JP6588042B2 - Inductor assembly comprising at least one inductor coil thermally coupled to a metal inductor housing - Google Patents

Inductor assembly comprising at least one inductor coil thermally coupled to a metal inductor housing Download PDF

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JP6588042B2
JP6588042B2 JP2016572755A JP2016572755A JP6588042B2 JP 6588042 B2 JP6588042 B2 JP 6588042B2 JP 2016572755 A JP2016572755 A JP 2016572755A JP 2016572755 A JP2016572755 A JP 2016572755A JP 6588042 B2 JP6588042 B2 JP 6588042B2
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Prior art keywords
inductor
coil
metal
assembly
winding
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JP2017522724A (en
Inventor
リルコ,マレク
ウォルザック,マリウシュ
ハンゼル,ミロシュ
グヴァデラ,マリウシュ
ハフロヴスキー,ヤクブ
Original Assignee
エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG
エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG
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Priority to EP14173136.4A priority patent/EP2958118A1/en
Application filed by エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG, エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG filed Critical エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG
Priority to PCT/EP2015/063361 priority patent/WO2015193252A1/en
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    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/30Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306Fastening or mounting coils or windings on core, casing or other support
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/324Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/34Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00Fixed inductances not covered by group H01F17/00
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • H01F2027/2857Coil formed from wound foil conductor

Description

  The present invention includes at least one inductor coil, a metal inductor housing that at least partially surrounds the inductor coil, and a potting material that contacts both the inductor coil and the inductor housing and thermally couples the inductor coil to the inductor housing. The present invention relates to an inductor assembly. More particularly, the present invention includes at least one inductor coil including a bobbin made of an electrically insulating material and an inductor winding made of a conductor wound on the bobbin, the inductor winding being an outer periphery And an inductor assembly having two end faces, the electrical insulator covering the outer periphery of the inductor winding.

  The electrical insulator covering the outer periphery of the inductor winding may be a separate electrical insulator, such as an electrical insulating foil wound around the outer periphery of the inductor winding. However, the electrical insulator covering the outer periphery of the inductor winding may also be provided by an electrical insulator wound on the bobbin along with the conductor. However, this is limited to the case where the electrical insulator of the conductor has sufficient strength. In many cases, the conductor wound on the bobbin of the inductor coil is provided with a thin layer of electrically insulating lacquer. Such an electrically insulating lacquer is only sufficient to provide sufficient electrical insulation between the inductor windings and is not sufficient to provide sufficient electrical insulation of the inductor windings relative to the metal inductor housing. Therefore, a separate electrical insulator that covers the outer periphery of the inductor winding is required.

  The metal housing of the inductor assembly is bowl shaped to receive the potting material. On the open side of the pot-shaped metal housing, the inductor assembly may end with the potting material at least partially surrounding the inductor coil in the metal housing, or it may be a metal closure plate or any other It may be closed by a kind of metal closure.

  An inductor assembly as defined at the beginning may be used, for example, as an AC or DC choke, as an AC or DC filter, or as an electrical energy storage inductor, for example. In any of these applications, it is necessary to electrically isolate the inductor winding from the metal inductor housing. In many cases, it is also a requirement that the inductor winding be electrically isolated from the core of the inductor assembly on which the bobbin of at least one inductor coil is disposed. On the other hand, good thermal coupling of the inductor housing to the inductor coil and the core, respectively, is required to dissipate the heat generated inside both the inductor coil and the core by the current flowing in the inductor coil. Therefore, there are different requirements for potting materials. This is because potting materials that provide good electrical insulation usually do not provide good thermal bonding. In addition, potting materials, including, for example, electrically insulating resin substrates such as polyurethane, epoxy or silicone resins, and fillers of thermally conductive particles such as ceramic, quartz, AlN or BN particles are both In many cases, these fluid states exhibit a high viscosity due to the filler. They are therefore not suitable for filling the small gap between the inductor coil and the metal housing without forming a gap. However, voids in the potting material can reduce the thermal coupling of the inductor coil to the metal housing and can trigger a breakdown of the electrical insulation between the inductor winding and the metal housing. In addition, the breakdown of the electrical insulation between the inductor winding and the metal housing can also be triggered by a filler of thermally conductive particles inside the resin substrate. This often occurs in regions where the average distance between thermally conductive particles is relatively small. Within the typical bulk volume of potting material inside the metal housing, the distribution of thermally conductive particles is not ideally uniform. Furthermore, it can change during the potting process, in particular due to agglomerates that can be generated, for example, in small gaps between the inductor winding and the metal housing. Within these agglomerates, the average distance between the thermally conductive particles is relatively small, and therefore the risk of triggering electrical breakdown is relatively high. Thus, the thermally conductive filler typically compromises the electrical insulation ability of the potting material. In addition, because of the small distance between the inductor coil and the metal housing, the inductor coil is designed so that all the gaps between the inductor coil to be filled with potting material and the metal housing have a uniform width. Accurate positioning within the metal housing is required.

  US 2013/0265129 A1 discloses an electromagnetic device including a transformer assembly. The transformer assembly includes a magnetic core, a winding, and a housing disposed around at least a portion of the magnetic core and the winding. An enclosure at least partially surrounds the transformer assembly. The transformer assembly is mounted on the first portion of the enclosure such that heat is transferred from the transformer assembly to the first portion of the enclosure. The second portion of the enclosure has an extension extending therefrom, whereby the extension is disposed in thermal contact with the transformer assembly and transfers heat from the transformer assembly to the extension. It is like that.

  German Offenlegungsschrift DE 10 210 1026 227 A1 discloses inductive components, such as chokes, which are used, for example, to smooth the voltage in a conductor. The inductive component has an inductor coil with at least one inductor winding of the wire conductor. The inductor coil is accommodated in the housing. A thermally conductive pad is disposed between the inductor coil and the housing. The pad may be a thermal pad, or it may be made of a phase change material, a gel-like consistency material, or a gap filler.

  WO 2005/052964 A1 discloses a heat conducting bridge for a toroidal core induction resistor. A toroidal core is surrounded by at least one winding. The heat-conducting bridge is formed by a base element and an element extending from the base element into the center of the toroidal core so that the toroidal core is arranged around this element. The base element closes the pot-shaped housing, in which the toroidal core is surrounded by the potting material.

  German Offenlegungsschrift 3,522,740 A1 discloses a further transformer or choke with a toroidal core. Here, a heat conducting element extending into the center of the toroidal core extends from the metal housing, in which the toroidal core and the windings on the toroidal core are surrounded by a particulate material, for example silica sand. The metal housing includes cooling ribs for dissipating heat from the windings and toroidal core.

  DE 19814897 A1 discloses an inductive component for high power in which a toroidal core with windings is arranged in a pot-shaped housing and embedded in a potting material. . From the housing, a heat pipe extends into the center of the toroidal core.

  Another inductive component with a toroidal core and a winding surrounded by a potting material in a metal housing is known from German Utility Model No. 9406996 U1. Here, the element of the housing that extends into the center of the toroidal core comprises a ring-shaped rib that increases the surface of this heat transfer element towards the potting material made of resin.

  US Pat. No. 4,000,483A surrounds a laminated magnetic core, an electrically insulating plastic bobbin wound with a primary coil, an electrically insulating plastic bobbin wound with a secondary coil, and the primary coil. Disclosed is a transformer comprising two interengaging electrically insulating plastic covers that provide additional electrical insulation between a primary coil and a laminated magnetic core and between a primary coil and a secondary coil. ing. The plastic component is formed to provide 2 mm of electrical insulation between the primary coil and the secondary coil and between the primary coil and the laminated magnetic core. The plastic component is arranged to provide a creepage distance of at least 10 mm between the primary and secondary coils and at least 8 mm between the primary coil and the laminated core. The resulting insulation will allow the laminated core to be mounted directly on the metal frame of the device.

  US 2008/0079525 A1 discloses a series filament transformer for a vacuum apparatus. The filament transformer includes a magnetic core, and a primary winding and a secondary winding wound around the magnetic core. The secondary winding is biased to a high voltage and the primary winding is placed in series with the secondary winding. The primary and secondary windings are incorporated in separate bobbins or in a common bobbin. The distance between the bobbin section incorporating the primary and secondary windings provides the creepage distance between the primary and secondary windings. In addition, a shield in the primary section of the bobbin is provided to shield the primary winding from the secondary winding. This shield may be in the form of a thin shield winding. The outer periphery of the secondary winding incorporated in the secondary bobbin section is surrounded by an insulator. For the magnetic core, the insulator may be made of an insulating sheet folded in a “C” shape, or a cap made of an electrically insulating polymer material. This seat or cap is secured in the free bobbin section on either side of the secondary bobbin section incorporating the secondary winding.

  There is still a need for an inductor assembly in which the inductor coil is efficiently and thermally coupled to the inductor housing but is electrically isolated from the inductor housing and nevertheless manufactured at low cost. Has been.

  The present invention provides an inductor assembly according to independent claim 1. The dependent claims define preferred embodiments of the inductor assembly according to the invention.

  An inductor assembly in accordance with the present invention includes at least one inductor coil, a metal inductor housing that at least partially surrounds the inductor coil, and contacts both the inductor coil and the inductor housing, and the inductor coil is thermally coupled to the inductor housing. A potting material. The inductor coil includes a bobbin made of an electrically insulating material and an inductor winding made of a conductor wound on the bobbin. The inductor winding has an outer periphery and two end faces. An electrical insulator covers the outer periphery of the inductor winding. A coil lid, also made of an electrically insulating material, at least partially covers the end face of the inductor winding and the adjacent area of the electrical insulation that covers the outer periphery of the inductor winding, so that the coil lid or bobbin electrical The distance of any point on the end face of the inductor winding to the metal housing along any path that does not penetrate the insulating material is at least the minimum required creepage distance.

  The present invention is based on the discovery that the most important point regarding electrical insulation between the inductor coil and the metal inductor housing is the point of the end face of the inductor winding of the inductor coil closest to the metal inductor housing. Even if these end faces themselves are covered by the flange of the bobbin around which the inductor winding is wound, and even if the inductor winding is covered by an electrical insulator at its outer periphery, the metal inductor housing There will be very close points on the end face of the inductor winding. Regardless of the potting material, the present invention ensures that no electrical breakdown occurs at these points between the inductor coil and the metal inductor housing by providing a coil lid. The lid of these coils is necessary between the end face of the inductor winding and the metal inductor housing by at least partially covering the end face of the inductor winding and the adjacent area of electrical insulation that covers the outer periphery of the inductor winding. Ensure that the minimum creepage distance is maintained. Now, assuming that the electrical insulation material of the coil lid and bobbin is of sufficient dielectric strength, the associated path from the end face of the inductor winding to the metal inductor housing is the electrical insulation of the coil lid or bobbin. Only those that do not penetrate the material. Thus, in the inductor assembly according to the present invention, the design of their overlap with the coil lid, in particular the adjacent area of the electrical insulator covering the outer periphery of the inductor winding, is the creepage distance between the inductor coil and the metal inductor housing. Affects. This results in the option of changing the creepage distance as desired through changes to the coil lid design without significantly increasing the installation space required by the inductor assembly. This is explained in more detail in the following figures.

  Maintaining the required minimum creepage distance, i.e., the minimum distance along the insulator surface between the end face of the inductor winding and the metal inductor housing, is the minimum spatial distance between the end face of the inductor winding and the metal inductor, That is, to ensure that the distance through any path through the air is also maintained if there is at least one such path through the air in the inductor assembly according to the present invention. Become.

  The present invention is completely independent of the dielectric strength of the potting material. Instead, the potting material only provides additional electrical insulation by maintaining a minimum creepage distance for all points on the end face of the inductor winding. Furthermore, maintaining a minimum creepage distance by the coil lid means that the inductor winding itself may be located at a negligible distance to the metal inductor housing. As a result, good thermal coupling is provided between these components due to the short distance between the inductor winding and the metal inductor housing. The present invention also does not depend at least significantly on the thermal conductivity of the potting material. This is because the inductor assembly of the present invention does not pass through the potting material, but through a path that is guided through the heat transfer facilitating joining member as described in more detail below. This is due to the fact that it provides significant heat transfer to the housing. Thus, the potting material does not necessarily require a filler of thermally conductive particles in order to provide sufficient thermal conductivity of the potting material. If there is no filler of thermally conductive particles in the potting material, the risk of dielectric breakdown triggered by that filler is also eliminated. In addition, the potting material is typically cheaper if it does not need to provide sufficient thermal conductivity.

  In addition, the coil lid may assist in the fabrication of the inductor assembly of the present invention in some aspects. One of these aspects is to place the inductor coil relative to the metal inductor housing. Another aspect is to place the inductor coil relative to other inductor coils and / or the core of the inductor assembly.

  In the inductor assembly according to the invention, the potting material is optimized for its low viscosity in its fluid state, for example to ensure that even a small gap between the inductor coil and the metal inductor housing is filled. Also good. Due to the small width of these gaps, the thermal conductivity of the potting material is not as important as with wider gaps. Of course, considering the cost of the potting material and the step of filling it into the metal inductor housing, the gap width, and the thermal conductivity of the potting material, the optimal thermal coupling of the inductor coil to the metal inductor housing May be optimized for.

  In addition to maintaining the required minimum creepage distance between all points on the end face of the inductor winding relative to the metal inductor housing, this required minimum creepage distance is also maintained for the core where the inductor coil bobbin is located. May be.

  The required minimum creepage distance value will depend on the actual application of the inductor assembly, for example, the potential difference between the respective components, the impurities in and on the surface of the potting material, and / or the respective configuration. Some parameters usually have to be taken into account, such as the environmental conditions that exist during the operation of the element. Suitable values for the required minimum creepage distance are well known to those skilled in the art. For example, the absolute value of the required minimum creepage distance between a raw component that is not insulated and the wall of the metal enclosure is 1.6 mm, depending on the peak value of the potential difference between the component and the metal enclosure, It can be 6.4 mm or 12.7 mm.

  In the inductor assembly according to the present invention, the coil lid may actually contact the metal inductor housing. Thus, they may be used, for example, to align the inductor coil within the metal inductor housing before filling with the potting material.

  In the inductor assembly according to the present invention, the coil lid-or the coil lid and the bobbin together-can completely cover the end face of the inductor winding, depending on the coil lid and the electrically insulating material of the bobbin. The whole end face is electrically insulated. Obviously, the coil lid and bobbin must overlap to provide the required minimum creepage distance between the end face and all points outside the cover. In such an embodiment, an electrical contact between the conductor of the inductor winding and an external electrical component or electronic component is provided between the coil lid and an electrical insulator covering the outer periphery of the inductor winding. Can be routed.

  In another embodiment of the present invention, the end of the inductor winding is completely removed except for the coil lid, or only the electrical contact window where the coil lid and bobbin together provide access to the inductor winding. Cover. This electrical contact window may be used in particular to connect the conductors of the inductor windings to external electrical or electronic components in the equipment in which the inductor assembly according to the present invention is used. . If a metal housing and a magnetic core are provided along any path that does not penetrate the coil lid or bobbin electrical insulation material, the distance of any point of the electrical contact window to the magnetic core is also at least the minimum required It is clear that there is a creepage distance.

  This creepage distance of the electrical contact window is, for example, at least partially framed by a continuous rib on the bobbin that extends through the opening in the lid of the adjacent coil, particularly with respect to the magnetic core. May be brought about in terms of being. Alternatively or in addition, the electrical contact window may be shielded by the ribs of the adjacent coil lid, particularly with respect to the metal housing.

  In the inductor assembly according to the present invention, the coil lid covers an area of the electrical insulator that covers the outer periphery of the inductor winding adjacent to the end face of the inductor winding. However, this does not mean that the coil lid completely covers the entire electrical insulator covering the outer periphery of the inductor winding. Rather, the coil lid does not specifically cover the area of the electrical insulator proximate to the end face and proximate to the metal inductor housing. Therefore, these uncovered areas of electrical insulation are not thermally separated from the metal inductor housing by the electrical insulation material of the coil lid, and the metal due to rapid heat transfer from the inductor winding to the metal inductor housing. It can be significantly better thermally coupled to the inductor housing. Specifically, thermal coupling can be achieved through direct contact of an uninsulated area of the electrical insulator with a heat transfer facilitating element that is simultaneously thermally coupled to the metal inductor housing.

  In one embodiment of the inductor assembly according to the present invention, the electrical insulator on the outer periphery of the inductor winding is provided by a continuous insulating foil surrounding the outer periphery of the inductor winding. The conductor winding may be a conductor foil, the conductor foil is wound on a bobbin together with the insulating foil, and the insulating foil is axial to prevent shorting between adjacent layers of the inductor winding In other words, it may be wound so as to extend beyond the conductor foil at both end faces of the inductor winding. However, the continuous insulating foil may also surround an inductor winding made of a lacquered conductor, such as, for example, a lacquered wire. For lower temperature applications, the insulating foil may be a polyvinyl chloride, polyethylene or rubber thermoplastic tape. For higher temperature applications, the insulating foil may be insulating paper. A suitable insulating foil thickness will typically be in the range of 25 μm to 100 μm.

  To facilitate heat transfer from the outer periphery of the inductor winding to the metal inductor housing, the outer periphery of the inductor winding is covered-not covered by the coil lid-between the area of electrical insulation and the metal inductor housing, At least one heat transfer promoting joining member may be provided. This heat transfer facilitating joining member may include, for example, a metal trunk wound so as to surround the circumference of the inductor winding. Alternatively, or in addition, the heat transfer facilitating joining member may be “C” shaped to cover only the three sides of the outer periphery of the inductor winding facing the inner surface of the pot-shaped metal inductor housing. Instead of a metal barrel, it is also possible to use a barrel made of another material with good thermal conductivity.

  If the inductor coil bobbin is arranged on the magnetic core, additionally or alternatively there may be at least one heat transfer facilitating joining member provided between the core area and the metal inductor housing. Good. For example, if there is no potential difference between the metal inductor housing and the magnetic core during operation of the inductor assembly, such as in the case of a PE grounded metal inductor housing and a PE grounded magnetic core, at least one heat The transmission facilitating joining member can advantageously be a metal element that is in direct contact with the magnetic core and the metal inductor housing, resulting in electrical conductivity between the magnetic core and the metal inductor housing. On the other hand, if there is a potential difference between the metal inductor housing and the magnetic core during operation of the inductor assembly, indirect contact to ensure good thermal coupling is sufficient to ensure sufficient electrical connection between both components. Combined with insulation advantageously. Such indirect contact prevents electrical connection between the metal inductor housing and the magnetic core and is provided by a thin insulating layer, such as a lacquer or thin insulating foil covering the outer surface of the magnetic core and / or metal inductor housing, for example. can do. A small gap between both components, advantageously filled with potting material, can be used as well. When the two inductor coil bobbins are coaxially disposed on the magnetic core, the at least one heat transfer facilitating joining member extends into the axial gap between the opposing end faces of the inductor windings of the two inductor coils. May be present.

  If the bobbins of the two inductor coils are arranged on the parallel legs of the magnetic core, i.e. side by side, the heat transfer facilitating joining members--alternatively or additionally-- It may be provided between the opposing areas of the electrical insulator covering the outer periphery of the inductor winding of the inductor coil. Such a heat transfer facilitating joining member is typically plate-shaped.

  In the inductor assembly according to the present invention, the optional heat transfer facilitating joining member may be either a protrusion or extension of the metal housing, or a separate element disposed within the metal inductor housing. However, such a separate element may be attached to, attached to, or glued to the metal inductor housing, or it may be disposed within the metal inductor housing along with the inductor coil or inductor coil It may be attached to, attached to, or glued to any component. For example, it may be a C-shaped element fastened on an electrical insulator that covers the outer periphery of the inductor winding of the inductor coil. The material of the separate elements is for example insulators, such as aluminum nitride, aluminum oxide and diamond, and for example aluminum, copper, brass, graphite, etc., or even if additional magnetic parameters are desired Can be any material with high thermal conductivity, including electrical conductors, such as iron.

  In the inductor assembly of the present invention, the two end faces of the inductor winding of each inductor coil are covered by two separate coil lids. However, the lids of these two coils may also cover the end face of the second inductor coil that is arranged side by side with the at least one inductor coil. On the other hand, the opposite end faces of two adjacent inductor windings of two coaxially arranged inductor coils will be covered by two separate coil lids. However, the separate coil lids inter-engage with each other in a predetermined manner, for example to align and / or maintain a predetermined distance between the two coaxially arranged inductor coils Or the like. They may also be configured to hold the core sections or legs of the inductor assembly.

  Advantageous developments of the invention result from the claims, the description and the drawings. The features mentioned at the beginning of the description and the advantages of the combination of features serve merely as examples and may be used alternatively or incrementally, and embodiments according to the present invention may be used. It does not require that these benefits have to be acquired. Without changing the scope of protection as defined by the enclosed claims, the following applies with respect to the disclosure of the original application and patent. That is, further features may be derived from the drawings, in particular from the design shown and the dimensions of the components relative to each other, as well as from their relative arrangement and their operational connections. Combinations of features of different embodiments of the invention or combinations of features of different claims independent of selected references of the claims are also possible and are motivated with them. This also relates to the features shown in the separate drawings or described in describing them. These features may also be combined with features of different claims. Furthermore, further embodiments of the invention may not have the features recited in the claims.

  The number of features stated in the claims and in the description includes this exact number and a number greater than the stated number without explicitly using the adverb “at least”. Should be understood. For example, when referred to as an inductor coil, this is understood to mean that there is exactly one inductor coil, or two inductor coils, or more inductor coils. It should be. Additional features may be added to these features, or the features of each product may be only these features.

  Reference signs included in the claims do not limit the scope of the matter protected by the claims. Their sole purpose is to make the claims more understandable.

  In the following, the invention will be further described and described with reference to preferred exemplary embodiments shown in the drawings.

FIG. 1 is a top view of a first embodiment of an inductor assembly according to the present invention before filling a potting material in a metal inductor housing of the inductor assembly. FIG. 2 separately shows the pot-shaped metal inductor housing of the inductor assembly according to FIG. FIG. 3 separately shows all components of the inductor assembly of FIG. 1 in a perspective view from below, except for the metal inductor housing according to FIG. FIG. 4 is a top view of another embodiment of an inductor assembly according to the present invention prior to filling the metal inductor housing of the inductor assembly with potting material and closing the metal inductor housing with a metal closure plate. is there. FIG. 5 separately shows one pair of inductor coils of the inductor assembly according to FIG. 4 surrounded by a dashed line in FIG. FIG. 6 is an exploded view of the inductor coil pair according to FIG. FIG. 7 separately shows a pot-shaped metal inductor housing of the inductor assembly according to FIG. FIG. 8 separately shows in perspective view all components of the inductor assembly shown in FIG. 4 except for the metal inductor housing portion shown in FIG. FIG. 9 is a top perspective view of a further embodiment of an inductor assembly according to the present invention before filling the potting material into the metal inductor housing of the inductor assembly. FIG. 10 is a longitudinal sectional view through the inductor coil of the inductor assembly according to the present invention in the first embodiment. FIG. 11 is a longitudinal sectional view through an inductor coil of the inductor assembly according to the present invention in the second embodiment. FIG. 12 is a partial longitudinal sectional view through an inductor coil of one embodiment of the inductor assembly according to the present invention, in which the position of the metal inductor housing and the position of the magnetic core of the inductor assembly are indicated.

  FIG. 1 shows a top view of an inductor assembly 1 before filling a potting material in a metal inductor housing 2 surrounding a plurality of inductor coils 3. Here, six inductor coils 3 are shown. Each conductor coil 3 comprises an inductor winding 4 covered by an electrical insulator 5 made of continuous insulating foil. The conductor of each inductor winding 4 is wound on a bobbin that is not within the field of view of FIG. The bobbins of all six inductor coils 3 are arranged on a common core 6 consisting of longitudinal sections and vertical sections 7 each extending inside one of the bobbins. The longitudinal sections are arranged in parallel pairs. These pairs are separated by a vertical section 7, and further vertical sections 7 are arranged at both ends of the magnetic core 6. The section of the magnetic core 6 extends through the end element 10 and is held together by a double-headed pull screw 8 into which a nut 9 is screwed. The basic arrangement of the inductor coil 3 on the common magnetic core 6 of the inductor assembly 1 may be the same as that disclosed in International Publication No. 2013/170906 A1.

  The end faces of each pair of inductor windings 4 of the inductor coil 3 arranged side by side on one parallel pair of the longitudinal sections of the magnetic core may be the same as the electrically insulating material of the bobbin of the inductor coil 3. Covered by a pair of coil lids 11 made of an electrically insulating material. The coil lid 11 also covers the area of the outer periphery of the inductor winding 4 covered by the electrical insulator 5. Thus, the coil lid 11 ensures that all points on the end face of the inductor winding 4 maintain the required minimum creepage distance to the metal inductor housing 2 and also the minimum clearance. Along with the bobbin carrying the inductor winding 4, the coil lid 11 also ensures that the required minimum creepage distance and minimum clearance are maintained for the magnetic core 6, in particular for the vertical section 7 of the magnetic core 6. To.

  However, the coil lid 11 does not cover the main part of the electrical insulator 5 and therefore the main part of the outer periphery of the inductor winding 4. Instead, the heat transfer facilitating joining member 12 thermally couples this major portion of the outer periphery of the inductor winding 4 remaining uncovered by the coil lid 11 to the metal inductor housing 2. Additional heat transfer facilitating joining members 13 extend between each pair of coaxially arranged inductor coils 3 to thermally couple the magnetic core 6 to the metal inductor housing 2. An additional heat transfer facilitating joining member 14 extends between the opposing outer peripheries of each pair of inductor windings 4 of the inductor coils 3 arranged side by side, with adjacent areas of the outer peripheries of the inductor windings 4 in the metal inductor It is thermally coupled to the bottom of the housing 2. The pull screw 8 extends through these heat transfer enhancing joining members 14 and secures them. The coil lid 11 comprises a magnetic core retaining extension 15 that partially surrounds the vertical section 7 of the magnetic core 6 and thus holds them. The core holding extensions 15 of the facing coil lids 11 covering the end faces of the inductor coils 3 adjacent in the axial direction are configured such that they overlap each other in the axial direction. It is also possible to ensure a predetermined distance between the axially adjacent inductor coils 3 by designing a dedicated shape matching element on the core holding extension 15.

  The inductor assembly 1 according to FIG. 1 is not yet completed. It will be completed by filling a potting material that surrounds the inductor coil 3 in the metal inductor housing 2 and thermally couples the inductor coil 3 to the metal inductor housing 2. Furthermore, the electrical contacts to the inductor winding 4 that extend through the potting material when filled in the inductor housing 2 are not shown in FIG. In particular, the contact wire to the inductor winding 4 may extend from the end face of the inductor winding 4 between the coil lid 11 and the electrical insulator 5 and then bend upward and out of the potting material. It may be reached. The thermal coupling provided by the heat transfer facilitating joining members 12, 13, 14 ensures an optimized heat transfer from the inductor coil 3 to the metal inductor housing 2. In addition, heat transfer is not governed by the potting material and therefore does not depend on the thermal conductivity of the potting material. As a result, the potting material can be designed primarily to have a low viscosity to fill small gaps during the potting process.

  The inductor housing 2 shown separately in FIG. 2 includes cooling ribs 24 on the outside thereof. In its interior, the inductor housing 2 comprises contact areas 16 and 17 for heat transfer facilitating joining members 12 and 13. Within these contact areas 16 and 17, the metal inductor housing 2 may be covered by some heat transfer material, such as a heat transfer paste, and / or heat transfer enhancement prior to inserting the heat transfer enhancement joining member. The joining members 12 and 13 may be glued to the contact areas 16 and 17.

  The bottom perspective view according to FIG. 3 shows the location of the heat transfer promoting joining members 12 and 13 with respect to the inductor winding 4 and the magnetic core 6. Instead of the C-shaped heat transfer facilitating joining member 12, each pair of inductor coils 3 arranged side by side could be provided with a continuous metal shell.

  The embodiment of the inductor assembly 1 according to FIG. 4 comprises a metal inductor housing 2 which will be closed by a metal closure plate or any other metal closure not shown here. Furthermore, an electrical contact window 18 for contacting the inductor winding 4 of the inductor coil 3 is provided. 5 and 6 showing the following details, one pair of inductor coils 3 covered by a common coil lid 11 is shown separately. For the magnetic core 6, the electrical contact window 18 is framed by ribs 19 on the bobbin 20 to maintain the required minimum creepage distance and spatial distance at any point of the electrical contact window 18 relative to the magnetic core 6. With respect to the metal closure plate of the metal inductor housing 2, the electrical contact window 18 is shielded by the ribs 21 of the adjacent coil lid 11 and the required minimum creepage distance and space at any point of the electrical contact window 18 relative to the metal closure plate. Maintain distance. Here, maintaining a minimum spatial distance would be a more important aspect. Advantageously, the ribs 21 of the adjacent coil lids 11 engage and / or overlap one another. Instead of maintaining a predetermined distance between the axially adjacent inductor coils 4 by using direct contact between the shape-matching elements of the core retaining extensions 15 of the adjacent coil lids 11, alternatively, Alternatively, it is possible to maintain the predetermined distance by using direct contact between the conformal elements disposed on the ribs 21 of the adjacent coil lid 11 progressively. These details will be better appreciated from FIG. 8 described below. The coil lid 11 additionally comprises a tubular projection 23 surrounding the pull screw 8, where the pull screw 8 extends through the coil lid 11. This ensures that the necessary minimum creepage distances and clearances at all points on the end face of the inductor winding 4 are maintained for the lead screw 8 as well. Furthermore, here, the heat transfer promoting joining member 14 extends only between the pull screws 8. That is, they are not provided with a through hole for the pull screw 8 as in the embodiment of FIGS. Nevertheless, they transport heat from between two adjacent inductor coils 3 to the metal inductor housing 2.

  5 and 6, it is shown that the coil lid 11 is configured to be attached to the inductor coil 3 in the axial direction of the inductor coil 3. In other words, looking at the illustrated embodiment, the lid 11 of each coil is attached to the respective end face 27 of the inductor coil 3 from above and from below. It is thus ensured via the coil lid 11 that the two parallel-oriented inductor coils 3 are positioned relative to each other in a predetermined axial direction. Coil lids 11 attached to their respective inductor coils 3 from the axial direction of the inductor coil 3 are shown for a common coil lid 11 attached simultaneously to two inductor coils 3. However, similarly, a coil lid 11 for a single inductor coil 3 is also preferably attached to the inductor coil 3 from the axial direction of the inductor coil 3. The coil lid 11 is either formed as a cup-like structure that completely covers the sides of the bobbin 20 having only an opening for the magnetic core 6 and provides the desired overlap on the electrical insulator 5 or the bobbin 20. It may be formed as a ring-like structure that covers the outer portion of just the right side of and provides the desired overlap. Other shapes can also be contemplated.

  FIG. 7 shows in more detail that the heat transfer facilitating joining members 12 and 13 are now part of the metal inductor housing 2. Furthermore, a mounting point 22 is provided for mounting the subassembly according to FIG. 6 to the metal inductor housing 2 according to FIG. 4 with screws.

  FIG. 8 is a perspective view of the inductor coil 3 according to FIG. 4 excluding the metal inductor housing 2 and disposed on the common magnetic core 6. Here, the entire arrangement of the inductor coils 3 and their common magnetic core 6 is fixed by the end element 10, the lead screw 8 and the nut 9 before inserting the inductor coil 3 into the metal inductor housing 2.

  The embodiment of the inductor assembly 1 according to FIG. 9 is the same as that shown in FIGS. The only difference here is that the metal closing plate is not used to close the metal inductor housing 2, so that the electrical contact window 18 is against the open side of the metal inductor housing 2 by the rib 21 of the coil lid 11. It is not shielded.

  FIG. 10 shows in more detail how the inductor winding 4 of the inductor coil 3 of the inductor assembly 1 according to the invention can be wound around the bobbin 20. In this embodiment, the conductor 25 of the inductor winding 4 has a foil shape, and individual layers of the conductor 25 are separated by an insulating foil 26. The insulating foil 25 made of an electrically insulating material also forms an electrical insulator 5 that covers the outer periphery of the inductor winding 4. The width of the insulating foil 26 is larger than the width of the foil-like conductor 25, and the insulating foil 26 extends beyond the conductor 25 on both end faces 27 of the inductor winding 4. Therefore, the individual layers of conductor 25 are sufficiently electrically isolated from one another. In addition to the bobbin 20, a coil lid 11 of electrically insulating material is also provided to provide the necessary minimum creepage distance 28 for any metal inductor housing in which the inductor coil 3 will be placed. . Like the bobbin 20, the coil lid 11 is also made of an electrically insulating material and covers the end face 27 of the inductor winding 4 alone or at least together with the bobbin 20. The coil lid 11 also covers the adjacent area of the electrical insulator 5 that covers the outer periphery of the inductor winding 4. By covering with the coil lid 11 as described above, at any point of the end face 27 of the inductor winding 4 to the metal housing 2 along any path that does not penetrate the electrical insulation material of the coil lid 11 or bobbin 20. It is ensured that the distance is at least the minimum required creepage distance 28.

  The creepage distance between two conductor portions typically does not penetrate the insulating bulk material at all and is the shortest distance of any possible surface-direction path between these conductor portions along the insulator surface. is there. FIG. 10 illustrates by way of example one possible creepage distance between the inductor winding 4 and the metal inductor housing 2 that does not penetrate the electrical insulation material of the electrical insulator 5, bobbin 20 and coil lid 11. Yes. Through the design of the coil lid 11, the creepage distance 28 is maintained longer than the minimum required creepage distance 28. This will be described in more detail below.

  By looking at FIG. 10, any leakage path that may occur—and in particular any leakage path starting from the end face 27 of the inductor winding 4 —is electrically insulated over the coil lid 11 and the outer periphery of the inductor winding 4. It will be apparent that they are guided along overlapping sections between adjacent areas of the body 5. Therefore, the creepage distance can be intentionally changed by changing the overlapping section. For example, reducing the overlapping section of the coil lid 11—and optionally further increasing the width of the heat transfer facilitating joining member 12—provides a decrease in creepage distance, whereas Increasing the overlapping section of the coil lid 11—and optionally further reducing the width of the heat transfer enhancing joining member 12—provides an increase in creepage distance. Thus, by changing the design of the coil lid 11, particularly with respect to its overlapping section, it can be ensured that any possible leakage path that may occur includes the required minimum creepage distance 28. The value of the minimum creepage distance 28 depends on the particular application, in particular on the peak value of the potential difference between the inductor coil 3 and the metal inductor housing 2. The value of the minimum required creepage distance 28 is specified in the specification and is therefore known to those skilled in the art. The same principle explained above with respect to creepage distances also applies to spatial distances.

  In the embodiment of the inductor coil 3 of FIG. 11, the conductor 25 is an electric wire having a lacquer insulator. The lacquer insulator is sufficient to electrically insulate the individual turns of the wires from each other. However, a separate electrical insulator 5 made of insulating foil is provided for the electrical insulator on the outer periphery of the inductor winding 4. Alternatively, the conductor 25 is foil-like and has a lacquer insulator that insulates the individual turns of the wire from each other and can have a separate electrical insulator 5 at the outer periphery of the inductor winding 4. I will. In this case as well, the coil lid 11 is formed between the inductor winding 4 and an arbitrary metal inductor housing 2 in which the inductor coil 3 is disposed, particularly considering the end face 27 of the inductor winding 4. It helps to ensure the required minimum creepage distance 28 between. The creepage distance between the end face 27 and such a metal inductor housing is again, as before, not extending through the electrical insulation material of the electrical insulator 5, bobbin 20 and coil lid 11. Its shortest distance between.

  The embodiment according to FIG. 12 incorporates the embodiment of the inductor coil 3 of FIG. In addition, the entire outer periphery of the inductor winding 4 that is not covered by the coil lid 11 outside the electrical insulator 5 may be surrounded, and the role of the heat transfer facilitating joining member 12 for the metal inductor housing 2 indicated in FIG. A metal body wrap 29 is shown which performs This metal winding 29 does not affect the required minimum creepage distance 28 maintained against the metal inductor housing 2 by the coil lid 11. The coil lid 11, along with the bobbin 20, also serves to maintain the required minimum creepage distance 28 relative to the core 6, even where the vertical section 7 of the core 6 extends along the end face 27 of the inductor winding 4. .

  In addition, the embodiment shown in FIGS. 11 and 12 intentionally increases the creepage distance by changing the overlapping section between the coil lid 11 and the adjacent area of the electrical insulator 5 covering the outer periphery of the inductor winding 4. Provide alternatives to change. Accordingly, the creepage distance changing principle described above with respect to FIG. 10 can also be applied to the embodiment shown in FIGS. 11 and 12.

DESCRIPTION OF SYMBOLS 1 Inductor assembly 2 Metal inductor housing 3 Inductor coil 4 Inductor winding 5 Electrical insulator 6 Magnetic core 7 Vertical section 8 Pull screw 9 Nut 10 End element 11 Coil lid 12 Heat transfer promotion joining member 13 Heat transfer promotion joining member 14 Heat transfer promoting joining member 15 Extension 16 Contact area 17 Contact area 18 Electrical contact window 19 Rib 20 Bobbin 21 Rib 22 Mounting point 23 Projection 24 Cooling rib 25 Conductor 26 Insulating foil 27 End face 28 Required minimum creepage distance 29 Metal body winding

Claims (17)

  1. In at least one inductor coil (3), the inductor coil (3)
    In an inductor winding (4) made of a bobbin (20) made of an electrically insulating material and a conductor (25) wound on the bobbin (20),
    The inductor winding (4) has an outer periphery and two end faces (27), an inductor winding (4), and an electrical insulator (5) covering the outer periphery of the inductor winding;
    An inductor coil (3) including:
    A metal inductor housing (2) at least partially surrounding the inductor coil (3);
    A potting material that contacts both the inductor coil (3) and the metal inductor housing (2) and thermally couples the inductor coil (3) to the metal inductor housing (2);
    In an inductor assembly (1) comprising:
    A coil lid (11) made of an electrically insulating material is provided in the electrical insulator (5) covering the end face (27) of the inductor winding (4) and the outer periphery of the inductor winding (4) . The metal inductor along any path that at least partially covers a region adjacent to the end face (27) , thereby not penetrating the electrically insulating material of the coil lid (11) or the bobbin (20). The distance from any point of the end face (27) of the inductor winding (4) to the housing (2) is at least the required minimum creepage distance (28) ,
    The inductor assembly (1), wherein the coil lid (11) contacts the metal inductor housing (2 ).
  2.   The inductor assembly (1) according to claim 1, wherein the bobbin (20) is disposed on a magnetic core (6) and does not penetrate the electrically insulating material of the lid (11) of the coil or the bobbin (20). A further distance at any point of the end face (27) of the inductor winding (4) to the magnetic core (6) along an arbitrary path is at least the required minimum creepage distance (28). Inductor assembly (1).
  3.   Inductor assembly (1) according to claim 1 or 2, characterized in that the required minimum creepage distance is 1.6 mm, 6.4 mm or 12.7 mm.
  4. 4. The inductor assembly (1) according to any one of claims 1 to 3 , wherein the coil lid (11) or the coil lid (11) together with the bobbin (20) is the inductor winding. An inductor assembly (1) characterized by completely covering the end face (27) of (4).
  5. 4. The inductor assembly (1) according to any one of claims 1 to 3 , wherein the coil lid (11) or the coil lid (11) together with the bobbin (20) is the inductor winding. An inductor assembly (1) characterized in that it completely covers the end face (27) of the inductor winding (4) except for an electrical contact window (18) that provides access to (4).
  6. The inductor assembly (1) according to claim 5 , wherein the electrical contact window (18) extends through an opening in a coil lid (11) adjacent to the bobbin (20). An inductor assembly (1), characterized in that it is at least partially framed by a rib (19) of 20).
  7. 7. Inductor assembly (1) according to claim 5 or 6 , wherein the electrical contact window (18) is relative to the metal inductor housing (2) and / or a metal closure plate of the metal inductor housing (2). In contrast, the inductor assembly (1) is shielded by a rib (21) of a coil lid (11) adjacent to the bobbin (20 ).
  8. The inductor assembly (1) according to any one of claims 1 to 7 , wherein the coil lid (11) covers the electrical insulator (5) covering the outer periphery of the inductor winding (4). Inductor assembly (1), characterized in that it is only partially covered.
  9. 9. The inductor assembly (1) according to any one of claims 1 to 8 , wherein the electrical insulator (5) on the outer periphery of the inductor winding (4) is the inductor winding (4). Inductor assembly (1), characterized in that it is provided by a continuous insulating foil (26) surrounding the outer periphery .
  10. The inductor assembly (1) according to claim 9, wherein the conductor (25) is a conductor foil, and the conductor foil is wound on the bobbin (20) together with the insulating foil (26), and the insulating An inductor assembly (1) characterized in that the foil (26) extends in the axial direction beyond the conductor foil.
  11. 11. Inductor assembly (1) according to any one of the preceding claims, wherein the area of the electrical insulator (5) covering the outer circumference of the inductor winding (4) and the metal inductor housing (2). ), At least one heat transfer promoting joining member (12) is provided.
  12. 12. Inductor assembly (1) according to claim 11, wherein the heat transfer promoting joining member (12) comprises a metal shell (29) surrounding the outer circumference of the inductor winding (4). Assembly (1).
  13. 13. Inductor assembly (1) according to any one of the preceding claims, wherein the bobbin (20) is arranged on the magnetic core (6), the area of the magnetic core (6) and the metal inductor housing ( 2), an inductor assembly (1), wherein at least one heat transfer facilitating joining member (13) is provided.
  14. Inductor assembly (1) according to any one of the preceding claims, wherein the bobbins (20) of two inductor coils (3) are arranged on parallel sections of the magnetic core (6), At least one heat transfer facilitating joining member (14) is provided between the opposing areas of the electrical insulator (5) covering the outer circumference of the inductor winding (4) of the two inductor coils (3). An inductor assembly (1) characterized by:
  15. 15. The inductor assembly (1) according to any one of claims 11 to 14 , wherein the heat transfer facilitating joining member (12, 13, 14) is a protrusion of the metal inductor housing (2) and the metal. An inductor assembly (1), comprising at least one of separate metal elements disposed in the inductor housing (2).
  16. 16. Inductor assembly (1) according to any one of the preceding claims, wherein at least one coil lid (11) is adjacent to two inductor coils (3) arranged side by side. Covering said end face (27) of the combined inductor winding (4) and / or a separate coil lid (11) of two adjacent inductor windings (4) of two inductor coils (3) An inductor assembly (1), characterized in that it is provided for each of two opposite end faces (27).
  17. The inductor assembly (1) according to any one of claims 1 to 16 , wherein the coil lid (11) is attached to the inductor coil (3) from an axial direction of the inductor coil (3). An inductor assembly (1) characterized by comprising:
JP2016572755A 2014-06-19 2015-06-15 Inductor assembly comprising at least one inductor coil thermally coupled to a metal inductor housing Active JP6588042B2 (en)

Priority Applications (3)

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EP14173136.4 2014-06-19
EP14173136.4A EP2958118A1 (en) 2014-06-19 2014-06-19 Inductor assembly comprising at least one inductor coil thermally coupled to a metallic inductor housing
PCT/EP2015/063361 WO2015193252A1 (en) 2014-06-19 2015-06-15 Inductor assembly comprising at least one inductor coil thermally coupled to a metallic inductor housing

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Also Published As

Publication number Publication date
EP2958118A1 (en) 2015-12-23
EP3158567B1 (en) 2019-12-11
CN106463244B (en) 2018-09-18
JP2017522724A (en) 2017-08-10
CN106463244A (en) 2017-02-22
WO2015193252A1 (en) 2015-12-23
EP3158567A1 (en) 2017-04-26

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