EP3001436B1 - Winding foil and winding for an inductive electrical device - Google Patents

Description

The invention relates to a winding film which can be wound along a winding direction into an electrically conductive winding for an inductive electrical device and is designed such that the electrical resistance of electrically conductive regions of the winding film varies along at least one direction, at least one extending along the winding direction electrically conductive edge region is provided, whose electrical resistance is smaller than an electrical resistance of an adjoining this edge region electrically conductive connection region.

The invention further relates to a winding for an inductive electrical device.

Such a winding foil and such a winding are for example from JP H04 109609 A known. The winding foil is composed of different conductor materials.

From the JP H02 278804 A a winding foil as well as a winding consisting of this winding foil is also known, wherein the winding foil forms a net-like structure with recesses. In the axial edge regions of the winding, the electrical conductivity of the winding film is greater than in its middle region.

In the WO 2005/096330 A1 discloses a winding which consists of a conductor foil which has a recess in its center region, so that set in the axial edge regions of the winding foil greater electrical conductivities, as in the middle region of the film.

The invention generally relates to windings of inductive electrical devices, such as transformers and choke coils, which are at least partially made of an electrically conductive wound coil film. In such windings, high eddy currents are sometimes induced due to magnetic fluxes penetrating radially through the windings. These eddy currents interfere with the load currents and, in total, lead to a significant increase in the current density at the axial edges of film turns. Since the power loss density is locally proportional to the square of the current density, the power dissipation density at these axial edges is significantly increased relative to the axial center region of the winding. By contrast, the current density and the power dissipation density in the axial center region of a film winding are significantly lower than those expected for a homogeneous distribution of current within a winding film.

In order to prevent overloading and temperature increase at the axial edges of the winding, the film thickness of the winding films is currently chosen to be sufficiently large and / or (for example, axially extending) cooling channels are provided within the windings to dissipate heat from the windings. The film thickness increases the amount of conductor material and the cost of the conductor material and the weight of the winding. Cooling channels within the winding increase the radial extent of the winding and thereby also the need for conductor material.

The invention has for its object to provide an improved winding foil and an improved winding for an inductive electrical device.

The object is achieved with respect to the winding film by the features of claim 1 and with respect to the winding by the features of claim 11.

Advantageous embodiments of the invention are the subject of the dependent claims.

A winding film according to the invention can be wound up along a winding direction into an electrically conductive winding for an inductive electrical device and designed such that the electrical resistance of electrically conductive regions of the winding film varies along at least one direction.

The invention makes it possible, in particular, to adapt the electrical resistance to the current densities actually occurring locally in a winding produced from the winding film by means of a spatial variation of the electrical resistance of the winding film. As a result, it can be advantageously avoided that the winding film is locally oversized, thereby unnecessarily consuming a large amount of material and installation space.

According to the invention, at least one electrically conductive edge region extending along the winding direction is provided, whose electrical resistance is smaller than an electrical resistance of an electrically conductive connection region adjoining this edge region.

This embodiment of the invention takes into account that, according to the above statements, high current densities often occur, in particular in the axial edge regions of windings made from winding foils, due to eddy currents. A lower electrical resistance in such areas can therefore advantageously prevent electrical and thermal overloads of these areas.

In the context of the invention, at least one support element connected to at least one edge region and the connection region is provided for stabilizing the edge region.

As a result, the winding film can advantageously be stabilized in the edge regions.

A preferred embodiment of the invention provides for the winding film to be formed in such a way that the electrical resistance of electrically conductive regions of the winding film varies along at least one direction orthogonal to the winding direction.

This embodiment advantageously takes into account that the current density in real windings varies particularly strongly by eddy currents in directions orthogonal to the winding direction.

A further embodiment of the invention provides that an extent of electrically conductive regions of the winding film varies in a first direction orthogonal to the winding direction along a second direction orthogonal to the winding direction.

This embodiment of the invention makes advantageous use of the fact that the electrical resistance of electrically conductive regions of the winding foil can be influenced by an expansion of these regions.

Another embodiment of the invention provides that materials from which electrically conductive regions of the winding film are made vary along at least one direction.

This embodiment of the invention makes advantageous use of the fact that the electrical resistance of electrically conductive regions of the winding foil can be influenced by the materials from which these regions are made.

A further embodiment of the aforementioned embodiment of the invention provides that at least one edge region has a greater thickness than the connection region.

This refinement advantageously takes into account that the increase in the thickness of an edge region can reduce the electrical resistance of the edge region.

A further development of the aforementioned embodiment of the invention provides that at least one edge region is at least partially made of a material having a higher electrical conductivity than a material from which the connection region is made.

This refinement advantageously takes into account that the electrical resistance of the edge region can be reduced by a material having a higher electrical conductivity.

A further development of the aforementioned embodiment of the invention provides that the connection region is electrically conductively connected to at least one edge region.

As a result, the electrical resistances of at least one edge region and the connection region can advantageously be influenced one another.

A further development of the aforementioned embodiment of the invention provides that the connection region has recesses.

On the one hand, such recesses advantageously reduce the electrical resistance of the connection region and, on the other hand, save conductor material for producing the connection region.

Further refinements of the abovementioned embodiment of the invention provide for two edge regions and a connection region lying between the edge regions, and preferably at least one support element connecting the two edge regions for stabilizing the edge regions.

These refinements take into account that usually in both axial edge regions of a winding increased current densities can occur, and that the two edge regions can be stabilized by a supporting element connecting them.

A winding according to the invention for an inductive electrical device is made at least partially from a winding film wound according to the invention along its winding direction with the above-mentioned advantages.

An inductive electrical device according to the invention has at least one winding according to the invention and is designed, for example, as a transformer or a choke coil.

FIG 1

eine Schnittdarstellung eines ersten Ausführungsbeispiels einer Wicklungsfolie,

FIG 2

eine Seitenansicht eines Abschnitts der in Figur 1 gezeigten Wicklungsfolie,

FIG 3

eine Schnittdarstellung eines zweiten Ausführungsbeispiels einer Wicklungsfolie,

FIG 4

eine Schnittdarstellung eines dritten Ausführungsbeispiels einer Wicklungsfolie,

FIG 5

eine Seitenansicht eines Abschnitts eines illustrativen Beispiels einer Wicklungsfolie,

FIG 6

eine Schnittdarstellung eines weiteren illustrativen Beispiels einer Wicklungsfolie,

FIG 7

eine Schnittdarstellung eines weiteren illustrativen Beispiels einer Wicklungsfolie,

FIG 8

schematisch eine Schnittdarstellung eines Transformators, und

FIG 9

schematisch eine Schnittdarstellung einer Drosselspule.

The above-described characteristics, features, and advantages of this invention, as well as the manner in which they will be achieved, will become clearer and more clearly understood in connection with the following description of exemplary embodiments which will be described in detail in conjunction with the drawings. Showing:

FIG. 1

a sectional view of a first embodiment of a winding foil,

FIG. 2

a side view of a section of in FIG. 1 shown winding film,

FIG. 3

a sectional view of a second embodiment of a winding film,

FIG. 4

a sectional view of a third embodiment of a winding film,

FIG. 5

3 is a side view of a portion of an illustrative example of a coil film;

FIG. 6

a sectional view of another illustrative example of a winding foil,

FIG. 7

a sectional view of another illustrative example of a winding foil,

FIG. 8

schematically a sectional view of a transformer, and

FIG. 9

schematically a sectional view of a choke coil.

Corresponding parts are provided in all figures with the same reference numerals.

The Figures 1 and 2 show a first embodiment of a winding film 1, which is wound along a winding direction to an electrically conductive winding 100 for an inductive electrical device 102 about a winding axis (embodiments of windings 100 and inductive electrical devices 102 are below with reference to FIGS. 8 and 9 ) Described.

For better understanding, a Cartesian coordinate system with coordinates X, Y, Z is shown in the figures, whose X-direction is parallel to the winding direction and whose Z-direction is parallel to the winding axis. The parallel to the winding axis Z-direction is hereinafter also referred to as axial direction, the winding direction parallel to the X-direction is also referred to as tangential direction and the Y-direction is also referred to as a radial direction to these directions with respect to a Winding the winding film 1 resulting winding 100 to set.

FIG. 1 shows a sectional view of the first embodiment of a winding film 1 in a direction orthogonal to the winding direction YZ plane. FIG. 2 shows a side view of this winding film 1 on an XZ plane.

The winding film 1 has four film components 3 to 6, each of which extends over the entire tangential extent of the winding film 1 in the X direction.

An electrically conductive first film component 3 extends in the Z direction over the entire axial extent of the winding film 1.

An electrically conductive second film component 4 extends in the Z direction over a first axial edge region 20 of the winding film 1 and abuts against the first film component 3 in the first axial edge region 20 in an XZ plane. In this XZ-plane, the second film component 4 is further electrically conductively connected to the first film component 3 and optionally in at least one area also materially connected, for example by welding, soldering and / or gluing, with the first film component 3.

An electrically conductive third film component 5 extends in the Z direction over a first axial edge region 20 axially opposite second axial Edge region 21 of the winding film 1 and lies in the second axial edge region 21 in an XZ plane on the first film component 3. In this XZ-plane, the third film component 5 is further electrically conductively connected to the first film component 3 and optionally in at least one area also materially connected, for example by means of welding, soldering and / or gluing, to the first film component 3.

A fourth film component 6 extends in the Z direction over a connection region 22 lying between the two axial edge regions 20, 21, which forms an axial middle region of the winding film 1. A first axial end region 6.1 of the fourth film component 6 abuts the second film component 4 in an XY plane and a second axial end region 6.2 of the fourth film component 6 abuts the third film component 5 in another XY plane, so that the fourth film component 6 forms a support element 6 for stabilizing the edge regions 20, 21. Optionally, the fourth film component 6 is also in an XZ plane in the connection region 22 on the first film component 3 and there in at least one area also cohesively, for example by welding, soldering and / or gluing, be connected to the first film component 3.

The fourth film component 6 may be formed electrically conductive. Alternatively, however, it may also be designed to be electrically insulating.

In the illustrated embodiment, the fourth film component 6 is solid, homogeneous and contiguous. Alternatively, however, it may also be formed inhomogeneous and / or structured and / or consist of several non-contiguous subcomponents. For example, the fourth film component 6 may be formed as a braid or consist of a plurality of rod-like subcomponents, each extending axially between the second film component 4 and the third film component 5.

The film components 3 to 6 are designed such that the electrical resistance of the winding film 1 in the axial edge regions 20, 21 is less in each case than in the connection region 22. This is achieved, for example, by a radial thickness, i. H. an extent in the Y direction, the second film component 4 and the third film component 5 are each greater than a radial thickness of the first film component 3. Alternatively or additionally, the second film component 4 and the third film component 5 are each made of a material having a higher electrical conductivity than a material from which the first film component 3 is made. Alternatively or additionally, the first film component 3 has recesses 25.

As a result of the lower electrical resistance in the axial edge regions 20, 21 compared to the connection region 22, the winding film 1 is particularly suitable for producing windings 100, in whose axial edge regions 20, 21 a higher electrical current density can occur than in the connection region 22 due to electrical eddy currents , In the Figures 1 and 2 For example, tangential load current directions 30 and eddy current directions 32 of load currents and eddy currents are indicated which may arise in the axial edge regions 20, 21 of a winding film 1 wound up into a winding 100.

The FIGS. 3 to 7 Each show a further embodiment of a winding film 1 which can be wound up in a winding direction into a winding 100 for an inductive electrical device 102.

This in FIG. 3 illustrated second embodiment of a winding film 1 shows the winding film 1 in one FIG. 1 analog sectional view. This embodiment differs from that in FIG FIG. 1 illustrated embodiment essentially only in that the first film component 3 does not extend in the Z direction over the entire axial extent of the winding film 1, but only over a region axially on both sides of the connection region 22 between the second film component 4 and the third film component 5 projects beyond, however, up to the axial Ends of the winding film 1 to extend. The first film component 3 abuts on the second film component 4 in an XZ plane in the first axial edge region 20 and on the third film component 5 in the second axial edge region 21, is electrically conductive with the second film component 4 and the third film component 5, respectively optionally in at least one area also cohesively, for example by means of welding, soldering and / or gluing, connected.

In addition, in each axial edge region 20, 21, an additional film component 7, 8 axially adjoins the first film component 3, which extends up to the axial end of the respective edge region 20, 21.

In this case, a first additional film component 7 rests against the second film component 4 in an XZ plane and can be connected to it in an at least one area by material bonding, for example by means of welding, soldering and / or gluing.

The second additional film component 8 abuts the third film component 5 in an XZ plane and may be connected to it in an at least one area in a materially bonded manner, for example by means of welding, soldering and / or gluing.

Furthermore, both additional film components 7, 8 can optionally be connected to the first film component 3 in a materially bonded manner in each case in at least one area, for example by means of welding, soldering and / or gluing.

The two additional film components 7, 8 serve as additional support elements 7, 8 for stabilizing the axial edge regions 20, 21 and may each be designed to be electrically conductive or alternatively electrically insulating. Furthermore, they can each be formed solid and coherent or inhomogeneous and / or structured and / or consist of several non-contiguous subcomponents.

This in FIG. 4 illustrated third embodiment of a winding film 1 shows the winding film 1 in one FIG. 1 analog sectional view. This embodiment differs from that in FIG FIG. 1 illustrated embodiment essentially in that the first film component 3 does not extend in the Z direction over the entire axial extent of the winding film 1, but only via the connection region 22 between the second film component 4 and the third film component 5. In addition, the second film component extend 4 and the third film component 5 radially over the entire radial expansions of the first film component 3 and the fourth film component 6, so that the first film component 3 abuts axially on one end of the second film component 4 and is electrically conductively connected thereto and the other End rests against the third film component 5 and is connected to this electrically conductive. Optionally, the first film component 3 can also be bonded to the second film component 4 and / or to the third film component 5 in at least one area in a materially bonded manner, for example by means of welding, soldering and / or gluing.

Analogous to that in the Figures 1 and 2 The first embodiment shown are also in the FIGS. 3 and 4 shown winding films 1 designed such that the electrical resistance of the winding film 1 in the axial edge regions 20, 21 is in each case less than in the connection region 22. This is in turn achieved, for example, in that a radial thickness of the second film component 4 and the third film component 5 is greater than is a radial thickness of the first film component 3. Alternatively or additionally, the second film component 4 and the third film component 5 are each made of a material having a higher electrical conductivity than a material from which the first film component 3 is made. Alternatively or additionally, the first film component 3 has recesses 25.

FIG. 5 1 shows a detail of an illustrative example of a winding film 1 not covered by the invention FIG. 2 analogue side view. This winding film 1 consists of only one electrically conductive film component 3, which extends in the Z direction over the entire axial extent of the winding film 1. The film component 3 is in each case homogeneously formed in both axial edge regions 20, 21 of the winding film 1 in the radial, axial and tangential direction, but has recesses 25 in the connection region 22 lying between the axial edge regions 20, 21. As a result, the electrical resistance of the winding film 1 in the axial edge regions 20, 21 is smaller in each case than in the connection region 22.

This in FIG. 6 Illustrated non-inventive illustrative example of a winding film 1 shows the winding film 1 in one FIG. 1 analog sectional view. The winding film 1 comprises two electrically conductive film components 3, 4 which each extend both tangentially and axially over the entire extent of the winding film 1, are arranged radially one behind the other and are optionally electrically conductively connected to one another. Optionally, the two film components 3, 4 are also connected to one another in at least one area in a material-bonded manner, for example by means of welding, soldering and / or gluing. The two film components 3, 4 differ from each other in terms of electrical conductivity of the material from which they are each made. For example, a first film component 3 is made of aluminum and the second film component 4 is made of copper. This varies the electrical resistance the winding film 1 in the radial direction. Optionally, the radial thicknesses of the two film components 3, 4 may differ from each other.

This in FIG. 7 Illustrated non-inventive illustrative example of a winding film 1 shows the winding film 1 in one FIG. 1 analog sectional view. This embodiment differs from that in FIG FIG. 6 illustrated embodiment only in that the second film component 4 projects beyond the first film component 3 axially on both sides. As a result, the electrical resistance of the winding film 1 varies both in the radial direction and in the axial direction.

The FIGS. 8 and 9 show purely schematically in a sectional view in each case an inductive electrical device 102 with a winding 100, which consists of a winding film wound along its winding direction 1 according to one of the embodiments described above. The coordinate systems shown in these figures with Cartesian coordinates X, Y, Z relate only to the respective sectional plane shown.

FIG. 8 1 schematically shows an inductive electrical device 102 designed as a transformer. The transformer comprises a two-limbed transformer core 104, around both of which a winding 100, which consists of a wound winding film 1, is guided around each. FIG. 9 schematically shows an inductive electric device 102 designed as a choke coil. The choke coil comprises a rod core 106, around which a winding 100 is guided, which consists of a wound coil film 1.

Although the invention has been illustrated and described in detail by preferred embodiments, the invention is not limited by the disclosed examples and other variations can be derived therefrom by those skilled in the art without departing from the scope of the invention as defined by the claims.

Claims (13)

1. Winding foil (1), which

   - is able to be wound along a winding direction to form an electrically conductive winding (100) for an inductive electrical apparatus (102)

   - and is formed in such a way that the electrical resistance of electrically conductive regions of the winding film (1) varies along at least one direction, wherein at least one electrically conductive edge region (20, 21) extending along the winding direction is provided, the electrical resistance of which is lower than an electrical resistance of an electrically conductive connection region (22) adjoining said edge region (20, 21),

   characterized by at least one support element (6, 7, 8) connected to at least one edge region (20, 21) and the connection region (22) for stabilizing the edge region (20, 21).
2. Winding film (1) according to Claim 1,
   characterized in that the winding film (1) is formed in such a way that the electrical resistance of electrically conductive regions of the winding film (1) varies along at least one direction orthogonal to the winding direction.
3. Winding film (1) according to either of the preceding claims,
   characterized in that an extent of electrically conductive regions of the winding film (1) in a first direction orthogonal to the winding direction varies along a second direction orthogonal to the winding direction.
4. Winding film (1) according to one of the preceding claims,
   characterized in that materials from which electrically conductive regions of the winding film (1) are produced vary along at least one direction.
5. Winding film (1) according to one of the preceding claims,
   characterized in that at least one edge region (20, 21) has a greater thickness than the connection region (22).
6. Winding film (1) according to Claim 5,
   characterized in that at least one edge region (20, 21) is at least partly produced from a material that has a higher electrical conductivity than a material from which the connection region (22) is produced.
7. Winding film (1) according to one of the preceding claims,
   characterized in that the connection region (22) is electrically conductively connected to at least one edge region (20, 21).
8. Winding film (1) according to one of Claims 5 to 7,
   characterized in that the connection region (22) has recesses (25).
9. Winding film (1) according to one of the preceding claims,
   characterized by two edge regions (20, 21) and one connection region (22) located between the edge regions (20, 21).
10. Winding film (1) according to Claim 9,
    characterized by at least one support element (6) connecting the two edge regions (20, 21) for stabilizing the edge regions (20, 21).
11. Winding (100) for an inductive electrical apparatus (102), wherein the winding (100) is at least partly produced from a winding film (1) according to one of the preceding claims that is wound along the winding direction of said winding.
12. Inductive electrical apparatus (102) having at least one winding (100) according to Claim 11.
13. Inductive electrical apparatus (102) according to Claim 12,
    characterized in that the inductive electrical apparatus (102) is formed as a transformer or an induction coil.

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