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EP2523198B1 - Transformateur avec bobine laminée - Google Patents

Transformateur avec bobine laminée Download PDF

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Publication number
EP2523198B1
EP2523198B1 EP12167728.0A EP12167728A EP2523198B1 EP 2523198 B1 EP2523198 B1 EP 2523198B1 EP 12167728 A EP12167728 A EP 12167728A EP 2523198 B1 EP2523198 B1 EP 2523198B1
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EP
European Patent Office
Prior art keywords
winding
coil body
transformer
bobbin
winding chamber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP12167728.0A
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German (de)
English (en)
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EP2523198A1 (fr
Inventor
Matthias Knogl
Manfred Kronawitter
Norbert Ginglseder
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumida Components and Modules GmbH
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Sumida Components and Modules GmbH
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Publication of EP2523198A1 publication Critical patent/EP2523198A1/fr
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    • 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
    • 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
    • H01F27/2866—Combination of wires and sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10—Connecting leads to windings

Definitions

  • the invention relates in general to transformers in which relatively large currents occur on the input side or the output side, so that one of the two windings has a large conductor cross-section in the form of bladed winding sections.
  • the rapid progress in electronics means that in many areas power electronics modules are used, which is usually to handle electrical energy at different voltage potentials.
  • power electronics modules are used, which is usually to handle electrical energy at different voltage potentials.
  • electrical consumers are used, such as to supply the complex electronic components in the vehicle, to provide additional drive energy, for storing braking energy and the like
  • relatively large powers in the range of some 100 watts to some Kilowatts or higher with partly very different operating voltages are to be processed.
  • a conversion of voltages and currents is often required, with a galvanic decoupling is required if required.
  • These include, for example, applications in inverters in photovoltaic systems, wind turbines, combined heat and power plants and the like.
  • so-called high-frequency transformers are often used, which have a suitable magnetic core and corresponding windings, so that operation at frequencies of a few 100 Hz to several 100 kilohertz and higher is made possible.
  • the overall construction volume of the transformers can be kept relatively small, which is particularly important in order to open up many new applications and to keep the overall manufacturing costs of corresponding electronic component groups low.
  • Transformers that can provide high input voltages or output voltages at high output currents are often constructed in the form of planar transformers having a winding that is provided in the form of conductor plates, such as copper sheets, such that a large copper surface and a large cross section lead to low DC losses and AC losses.
  • conductor plates such as copper sheets
  • transformers with a laminated winding By using such transformers with a laminated winding, on the one hand, relatively large differences in voltage can be generated, while at the same time a very small volume of construction can be achieved, so that at an operating frequency of approximately 100 kilohertz, powers of 1 to several kilowatts contribute a component volume of about 100 cubic centimeters can be processed.
  • the publication JP 08107026 A shows an ignition transformer with a bobbin having blocks separated by barriers.
  • the thickness of the bobbin is designed in each block in such a way that insulation is achieved for a winding applied to the winding body with respect to the electric potential gradient occurring across the blocks when the voltage is applied.
  • a performance improvement such as compliance with isolation distances with high reliability and reproducibility, reduced losses, etc.
  • AC losses caused by windings are to be reduced.
  • this object is achieved by a transformer according to the independent claim 1, further embodiments of which are defined in the dependent claims 1 to 11.
  • insulation caps are provided, which are respectively attached to the terminals of the first and the second winding, so that can be achieved by the insulation caps defined isolation distances in the region of the terminal assemblies. That is, the insulation caps represent component parts made by, for example, injection molding and the like, so that their dimensions and shapes are predetermined with a high degree of reproducibility. This is in cooperation with the bobbin precisely defined distances, such as between the core and leads for the first and the second winding specified.
  • the first and the second insulation cap recesses which are filled with a potting material.
  • a potting material as it is typically used for potting the transformer components in a housing, a high mechanical strength can be achieved because the recesses result in an improved connection between the cap and the potting material.
  • the mechanical coupling of the insulation caps and thus the entire bobbin to the potting material and thus to the housing and the core of the transformer is improved by the recesses, but it is also an improved thermal coupling of the transformer inside the potting material and finally to the Housing allows.
  • potting materials with high thermal conductivity can preferably be used, so that a very efficient heat conduction from the bobbin and thus the windings to the housing is formed.
  • the first insulation cap has a receptacle for guiding connection lines of the second connection arrangement. Since the second winding usually receives a higher voltage than the laminated winding, which typically has a smaller number of turns, results from the formation of the guide in the first insulation cap a precisely set distance and course of the corresponding leads for the higher operating voltage second winding.
  • the second winding usually receives a higher voltage than the laminated winding, which typically has a smaller number of turns, results from the formation of the guide in the first insulation cap a precisely set distance and course of the corresponding leads for the higher operating voltage second winding.
  • the bobbin has a plurality of bobbin segments, which are put together, wherein each bobbin segment has at least one winding chamber and a bearing surface.
  • This modular design of the bobbin thus individual turns of the laminated winding can be applied, so that there is approximately a circumferential winding section, wherein the segments nevertheless a high mechanical precision in the positioning of the laminated winding sections is ensured.
  • the modular design allows the provision of a desired number of winding chambers for the further wire winding, wherein at the same time interleaving of the first and the second winding takes place through the segments, so that a total of high efficiency due to the intensive coupling of the first and the second winding allows becomes.
  • the circumferential length of the winding chamber has the largest value, which has the smallest distance to the terminal assembly, while other winding chambers having a larger distance have a correspondingly smaller circumferential length, so that the shorter line length for respective turns in these winding sections at least to a high Grade compensated for the longer path to the terminal assembly.
  • the line lengths of the respective winding sections in the winding chamber can be adapted to each other, so that the total AC losses due to a reduction possible equalizing currents are lower.
  • an "approximately" equal length of wiring for the individual winding sections is achieved, which is to be understood so that a deviation of the line length of the respective winding sections and the associated leads to the terminal assembly is 10% or less compared to the winding chamber that has the maximum cable length. It also includes the possibility that the line lengths are the same within the measurement accuracy.
  • the different configuration of the circumferential lengths of the individual winding chambers can already take place in the production of the individual bobbin segments or can also be achieved by subsequent adjustment, such as by introducing material sections, etc., in the assembly of the transformer.
  • the insulation caps are attached to the bobbin, d. H. during assembly, the insulation caps are present as separate individual parts, so that an efficient application of the first and the second winding on the actual bobbin is possible, and subsequently set by the attachment of the insulation caps the desired properties in terms of insulation resistance and the like with high mechanical precision become.
  • the insulation caps when providing the bobbin in the form of individual modules, d. H. in the form of individual bobbin segments, thus suitably adapted insulation caps can be produced in separate manufacturing operations, so that different "lengths" of the bobbin due to the modular design can be used, then to the desired length, a suitable insulation cap can be provided without otherwise Changes in the assembly process are required.
  • one or more of the support surfaces on a recess By the recesses in the bearing surfaces, a portion of the laminated winding is thus exposed on the respective bearing surface, so that thus takes place an improved mechanical and thermal coupling of the winding to a corresponding potting material.
  • both the mechanical stability and the thermal behavior can be improved because, for example, when using a highly thermally conductive potting material efficient connection of the laminated winding to the potting material and thus to the housing and the other components, such as the core of the transformer, he follows.
  • the first winding and the second winding are interleaved with each other, i. H.
  • a longitudinal direction of the bobbin winding sections of the first winding and the second winding are provided alternately, so that an intensive coupling of the two windings is formed.
  • the transformer according to the invention according to the independent claim 1 enables a reduction in the AC losses by suitable adaptation of the circumferential lengths of the winding chambers, which are provided in the bobbin segments, which also serve to receive the laminated winding sections by providing the bearing surfaces. That By adjusting the circumferential lengths corresponding compensation currents, which can occur in a parallel connection of the individual winding sections of the higher voltage leading winding can be reduced because, for example, a certain compensation of the different cable lengths, in conventional transformers, in particular by the different spacing of the individual winding sections arising from the terminal arrangement is achieved. By compensating for the differences in length, it is thus possible for otherwise identical winding sections, i.
  • this design of the transformer according to the invention can also be combined with further measures, as described above, for example by the provision of insulation caps for the terminal arrangements, so that at the same time a further behavioral improvement by the exact adjustment of the air in conjunction with an improved AC behavior. Creepage distances is achieved, as already explained above.
  • a method of manufacturing a transformer in another aspect of the present invention, according to independent claim 12, there is provided a method of manufacturing a transformer, further embodiments of which are defined in dependent claims 13 and 14.
  • a segmented bobbin is provided, so that corresponding turn sections in the laminated winding can already be applied to the respective bobbin segments before the actual assembly of the bobbin takes place.
  • the winding sections of the second winding may be introduced into the winding chamber prior to the laying of the laminated windings, while in other embodiments the application of the winding sections of the second winding after placing or after the assembly of the individual bobbin segments takes place.
  • a method of manufacturing a transformer wherein a laminated core of a first winding is inserted into a bobbin having a plurality of stacked bearing surfaces for receiving a respective winding section.
  • the method further comprises applying winding sections of a second winding on the bobbin, wherein a plurality of winding chambers are provided for receiving the second winding.
  • the first laminated core is electrically connected to produce the first winding.
  • a first insulating cap and a second insulating cap is fitted onto the bobbin and a core is attached to the bobbin.
  • connection line for the second winding is furthermore attached by means of a guide provided in the second insulation cap, in order thereby to observe a precisely defined isolation distance from the core.
  • the insulation caps are applied after connecting the first winding, so that they can also have a suitable shape to cover corresponding connection lines. In this way, exactly reproducible isolation distances can also be realized.
  • a method of manufacturing a transformer includes providing a bobbin having a plurality of bobbin segments, each having one or more bearing surfaces for receiving one or more bladed windings of a first winding and a winding chamber having a winding chamber bottom for receiving a winding section of a second winding.
  • the method further comprises adjusting a circumferential length at the winding chamber bottom in each winding chamber in dependence on the position of a winding chamber in the bobbin.
  • the method further comprises applying an equal number of turns in each winding chamber to make a respective winding section and separately connecting each winding section to a terminal assembly.
  • This inventive method thus enables an efficient adaptation of the total line length of winding sections, which are distributed over the bobbin time and therefore have different distances to the respective terminal arrangement, in which the individual winding sections are connected in parallel with each other.
  • Fig. 1 a schematically shows a perspective view of a transformer 100 which, for example, depending on the circuit topology of a corresponding electronic module has a volume of about 100 cubic centimeters or significantly less, with powers of one kilowatt to several kilowatts can be implemented.
  • the transformer 100 includes a schematically arranged housing 101, which may be provided in the form of a plastic material, a metal housing, and the like, depending on the desired characteristics with respect to the interference radiation suppression, and the like.
  • a potting material 102 is provided in the housing 101 which may be provided in the form of any suitable insulating material, in some illustrative embodiments a potting material with improved thermal conductivity is used to allow a better thermal coupling of other components of the transformer 100 to the housing 101.
  • a suitable potting material with high thermal conductivity is SE4445CV.
  • the transformer 100 further comprises a bobbin 110 and a magnetic core 103, which encloses a part of the bobbin 110 and also passes through an opening in the bobbin, as described below in connection with Fig. 1b is shown in more detail.
  • terminal assemblies 106 and 105 are provided which serve as connection to respective windings which are incorporated in US Pat Fig. 1 a are not shown.
  • a first insulation cap 107 is attached to the bobbin 110 and covers part of the terminal assembly 106 in the illustrated embodiment.
  • an insulating cap 108 is attached to the bobbin 110 opposite the cap 107, the cap 108 having a suitable shape to, inter alia, allow precise guidance of leads of the terminal assembly 105, as also explained in more detail below.
  • the insulation caps 107 and 108 are thus mounted on corresponding opposite sides of the bobbin 110, which are not covered by the core 103.
  • Fig. 1b schematically shows an exploded perspective view of the transformer 100, for the sake of clarity, the housing 101 and the potting compound 102 from Fig. 1a are not shown.
  • the core 103 is constructed of two core halves 103A and 103B, such as an E-core. D. h., Corresponding side legs 103 S of the core 103 surround a central part of the bobbin 110, while a center leg 103 M passes through an opening 113 of the bobbin, and, depending on the circuit topology to be used, also an air gap in the center leg 103 M and / or in the Side legs 103S may be provided.
  • the bobbin 110 which in the illustrated embodiment has a generally rectangular shape but in other embodiments may have a suitable other shape, such as oval, round, etc., further comprises a plurality of bearing surfaces 111, so that on these bearing surfaces 111 corresponding winding sections 121 of a Winding 120 can be arranged. As shown, the bearing surfaces 111 form suitable "pockets" for receiving one of a plurality of stacked turns 121 of the winding or sheet stack 120, respectively.
  • the winding 120 has a suitable number of winding sections 121, which thus represent a self-supporting winding in connection with the connection arrangement 106 and is constructed in such a way that as required for voltage and current conversion.
  • connection arrangement 106 has a corresponding suitable design with regard to interconnection of the respective turn portions 121 such that the desired electrical properties of the winding 120 are achieved. If, for example, only a single turn is required, then all turn sections 121 can be contacted in parallel through the connection lines of the arrangement 106. If a different interconnection of the turn portions 121 is required, additional leads may optionally be added in the assembly 106, such as after insertion of the coil 120 into the bobbin 110, or appropriate connections via an electronic board or other connection means outside the transformer produced.
  • the turn portions 121 have a suitable cross-section, for example a substantially rectangular cross-section, wherein due to the greater material thickness, the individual turn portions 121 are substantially inherently stable, which is also referred to in the present application as a bladed turn portion. Due to this design form, the turn portions 121 have a low thermal resistance, wherein also a relatively large surface is generated, so that the corresponding AC resistance remains low at higher clock frequencies.
  • a width 121B of the turn portions 121 is set so that, when resting on the bearing surfaces 111, a desired lateral distance to the side legs 103S of the core 103 exists.
  • the distance may be suitably controlled by selecting a "depth" 111B of the bearing surfaces 111. That is, the depth 111B is selected to be at least equal to the width 121B, wherein the depth 111B may be selected to be larger if necessary. a greater distance to the material of the core 103 is desired.
  • the sheet metal cross section 121B or the depth 111B of the bearing surfaces is selected so that a desired depth of winding chambers 112 is formed, which are provided in the bobbin 110 alternately to the bearing surfaces 111 to accommodate corresponding winding sections of a second winding 130, which in the Usually contains substantially more turns, so that in the transformer relatively high voltages can be converted into small voltages and vice versa.
  • the width 111B of the bearing surfaces 111 essentially defines, for a given wire cross-section of the winding 130, the number of possible layers and thus the number of turns of the winding sections of the winding 130 "Width" 112B of the winding chambers 112 set so that on the one hand, a desired Kupferhell310 is achieved in the bobbin 110, and on the other hand, the number of winding sections of the winding 130 is set. In this way, a high degree of interleaving of the windings 120 and 130 is ensured.
  • the galvanic separation of the winding 120 and 130 is thus essentially given by the geometric design of the bobbin 110, so that corresponding air and creepage distances are predetermined by constructively defined properties of the bobbin 110.
  • bobbin 110 has suitable formed guides 114 to suitably guide the wires of winding 130 from one winding chamber 112 to another winding chamber or as a separate lead to terminal assembly 105 according to a desired wiring scheme so that also in this case a well-defined spatial positioning is guaranteed.
  • the insulation caps 107 and 108 are shown, which are mounted after insertion of the laminated core of the winding 120 in the bobbin 110 on the opposite sides of the bobbin 110.
  • the insulation cap 107 has a corresponding recess 107A, which thus for improved mechanical and thermal coupling of the bobbin interior and thus the windings 120 and 130 to a potting material, such as the material 102 in Fig. 1a ensures, while on the other hand, the terminal assembly 106 and the ends of the turns 121 remain covered in a suitable manner, so that after the mechanical coupling of the cap 107 exactly defined isolation distances and distances are given.
  • the isolation cap 108 has recesses 108A which also provide improved thermal and mechanical coupling to a potting material while concealing relevant portions of the port assembly 105.
  • guides 108A and 108B are provided for receiving and guiding wires of the terminal assembly 105, so that after the cap 108 has been mounted and the terminal assembly 105 has been mounted, accurate positioning of the lead wires is maintained and maintained during the further processing steps becomes.
  • lead wires of the terminal assembly 105 can also be suitably insulated, such as by means of heat shrink tubing and the like, the insulation can be made at well-defined areas of the leads, since the cap 108 guarantees accurate positioning of the leads of the assembly 105.
  • the individual components i. H. the bobbin 110, the insulating caps 107 and 108 are formed by suitable methods such as injection molding, and the like, so that material composition and geometric shape of these components are given with high precision and reproducibility.
  • the winding or the laminated core 120 is prepared separately in connection with the connection arrangement 106.
  • the package 120 is inserted with the side of the terminal assembly 106 in the bobbin 110 and thus is positioned in its position due to the bearing surfaces 111 exactly.
  • the winding 130 can be applied, wherein any suitable winding and contacting methods can be used.
  • the support surfaces 111 corresponding recesses 111 E, so that after insertion of the laminated core 120 areas of individual turns 121 are exposed, while still a precise mechanical fixation is done.
  • These exposed surfaces of the turns 121 thus provide a larger area for connection to a potting material, so that on the one hand an intimate mechanical connection between bobbin 110 and winding 120 takes place, while on the other hand, a good thermal connection to the potting material is achieved, especially with higher Thermal conductivity can be provided, so that a total of a very efficient heat flow from the inside out in the transformer 100 is given.
  • insulation caps 108 are then attached and finally the core 103 is assembled and mechanically fixed, whereupon the entire assembly is placed in a housing and potted with potting material, as in Fig. 1a is shown.
  • Fig. 2a schematically shows an exploded perspective view of a transformer 200, which may have a similar configuration in the final state, as well as for the transformer 100 in Fig. 1 a is shown.
  • the transformer 200 is optionally housed in a housing which is filled with a suitable potting material.
  • the transformer 200 may be used for power applications in which power ranges from several hundred watts to several kilowatts and more with a small volume of construction must be handled.
  • the transformer 200 includes a core 203 constructed of approximately core halves 203A, 203B.
  • a modular bobbin 210 which has a plurality of bobbin segments 210A, ..., 210D.
  • the bobbin segments 210A,..., 210D each have a bearing surface 211 which is designed such that corresponding winding sections 221 of a winding 220, which in turn is to be understood as a laminated winding, are fixed between two of the bobbin segments 210A,..., 210D is.
  • the bearing surfaces 211 the same criteria apply as previously described with reference to the bearing surfaces of the bobbin 210 of the transformer 100.
  • each of the bobbin segments 210A, ..., 210D has a winding space 212 serving to receive a winding portion of a second winding (not shown). Again, the same criteria apply as previously described for the winding chambers 112 of the transformer 110.
  • Fig. 2b schematically shows an enlarged view of the bobbin segment 210 B, in which the support surface 211 is shown having an effective width 211 B for receiving a winding portion of the laminated winding. Furthermore, the winding chamber 212 is shown, whose height is given by the width 211B and is set so that a desired number of winding layers and thus windings for the corresponding winding section of the second winding (not shown) is formed, yet still a high overall degree of filling assembled bobbin is achieved. Further, guides 214 are provided which allow a precise guidance of winding wires from one winding chamber to another or to a connection arrangement, so that corresponding insulation distances are specified in a precise manner.
  • connection arrangements 205 are provided for the winding sections in the winding chambers 212 and a connection arrangement 206 for interconnecting the individual winding sections 221.
  • an insulation cap 207 is provided to be attached to the bobbin on the side of the terminal assembly 206, while an insulation cap 208 on the side of the terminal assembly 205 is to be attached to the modular bobbin.
  • the caps 207 208 apply the same criteria as previously described for the insulation caps of the transformer 100.
  • the cap 208 has guides 208B and 208C for connecting wires of the Portion 205 in a suitable manner to lead and position, as also previously explained.
  • the individual coil body segments 210A,..., 210D and the insulation caps 207 and 208 can thus be manufactured separately in a suitable manner, in particular the size of the caps 207, 208 being adapted to the desired number of coil body segments is to be provided in the transformer 200. Furthermore, the turn portions 221 are provided and individually applied first to each one of the bobbin segments, which are then in turn mechanically mated, so that the desired number of turns for the laminated winding is formed. Further, by assembling a desired number of the segments, the bobbin 210 is made in which the segments are already wound or wound so that the respective winding sections 212 of the other winding, which is not shown for simplicity, are applied in the winding chambers 212 are.
  • connection arrangements 205 and 206 can then also be mounted so that the desired interconnection of the individual windings results. Thereafter, the insulation caps 207, 208 are placed and thus give the desired isolation distances, as previously explained. After inserting the core 203, the resulting assembly can then be placed in a housing and potted.
  • Fig. 2c schematically shows a part of the transformer 200, that is, one of the portions 221 of the laminated winding 220 (see Fig. 2a ), with section 221 in FIG Fig. 2c has two windings 221A, 221B.
  • an insulating film 225 is provided in the illustrated embodiment, which thus prevents a direct mechanical contact of the two windings 221A, 221B.
  • a different geometry is provided for the windings 221 in comparison to the previously illustrated embodiments, for example in the form of a circular geometry, so that a corresponding circular design of the bobbin and, if necessary, the magnetic components of the transformer 200 is provided ,
  • Fig. 2d 12 schematically illustrates a portion of the transformer 200 according to another embodiment, in which a bobbin segment 210A having a substantially oval or circular geometry corresponding to the desired overall geometric configuration of the transformer 200 is illustrated.
  • the bobbin segment 210A is designed so that it serves as a bearing surface or contact surface for the laminated winding section 221 and thus as an efficient insulation for the individual winding 221A, 221B. That is, the insulation of the windings 221A, 221B is carried out by the bobbin segment 210A itself and is thus determined by design measures, wherein the material of the segment 210A serves as an efficient insulating material.
  • a holder 214 is further provided, in which corresponding connecting wires of winding sections can be guided, wherein in each case a single winding section is provided in the winding chamber 212.
  • a notch 214S is provided in the brackets 214 so that when winding the coil body segment 210A, the winding wires in the slot 214S can be mechanically fixed so that a very efficient automatic winding can be achieved without conventional fastening methods by means of adhesive tapes, etc. are required.
  • the winding section 221 can then be slid so that, for example, the winding 221A rests on the support surface 211 and is thus suitably positioned.
  • Fig. 2e schematically shows the bobbin segment 210A with the deferred winding portion 221 and the lead wires 235 of a winding portion 230A, which is housed in the winding chamber 212 (not visible).
  • the embodiments of the transformer 200 in the Fig. 2d and 2e show substantially circular geometries, such as for the opening 213 of the bobbin segment 210A, wherein the outer contour of the bobbin segment 210A has a substantially circular shape, with the exception of the brackets 214. It should be noted, however, that other geometric shapes, such as an oval Shape for the central opening 213 and / or the outer shape of the segment 210A or combinations of substantially rectangular geometries can be used with substantially circular geometries.
  • Fig. 3a 11 shows a perspective schematic illustration, partly in elevation, of a transformer 300 in which a further improvement of the electrical behavior is achieved, for example in addition to or as an alternative to the measures already described with respect to the transformers 100 and 200, by improving the alternating current behavior.
  • the transformer 300 has, in a similar manner as before for the devices 100 and 200, has a magnetic core, only one core half 303B being shown in the illustrated elevational view.
  • a bobbin 310 is provided, which comprises a plurality of bobbin segments 310A, ... 310G, which are arranged in the illustrated elevational view along a longitudinal direction of a center leg 303M.
  • the bobbin segments each have a central opening 313A, ....
  • the distances of the segments 310A, ... 310G do not yet correspond to the final positioning of these segments.
  • the segments 310A, ... 310G have a corresponding bearing surface 311, possibly in connection with an opposing contact surface for receiving a laminated winding section with one or more windings, as previously explained.
  • a winding chamber 312 which is partially shown in elevational view for the segment 310A.
  • the "depth" of the winding chamber 312 depends on the width of the support surface 311, wherein the usable depth of the winding chamber 312 is also determined by a winding chamber bottom 315. That is, as the winding chamber bottom 315 is displaced outwardly as appropriate, a greater circumferential length 315U results, which in turn determines the length of pipe required to create a single turn in the winding chamber 312.
  • the circumferential length 315U for the segment 310A is set to be greater than the corresponding circumferential length for all subsequent segments 310b,... 310G, to provide suitable line length adaptation for winding sections included in the respective winding chambers 312 of the segments 310A, ... 310G are to be produced.
  • a winding section to be generated in the segment 310A has the shortest connection line, so that at the connection point where all the connection lines are merged, some compensation of the different connection line lengths can be made by the respective associated line lengths for the turns the winding sections are provided in a complementary manner. That is, for the segment 310A, the connection line is the shortest, while the line length for the individual turns of the associated winding section is largest due to the largest circumferential length 315U, so as to give a total line length comparable to the winding section for the segment 310G Although the smallest line length for the actual turns has, however, has the largest length of the associated connecting lines. The same applies to the segments lying in between, so that an efficient alignment of the total line lengths of all winding sections succeeds.
  • the corresponding circumferential length 315U is set in dependence on the current position of the associated segment so that the desired alignment of the total line length results.
  • approximately equal line lengths can be obtained for each winding section in the respective segments 310A, ... 310G.
  • approximately equal is to be understood as meaning that a deviation from a maximum line length involved in one of the segments 310A, ... 310G is 10% or less for all other winding sections.
  • other values for the various line lengths may be adjusted to give greater than 10% deviation, if deemed appropriate for the overall performance of the transformer 300.
  • the position of the associated segment 310A,... 310G can thus be determined, for example by simple length measurement, and a suitable "padding" of the respective winding chamber bottom 315 is determined therefrom for a predetermined number of turns and a given wire diameter, so that the desired alignment of the respective line lengths results.
  • the setting of the respective circumferential lengths 315U can be done already in the production of the segments 310A, ... 310G by just different injection molds and the like can be used, while in other embodiments, a corresponding subsequent adaptation of segments having a minimum circumferential length, is accomplished.
  • appropriate material can be subsequently applied in a suitable manner in order to obtain the desired enlargement of the circumferential length in a position-dependent manner, as also explained above.
  • the wrapping may be performed by automated methods, for example using corresponding gaps 314S in holders 314 to mechanically fix the wire ends in the automated wrapping operation, as previously described with respect to the transformer 200.
  • Fig. 3b 12 schematically illustrates a side sectional view of a portion of the transformer 300.
  • the bobbin segments of which the segments 310A,... 310D are shown are arranged in a suitable spatial relationship to one another such that a winding portion 330A of a winding 330 is a smallest distance from a terminal assembly 305 has. That is, a line length of connection lines 335A of the winding section 330A to the terminal arrangement 305 is the shortest for all the coil body segments shown.
  • the length of a connecting line 335D of a Wicktungsabitess 330D in the segment 310D is the longest.
  • the spacings of line sections 330B, 330C in segments 310B and 310C, respectively, are correspondingly greater than for segment 310A and smaller than for segment 310D.
  • suitable measures on the segment structure eg the shape and position of recesses 338A (or 238A in the Fig. 2e ) in the inner circumference of the central openings can be excluded a confusion of the individual bobbin segments.
  • transformer 300 can also be constructed in a similar manner, as described in connection with the transformers 100 and 200, so that in particular also for the transformer 300 well-defined creepage distances and clearances are obtained, and in particular Also suitable insulation caps can be provided, as also explained above.
  • the present invention thus provides transformers and manufacturing methods in which isolation distances and / or line lengths are set constructively by the geometry of the bobbin and the insulation caps. At the same time the caps are provided with corresponding recesses or slots, so that a suitable mechanical and thermal coupling to a housing is achieved.
  • the formation of suitable guides in the bobbin in conjunction with an adjustment of the circumferential lengths allows precise wire guidance and adjustment of the wire length of the winding, so that, for example, the AC resistance in the individual winding chambers is approximately equal, which keeps the total AC losses of the transformer low.
  • the bobbin or the bearing surfaces can be designed suitable for the laminated winding, so that there is a good thermal and mechanical coupling to the potting material.
  • connecting wires for example for the wire winding
  • very high efficiency is achieved by the nested arrangement of the laminated winding and the wire winding, wherein in the described modular system the degree of coupling, i. H. the number of individual winding sections can be specified in a very flexible manner.

Landscapes

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

Claims (14)

  1. Transformateur comprenant
    un noyau magnétique (103, 203, 303B) avec une branche centrale (103M) et des branches latérales (103S),
    un premier enroulement (120, 220) et un deuxième enroulement (130, 330),
    un corps de bobine (110, 210, 310) avec une ouverture centrale (113, 313A) pour entourer la branche centrale (103M, 303M), le corps de bobine comportant plusieurs segments de corps de bobine (210, 310) et chaque segment de corps de bobine présentant une ou plusieurs surfaces d'appui (111, 211, 311) destinées à accueillir une ou plusieurs spires tôlées (121, 221) du premier enroulement (120, 220), et une chambre d'enroulement (112, 212, 312) avec un fond de chambre d'enroulement (315), qui fixe une profondeur de la chambre d'enroulement (112, 212, 312) et est destiné à accueillir un tronçon d'enroulement (330A, ..., 330D) du deuxième enroulement (130, 330), et une première longueur périphérique (315U) du fond de chambre d'enroulement (315) d'un premier segment de corps de bobine étant différente d'une deuxième longueur périphérique du fond de chambre d'enroulement d'un deuxième segment de corps de bobine,
    un premier agencement de raccordement (106, 206), qui est agencé sur un premier côté de corps de bobine et est relié électriquement au premier enroulement (120, 220),
    le premier côté de corps de bobine étant un côté de corps de bobine non couvert par les branches latérales (103S), et
    un deuxième agencement de raccordement (105, 205, 305), qui est agencé sur un deuxième côté de corps de bobine et est relié électriquement au deuxième enroulement (130, 330), le deuxième côté de corps de bobine étant un autre côté de corps de bobine non couvert par les branches latérales (103S),
    transformateur
    dans lequel la longueur périphérique au niveau du fond de chambre d'enroulement (315) est réglée dans chaque chambre d'enroulement (112, 212, 312) de manière à ce qu'une longueur de conducteur totale de chaque tronçon d'enroulement (330A, ..., 330D), y compris la longueur de la liaison avec l'agencement de raccordement (105, 205, 305), soit approximativement identique pour tous les tronçons d'enroulement (330A, ..., 330D).
  2. Transformateur selon la revendication 1, dans lequel la première chambre d'enroulement présente une distance au premier agencement de raccordement plus petite que la deuxième chambre d'enroulement, et la première longueur périphérique est plus grande que la deuxième longueur périphérique.
  3. Transformateur selon la revendication 1 ou la revendication 2, dans lequel le nombre de spires est identique pour chaque tronçon d'enroulement du deuxième enroulement.
  4. Transformateur selon l'une des revendications 1 à 3, dans lequel les longueurs périphériques des chambres d'enroulement de trois segments de corps de bobine ou davantage, sont différentes.
  5. Transformateur selon l'une des revendications 1 à 4, dans lequel les longueurs périphériques de toutes les chambres d'enroulement sont différentes.
  6. Transformateur selon l'une des revendications 1 à 5, dans lequel la longueur périphérique de la chambre d'enroulement du segment de corps de bobine (310A), qui présente la distance la plus petite au deuxième agencement de raccordement (305), est la plus grande.
  7. Transformateur selon l'une des revendications 1 à 6, dans lequel la longueur périphérique de la chambre d'enroulement du segment de corps de bobine (310G), qui présente la distance la plus grande au deuxième agencement de raccordement (305), est la plus petite.
  8. Transformateur selon l'une des revendications 1 à 7, comportant, par ailleurs, un premier capot d'isolation, qui est engagé sur un premier côté de corps de bobine du corps de bobine, non couvert par les branches latérales, et un deuxième capot d'isolation, qui est engagé sur un deuxième côté de corps de bobine du corps de bobine, non couvert par les branches latérales.
  9. Transformateur selon la revendication 8, dans lequel le premier capot d'isolation présente un logement d'accueil (108B, 108C) pour guider des conducteurs de raccordement (335) du premier agencement de raccordement.
  10. Transformateur selon la revendication 8 ou la revendication 9, dans lequel le premier et le deuxième capot d'isolation (107, 108) présentent des évidements (107A, 108A), qui sont remplis par un matériau de scellement (102).
  11. Transformateur selon l'une des revendications précédentes, dans lequel une ou plusieurs des surfaces d'appui présentent un évidement.
  12. Procédé de fabrication de transformateurs, comprenant :
    la fourniture d'un corps de bobine (110, 210, 310) avec plusieurs segments de corps de bobine (210, 310), dont chacun présente une ou plusieurs surfaces d'appui (111, 211, 311) destinées à accueillir une ou plusieurs spires tôlées (121, 221) d'un premier enroulement (120, 220), et une chambre d'enroulement (112, 212, 312) avec un fond de chambre d'enroulement (315) destiné à accueillir un tronçon d'enroulement (330A, ..., 330D) d'un deuxième enroulement (130, 330),
    la définition d'une profondeur de chaque chambre d'enroulement (112, 212, 312) au moyen du fond de chambre d'enroulement (315), pour régler une longueur périphérique du fond de chambre d'enroulement (315) dans chaque chambre d'enroulement (112, 212, 312) en fonction de la position d'une chambre d'enroulement (112, 212, 312) dans le corps de bobine (110, 210, 310),
    la mise en place d'un nombre identique de spires dans chaque chambre d'enroulement (112, 212, 312) pour la réalisation d'un tronçon d'enroulement respectif (330A, ..., 330D), et
    la liaison séparée de chaque tronçon d'enroulement (330A, ..., 330D) à un agencement de raccordement (105, 205, 305),
    procédé d'après lequel on règle la longueur périphérique au niveau du fond de chambre d'enroulement (315) dans chaque chambre d'enroulement (112, 212, 312) de manière à ce qu'une longueur de conducteur totale de chaque tronçon d'enroulement (330A, ..., 330D), y compris la longueur de la liaison avec l'agencement de raccordement (105, 205, 305), soit approximativement identique pour tous les tronçons d'enroulement (330A, ..., 330D).
  13. Procédé selon la revendication 12, le procédé comprenant par ailleurs :
    l'engagement d'un premier capot d'isolation (107) et d'un deuxième capot d'isolation (108) sur le corps de bobine (110, 210, 310), et
    la mise en place d'un noyau (103, 203, 303B) sur le corps de bobine (110, 210, 310).
  14. Procédé selon la revendication 13, d'après lequel on met en place par ailleurs, un conducteur de raccordement pour le deuxième enroulement au moyen d'un guidage (108A, 108B) prévu dans le deuxième capot d'isolation (108), en vue de respecter une distance d'isolation par rapport au noyau (103, 203, 303B), prédéterminée par le guidage (108A, 108B).
EP12167728.0A 2011-05-12 2012-05-11 Transformateur avec bobine laminée Active EP2523198B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE201110075707 DE102011075707A1 (de) 2011-05-12 2011-05-12 Transformator mit geblechter Wicklung

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EP2523198B1 true EP2523198B1 (fr) 2015-09-30

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Publication number Priority date Publication date Assignee Title
US11670448B2 (en) 2018-05-07 2023-06-06 Astronics Advanced Electronic Systems Corp. System of termination of high power transformers for reduced AC termination loss at high frequency
CN113539667B (zh) * 2021-05-19 2025-01-14 广东中顺电气制造有限公司 浇注线圈装置及其生产方法

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Publication number Priority date Publication date Assignee Title
US4234865A (en) * 1979-07-09 1980-11-18 Katsumi Shigehara Transformer framing structure
DE3718383A1 (de) * 1987-06-02 1988-12-15 Vacuumschmelze Gmbh Hochfrequenz-leistungsuebertrager
DE4022243A1 (de) * 1990-07-12 1992-01-23 Gernot Sikora Scheibentransformator
US5345670A (en) * 1992-12-11 1994-09-13 At&T Bell Laboratories Method of making a surface-mount power magnetic device
JPH08107026A (ja) * 1994-10-03 1996-04-23 R B Controls Kk イグナイタ用トランスのボビン
DE19629067A1 (de) * 1996-07-18 1998-01-22 Rene Weiner Spulenkörper für eine Flachspule
JP3729439B2 (ja) * 2000-03-21 2005-12-21 Ｔｄｋ株式会社 電源トランス
WO2002017335A1 (fr) * 2000-08-18 2002-02-28 Mitsubishi Denki Kabushiki Kaisha Transformateur pour allumeur
DE10148133A1 (de) * 2001-09-28 2003-04-24 Ascom Energy Systems Ag Bern Flachtransformator mit gesteckten Sekundärwicklungen
ES2197830B1 (es) * 2002-06-26 2005-01-01 Premo, S.A. Procedimiento para la fabricacion de transformadores planares y transformador planar fabricado de acuerdo con el mismo.
US7429908B2 (en) * 2002-10-01 2008-09-30 Det International Holding Limited Coil form
US7439838B2 (en) * 2005-09-09 2008-10-21 Delta Electronics, Inc. Transformers and winding units thereof
US7439839B2 (en) * 2006-01-30 2008-10-21 Nemic-Lambda Ltd. High-current electrical coil, and transformer construction including same
EP1826785B1 (fr) * 2006-02-23 2010-09-08 POWER ONE ITALY S.p.A. Transformateur et circuit comportant un tel transformateur
DE202006013658U1 (de) * 2006-09-06 2008-01-24 Vogt Electronic Components Gmbh Transformator mit Steckblechwicklung

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EP2523198A1 (fr) 2012-11-14

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