WO2018037029A2 - Inducteur électrique isolé et son agencement d'étanchéité isolé - Google Patents

Inducteur électrique isolé et son agencement d'étanchéité isolé Download PDF

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Publication number
WO2018037029A2
WO2018037029A2 PCT/EP2017/071193 EP2017071193W WO2018037029A2 WO 2018037029 A2 WO2018037029 A2 WO 2018037029A2 EP 2017071193 W EP2017071193 W EP 2017071193W WO 2018037029 A2 WO2018037029 A2 WO 2018037029A2
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WO
WIPO (PCT)
Prior art keywords
insulated
sealing arrangement
inductor
arrangement according
system sheet
Prior art date
Application number
PCT/EP2017/071193
Other languages
English (en)
Other versions
WO2018037029A3 (fr
Inventor
Michael Feller
Jim CLAERBOUT
Original Assignee
Danfoss Power Electronics A/S
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 Danfoss Power Electronics A/S filed Critical Danfoss Power Electronics A/S
Publication of WO2018037029A2 publication Critical patent/WO2018037029A2/fr
Publication of WO2018037029A3 publication Critical patent/WO2018037029A3/fr

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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
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • H01F27/2828—Construction of conductive connections, of leads
    • 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
    • H01F27/06—Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H01F27/2852—Construction of conductive connections, of leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/06—Insulation of windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F2027/297—Terminals; Tapping arrangements for signal inductances with pin-like terminal to be inserted in hole of printed path

Definitions

  • Embodiments of the present invention generally relate to the technical field of electrical power devices such as those inductors for used in electrical power conversion and rectification of AC/DC and/or DC/ AC power for variable frequency drives; and in particular, to insulated inductors that include coil windings and sealing arrangement thereof; and more particularly to an insulated sealing arrangement of windings thereof.
  • circuitry In the field of power electronic devices, a wide range of circuitry is known and currently available for converting, producing and applying power to loads. Depending upon the invention, such circuitry may convert incoming power from one form to another as needed by the load. In a typical arrangement, for example, constant (or varying) frequency alternating current power (such as from a utility grid or generator) is converted to controlled frequency alternating current power to drive motors, and other loads. In this type of invention, the frequency and voltage of the output power may be regulated to control the speed of the motor or other device. Many other inventions exist, however, for power electronic circuits that convert alternating current power to direct current power, or vice versa, or that otherwise manipulate, filter, or modify electric signals for powering a load.
  • constant (or varying) frequency alternating current power such as from a utility grid or generator
  • the frequency and voltage of the output power may be regulated to control the speed of the motor or other device.
  • Circuits of this type generally include rectifiers (converters), inverters, and power conditioning circuits.
  • a motor drive will typically include a rectifier that converts AC voltage to DC.
  • Inverter circuitry then converts the DC voltage into an AC voltage of a particular frequency desired for driving a motor at a particular speed.
  • power conditioning circuits for example, electrical power conversion and rectification of AC/DC and/or DC/AC power for variable frequency drives, especially the low profile inductive coils 100 which consist of flat sheet(s) wound with NOMEX paper insulating each turn and overlapping on inductor iron core with much less thickness, as shown in Fig.
  • insulated inductor is an open architecture circuit assembly essentially with no enclosure rating, which fails to provide dustproof and waterproof sealing during normal operation. And the overlapping arrangement of wound turns of coils on the iron core may generate and accumulate significant levels of heat, thus resulting in the risk of overheating of the coils.
  • an electrical insulation system with sealing property is developed to achieve the required sealing rating, as in Fig. 2.
  • coil windings are enclosed by UL rated injection molded plastic cup 101, thus facilitating certain level (e.g., IP54 / Nema Type 12) of dustproof and waterproof enclosure, i.e., to provide certain level of resistance to entrance of dusty gas and slight splash-proof protection performance in various directions during operation.
  • certain level e.g., IP54 / Nema Type 12
  • such sealing arrangement further introduces high thermal resistance between winding and air, thus resulting in significant thermal penalty which requires the design of related components to increase margin and thus cost.
  • the present invention has been made to overcome or alleviate at least one aspect of the above mentioned disadvantages and/or shortcomings existing in the conventional technical solutions.
  • an insulated electrical inductor comprising: at least one coil winding spirally wounded as a plurality of turns, outer surfaces of which are processed by an insulation disposal, each coil winding being provided with two terminal leads respectively at either end thereof, both being configured to be directed outwards the inductor along a single direction in a plane parallel to the plurality of turns; each of the terminal leads is configured to be terminated with a bare conductive terminal connection respectively, lower surfaces of all terminal connections being aligned to be co-planar, and the terminal connections are covered and sealed immediately adjacent to the aligned lower surfaces, collectively by a waterproof and dustproof insulative sealing.
  • the insulation disposal is completed by application of powder coating onto the outer surface of the turns of the coil windings.
  • the powder coating is electrically insulated but thermally conductive.
  • the powder coating is formed by a material chosen from a group comprising resin, ceramics, and any metallic oxide, metallic nitride, high-molecular polymer which material is electrically insulated and thermally conductive, or combination thereof.
  • the seal is detachable from the terminal connections.
  • an insulated sealing arrangement of coil windings of the inductor comprising: a system sheet provided with a plurality of through-holes, by which system sheet the inductor is covered and sealed from an exposed side thereof, the system sheet being configured to function as a cover plate for covering the inductor; and a plurality of removable seals, each of which is positioned between each terminal lead and respective one of the through-hole and comprises: a base seat portion, which has a lower surface seated against from outside of the turns of the inductor and an upper surface configured to abut against an lower surface of the system sheet; a cylinder portion, which extends vertically from the upper surface of the base seat portion; and a through-channel, which passes through the base seat portion and the cylinder portion centrally.
  • the cylinder portion has an outer diameter smaller than that of the base seat portion and substantially equal to or slightly less than an diameter of the respective through-hole for passing therethrough; and the through-channel has an inner diameter substantially equal to or slightly larger than an diameter of the respective terminal lead for passing the terminal lead through.
  • the each of the plurality of removable seals is made of a UL approved plastic material.
  • an additional bonding layer is provided between the upper surface of the base seat portion and the lower surface of the system sheet.
  • the insulated sealing arrangement further comprises a plurality of first mounting holes distributed around the cylinder portion on the base seat portion, and a plurality of second mounting holes distributed around each through-hole on the system sheet on a surface thereof facing towards the system sheet.
  • the plurality of first mounting holes have same number, shape and distribution pattern as those of the plurality of second mounting holes.
  • the plurality of first mounting holes and their respective second mounting holes are aligned with each other, in pairs, and is secured by inserts passing through each pair of the fist and the second mounting holes.
  • each seal is configured to be an interlocked sealing assemble, being configured to be in a form of a hollow cylindrical boss and comprises two opposite identical semi-cylindrical boss halves fitted together; and each semi-cylindrical boss half of each interlocked sealing assemble has sealing surfaces comprising: two end surfaces for aligning and fitting with respective end surfaces of opposite half, a upper surface for sealing against the lower surface of the system sheet, and a semi-cylindrical inner surface for fitting with the respective semi-cylindrical inner surface of the opposite halve so as to enclose and seal against the outer surface of the terminal lead.
  • each end surface of each half is provided with a central hole for insertion of coupling member therethrough.
  • a coupling member is inserted the central holes of opposite end surfaces for facilitating assembly of the two halves.
  • each interlocked sealing assemble is in a form of a hollow stepped cylindrical boss of two co-axial cylinders superimposed on each other.
  • each semi-cylindrical boss half essentially comprises a semicircular base portion and a upper semicircular flange which has a smaller outer diameter than that of the base portion, and the base seat portion consists of two semicircular base portions fitted in pairs, while the cylinder portion consists of two upper semicircular flanges fitted in pairs.
  • the sealing surfaces are flat and smooth surfaces.
  • the sealing surfaces are surfaces with textures, bumps, and knurls.
  • each of the through-hole is configured to be in the form of a tapered hole while the upper flange is correspondingly formed as a semi-frustum shaped construction which fits into the tapered hole.
  • each interlocked sealing assemble comprises two individual hollow cylinder members disposed on opposed sides of respective through-hole on the system sheet, respectively, which are fitted together in a positive fit manner and each of which is also formed by two mirror- symmetric halves.
  • the system sheet is sandwiched between the two individual hollow cylinder members.
  • each interlocked sealing assemble is configured to be in a form of a construction chosen from a group comprising any stepped boss, frustum construction or combination thereof.
  • a novel insulated inductor and an insulated sealing arrangement thereof are provided, which can provide a waterproof and dustproof sealing to some extent which ensures normal operation of a inductor under dusty and slight splash water environment, meeting or even exceeding requirement of UL Type 12 and IEC IP54, while also maintains thermally conductive with outer environment to facilitate dissipation of heat produced by the coil windings of the inductor to eliminate any failure therefrom.
  • Fig. 1 is a perspective view showing an electrical insulation inductors arrangement consisting of flat sheet wound with nomex paper insulating each turn;
  • FIG. 2 is another perspective view showing an electrical insulation enclosure of inductors for IP54/Nema Type 12 rating of the inductor arrangement as shown in Fig. 1;
  • FIG. 3 illustrates a schematic perspective view of exemplary improved insulated inductor windings, with optimal dimension, according to an embodiment of the present invention
  • Fig.4 is a partially perspective view of an improved insulation enclosure of inductors, with the system sheet removed for clarity, which exceeds requirements for IP54/Nema Type 12 rating and provided with much lower thermal resistance, containing the whole insulated inductor windings as in Fig. 3;
  • FIG.5 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to an exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the system sheet, via a two-piece base seat portion;
  • FIG.6a-6c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the system sheet, according to the exemplary embodiment of the invention as illustrated in Fig. 5;
  • Fig.7 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to another exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the system sheet, via a one-piece base seat portion;
  • FIG.8a-8c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the system sheet, according to the exemplary embodiment of the invention as illustrated in Fig. 7;
  • Fig.9 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to still another exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the system sheet, via another one-piece base seat portion;
  • Fig.10a- 10c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the system sheet, according to the exemplary embodiment of the invention as illustrated in Fig. 9.
  • FIG. 3 illustrates a schematic perspective view of exemplary improved insulated inductor windings, with optimal dimension, according to an embodiment of the present invention
  • Fig.4 is a partially perspective view of an improved insulation enclosure of inductors, with the system sheet removed for clarity, which exceeds requirements for IP54/Nema Type 12 rating and provided with much lower thermal resistance, containing the whole insulated inductor windings as in Fig. 3.
  • an insulated electrical inductor comprising at least one coil winding (e.g., a set of three coil windings 12, 12', 12" as illustrated) spirally wounded as a plurality of turns, outer surfaces of which are processed by an insulation disposal, each coil winding being provided with two terminal leads 13 respectively at either end thereof, both being configured to be directed outwards the inductor along a single direction in a plane parallel to the plurality of turns; each of the terminal leads 13 is configured to be terminated with a bare conductive terminal connection 121, 122 respectively, lower surfaces 14 of all terminal connections 121, 122 being aligned to be co-planar, and the terminal connections are covered and sealed immediately adjacent to the aligned lower surfaces 14, collectively by a waterproof and dustproof insulative sealing.
  • coil winding e.g., a set of three coil windings 12, 12', 12" as illustrated
  • each coil winding being provided with two terminal leads 13 respectively at either end thereof, both being configured to be directed outwards the inductor along a
  • an improved insulated electrical inductor 1 comprising a core frame 11 and at least one coil winding 12 wound thereon.
  • the core frame 11 which may be a ferrite core, comprises three core legs 110, 111, 112 arranged in parallel for winding coils respectively thereon to form an inductive element, and further comprises two end bars 113, 113' each of which is orthogonal to and jointed with the corresponding neighboring ends of each of the legs 110,111,112, respectively, so as to form a closed frame 11.
  • Some through-holes are formed on both of the end bars so as to facilitate the installation of the inductor element in place.
  • each of the core legs 110, 111, 112 there is a coil winding wound spirally thereon.
  • a coil winding 12 is wound spirally around the central core leg 110, i.e., the coil winding 12 has a plurality of turns aligned/registered in the longitudinal direction of the core leg 110.
  • each of the side core legs 111 and 112 has a coil winding 12" or 12' spirally wound thereon and extending longitudinally, respectively.
  • both terminal leads 13 of the same coil winding are oriented orthogonal to a plane within which the three parallel core legs are positioned, and on a same side of the plane for facilitating the connection of both terminal leads 13 to PCB.
  • All of these coil windings 12, 12', 12" are achieved with the use of round stock which is bent as a plurality of aligned/registered turns spirally wound and connected in series, with adjacent turns being spaced apart in the longitudinal direction of respective core leg but without any sharp edges at either corner of each turn.
  • This winding structure contributes to a slimmer structure of inductive coil windings, due to the single-turn layer thickness around the core leg, as compared with another common inductor winding structure with a plurality of winding turns overlaid/superimposed one on another which are insulated by interposed insulation paper or insulation coating, since the latter has winding thickness of multiple-turns.
  • copper can be a preferred material suitable for windings but other conductive materials can be used, alternatively.
  • core frame materials other than ferrite including iron laminations or tape wound amorphous materials can also be utilized.
  • an approved powder coating is applied onto each coil winding.
  • the use of powder coating is especially advantageous owing to the thin but uniform thickness which can be achieved while still providing necessary insulation between respective adjacent turns in a winding.
  • the good thermal conductivity of the powder coating is especially advantageous as this allows a good heat outflow from the heat generating windings, for example, through and/or out of the holding shell of the inductor and in turn to a heat sink or to atmosphere.
  • a homogenous powder coating can be applied thinly on the core leg, and the specific thickness thereof can be varied depending upon the application to which the winding is to be put, be it a high or a low voltage specification.
  • powder coated windings can have larger power handling capability whilst maintaining a low profile and a lower operating temperature.
  • the powder coating is formed of insulation but thermal conductive material, such as resin, ceramic, and the like.
  • the powder coating is formed by a material such as resin, ceramics, and any metallic oxide, metallic nitride, high-molecular polymer which material is electrically insulated and thermally conductive, or combination thereof.
  • powder coating can be applied by various processes.
  • the powder may be applied a number of times in succession, in the form of individual layers which follow one another, until a layer of certain upper thickness is reached, and each of the individual layers undergoes intermediate heat curing before the next individual is applied. Finally, the entire insulation undergoes final curing.
  • powder coating can also be manufactured in other way.
  • bare electrically conductive coil is first bathed in a mild acidic solution for cleaning and removing of any impurities thereon, and then supported on a coating frame extending therethrough.
  • the bare coil winding is transported to a coating station where the entire coil winding is coated with an insulative powder coating material ejected from a delivery device such as a nozzle.
  • the powder coating material comprises a high temperature epoxy, or other alternative suitable high temperature insulated material.
  • the powder coating material is then electrostatically charged so as to be attracted to the electrically grounded bare coil such that, once the powder coating material is ejected from the delivery device in naturally gravities towards and adheres to all surfaces of the coil winding. And to ensure complete coverage of each coil turn, each turn are separated by for example a gap from one another.
  • the coating material at the terminal leads of each coil winding is removed, for example, through the use of a vacuum source from which the powder coating material can be suctioned away from the surface of the coil winding.
  • a vacuum source from which the powder coating material can be suctioned away from the surface of the coil winding.
  • the terminal leads may instead be masked prior to the powder coating application step, if desired.
  • the powder coated coil winding is transported to an oven or a heat source to be heated to a high temperature and in turn cooled to effect partial cure of the powder coating. Such procedures are repeated twice or more to obtain complete curing of the powder coating material on the winding(s).
  • an inductor with electrically insulated but thermal conductive coil winding(s) can be obtained by the application of powder coating thereon. And it is suitable for operating in a relatively clean environment, for example, dust-free and water-free environment, without any additional enclosure/protection element, due to its electrical insulating, moisture-proof and fine thermal conductive property, and can also be suitable for working in limited space due to its relatively compact structure and dimension.
  • each coil winding has two bare terminal connections, one per end.
  • the bare conductive terminal connections are electrically conductive, either being not processed by an insulation process (e.g., application of insulative powder coating) or being removed of any additional insulative coating therefrom.
  • the central coil winding 12 wound on the central core leg 110 has two terminal connections 121, 122 at both sides, respectively.
  • each of the terminal connections 121, 122 is formed by the previous terminal leads at both ends, by being pressed as a flat and round or oval shaped insulated piece and then bored thereon to form an electrically conductive hole centrally in the piece, so as to form the electrical conductive pin to external circuit such as PCB.
  • the terminal connections are bare terminals, with lower surfaces 14 thereof being arranged to align with one another, i.e., to be co-planar, the terminal connections are in turn covered and sealed immediately adjacent to the aligned lower surfaces 14, collectively by a waterproof and dustproof insulative sealing; for example, such sealing may be detachable from the terminal connections. And its specific construction is illustrated in details hereinafter.
  • a powder-coated insulated inductor which is partially disposed and installed securely within an opened channel partially embedded in and going through an enclosure shell of a drive (e.g., a variable frequency drive), i.e., an coated insulative inductor provided with an uncovered portion thereof exposed from the channel, which channel opens to the atmosphere (and with walls thereof being a part of the enclosure shell), for example, a sealing arrangement 2 for coil windings of the inductor as above is contemplated.
  • a drive e.g., a variable frequency drive
  • FIG.5 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to an exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the system sheet, via a two-piece base seat portion;
  • Fig.6a-6c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the system sheet, according to the exemplary embodiment of the invention as illustrated in Fig. 5.
  • such a sealing arrangement 2 comprises a system sheet 3 provided with a plurality of through-holes 31, by which system sheet the insulated inductor is covered and sealed from an exposed side thereof (e.g., an upper side as illustrated), the system sheet 3 essentially being configured to function as a system sheet for covering the inductor partially embedded in the enclosure shell (i.e., also functioning as an upper wall of the enclosure shell of the drive); and a plurality of removable seals, each of which is positioned between each terminal lead and respective one of the through-hole and comprises: a base seat portion, which has a lower surface seated against from outside of the turns of the inductor and an upper surface configured to abut against an lower surface of the system sheet; a cylinder portion, which extends vertically from the upper surface of the base seat portion; and a through-channel, which passes through the base seat portion and the cylinder portion centrally.
  • a base seat portion which has a lower surface seated against from outside of the turns of the inductor and an upper surface configured to abut
  • the cylinder portion has an outer diameter smaller than that of the base seat portion and substantially equal to or slightly less than an diameter of the respective through-hole for passing therethrough; and the through-channel has an inner diameter substantially equal to or slightly larger than an diameter of the respective terminal lead for passing the terminal lead through.
  • the each of the plurality of removable seals is made of a UL approved plastic material.
  • an additional bonding layer may be provided therebetween the upper surface of the base seat portion.
  • each seal of the sealing arrangement 2 is implemented as an interlocked sealing assemblies positioned between each terminal connection and respective through-hole, i.e., with a two-piece base seat portion.
  • Such insulated inductor is located on one side of and is to be sealed to the system sheet 3 which has other circuits such as PCB on other side.
  • system sheet can be made of UL approved plastic material.
  • a partial enlarged view of the sealing arrangement 2 is illustrated, e.g., for sealing at the terminal connection 122 of the inductor.
  • the system sheet 3 is placed upon the inductor, and provided at one corner a through-hole 31 through which the terminal connection 122 can pass.
  • An interlocked sealing assembly 20, which is provided beneath the through-hole 31, is in the form of a hollow stepped cylindrical boss comprising two semi-cylindrical boss halves 21, 2 ⁇ which are identical and mirror-symmetrically disposed about the common axis thereof.
  • Such two halves are made of any rigid and robust material for facilitating strong fixation/coupling between the inductor 1 and the system sheet 3.
  • such halves which used to seal the coil windings to the system sheet 3 are made of an UL-approved plastic material.
  • stepped sealing assembly 20 which is in the form of a stepped construction of two co-axial cylinders superimposed on each other, with a cylindrical through-hole in the center.
  • the semi-cylindrical boss half 21 is exactly half of the stepped sealing assembly 20, i.e., as in Fig. 5, it can be seen that the semi-cylindrical boss half 21 essentially comprises a semicircular base portion 211 and a upper semicircular flange 212 which has a smaller outer diameter than that of the base portion 211. And another semi-cylindrical boss half 21 ' has the same structure as the semi-cylindrical boss half 21, with their opposite end surfaces of the semicircular base portion can be aligned and fitted exactly in pairs upon assembly.
  • each pair of opposite end surfaces of the semicircular base portions of the two halves 21, 21 ' there are provided with a pair of holes 204, 204' extending perpendicular to respective end surface, one hole per end surface, respectively, for receiving a coupling member therebetween, for example, a coupling screw received in holes 204, 204' at both ends thereof, such that the two halves 21, 21 ' can be fixedly assembled and fitted together to form the interlocked sealing assembly 20.
  • each of the two halves 21, 21 ' has three types of sealing surfaces, respectively.
  • the half 21 is provided with a half cylindrical inner wall surface 201 while another half 21 ' is also provided with a half cylindrical inner wall surface (not shown), with identical inner diameters which are equal to or slightly larger than the diameter of the cross section of the coil.
  • the half 21 also has two end surfaces 202 at each end of the base portion 211 thereof, as well as a upper semicircular surface 203 of the base portion for abutting the system sheet 3.
  • the outer diameter of the upper flange 212 is substantially equal to or slightly less than the diameter of corresponding through-hole 301.
  • the outer diameter of the assembled two flanges is equal to or less than the diameter of the through-hole 301, and the hole 31 is dimensioned sufficiently for passing the terminal connection 122 therethrough, such terminal connection 122 and then the assembled annular upper flange are sequentially inserted through the hole 31, the whole assembled upper annular surface composed by two upper semicircular surfaces 203 in turn abuts directly against the lower surface of the system sheet.
  • bonding agent or a bonding layer between the upper surface of the base portions and the lower surface of the system sheet so as to secure the sealing therebetween.
  • the upper surface of the base portions on the stepped cylindrical boss construction functions as the stopper for preventing excessive movement of coil windings towards the system sheet so as to avoid the pressing of the turns of the winding(s) against the system sheet.
  • the additionally applied bonding agent or bonding layer functions as a retainer layer for firmer secure of the terminal lead(s) onto the system sheet around the respective hole(s) 31, so as to prevent the inserted terminal lead from retracting backward and out of the sealing/engagement with hole(s) 31.
  • the interlocked sealing assembly 20 in the form of a cylindrical boss which is formed by the fitting assembly of two semi-cylindrical bosses 21, 21 ', can be replaced with two individual hollow cylinder member disposed on opposed sides of the system sheet 3, respectively, which can be fitted together in a positive fit manner and each of which is also formed by two mirror- symmetric halves.
  • a lower cylinder member is formed by two opposite and mirror- symmetric halves with similar shape, which two halves clamped around a lower portion of respective terminal lead and fitted against each other, e.g., by screws therebetween.
  • the terminal connection at the end of the terminal lead is inserted through the hole on the system sheet, i.e., the system sheet is then positioned above and against the upper surfaces of the halves of the lower cylinder member.
  • an upper cylinder member of similar construction to that of the lower one, which is also formed by two opposite and mirror- symmetric halves, is clamped around the outer surface of a upper portion of the terminal lead which passes through the hole, at opposed side of the system sheet. Therefore, a sandwiched construction of the system sheet between the lower and the upper cylinder member is formed, facilitating the dustproof and splash-proof effect of the underlying inductor covered by the system sheet, similarly.
  • the mating sealing surfaces can be either flat and smooth, or can be surfaces with textures, bumps, and knurls such that the bonding force or adhesion force therebetween can be increased to a certain extent to ensure secure fixation, possibly with additional bonding layers provided therebetween for better sealing effect.
  • the shape of mating hole 31 and respective outer wall surface of upper semicircular flange can be varied, for example, the hole 31 may be in the form of a tapered hole while the upper flange can correspondingly be formed as a semi-frustum shaped construction which fits into the tapered hole.
  • the interlocked stepped cylindrical boss assembly 20 can also be formed by at least three individual members which can be fitted together.
  • the assembled halves are formed by metal.
  • the assembled halves can also be a composite element or an assembly of metal component and plastic component.
  • the sealing arrangement 2 can be formed enclosing the inductor firmly so that a sealing enclosure with certain level of resistance to entrance of dusty gas and splash-proof protection in various directions during operation can be obtained, while the inductor therein is electrically insulated but thermally conductive with the environment outside such enclosure, due to the electrically insulated but thermally conductive terminal leads passing through the holes of the system sheet via the fixation and abutting sealing of the interlocked sealing assembly 20 between the insulated system sheet and the externally insulated inductor.
  • FIG.7 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to another exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the cover plate, via a one-piece base seat portion; and Fig.8a-8c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the cover plate, according to the exemplary embodiment of the invention as illustrated in Fig. 7.
  • each seal of the sealing arrangement 2' is implemented, only with a one-piece base seat portion.
  • the insulated sealing arrangement 2' as illustrated in Figs. 7 and 8a-8c only differs from the insulated sealing arrangement 2 as illustrated in Figs. 5 and 6a-6c in the specific structure of each of the removable seals.
  • each of the removable seals may be formed as a two-piece interlocked sealing assembly; in contrast, in the sealing arrangement 2' as illustrated in Figs.
  • each of the removable seals is formed as a one-piece integral hollow component comprising three portions (i.e., comprising a base seat portion 221, a cylinder portion 222 formed integrally with the base seat portion, and a through-channel therethrough).
  • the two semicircular base portions 211 fitted together is replaced by the base seat portion 221, while the two upper semicircular flanges 212 fitted together is also replaced by a cylinder portion 222.
  • each seal may facilitate a simplified and faster assembly process between the system sheet 3 and the integral seal. And in order to obtain a more secured fixing and sealing therebetween, some additional fixing means may be adopted, e.g., by providing an additional bonding layer therebetween, or by applying an additional clamp to act on opposed outer surfaces of the system sheet 3 and the seal for fastening them together.
  • Fig.9 is a locally enlarged exploded view of an insulated sealing arrangement for coil windings as illustrated in Fig. 4, according to still another exemplary embodiment of the invention, illustrating the engaging/sealing structure between the coil winding terminals and the cover plate, via another one-piece base seat portion; and Fig.10a- 10c illustrate schematic views of an exemplary assembly process and a completed assembled product of the insulation enclosure structure between the coil winding terminals and the cover plate, according to the exemplary embodiment of the invention as illustrated in Fig. 9.
  • each seal of the sealing arrangement 2" is implemented, only with a one-piece base seat portion.
  • the insulated sealing arrangement 2" as illustrated in Figs. 9 and lOa-lOc only differs from the insulated sealing arrangement 2' as illustrated in Figs. 7 and 8a-8c in the specific structure of each of the removable seals.
  • each of the removable seals is also formed as a one-piece integral hollow component comprising three portions (i.e., comprising a base seat portion 221, a cylinder portion 222 formed integrally with the base seat portion, and a through-channel therethrough).
  • each sealing arrangement 2" in this third embodiment is provided with a plurality of first mounting holes 22 distributed around the cylinder portion 222 on the upper surface (i.e., a surface facing towards the system sheet 3) of the base seat portion 221 and a plurality of second mounting holes 23 distributed around each through-hole on the system sheet 3.
  • the plurality of first mounting holes 22 have same number, shape and distribution pattern as those of the plurality of second mounting holes 23, and may be aligned with their respective second mounting holes 23 for allowing additional inserts passing through to facilitate a more secured interconnection therebetween.
  • the plurality of first mounting holes 22 and their respective second mounting holes 23 are aligned with each other, in pairs, and is secured by inserts passing through each pair of the fist and the second mounting holes 22, 23.
  • the mounting holes may be screw holes and thus the inserts may be screws, for fastening by screw threading.
  • each seal may not only facilitate a simplified and faster assembly process between the system sheet 3 and the integral seal, but also ensure a more secured and detachable fastening therebetween without the aid of any permanent fixing means such as bonding, interference fit of mating components, etc.
  • inductor or transformer other magnetic component assemblies such as coupled inductors, transformers are also envisaged using similar inductor structure and the insulated sealing arrangement thereof. It may also desirable in some application scenarios to add additional insulation material between core and winding for abrasion resistance. This might involve partial powder coating of the core, sheet material, or a molded plastic part. This last option would significantly reduce heat flow from winding to core but increase the heat outflow outside the holding shell/sealing arrangement and even to the ambient environment.

Landscapes

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

Abstract

La présente invention concerne un inducteur isolé comprenant au moins un enroulement de bobine enroulé en spirale sous la forme d'une pluralité de spires, dont les surfaces externes sont traitées par un dépôt d'isolation, chaque enroulement de bobine étant pourvu de deux conducteurs de borne respectivement à chacune de ses extrémités. La présente invention concerne également un agencement d'étanchéité isolé d'enroulements de bobine, comprenant une feuille de système pourvue d'une pluralité de trous traversants, ladite feuille de système recouvrant et rendant étanche l'inducteur à partir d'un côté exposé de celui-ci. La présente invention vise à fournir une protection satisfaisant ou dépassant les exigences des normes IEC IP54 et UL Type 12, tout en continuant à fournir une isolation électrique et une propriété de conduction thermique.
PCT/EP2017/071193 2016-08-26 2017-08-23 Inducteur électrique isolé et son agencement d'étanchéité isolé WO2018037029A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201662380012P 2016-08-26 2016-08-26
US62/380,012 2016-08-26

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WO2018037029A2 true WO2018037029A2 (fr) 2018-03-01
WO2018037029A3 WO2018037029A3 (fr) 2018-06-28

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EP0662696B1 (fr) * 1994-01-11 1998-03-18 Smc Corporation Procédé de fabrication d'un dispositif à solénoide pour values électromagnétiques
JP2004319157A (ja) * 2003-04-14 2004-11-11 Tokyo Seiden Kk 平角導線と圧着端子の接続方法
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JP5566071B2 (ja) * 2009-09-24 2014-08-06 日本電産サンキョー株式会社 コイル巻回体およびモータ
EP2709118A1 (fr) * 2012-09-14 2014-03-19 Magnetic Components Sweden AB Inducteur optimal
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JP2019169562A (ja) * 2018-03-22 2019-10-03 スミダコーポレーション株式会社 コイル部品及びトランス
JP7225547B2 (ja) 2018-03-22 2023-02-21 スミダコーポレーション株式会社 コイル部品及びトランス

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