminals for the first and second secondary winding 5a and 5b, respectively.
Isolationselemente 10 dienen zum elektrischen Isolieren zwischen Primär- und Sekundärkreis. Isolation elements 10 serve for electrically insulating between the primary and secondary circuits.
Die Sekundärwicklungsleiter 6a und 6b umschließen ihren zugehörigen Primärwicklungsleiter, so dass sie axial benachbart auf dem Schenkel angeordnet sind. Die Sekundärwicklungsleiter 6a und 6b sind jeweils einlagig gebildet und weisen jeweils in Wicklungsrichtung einen recht- eckförmigen Querschnitt auf, der in Wicklungsrichtung veränderlich ist. The secondary winding conductors 6a and 6b enclose their associated primary winding conductor so as to be axially adjacent to the leg. The secondary winding conductors 6a and 6b are each formed in one layer and each have a rectangular cross-section in the winding direction, which is variable in the winding direction.
Der Transformator weist eine spezifische Nenn-Leistung auf, wobei der Querschnitt der Sekundärwicklungsleiter 6a und 6b derart dimensioniert ist, dass deren Strombelastbarkeit größer ist als für die Nenn-Leistung erforderlich. - - The transformer has a specific rated power, wherein the cross section of the secondary winding conductors 6a and 6b is dimensioned such that their current carrying capacity is greater than required for the nominal power. - -
Zur effizienten Kühlung ist weiter ein flächiges Kühlelement 7 vorgesehen, welches thermisch mit der von der Wicklungsachse 3 des Kerns 2 abgewandten Seite bzw. Oberfläche der Sekundärwicklungen 5a und 5b zu koppeln ist, wobei zwischen dem Kühlelement 7 und den Sekundärwicklungen 5a und 5b ein wärmeleitender elektrischer Isolator in Form einer elektrisch isolierenden Wärmeleitfolie 8 vorgesehen ist. Entsprechende Kühlelemente können auf der Oberseite und/oder der Unterseite der Sekundärwicklungen 5a und 5b vorgesehen sein. For efficient cooling a flat cooling element 7 is further provided, which is thermally coupled to the side facing away from the winding axis 3 of the core 2 side or surface of the secondary windings 5a and 5b, wherein between the cooling element 7 and the secondary windings 5a and 5b, a heat-conducting electrical Insulator in the form of an electrically insulating heat conducting foil 8 is provided. Corresponding cooling elements may be provided on the upper side and / or the lower side of the secondary windings 5a and 5b.
Die Sekundärwicklungen 5a und 5b sind jeweils aus einem massiven Aluminium-Materialblock gebildet, welcher geeignet durch Bohren, Sägen, Funkenerodieren und/oder Fräsen strukturiert ist. The secondary windings 5a and 5b are each formed from a solid aluminum block of material, which is suitably structured by drilling, sawing, spark erosion and / or milling.
Der Querschnitt der Sekundärwicklungsleiter 6a und 6b bzw. deren minimaler Querschnitt über die gesamte Wicklung ist derart dimensioniert, dass bei gegebener Arbeitsfrequenz die durch Stromverdrängung wirksame Ersatzfläche (Skin-Tiefe) deutlich kleiner ist als der geometrische Querschnitt der massiven Sekundärwicklungsleiter 6a und 6b. Dadurch fließt der dominierende Wechselstrom-Verlustanteil im Außenbereich der Wicklung in Richtung des Kernbereichs der Wicklung und schließlich längs der Wicklung zur thermischen Senke in Form des Kühlelements 7. The cross-section of the secondary winding conductors 6a and 6b or their minimal cross-section over the entire winding is dimensioned such that at a given operating frequency effective by current displacement replacement surface (skin depth) is significantly smaller than the geometric cross-section of the massive secondary winding conductors 6a and 6b. As a result, the dominant AC loss component flows in the outer region of the winding in the direction of the core region of the winding and finally along the winding to the thermal sink in the form of the cooling element. 7
Fig. 2 zeigt zur Verdeutlichung eine Explosionsdarstellung des in Fig. 1 gezeigten Transformators. Fig. 2 shows for clarity an exploded view of the transformer shown in Fig. 1.
Fig. 3 zeigt ein elektrisches Ersatzschaltbild des in Fig. 1 und 2 gezeigten Transformators 1 mit den Primärwicklungen 4a und 4b und den Sekundärwicklungen 5a und 5b. Fig. 3 shows an equivalent electrical circuit diagram of the transformer 1 shown in Figs. 1 and 2 with the primary windings 4a and 4b and the secondary windings 5a and 5b.
Die gezeigten Ausführungsformen weisen massive sekundärseitige Wicklungen 5a und 5b auf, die direkt über den Primärwicklungen 4a - - bzw. 4b aus mehrfach isolierter Hochfrequenzlitze liegen. Die Primärwicklungen 4a und 4b sind mit minimalem Abstand über dem Ferritkern 2 angeordnet. The embodiments shown have massive secondary-side windings 5a and 5b, which are directly above the primary windings 4a - - or 4b are made of multi-insulated high-frequency stranded wire. The primary windings 4a and 4b are arranged at a minimum distance above the ferrite core 2.
Durch gerade Oberflächen der massiven Sekundärwicklungen 5a und 5b ist eine einfache und effiziente Ankopplung an die Kühlfläche 7 möglich. Der (minimale) Querschnitt der massiven Sekundärwicklungen 5a und 5b wird dabei bewusst überdimensioniert, um so einen effizienten Wärmefluss innerhalb der Sekundärwicklungen 5a und 5b zu erreichen. Die Isolation der Wicklungen 5a und 5b gegen die Kühlfläche 7 erfolgt mit einer dünnen Wärmeleitfolie 8 oder keramischen Material. By straight surfaces of the massive secondary windings 5a and 5b, a simple and efficient coupling to the cooling surface 7 is possible. The (minimum) cross section of the massive secondary windings 5a and 5b is deliberately oversized, so as to achieve an efficient heat flow within the secondary windings 5a and 5b. The insulation of the windings 5a and 5b against the cooling surface 7 takes place with a thin heat-conducting foil 8 or ceramic material.
Aufgrund der minimalen Abstände zwischen den Wicklungen 4a, 4b, 5a und 5b und dem Transformatorkern 2 wird einerseits eine optimale Kühlung gewährleistet und andererseits werden die Streuflüsse minimiert bzw. die Kopplung zwischen Primär- und Sekundärseite maximiert. On account of the minimal distances between the windings 4a, 4b, 5a and 5b and the transformer core 2, optimal cooling is ensured on the one hand and, on the other hand, the stray fluxes are minimized or the coupling between the primary and secondary side is maximized.
Die gezeigten Ausführungsformen ermöglichen eine einfache Kühlung des Transformators 1 über die thermisch gut ankoppelbaren massiven Sekundärwicklungen 5a und 5b. The embodiments shown allow a simple cooling of the transformer 1 via the thermally well connectable massive secondary windings 5a and 5b.
Der Transformatorkern 2 kann ebenfalls sehr einfach thermisch angekoppelt werden, so dass eine optimale Kühlung des Gesamtbauteils möglich ist. Weiterhin kann durch den großen Querschnitt der Sekundärwicklungen 5a und 5b Aluminium eingesetzt werden, das Gewicht und Kosten spart. The transformer core 2 can also be easily thermally coupled, so that optimal cooling of the entire component is possible. Furthermore, due to the large cross section of the secondary windings 5a and 5b aluminum can be used, which saves weight and costs.
Der Transformator 1 für getaktete Stromversorgungen weist mindestens eine massive (Sekundär-)Wicklung auf, deren Querschnitt derart gewählt ist, dass ein Transport der im Betrieb entstehenden Verlustwärme hin zu einer flächigen Wärmesenke möglich ist, ohne dass zusätzliche Kühlmittel erforderlich sind. - - The transformer 1 for clocked power supplies has at least one massive (secondary) winding whose cross-section is chosen such that a transport of heat generated during operation loss is possible to a flat heat sink without additional coolant is required. - -
Es versteht sich, dass auch lediglich eine einzelne oder mehr als Primär- und Sekundärwicklung(en) vorgesehen sein kann/können. It is understood that only a single or more than primary and secondary winding (s) can be provided / can.

Claims

Patentansprüche claims
1. Transformator (1 ) für getaktete Stromversorgungen mit 1. Transformer (1) for switched-mode power supplies with
einem magnetisierbaren Kern (2) mit einer Wicklungsachse (3),  a magnetizable core (2) having a winding axis (3),
mindestens einer Primärwicklung (4a, 4b), die durch einen Primärwicklungsleiter gebildet ist, der die Wicklungsachse des Kerns zumindest teilweise umschließt, und  at least one primary winding (4a, 4b) formed by a primary winding conductor which at least partially encloses the winding axis of the core, and
mindestens einer Sekundärwicklung (5a, 5b), die durch einen Sekundärwicklungsleiter (6a, 6b) gebildet ist,  at least one secondary winding (5a, 5b) formed by a secondary winding conductor (6a, 6b),
dadurch gekennzeichnet, dass  characterized in that
der Sekundärwicklungsleiter den Primärwicklungsleiter umschließt,  the secondary winding conductor encloses the primary winding conductor,
die Sekundärwicklung einlagig gebildet ist und  the secondary winding is formed in one layer and
ein Querschnitt des Sekundärwicklungsleiters rechteckförmig, insbesondere quadratisch, ist.  a cross section of the secondary winding conductor is rectangular, in particular square, is.
2. Transformator nach Anspruch 1 , dadurch gekennzeichnet, dass 2. Transformer according to claim 1, characterized in that
der Sekundärwicklungsleiter massiv ausgebildet ist.  the secondary winding conductor is solid.
3. Transformator nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass 3. Transformer according to claim 1 or 2, characterized in that
die mindestens eine Sekundärwicklung aus einem massiven Materialblock gebildet ist, welcher zur Bildung des Sekundärwicklungsleiters strukturiert ist, insbesondere durch ein materialabtragendes Bearbeiten strukturiert ist, insbesondere durch Bohren, Sägen, Fräsen und/oder Funkenerodieren strukturiert ist.  the at least one secondary winding is formed from a solid block of material, which is structured to form the secondary winding conductor, in particular structured by a material-removing machining, in particular by drilling, sawing, milling and / or spark erosion is structured.
4. Transformator nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die mindestens eine Sekundärwicklung aus einem Druckgussformteil gebildet ist. 4. Transformer according to claim 1 or 2, characterized in that the at least one secondary winding is formed from a die-cast molding.
5. Transformator nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 5. Transformer according to one of the preceding claims, characterized in that
der Transformator eine Nenn-Leistung aufweist, wobei der Querschnitt des Sekundärwicklungsleiters derart dimensioniert ist, dass eine Strombelastbarkeit des Sekundärwicklungsleiters größer ist als für die Nenn-Leistung erforderlich.  the transformer has a rated power, wherein the cross section of the secondary winding conductor is dimensioned such that a current carrying capacity of the secondary winding conductor is greater than required for the nominal power.
6. Transformator nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 6. Transformer according to one of the preceding claims, characterized in that
der Sekundärwicklungsleiter aus Aluminium, Kupfer oder Titan besteht.  the secondary winding conductor consists of aluminum, copper or titanium.
7. Transformator nach einem der vorhergehenden Ansprüche, gekennzeichnet durch 7. Transformer according to one of the preceding claims, characterized by
ein flächiges Kühlelement (7), welches thermisch mit der Sekundärwicklung, insbesondere mit der von der Wicklungsachse des Kerns abgewandten Seite der Sekundärwicklung, gekoppelt ist.  a planar cooling element (7), which is thermally coupled to the secondary winding, in particular to the side remote from the winding axis of the core side of the secondary winding.
8. Transformator nach Anspruch 7, gekennzeichnet durch 8. Transformer according to claim 7, characterized by
einen wärmeleitenden, elektrischen Isolator (8), der zwischen dem Kühlelement und der Sekundärwicklung angeordnet ist.  a heat conductive electrical insulator (8) disposed between the cooling element and the secondary winding.
9. Transformator nach Anspruch 8, dadurch gekennzeichnet, dass der elektrische Isolator eine elektrisch isolierende Wärmeleitfolie ist. 9. Transformer according to claim 8, characterized in that the electrical insulator is an electrically insulating heat conducting foil.
10. Transformator nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Sekundärwicklung einen Kühlkörper bildet. 10. Transformer according to one of the preceding claims, characterized in that the secondary winding forms a heat sink.
1 1. Transformator nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 1 1. Transformer according to one of the preceding claims, characterized in that
ein Abstand zwischen der Primärwicklung und dem Kern und ein Abstand zwischen der Sekundärwicklung und der Primärwicklung derart gewählt sind, dass Streuverluste minimiert sind.  a distance between the primary winding and the core and a distance between the secondary winding and the primary winding are chosen such that leakage losses are minimized.
12. Verfahren zur Herstellung eines Transformators nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 12. A method for producing a transformer according to one of the preceding claims, characterized in that
die Sekundärwicklung aus einem massiven Materialblock gebildet wird, welcher zur Bildung des Leiters strukturiert wird.  the secondary winding is formed of a solid block of material which is patterned to form the conductor.
13. Verfahren nach Anspruch 12, dadurch gekennzeichnet, dass 13. The method according to claim 12, characterized in that
das Strukturieren ein materialabtragendes Bearbeiten des Materialblocks umfasst, insbesondere in Form von Bohren, Sägen, Fräsen und/oder Funkenerodieren.  the structuring comprises a material-removing machining of the material block, in particular in the form of drilling, sawing, milling and / or spark erosion.
EP12751490.9A 2011-09-02 2012-08-20 Transformer and method of manufacturing thereof Active EP2751814B1 (en)

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DE102011082046A DE102011082046A1 (en) 2011-09-02 2011-09-02 Transformer and related manufacturing process
PCT/EP2012/066207 WO2013030031A1 (en) 2011-09-02 2012-08-20 Transformer and associated production method

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DE102011082046A1 (en) 2013-03-07
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CN109346296A (en) 2019-02-15
US10734151B2 (en) 2020-08-04
EP2751814B1 (en) 2018-04-18

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