EP3319096A1 - Unité de puissance magnétique compacte - Google Patents

Unité de puissance magnétique compacte Download PDF

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Publication number
EP3319096A1
EP3319096A1 EP16002354.5A EP16002354A EP3319096A1 EP 3319096 A1 EP3319096 A1 EP 3319096A1 EP 16002354 A EP16002354 A EP 16002354A EP 3319096 A1 EP3319096 A1 EP 3319096A1
Authority
EP
European Patent Office
Prior art keywords
magnetic
power unit
magnetic core
compact
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16002354.5A
Other languages
German (de)
English (en)
Inventor
Antonio Rojas Cuevas
Francisco Ezequiel NAVARRO PÉREZ
Jorge RODRÍGUEZ
Marina ARCOS
Patrick Fouassier
Raquel RODRÍGUEZ
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.)
Premo SA
Original Assignee
Premo SA
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 Premo SA filed Critical Premo SA
Priority to EP16002354.5A priority Critical patent/EP3319096A1/fr
Priority to CN201780068347.1A priority patent/CN110192256B/zh
Priority to JP2019522695A priority patent/JP7277362B2/ja
Priority to US16/347,442 priority patent/US11495394B2/en
Priority to PCT/EP2017/078203 priority patent/WO2018083249A1/fr
Priority to KR1020197016048A priority patent/KR102486366B1/ko
Publication of EP3319096A1 publication Critical patent/EP3319096A1/fr
Withdrawn legal-status Critical Current

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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
    • H01F27/10—Liquid cooling
    • H01F27/18—Liquid cooling by evaporating liquids

Definitions

  • the present invention refers to a significantly reduced size integrated magnetic power unit comprising a magnetic core generally including a first, a second and a third winding channels respectively arranged around a first, a second and a third intersecting axis, orthogonal to each other, each of said winding channels intended for receiving at least one coil wound around the magnetic core each coil having at least one turn, and the magnetic power unit further having associated one cooling structure of the core including a non-metallic thermally conductive element.
  • This magnetic power unit is particularly adapted to be used for example as a transformer or inductor in the electrical power field, suitable for operating a high power electrical device, especially usable in the field of hybrid and electrical vehicles (HEVs) that nowadays is growing quite fast.
  • HEVs hybrid and electrical vehicles
  • the new models of electrical vehicles require more and more power electronics inside, not only for the electrical motor supply with speed and torque control, but also for high-voltage (HV) battery chargers and stable in-car continuous low-voltage (LV) power supplies.
  • the magnetic power unit of this invention responds to a new volumetric efficiency concept on magnetic units (better volumetric performance, mainly when a 3D magnetic flux is involved) with a magnetic core including around it orthogonal windings for producing two or three substantially orthogonal magnetic fields at all point within the core
  • references to geometric position such as parallel, perpendicular, tangent, etc. allow deviations up to ⁇ 5° from the theoretical position defined by this nomenclature. It will also be understood that any range of values given may not be optimal in extreme values and may require adaptations of the invention to these extreme values are applicable, such adaptations being within reach of a skilled person.
  • DE19814896 discloses a power transformer for high current having a closed cylindrical core of soft magnetic high permeability material high saturation induction and low magnetic losses. This is wound with a primary coil and a secondary coil. The core is within a casing that is then filled with a suitable resin. At least one heat pipe (9) for cooling the unit is set in the centre. The heat pipe forms at least one part of the winding of the transformer.
  • EP0498897 (B1) reveals an electrical wiring material that can use as cooling means for heating portions in electronic apparatuses and a transformer having a coil of one side also serving as the cooling means.
  • the document discloses a material for electrical wirings provided with a cooling function.
  • the material is characterized in that it comprises a slender hollow conductor in which an operating liquid is sealed. Preferably, pieces for electric connections are provided on the end parts or other parts of the hollow conductor.
  • the transformer in accordance with the present invention is constituted as described above, due to a coil itself on a low voltage side in which a large current flow, the heat generated in the coil can be radiated. Consequently, no other cooling means is needed to the transformer or it may be enough by installing with extremely small capacity cooling means.
  • US6777835B1 discloses an electrical power cooling technique and particularly an apparatus for cooling a high power electrical transformer and electrical motors by using thermally conductive material interleaved between the turn layers of a high-power transformer and iron core laminates to provide a low resistant thermal path to ambient.
  • the strips direct excess heat from within the interior to protrusions outside of the windings (and core) where forced air or thermally conductive potting compound extracts the heat.
  • This technique provides for a significant reduction of weight and volume along with a substantial increase in the power density while operating at a modest elevated temperature above ambient.
  • a transformer is made of material such as laminated iron, ferrite and other core materials and the transformer is formed of insulated copper windings wrapped around the core. Heat is dissipated through the core to a base plate, while thermally conductive strips are placed in preselected positions between the windings and are preferably of high modulus graphite laminate material, to conduct heat along its fibre orientation, which is unidirectional.
  • the invention provides an alternative structure of a compact magnetic power unit particularly adapted to be used as a transformer or inductor in the power industry and especially applicable in the electrical automobile field (mainly for hybrid and electrical vehicles) and comprising a magnetic core including at least one coil wound around the magnetic core and at least one cooling structure including a non-metallic thermally conductive element, such as the one disclosed in the cited US6777835B
  • the non-metallic thermally conductive element is a heat pipe arranged inside (almost all the heat pipe is located within) a hole or inner cavity of the magnetic core and comprising at one of its ends a heat dissipation member.
  • the heat pipe is made of a thermoplastic or ceramic material having magnetic, or non-magnetic, paramagnetic or diamagnetic properties and said heat dissipation member can be embodied by a plate.
  • the heat pipe is arranged coaxial with an axis (A-A) orthogonal to a plane containing at least a turn of said at least one coil, so that the heat pipe extending through the magnetic core (capturing the heat generated therein.
  • the heat pipe is a hollow pipe filled with a fluid having a low boiling point.
  • the compact magnetic power unit of this invention can be embodied in many ways being any of:
  • a compact magnetic power unit 100 adapted to be used as a transformer or inductor in the electrical power industry and especially in the field of hybrid and electrical vehicles (involving among other DC/DC power transformer, and converters, DC/AC on board charger, or DC/DC power supply units), is shown.
  • the compact magnetic power unit 100 comprises a magnetic core 10 which enables winding around it one or more orthogonal coils, and a cooling structure 50.
  • the magnetic core 10 is provided with a through hole 30 for housing almost all a non-metallic thermally conductive element constituting the cooling structure 50.
  • the non-metallic thermally conductive element is a heat pipe 51 configured to be arranged inside the magnetic core 10.
  • the magnetic core 10 has a blind hole or in general a hole or inner cavity 30 inside of which a heat pipe 51 can be arranged.
  • the cooling structure 50 includes a heat dissipation member 52, preferably a heat dissipation plate, connected to the heat pipe 51 at one of its ends.
  • the heat pipe 51 allows capturing the heat generated into the magnetic core 10 for carrying it to the dissipation plate 52.
  • the compact magnetic power unit 100 provides a better volumetric performance (particularly 3D magnetic flux when three orthogonal windings are involved) and therefore can support density energy until a value of about 200 W/cm 3 . In this way, the compact magnetic power unit 100 can be realized with reduced dimensions without the risk of overheating that may be occur in some power application (e.g. battery charging in automotive field).
  • the heat pipe 51 is made of a thermoplastic or ceramic material having magnetic, or non-magnetic, paramagnetic or diamagnetic properties. More preferably, the eat pipe 51 is a hollow pipe filled with a fluid having a low boiling point implementing a technique well known in the art.
  • the compact magnetic power unit 100 comprises at least one coil, wound around the magnetic core 10, not shown in figure 1 for a better clarity of the arrangement of hole 30 on the magnetic core 10.
  • the compact magnetic power unit 100 provides different working configurations that will be discussed with greater details in the following description.
  • the magnetic core 10 includes a first, a second and a third winding channel 2a, 2b, 2c, respectively arranged around a first, a second and a third intersecting axis A-A, B-B, C-C orthogonal to each other.
  • Each winding channel 2a, 2b, 2c is intended for receiving at least one coil, having at least one turn, wound around the magnetic core 10.
  • the three axes are pairwise perpendicular and define a first, a second and a third plane in which the winding channels are located respectively.
  • the first winding channel 2a that is arranged around the first axis A-A, is located in the first plane that is defined by the other two axis B-B and C-C (i.e. the first plane is the plane orthogonal to the first axis A-A and on which the axes B-B and C-C lie).
  • the three planes define eight octants, each including a protrusion defining a protruding spacer 20.
  • the eight protruding spacers 20 are spaced to each other by the winding channels 2a, 2b, 2c.
  • the heat pipe 51 is arranged coaxial with the axis A-A orthogonal to a plane containing at least a turn of the coil wound around the winding channel 2a.
  • the body of the magnetic core is preferably composed of at least two parts 11, 12 assembled together by means of an attachment.
  • the magnetic core 10 is formed by a plurality of different partial magnetic cores 11, 12 made of a magnetic material selected among ferrite, ferromagnetic material, or a Polymer Bonded Soft Magnetic (PBSM) injectable material.
  • the partial magnetic cores are assembled together (for example by an adhesive) forming a composed core 10 in a layered configuration (i.e. the partial magnetic cores are stacked to each other).
  • the magnetic core 10 is preferably formed by three different partial magnetic cores comprising a central partial magnetic core 11 and two side partial magnetic cores 12, wherein each of the two side partial magnetic cores 12 includes four protruding spacers 20.
  • the central partial magnetic core 11 is interposed between the two-side partial magnetic cores 12 and lacks of protruding spacers 20.
  • the two side partial magnetic cores 12 have a substantially flat surface configured to be attached to the central partial magnetic core 11 by means of an adhesive (not shown and having a thickness negligible with respect to the dimensions of the magnetic core 10).
  • the composed core 10, when assembled, has a general geometric shape of a rectangular parallelepiped or a cube.
  • each protruding spacer 20 has a general geometric shape substantially cubic shape.
  • An alternative embodiment can provide that the composed core 10, when assembled, has a general geometric shape of a sphere.
  • each protruding spacer 20 has a general geometric shape comprising an external surface rounded.
  • the magnetic core 10 is formed by only two partial magnetic cores each having the protruding spacers 20 (for example two half partial magnetic cores having the same shape and configured to be assembled symmetrically), or by more than three partial magnetic cores.
  • the magnetic core 10 is preferably formed by two side partial magnetic cores 12, each including four protruding spacers 20, and a plurality of central partial magnetic cores 11 lacking of protruding spacers 20 stacked to each other.
  • the core of the compact magnetic power unit 100 is preferably surrounded by flux closing magnetic covers 40 preferably made of a material selected among ferrite, ferromagnetic material, or a Polymer Bonded Soft Magnetic (PBSM) injectable material, more preferably the same material of which the composed magnetic core 10 is made.
  • the through hole 30 extends also through the flux closing magnetic covers 40, so that the dissipation pipe 51 can pass through the composed magnetic core 10 and the heat dissipation plate can be arranged externally to the flux closing magnetic covers 40.
  • the flux closing covers 40 are preferably constituted by three pairs of flux closing covers 40, arranged at the opposite sides of the magnetic core 10. Each cover 40 is in contact (for example attached by means of adhesive) with four protruding members 20 and is spaced from the central partial magnetic core 11.
  • each flux closing cover 40 is in contact with other four flux closing covers 40 perpendiculars to it, through four perimeter faces 41.
  • the perimeter faces 41 are advantageously bevelled i.e. tapered towards the magnetic core 10 with an inclined coupling surface forming a truncated pyramid having preferably with a surface inclined of about 45°.
  • covers 40 can be all realized with the same shape.
  • the composed magnetic core 10 has a general geometric shape of a sphere.
  • the flux closing covers 40 are constituted by at least two opposed spherical caps, and each flux closing cover is in contact (for example attached by means of adhesive) with four different protruding spacers 20.
  • Figure 4 shows three coils 70a, 70b, 70c wound around the three winding channels 2a, 2b, 2c of the composed magnetic core 10 shown in figure 1 , respectively.
  • the magnetic power unit 100 provides a transformer comprising three coils 70a, 70b, 70c wound around the three-respective axis A-A, B-B, C-C orthogonal to each other, but as mentioned above, depending on the number and on the arrangement of one or more coils wound around the composed magnetic core 10, the magnetic power unit 100 may provide different device configurations.
  • the through hole 30 is not shown for a better clarity of the arrangement of the three coils 70a, 70b, 70c. It is intended that the turns of the coils 70b and 70c wound around the winding channels 2b and 2c are arranged for avoiding the hole 30 for allowing the passage of the heat dissipation pipe 51.
  • the magnetic power unit 100 is a transformer having two coils wound around two respective winding channels (i.e. arranged around two respective axes) and the third winding channel without coil. Furthermore, a third coil wound around the third winding channel may provide a choke for the transformer formed by the two coils wound around the other two winding channel.
  • the magnetic power unit 100 is a choke comprising three coils wound in the three-respective winding channel, or comprising two coils wound around two respective winding channels.
  • FIG 4 another embodiment of the compact magnetic power unit 100 according to the present invention is shown. Unlike the embodiment shown in figures 1 and 2 , this embodiment provides that the two-side partial magnetic cores 12 have a substantially flat surface configured to be arranged to ward the outside of the magnetic core 10 when it is assembled.
  • each coupling member 60a, 60b comprises a first wall 61 and two second walls 62 extending from two opposite sides of the first wall 61 towards an orthogonal direction with respect to the first wall.
  • the ends of the two second walls 62 of a coupling member 60a, 60b are configured to snap with the first wall 61 of the other coupling member 60b, 60a.
  • the central partial magnetic core 11 is surrounded by six walls of the auxiliary elements 60 (the first walls and second walls of the coupling members 60a, 60b).
  • the first wall 61 of each coupling member 60a, 60b is provided with an opening 63, for passing the heat dissipation pipe 51 through the hole 30, and a sleeve 64 arranged around the opening 63.
  • the end 65 of sleeves 64 are configured to snap with the flat surface of the side partial magnetic cores 12 when the composed magnetic core 10 is assembled.
  • each coupling member 60a, 60b are provided with a plurality of notches configured to leave open a plurality of passages for allow a direct contact between the central partial magnetic core 10 and the protruding spacers 20 of the side partial magnetic cores 12.
  • each protruding spacer 20 is preferably provided with a seat having a shape complementary to the respective corner.
  • the compact magnetic power unit 100 is preferably surrounded by flux closing magnetic covers 40 preferably made of a material selected among ferrite, ferromagnetic material, or a Polymer Bonded Soft Magnetic (PBSM) injectable material, more preferably the same material of which the composed magnetic core 10 is made.
  • flux closing magnetic covers 40 preferably made of a material selected among ferrite, ferromagnetic material, or a Polymer Bonded Soft Magnetic (PBSM) injectable material, more preferably the same material of which the composed magnetic core 10 is made.
  • PBSM Polymer Bonded Soft Magnetic
  • the flux closing covers 40 are preferably constituted by two pairs of flux closing covers 40, arranged at the opposite sides of the magnetic core 10 and orthogonally with respect to the side partial magnetic covers 12. Each cover 40 is in contact (for example attached by means of adhesive) with four protruding members 20 and is spaced from the central partial magnetic core 11.
  • each flux closing cover 40 includes preferably four notches 42, each notch 42 for providing winding connection windows when flux closing covers 40 are in contact with the protruding spacers 20.
  • the magnetic core 10 is a single piece body.
  • the magnetic core 10 is preferably a pot shaped core, i.e. a core provided with an inner housing inside of which a coil can be wound.
  • the magnetic core 10 has a substantially tubular shape inside of which a coil 70a is arranged around the axis A-A which is orthogonal to the plane defined by at least a turn of the coil 70a.
  • the pot shaped magnetic core 10 has preferably a toroidal shape so that a hole or cavity 30 is defined at the centre of the toroid.
  • the heat pipe 51 is arranged inside the hole 30 coaxially with the axis A-A, and the plate 52 is arranged as a base for the toroidal magnetic core 10.
  • coils 70b, 70c are wound around the magnetic core externally.
  • the coils 70b, 70c are wound around the curvilinear axis p arranged into the inner housing of the pot shaped magnetic core 10.
  • the curvilinear axis p lies on a plane orthogonal to the axis A-A.
  • the embodiment of figure 5 includes four coils 70a, 70b, 70c and 70d wound around the magnetic core 10.
  • the compact magnetic power unit 100 can provide a transformer comprising two coils 70b, 70c wound externally around the magnetic core 10 (around the curvilinear axis p) and a coil 70a wound internally within the housing of the pot shaped core 10 around the axis A-A, and a further winding 70d, but as mentioned above, depending on the number and on the arrangement of one or more coils wound around the composed magnetic core 10, the magnetic power unit 100 may provide different device configurations.
  • Two magnetic core 10 as per figure 5 can be assembled with their bases facing and sharing a central heat pipe (optionally with protruding heat dissipation fins) and external dissipation plates to provide a more complex unit involving several coils in orthogonal planes operating either as a transformer or simply inductor or as a choke related to the associated winding configuration.
  • the compact magnetic power unit 100 may be a transformer having two coils wound around two respective winding channels (i.e. arranged around two respective axes) and the third winding channel without coil. Furthermore, a third coil wound around the third winding channel may provide a choke for the transformer formed by the two coils wound around the other two winding channel.
  • the compact magnetic power unit 100 is a choke comprising three coils wound in the three-respective winding channel, or comprising two coils wound around two respective winding channels.
  • the heat pipe feature of this invention and its arrangement within the magnetic core along with the special structure of the magnetic core result in a compact magnetic unit with high electrical and magnetic performances highlighting among them the fact that it can support density energy until a value of about 200 W/cm 3 .

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)
EP16002354.5A 2016-11-04 2016-11-07 Unité de puissance magnétique compacte Withdrawn EP3319096A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
EP16002354.5A EP3319096A1 (fr) 2016-11-07 2016-11-07 Unité de puissance magnétique compacte
CN201780068347.1A CN110192256B (zh) 2016-11-04 2017-11-03 用于功率电子系统的紧凑型磁性功率单元
JP2019522695A JP7277362B2 (ja) 2016-11-04 2017-11-03 パワーエレクトロニクスシステム用小型磁気パワーユニット
US16/347,442 US11495394B2 (en) 2016-11-04 2017-11-03 Compact magnetic power unit for a power electronics system
PCT/EP2017/078203 WO2018083249A1 (fr) 2016-11-04 2017-11-03 Unité de puissance magnétique compacte pour un système électronique de puissance
KR1020197016048A KR102486366B1 (ko) 2016-11-04 2017-11-03 파워 일렉트로닉스 시스템용 컴팩트형 자력 유닛

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16002354.5A EP3319096A1 (fr) 2016-11-07 2016-11-07 Unité de puissance magnétique compacte

Publications (1)

Publication Number Publication Date
EP3319096A1 true EP3319096A1 (fr) 2018-05-09

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Family Applications (1)

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EP16002354.5A Withdrawn EP3319096A1 (fr) 2016-11-04 2016-11-07 Unité de puissance magnétique compacte

Country Status (1)

Country Link
EP (1) EP3319096A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3578880A1 (fr) * 2018-06-07 2019-12-11 Tridonic GmbH & Co. KG Appareil de fonctionnement pourvu de structure thermoconductrice
US11152146B2 (en) 2017-11-30 2021-10-19 Premo, S.A. Annular magnetic power unit
CN114005651A (zh) * 2021-11-16 2022-02-01 深圳顺络电子股份有限公司 电磁线圈组件及电磁设备
EP4254444A1 (fr) * 2022-03-30 2023-10-04 Schaffner EMV AG Composant magnétique de puissance

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3541487A (en) * 1968-11-18 1970-11-17 Westinghouse Electric Corp Electrical winding having heat exchangers between layers of the winding for cooling the windings
US3681628A (en) * 1970-09-14 1972-08-01 Christoslaw Krastchew Cooling arrangement for a dynamoelectric machine
US4210859A (en) * 1978-04-18 1980-07-01 Technion Research & Development Foundation Ltd. Inductive device having orthogonal windings
EP0498897A1 (fr) 1990-09-03 1992-08-19 The Furukawa Electric Co., Ltd. Materiau pour cablage electrique et transformateur
DE19814896A1 (de) 1998-04-02 1999-07-08 Vacuumschmelze Gmbh Leistungsübertrager für hohe Ströme
DE19814897A1 (de) * 1998-04-02 1999-10-14 Vacuumschmelze Gmbh Induktives Bauelement für hohe Leistungen
US6777835B1 (en) 1997-09-30 2004-08-17 The United States Of America As Represented By The Secretary Of The Navy Electrical power cooling technique
US20070251673A1 (en) * 2006-04-28 2007-11-01 Foxconn Technology Co., Ltd. Heat pipe with non-metallic type wick structure
US20150310976A1 (en) * 2014-04-25 2015-10-29 Delta Electronics (Shanghai) Co., Ltd. Magnetic element

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3541487A (en) * 1968-11-18 1970-11-17 Westinghouse Electric Corp Electrical winding having heat exchangers between layers of the winding for cooling the windings
US3681628A (en) * 1970-09-14 1972-08-01 Christoslaw Krastchew Cooling arrangement for a dynamoelectric machine
US4210859A (en) * 1978-04-18 1980-07-01 Technion Research & Development Foundation Ltd. Inductive device having orthogonal windings
EP0498897A1 (fr) 1990-09-03 1992-08-19 The Furukawa Electric Co., Ltd. Materiau pour cablage electrique et transformateur
US6777835B1 (en) 1997-09-30 2004-08-17 The United States Of America As Represented By The Secretary Of The Navy Electrical power cooling technique
DE19814896A1 (de) 1998-04-02 1999-07-08 Vacuumschmelze Gmbh Leistungsübertrager für hohe Ströme
DE19814897A1 (de) * 1998-04-02 1999-10-14 Vacuumschmelze Gmbh Induktives Bauelement für hohe Leistungen
US20070251673A1 (en) * 2006-04-28 2007-11-01 Foxconn Technology Co., Ltd. Heat pipe with non-metallic type wick structure
US20150310976A1 (en) * 2014-04-25 2015-10-29 Delta Electronics (Shanghai) Co., Ltd. Magnetic element

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11152146B2 (en) 2017-11-30 2021-10-19 Premo, S.A. Annular magnetic power unit
EP3578880A1 (fr) * 2018-06-07 2019-12-11 Tridonic GmbH & Co. KG Appareil de fonctionnement pourvu de structure thermoconductrice
CN114005651A (zh) * 2021-11-16 2022-02-01 深圳顺络电子股份有限公司 电磁线圈组件及电磁设备
EP4254444A1 (fr) * 2022-03-30 2023-10-04 Schaffner EMV AG Composant magnétique de puissance
EP4254445A1 (fr) * 2022-03-30 2023-10-04 Schaffner EMV AG Composant magnétique de puissance

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Inventor name: RODRIGUEZ, RAQUEL

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Inventor name: NAVARRO PEREZ, FRANCISCO EZEQUIEL

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Inventor name: ARCOS MORENO, MARINA