EP2751815A1 - Inductor and associated production method - Google Patents

Inductor and associated production method

Info

Publication number
EP2751815A1
EP2751815A1 EP12753104.4A EP12753104A EP2751815A1 EP 2751815 A1 EP2751815 A1 EP 2751815A1 EP 12753104 A EP12753104 A EP 12753104A EP 2751815 A1 EP2751815 A1 EP 2751815A1
Authority
EP
European Patent Office
Prior art keywords
winding
conductor
core
throttle
carrying capacity
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
EP12753104.4A
Other languages
German (de)
French (fr)
Other versions
EP2751815B1 (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 EP2751815A1 publication Critical patent/EP2751815A1/en
Application granted granted Critical
Publication of EP2751815B1 publication Critical patent/EP2751815B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

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
    • H01F27/008—Details of transformers or inductances, in general with temperature compensation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • H01F27/22—Cooling by heat conduction through solid or powdered fillings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • 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
    • 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 throttle and an associated manufacturing method.
  • Chokes are preferably used to integrate pulsed voltage signals, e.g. used in DC controllers. Significant problems with regard to losses and cooling of the winding arise in particular at high mean currents with significant current ripple.
  • Conventional windings of storage chokes are formed, for example, of layered sheet metal structures, flat wire core windings, and copper tape windings.
  • Core materials include ferrite, amorphous metal glass, nanocrystalline ribbons or metal powders.
  • the invention has for its object to provide a throttle and an associated manufacturing method available that allow efficient cooling of the throttle with the least possible effort.
  • the choke in particular in the form of a so-called memory or high-current choke, has a magnetic or magnetizable core, which defines a winding axis or a winding axis, and at least one winding, which is formed by a conductor, the at least one winding axis the core or a leg of the core, through which the at least one winding axis extends, at least partially, in particular with the smallest possible distance, surrounds.
  • the at least one winding is formed in one layer, ie turns formed by the conductor only run adjacent and are not layered.
  • a cross section of the conductor in the winding direction is rectangular, in particular square.
  • the 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 throttle has a magnetic or magnetizable core, in which the dehumidification takes place substantially via the winding thermally coupled to the core. Due to the choice of a large solid conductor or winding cross-section sufficient heat flow and thus the dehumidification is possible for example via a one-sided water-cooled plate.
  • the ladder 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 winding of a profile tube, in particular a rectangular profile raw r formed, which is structured to form the conductor, in particular by a material-removing machining is structured, in particular by drilling, sawing, milling and / or spark erosion is structured.
  • the at least one winding is formed from a die-cast molding.
  • the inductor has a rated current carrying capacity, wherein the cross section of the conductor is dimensioned such that a current carrying capacity of the conductor is greater than the rated current carrying capacity, ie the cross section of the conductor is oversized relative to the nominal current carrying capacity.
  • the winding and the core can be dimensioned such that, when the reactor is loaded with its rated current carrying capacity, the winding losses are greater than the core losses, so that overall efficient cooling can be ensured on account of the optimized cooling capability of the winding.
  • the conductor consists of copper or titanium, particularly preferably aluminum.
  • a planar cooling element is provided, which is thermally coupled to the winding, in particular to the side or surface of the 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 winding.
  • the electrical insulator is preferably an electrically insulating heat conducting foil.
  • the winding forms a heat sink.
  • a distance between the winding and the core is selected such that the losses due to stray fields are minimized.
  • the winding is formed from a profile tube, in particular from a rectangular profile tube, which is structured to form the conductor, in particular by material-removing machining in the form of drilling, sawing, milling and / or spark erosion of the profile tube.
  • Fig. 1 is an illustration of a throttle according to the invention with cooling element
  • Fig. 2 is an exploded view of the throttle shown in Fig. 1.
  • 1 shows a storage choke 1 for high currents, for example 200 amps or more, with an El-shaped, magnetizable core 2, for example of ferrite, amorphous metal glass, nanocrystalline ribbons or metal powders as core material, with a limb defining a winding axis 3 , and a single-layer winding 4, which is formed by a solid conductor 5 made of aluminum with a rectangular cross-section, which surrounds the winding axis 3 of the core 2 in an annular manner.
  • an El-shaped, magnetizable core 2 for example of ferrite, amorphous metal glass, nanocrystalline ribbons or metal powders as core material
  • a limb defining a winding axis 3
  • a single-layer winding 4 which is formed by a solid conductor 5 made of aluminum with a rectangular cross-section, which surrounds the winding axis 3 of the core 2 in an annular manner.
  • the reactor 1 has a rated current carrying capacity of nominal 200 A average current, wherein the cross section of the conductor 5 is dimensioned such that it can lead more than the nominal current.
  • the winding 4 and the core 2 are dimensioned such that at a load of the reactor 1 with the nominal current winding losses are greater than core losses, so that by means of cooling the winding 4, which can be designed much easier than cooling the core 2, the Heat generated during operation is easily dissipated.
  • 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 winding 4, wherein between the cooling element 7 and the winding 4, a heat-conducting electrical insulator in the form of a 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 winding 4.
  • a distance between the leg of the core 2 and the leg facing surface of the winding 4 is set so low that leakage losses are minimized.
  • the cross-section of the conductor 5 is dimensioned such that at a designated operating frequency, the throttle 1, the current through Verdichtverdrän- As a result, the dominant AC loss component in the outer region of the conductor 5 or the winding 4 flows in the direction of the core region of the winding 4 and finally along the winding 4 for thermal sink in the form of the Cooling element 7.
  • Holes 10 serve as connection elements for further, not shown circuit parts of a circuit which uses the throttle 1.
  • FIG. 2 shows an exploded view of the throttle 1 shown in FIG. 1 for clarification.
  • the structuring is carried out by helical milling to form the winding 4 and the conductor 5, wherein by sawing in the transverse direction of the profile tube 6 individual winding segments are generated, each forming together with an associated core and the other components shown a respective coil. By drilling the terminals 10 are generated.
  • the winding 4 may alternatively be formed from a die-cast molding.
  • a massive winding 4 which has square or rectangular outer dimensions.
  • the winding 4 can be coupled very easily and with low thermal resistance to a cooling surface 7.
  • the cross section of the massive winding 4 is deliberately oversized, so that a efficient heat flow within the winding 4 is possible, ie the winding 4 is also the inner heat sink of the device. 1
  • the electrical insulation of the winding 4 against the cooling plate or the heat sink 7 is carried out with a thin heat-conducting foil 8 or ceramic material.
  • the material of the winding 4 is aluminum, copper or titanium.
  • aluminum can be used as a conductor material due to the large cross section, whereby weight and cost can be saved.
  • the reactor 1 according to the invention has a massive winding whose cross-section is dimensioned so large that a transport of the resulting heat loss to a flat heat sink 7 is possible, so that expensive cooling measures can be omitted.
  • a differently shaped core can be used, for example, a U-shaped core with two outer windings.

Abstract

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

Description

Drossel und zugehöriges Herstellungsverfahren  Throttle and related manufacturing process
Die Erfindung betrifft eine Drossel und ein zugehöriges Herstellungsverfahren. The invention relates to a throttle and an associated manufacturing method.
Drosseln bzw. Speicherdrosseln werden vorzugsweise zur Integration getakteter Spannungssignale z.B. in Gleichstromstellern eingesetzt. Insbesondere bei hohen mittleren Strömen mit signifikanter Stromwelligkeit ergeben sich erhebliche Probleme in Hinblick auf Verluste und Kühlung der Wicklung. Chokes are preferably used to integrate pulsed voltage signals, e.g. used in DC controllers. Significant problems with regard to losses and cooling of the winding arise in particular at high mean currents with significant current ripple.
Herkömmliche Wicklungen von Speicherdrosseln sind beispielsweise aus geschichteten Blechkonstruktionen, Flachdrahthochkantwicklungen und Kupferbandwicklungen gebildet. Als Kernmaterialien kommen Materialien aus Ferrit, amorphem Metallglas, nanokristallinen Bänder oder Metallpulvern zu Einsatz. Conventional windings of storage chokes are formed, for example, of layered sheet metal structures, flat wire core windings, and copper tape windings. Core materials include ferrite, amorphous metal glass, nanocrystalline ribbons or metal powders.
Allen oben genannten Lösungen gemein ist das Problem einer effizienten Kühlung der Drossel. Beispielsweise ist in einem geschlossenen Gehäuse typisch eine definierte Kühlung mittels einer durch ein Kühlmedium durchströmten Platte erforderlich. Die Wärme entsteht jedoch bei induktiven Bauelementen allgemein in einem Volumen, so dass in der Regel aufwendige Kühlkonzepte erforderlich sind. Common to all the above solutions is the problem of efficient throttle cooling. For example, in a closed housing, a defined cooling is typically required by means of a plate through which a cooling medium flows. However, the heat is generally produced in inductive components in a volume, so that usually complex cooling concepts are required.
Der Erfindung liegt die Aufgabe zugrunde, eine Drossel sowie ein zugehöriges Herstellungsverfahren zur Verfügung zu stellen, die eine effiziente Kühlung der Drossel mit möglichst geringem Aufwand ermöglichen. The invention has for its object to provide a throttle and an associated manufacturing method available that allow efficient cooling of the throttle with the least possible effort.
Die Erfindung löst diese Aufgabe durch eine Drossel nach Anspruch 1 und ein Herstellungsverfahren nach Anspruch 13. Bevorzugte Ausführungsformen sind Gegenstand der Unteransprüche, deren Wortlaut hiermit zum Inhalt der Beschreibung gemacht wird. The invention solves this problem by a throttle according to claim 1 and a manufacturing method according to claim 13. Preferred embodiments are the subject of the dependent claims, the wording of which is hereby made part of the description.
Die Drossel, insbesondere in Form einer so genannten Speicher- oder Hochstromdrossel, weist einen magnetischen bzw. magnetisierbaren Kern, der eine Wicklungsachse definiert bzw. eine Wicklungsachse aufweist, und mindestens eine Wicklung auf, die durch einen Leiter gebildet ist, der die mindestens eine Wicklungsachse des Kerns bzw. einen Schenkel des Kerns, durch den die mindestens eine Wicklungsachse verläuft, zumindest teilweise, insbesondere mit möglichst geringem Abstand, umschließt. Die mindestens eine Wicklung ist einlagig gebildet, d.h. durch den Leiter gebildete Windungen verlaufen nur benachbart und sind nicht geschichtet. Ein Querschnitt des Leiters in Wicklungsrichtung ist rechteckförmig, insbesondere quadratisch. Aufgrund des Querschnitts und der dadurch bedingten Außenkontur kann die Wicklung 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. Erfindungsgemäß weist die Drossel einen magnetischen bzw. magneti- sierbaren Kern auf, bei der die Entwarmung maßgeblich über die thermisch an den Kern angekoppelte Wicklung erfolgt. Aufgrund der Wahl eines großen massiven Leiter- bzw. Wicklungsquerschnitts ist ein ausreichender Warmefluss und damit die Entwarmung beispielsweise über eine einseitige wassergekühlte Platte möglich. The choke, in particular in the form of a so-called memory or high-current choke, has a magnetic or magnetizable core, which defines a winding axis or a winding axis, and at least one winding, which is formed by a conductor, the at least one winding axis the core or a leg of the core, through which the at least one winding axis extends, at least partially, in particular with the smallest possible distance, surrounds. The at least one winding is formed in one layer, ie turns formed by the conductor only run adjacent and are not layered. A cross section of the conductor in the winding direction is rectangular, in particular square. Due to the cross section and the consequent outer contour, the 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. According to the invention, the throttle has a magnetic or magnetizable core, in which the dehumidification takes place substantially via the winding thermally coupled to the core. Due to the choice of a large solid conductor or winding cross-section sufficient heat flow and thus the dehumidification is possible for example via a one-sided water-cooled plate.
In einer Weiterbildung ist der Leiter 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 one embodiment, the ladder 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 Wicklung aus einem Profilrohr, insbesondere einem Rechteckprofil roh r, gebildet, welches zur Bildung des Leiters strukturiert ist, insbesondere durch ein materialabtragendes Bearbeiten strukturiert ist, insbesondere durch Bohren, Sägen, Fräsen und/oder Funkenerodieren strukturiert ist. Alternativ ist die mindestens eine Wicklung aus einem Druckgussformteil gebildet. In a further development, the at least one winding of a profile tube, in particular a rectangular profile raw r formed, which is structured to form the conductor, in particular by a material-removing machining is structured, in particular by drilling, sawing, milling and / or spark erosion is structured. Alternatively, the at least one winding is formed from a die-cast molding.
In einer Weiterbildung weist die Drossel eine Nenn-Strombelastbarkeit auf, wobei der Querschnitt des Leiters derart dimensioniert ist, dass eine Strombelastbarkeit des Leiters größer ist als die Nenn- Strombelastbarkeit, d.h. der Querschnitt des Leiters ist bezogen auf die Nenn-Strombelastbarkeit überdimensioniert. Zusätzlich oder alternativ können die Wicklung und der Kern derart dimensioniert sein, dass bei einer Belastung der Drossel mit ihrer Nenn-Strombelastbarkeit die Wicklungsverluste größer sind als die Kernverluste, so dass aufgrund der optimierten Kühlbarkeit der Wicklung insgesamt eine effizient Kühlung sichergestellt werden kann. In einer Weiterbildung besteht der Leiter aus Kupfer oder Titan, besonders bevorzugt aus Aluminium. In a development, the inductor has a rated current carrying capacity, wherein the cross section of the conductor is dimensioned such that a current carrying capacity of the conductor is greater than the rated current carrying capacity, ie the cross section of the conductor is oversized relative to the nominal current carrying capacity. In addition or as an alternative, the winding and the core can be dimensioned such that, when the reactor is loaded with its rated current carrying capacity, the winding losses are greater than the core losses, so that overall efficient cooling can be ensured on account of the optimized cooling capability of the winding. In a development, the conductor consists of copper or titanium, particularly preferably aluminum.
In einer Weiterbildung ist ein flächiges Kühlelement vorgesehen, welches thermisch mit der Wicklung, insbesondere mit der von der Wicklungsachse des Kerns abgewandten Seite bzw. Oberfläche der Wicklung, gekoppelt ist. Bevorzugt ist ein wärmeleitender elektrischer Isolator vorgesehen, der zwischen dem Kühlelement und der Wicklung angeordnet ist. Der elektrische Isolator ist bevorzugt eine elektrisch isolierende Wärmeleitfolie. In a development, a planar cooling element is provided, which is thermally coupled to the winding, in particular to the side or surface of the 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 winding. The electrical insulator is preferably an electrically insulating heat conducting foil.
In einer Weiterbildung bildet die Wicklung einen Kühlkörper. In a development, the winding forms a heat sink.
In einer Weiterbildung ist ein Abstand zwischen Wicklung und Kern derart gewählt, dass die Verluste durch Streufelder minimiert sind. In a further development, a distance between the winding and the core is selected such that the losses due to stray fields are minimized.
Bei dem Verfahren zur Herstellung der oben genannten Drossel wird die Wicklung aus einem Profilrohr, insbesondere aus einem Rechteckprofilrohr gebildet, welches zur Bildung des Leiters strukturiert wird, insbesondere durch materialabtragendes Bearbeiten in Form von Bohren, Sägen, Fräsen und/oder Funkenerodieren des Profilrohrs. In the method for producing the above-mentioned choke, the winding is formed from a profile tube, in particular from a rectangular profile tube, which is structured to form the conductor, in particular by material-removing machining in the form of drilling, sawing, milling and / or spark erosion of the profile tube.
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 einer erfindungsgemäßen Drossel mit Kühlelement und Fig. 1 is an illustration of a throttle according to the invention with cooling element and
Fig. 2 eine Explosionsdarstellung der in Fig. 1 gezeigten Drossel. Fig. 1 zeigt eine Speicherdrossel 1 für hohe Ströme, beispielsweise 200 Ampere oder mehr, mit einem E-l-förmigen, magnetisierbaren Kern 2, beispielsweise aus Ferrit, amorphem Metallglas, nanokristallinen Bändern oder Metallpulvern als Kernmaterial, mit einem Schenkel, der eine Wicklungsachse 3 definiert, und einer einlagigen Wicklung 4, die durch einen massiven Leiter 5 aus Aluminium mit rechteckförmigem Querschnitt gebildet ist, der die Wicklungsachse 3 des Kerns 2 ringförmig umschließt. Fig. 2 is an exploded view of the throttle shown in Fig. 1. 1 shows a storage choke 1 for high currents, for example 200 amps or more, with an El-shaped, magnetizable core 2, for example of ferrite, amorphous metal glass, nanocrystalline ribbons or metal powders as core material, with a limb defining a winding axis 3 , and a single-layer winding 4, which is formed by a solid conductor 5 made of aluminum with a rectangular cross-section, which surrounds the winding axis 3 of the core 2 in an annular manner.
Die Drossel 1 weist eine Nenn-Strombelastbarkeit von nominal 200 A mittlerem Strom auf, wobei der Querschnitt des Leiters 5 derart dimensioniert ist, dass dieser mehr als den Nominalstrom führen kann. Die Wicklung 4 und der Kern 2 sind derart dimensioniert, dass bei einer Belastung der Drossel 1 mit dem Nominalstrom Wicklungsverluste größer sind als Kernverluste, so dass mittels einer Kühlung der Wicklung 4, die wesentlich einfacher als eine Kühlung des Kerns 2 gestaltet werden kann, die im Betrieb entstehende Wärme einfach abführbar ist. The reactor 1 has a rated current carrying capacity of nominal 200 A average current, wherein the cross section of the conductor 5 is dimensioned such that it can lead more than the nominal current. The winding 4 and the core 2 are dimensioned such that at a load of the reactor 1 with the nominal current winding losses are greater than core losses, so that by means of cooling the winding 4, which can be designed much easier than cooling the core 2, the Heat generated during operation is easily dissipated.
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 Wicklung 4 zu koppeln ist, wobei zwischen dem Kühlelement 7 und der Wicklung 4 ein wärmeleitender elektrischer Isolator in Form einer elektrisch isolierenden Wärmeleitfolie 8 vorgesehen ist. Entsprechende Kühlelemente können auf der Oberseite und/oder der Unterseite der Wicklung 4 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 winding 4, wherein between the cooling element 7 and the winding 4, a heat-conducting electrical insulator in the form of a 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 winding 4.
Mittels eines Abstandhalters 9 wird ein Abstand zwischen dem Schenkel des Kerns 2 und der dem Schenkel zugewandten Oberfläche der Wicklung 4 derart gering festgelegt, dass Streuverluste minimiert sind. By means of a spacer 9, a distance between the leg of the core 2 and the leg facing surface of the winding 4 is set so low that leakage losses are minimized.
Der Querschnitt des Leiters 5 ist derart dimensioniert, dass bei einer vorgesehenen Arbeitsfrequenz der Drossel 1 die durch Stromverdrän- gung wirksame Ersatzfläche deutlich kleiner ist als der Querschnitt des massiven Leiters 5. Dadurch fließt der dominierende Wechselstrom- Verlustanteil im Außenbereich des Leiters 5 bzw. der Wicklung 4 in Richtung des Kernbereichs der Wicklung 4 und schließlich längs der Wicklung 4 zur thermischen Senke in Form des Kühlelements 7. The cross-section of the conductor 5 is dimensioned such that at a designated operating frequency, the throttle 1, the current through Verdichtverdrän- As a result, the dominant AC loss component in the outer region of the conductor 5 or the winding 4 flows in the direction of the core region of the winding 4 and finally along the winding 4 for thermal sink in the form of the Cooling element 7.
Bohrungen 10 dienen als Anschlusselemente für weitere, nicht dargestellte Schaltungsteile einer Schaltung, welche die Drossel 1 verwendet. Holes 10 serve as connection elements for further, not shown circuit parts of a circuit which uses the throttle 1.
Fig. 2 zeigt zur Verdeutlichung eine Explosionsdarstellung der in Fig. 1 gezeigten Drossel 1. FIG. 2 shows an exploded view of the throttle 1 shown in FIG. 1 for clarification.
Ein Rechteckprofilrohr 6, welches in bereits strukturierter bzw. bearbeiteter Form dargestellt ist, wird zur Bildung der Wicklung 4 bzw. des Leiters 5 strukturiert. A rectangular profile tube 6, which is shown in already structured or processed form, is structured to form the winding 4 or the conductor 5.
Die Strukturierung erfolgt durch wendeiförmiges Fräsen zur Bildung der Wicklung 4 bzw. des Leiters 5, wobei durch Sägen in Querrichtung des Profilrohrs 6 einzelne Wicklungssegmente erzeugt werden, die jeweils gemeinsam mit einem zugehörigen Kern und den weiteren dargestellten Bauelementen eine jeweilige Spule bilden. Mittels Bohren werden die Anschlüsse 10 erzeugt. The structuring is carried out by helical milling to form the winding 4 and the conductor 5, wherein by sawing in the transverse direction of the profile tube 6 individual winding segments are generated, each forming together with an associated core and the other components shown a respective coil. By drilling the terminals 10 are generated.
Bei sehr großen Stückzahlen kann die Wicklung 4 alternativ aus einem Druckgussformteil gebildet sein. For very large numbers, the winding 4 may alternatively be formed from a die-cast molding.
Erfindungsgemäß ist eine massive Wicklung 4 vorgesehen, die quadratische oder rechteckförmige Außenabmessungen aufweist. Damit kann die Wicklung 4 sehr einfach und mit geringem thermischem Widerstand an eine kühlende Fläche 7 angekoppelt werden. Der Querschnitt der massiven Wicklung 4 wird dabei bewusst überdimensioniert, so dass ein effizienter Wärmefluss innerhalb der Wicklung 4 möglich ist, d.h. die Wicklung 4 ist gleichzeitig der innere Kühlkörper des Bauelements 1 . According to the invention, a massive winding 4 is provided which has square or rectangular outer dimensions. Thus, the winding 4 can be coupled very easily and with low thermal resistance to a cooling surface 7. The cross section of the massive winding 4 is deliberately oversized, so that a efficient heat flow within the winding 4 is possible, ie the winding 4 is also the inner heat sink of the device. 1
Die elektrische Isolation der Wicklung 4 gegen die Kühlplatte bzw. den Kühlkörper 7 erfolgt mit einer dünnen Wärmeleitfolie 8 oder keramischem Material. The electrical insulation of the winding 4 against the cooling plate or the heat sink 7 is carried out with a thin heat-conducting foil 8 or ceramic material.
Das Material der Wicklung 4 ist Aluminium, Kupfer oder Titan. The material of the winding 4 is aluminum, copper or titanium.
Vorteilhaft ist die hocheffiziente Kühlbarkeit der Spule bzw. des Bauteils 1 über die thermisch gut ankoppelbare massive Wicklung 4. Weiterhin kann durch den großen Querschnitt Aluminium als Leitermaterial verwendet werden, wodurch Gewicht und Kosten eingespart werden. Advantageously, the highly efficient coolability of the coil or of the component 1 via the thermally well connectable massive winding 4. Furthermore, aluminum can be used as a conductor material due to the large cross section, whereby weight and cost can be saved.
Die erfindungsgemäße Drossel 1 weist eine massive Wicklung auf, deren Querschnitt derart groß dimensioniert ist, dass ein Transport der entstehenden Verlustwärme hin zu einer flächigen Wärmesenke 7 möglich ist, sodass aufwendige Kühlmaßnahmen entfallen können. The reactor 1 according to the invention has a massive winding whose cross-section is dimensioned so large that a transport of the resulting heat loss to a flat heat sink 7 is possible, so that expensive cooling measures can be omitted.
Anstelle des dargestellten E-l-förmige Kerns 2 kann selbstverständlich ein anders geformter Kern verwendet werden, beispielsweise eine U- förmiger Kern mit zwei außen liegenden Wicklungen. Instead of the illustrated E-l-shaped core 2, of course, a differently shaped core can be used, for example, a U-shaped core with two outer windings.

Claims

Patentansprüche claims
1. Drossel (1 ) mit 1. Throttle (1) with
einem magnetisierbaren Kern (2) mit einer Wicklungsachse (3) und  a magnetizable core (2) having a winding axis (3) and
mindestens einer Wicklung (4), die durch einen Leiter (5) gebildet ist, der die Wicklungsachse des Kerns zumindest teilweise umschließt,  at least one winding (4) formed by a conductor (5) which at least partially surrounds the winding axis of the core,
dadurch gekennzeichnet, dass  characterized in that
die mindestens eine Wicklung einlagig gebildet ist und ein Querschnitt des Leiters rechteckförmig, insbesondere quadratisch, ist.  the at least one winding is formed in one layer and a cross section of the conductor is rectangular, in particular square.
2. Drossel nach Anspruch 1 , dadurch gekennzeichnet, dass 2. Throttle according to claim 1, characterized in that
der Leiter massiv ausgebildet ist.  the ladder is solid.
3. Drossel nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die mindestens eine Wicklung aus einem Profilrohr (6) gebildet ist, welches zur Bildung des Leiters strukturiert ist, insbesondere durch materialabtragendes Bearbeiten strukturiert ist, insbesondere durch Bohren, Sägen, Fräsen und/oder Funkenerodieren strukturiert ist. 3. choke according to claim 1 or 2, characterized in that the at least one winding of a profile tube (6) is formed, which is structured to form the conductor, in particular by material-removing machining is structured, in particular by drilling, sawing, milling and / or spark erosion is structured.
4. Drossel nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die mindestens eine Wicklung aus einem Druckgussformteil gebildet ist. 4. choke according to claim 1 or 2, characterized in that the at least one winding is formed from a die-cast molding.
5. Drossel nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 5. Throttle according to one of the preceding claims, characterized in that
die Drossel eine Nenn-Strombelastbarkeit aufweist, wobei der Querschnitt des Leiters derart dimensioniert ist, dass eine Strombelastbarkeit des Leiters größer ist als die Nenn- Strombelastbarkeit. the reactor has a rated current carrying capacity, wherein the cross section of the conductor is dimensioned such that a Current carrying capacity of the conductor is greater than the nominal current carrying capacity.
6. Drossel nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 6. Throttle according to one of the preceding claims, characterized in that
die Drossel eine Nenn-Strombelastbarkeit aufweist, wobei die Wicklung und der Kern derart dimensioniert sind, dass bei einer Belastung der Drossel mit ihrer Nenn-Strombelastbarkeit die Wicklungs Verluste größer sind als die Kernverluste.  the inductor has a nominal current carrying capacity, wherein the winding and the core are dimensioned such that when the inductance of the inductor with its rated current carrying capacity is loaded, the winding losses are greater than the core losses.
7. Drossel nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 7. choke according to one of the preceding claims, characterized in that
der Leiter aus Aluminium, Kupfer oder Titan besteht.  the conductor is made of aluminum, copper or titanium.
8. Drossel nach einem der vorhergehenden Ansprüche, gekennzeichnet durch 8. choke according to one of the preceding claims, characterized by
ein flächiges Kühlelement (7), welches thermisch mit der Wicklung, insbesondere mit einer von der Wicklungsachse des Kerns abgewandten Seite der Wicklung, gekoppelt ist.  a planar cooling element (7), which is thermally coupled to the winding, in particular with a side facing away from the winding axis of the core side of the winding.
9. Drossel nach Anspruch 8, gekennzeichnet durch 9. choke according to claim 8, characterized by
einen wärmeleitenden, elektrischen Isolator (8), der zwischen dem Kühlelement und der Wicklung angeordnet ist.  a heat conductive electrical insulator (8) disposed between the cooling element and the winding.
10. Drossel nach Anspruch 9, dadurch gekennzeichnet, dass 10. choke according to claim 9, characterized in that
der wärmeleitende, elektrische Isolator eine elektrisch isolierende Wärmeleitfolie ist.  the heat-conducting, electrical insulator is an electrically insulating heat conducting foil.
1 1. Drossel nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 1 1. Throttle according to one of the preceding claims, characterized in that
die Wicklung einen Kühlkörper bildet.  the winding forms a heat sink.
Drossel nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass Throttle according to one of the preceding claims, characterized in that
ein Abstand zwischen Wicklung und Kern derart gewählt ist, dass die Verluste durch Streufelder minimiert sind.  a distance between winding and core is chosen such that the losses are minimized by stray fields.
13. Verfahren zur Herstellung einer Drossel (1 ) nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass 13. A method for producing a throttle (1) according to one of the preceding claims, characterized in that
die Wicklung aus einem Profilrohr (6) gebildet wird, welches zur Bildung des Leiters strukturiert wird.  the winding is formed from a profile tube (6), which is structured to form the conductor.
14. Verfahren nach Anspruch 13, dadurch gekennzeichnet, dass 14. The method according to claim 13, characterized in that
das Strukturieren ein materialabtragendes Bearbeiten des Profilrohrs umfasst, insbesondere in Form von Bohren, Sägen, Fräsen und/oder Funkenerodieren.  the structuring comprises a material-removing machining of the profile tube, in particular in the form of drilling, sawing, milling and / or spark erosion.
EP12753104.4A 2011-09-02 2012-08-20 Inductor Active EP2751815B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011082045A DE102011082045A1 (en) 2011-09-02 2011-09-02 Throttle and related manufacturing process
PCT/EP2012/066205 WO2013030029A1 (en) 2011-09-02 2012-08-20 Inductor and associated production method

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EP2751815A1 true EP2751815A1 (en) 2014-07-09
EP2751815B1 EP2751815B1 (en) 2019-01-16

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CN (2) CN109637774A (en)
DE (1) DE102011082045A1 (en)
WO (1) WO2013030029A1 (en)

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CN109637774A (en) 2019-04-16
US10699836B2 (en) 2020-06-30
WO2013030029A1 (en) 2013-03-07
CN104040653A (en) 2014-09-10
EP2751815B1 (en) 2019-01-16
US20140327505A1 (en) 2014-11-06
DE102011082045A1 (en) 2013-03-07

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