U.S. patent application number 13/524154 was filed with the patent office on 2012-11-29 for flat band winding for an inductor core.
Invention is credited to Franc Zajc.
Application Number | 20120299681 13/524154 |
Document ID | / |
Family ID | 47218835 |
Filed Date | 2012-11-29 |
United States Patent
Application |
20120299681 |
Kind Code |
A1 |
Zajc; Franc |
November 29, 2012 |
FLAT BAND WINDING FOR AN INDUCTOR CORE
Abstract
The invention provides a flat band winding for an inductor core
comprising at least one insulated conductive flat band having a
first linear region, a second linear region, and a third linear
region, wherein the third linear region is substantially
orthogonally connected to said first linear region and to said
second linear region such that said first linear region and said
second linear region are displaced by a distance and run in
parallel or anti-parallel, and wherein said first linear region and
said second linear region are wound in opposite directions around
the inductor core and around said third region.
Inventors: |
Zajc; Franc; (Medvode,
SI) |
Family ID: |
47218835 |
Appl. No.: |
13/524154 |
Filed: |
June 15, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13116699 |
May 26, 2011 |
|
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13524154 |
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Current U.S.
Class: |
336/180 ;
336/223 |
Current CPC
Class: |
G11B 5/17 20130101; Y10T
29/4902 20150115; Y10T 29/49075 20150115; H01F 27/26 20130101; Y10T
29/49078 20150115; H01F 27/25 20130101; H01F 27/263 20130101; H01F
27/2847 20130101; H01F 7/06 20130101; H01F 27/2828 20130101; Y10T
29/49126 20150115; H02K 15/03 20130101; H01F 2027/2861 20130101;
H01F 27/245 20130101; H01J 3/08 20130101; H01J 3/14 20130101; H02K
15/024 20130101; H01F 7/127 20130101 |
Class at
Publication: |
336/180 ;
336/223 |
International
Class: |
H01F 27/32 20060101
H01F027/32 |
Claims
1. Flat band winding for an inductor core, comprising: at least one
insulated conductive flat band having a first linearregion, a
second linear region, and a third linearregion, wherein the third
linear region is substantially orthogonally connected to said first
linear region and to said second linear region such that said first
linear region and said second linear region are displaced by a
distance and run in anti-parallel, and wherein said first linear
region and said second linear region are wound in opposite
directions around the inductor core and around said third
region.
2. Flat band winding for an inductor core, comprising: at least one
insulated conductive flat band having a first linear region, a
second linear region, and a third linear region, wherein the third
linear region is substantially orthogonally connected to said first
linear region and to said second linear region such that said first
linear region and said second linear region are displaced by a
distance and run in parallel, and wherein said first linear region
and said second linear region are wound in opposite directions
around the inductor core and around said third region.
3. Flat band winding of claim 1, wherein a width b1 of the first
linear region is equal to a width b1 of the second linear region,
and wherein a width b2 of the third linear region is 2.times.b1+S,
where S is the given distance.
4. Flat band winding of claim 1, wherein the first linear region,
the second linear region and the third linear region are
rectangular.
5. Flat band winding of claim 1, wherein a plurality insulated
conductive flat bands is isolatedly stacked on top of each
other.
6. Flat band winding of claim 1, wherein a first and second
insulated conductive flat bands are isolatedly stacked on top of
each other such that there is a crossover such that on one side the
first linear region of the first insulated conductive flat band
lies above the first linear region of the second insulated
conductive flat band, and on the other side the second linear
region of the first insulated conductive flat band 5a lies below
the second linear region of the first insulated conductive flat
band 5a lies below the second linear region of the second insulated
conductive flat band.
7. Flat band winding of claim 2, wherein a width b1 of the first
linear region is equal to a width b1 of the second linear region,
and wherein a width b2 of the third linear region is 2.times.b1+S,
where S is the given distance.
8. Flat band winding of claim 2, wherein the first linear region,
the second linear region and the third linear region are
rectangular.
9. Flat band winding of claim 2, wherein a plurality insulated
conductive flat bands is isolatedly stacked on top of each other.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 13/116,699, filed May 26, 2011, the contents of which are
hereby incorporated by reference
[0002] This invention relates to a flat band winding for an
inductor core
STATE OF THE ART
[0003] U.S. Pat. No. 7,573,362 B2 discloses a high-current,
multiple air gap, conduction-cooled, stacked lamination inductor.
Particularly, the magnetic core section of this known inductor
includes substantially rectangular profiled magnetic laminations
arranged in a stack.
[0004] Generally, in order to reduce the size of power electronics
devices, converters are designed which use working frequencies that
for small power converters up to 10 V have risen into the MHz
range. The research of middle power converters up to 200V and high
power converters up to 500V is seeking to reach frequencies in the
range of 300 kHz up to 1 MHz.
[0005] In such converters, the inductor presents an important part
regarding the losses and the size. Particularly, the inductor's
size should be minimal, and if possible, the inductor shape should
be square and the inductor should have the lowest possible AC/DC
resistance ratio at the desired working frequency. In the existing
inductors which are used in the high frequency area the skin
effect, proximity effect and fringing effect are the reason for
comparatively high losses and correspondingly required big
size.
[0006] In order to obtain the smallest possible inductor with a low
DC resistance the majority of the known switching converter
inductors is wound with a circular or squared wire on different
shape ferrite cores with one or two air gaps. Better results are
reached with inductors having their winding enclosed in powder
material which due to low permeability replaces the air gap.
[0007] Relatively best results are achieved by the prior art
inductor shown in FIG. 14, where TC denotes a toroidal ferrite core
with an air gap AG and having strand wire SW wound around the core
TC. The prior art inductors shown in FIG. 14 show a favourable
AC/DC current resistance ratio, however, their field radiation is
high, their size is big, and their shape is inconvenient to be
fixed on a circuit board.
[0008] High-frequency current in circular or square-shape free
wires is conducted only in the wire surface area which is called
skin effect. That effects that the known inductors wound with such
wires to have very low resistance and also high inductivity vary
their resistance with increasing frequency very dramatically.
Therefore, the high-frequency losses make the known inductors only
useful for low alternating current frequencies. The air gap also
contributes to increase the high-frequency losses. The magnetic
flux exits the core in the area of the air gap and enters the
winding causing heating of the winding. Even the replacement of a
single air gap by plural air gaps does not reduce the effect of
this heating phenomenon very much at high frequencies. Although the
effect can be completely eliminated by using a composite ferrite
material as core material, the permeability of a corresponding
inductor depends very much on the magnetic density. Moreover, the
composite ferrite material has a much lower saturation level than
the sintered ferrite material. This effects that the inductivity of
such composite ferrite material inductors varies drastically with
current changes.
DISCLOSURE OF THE INVENTION
[0009] The invention provides a flat band winding as defined in
independent claims 1 and 2, respectively
[0010] Preferred embodiments are listed in the respective dependent
claims.
ADVANTAGES OF THE INVENTION
[0011] The invention is well suited for high ripple current
applications at high frequencies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the following embodiments of the invention will be
described with reference to the drawings, wherein:
[0013] FIG. 1 shows a cross-section of a multi gap inductor
core;
[0014] FIG. 2 shows a cross-section of a multi gap inductor core of
FIG. 1 in order to explain a corresponding manufacturing method
thereof;
[0015] FIG. 3, 4 are perspective views in order to explain the step
of separating individual multi gap inductor cores from the hardened
stack manufactured as explained in FIG. 2;
[0016] FIG. 5a is a plain view of a first embodiment of an
insulated conductive flat band used as a winding in connection with
the multi gap inductor core;
[0017] FIG. 5b,c are perspective views of the insulated conductive
flat band shown in FIG. 5a in order to illustrate a first winding
procedure;
[0018] FIG. 6 is a perspective view of the first embodiment of
insulated conductive flat band used as a winding in connection with
the multi gap inductor core after the first winding procedure is
finished;
[0019] FIG. 7 shows a cross-section of a multi gap inductor having
the winding type of FIG. 6;
[0020] FIG. 8 shows a cross-section of a multi gap inductor having
a strand wire winding type;
[0021] FIG. 9a is a plain view of a second embodiment of an
insulated conductive flat band used as a winding in connection with
the multi gap inductor core;
[0022] FIG. 9b,c are perspective views of multiple parallel
windings of the insulated conductive flat band shown in FIG. 9a in
order to illustrate a second winding procedure;
[0023] FIG. 10 is a perspective view of the second embodiment of
multiple parallel windings of insulated conductive flat band used
as a winding in connection with the multi gap inductor core after
the second second winding procedure is finished;
[0024] FIG. 11a,b are plain views of the first example of insulated
conductive flat bands in form of a first and second specially
stacked flat bands used as a winding in connection with the multi
gap inductor core;
[0025] FIG. 12 shows a partial cross-section of a multi gap
inductor core;
[0026] FIG. 13 shows a schematic view of a transformer including a
multi gap inductor core; and
[0027] FIG. 14 shows an example of a inductor core according to the
prior art.
EMBODIMENTS OF THE INVENTION
[0028] Throughout the figures, the same reference signs denote same
or equivalent parts.
[0029] FIG. 1 shows a cross-section of a multi gap inductor
core.
[0030] In FIG. 1 reference sign 1 denotes a multi gap inductor core
according an embodiment of the present invention. The core 1
includes a plurality of seven magnetic lamination sheets 2a-2g made
of a ferrite material with lowest possible losses for the desired
frequency range. Reference sign HA denotes a length axis of the
core 1, i.e. along the staggering direction of the laminations
2a-2g.
[0031] If, for example, the 1 MHz frequency range is desired, an
appropriate ferrite material would be Ferrouxcube 3F45. By
presently known cutting methods a minimum lamination thickness dl
of about 0.2 mm can be reached, allowing the permeability to be low
and to have a good gap distribution.
[0032] Between corresponding pairs of adjacent magnetic laminations
there is provided a corresponding hardened non magnetic and non
conducting glue layer 3a-3f. Each glue layer 3a-3f includes a
spacer means 4 in form of spherical particles made of carbon,
so-called glassy carbon spherical powder, which define a gap G
having a predetermined thickness d2 between each corresponding pair
of magnetic lamination sheets 2a-2g. Since a narrow size diameter
distribution can be obtained by filtering such carbon material, the
diameter d3 of the carbon particles 4 substantially equals the
predetermined thickness d2 of the gap G. In other words, there is a
monolayer of carbon particles included in the hardened glue layers
3a-3f acting as said mechnical spacer means. Only a few carbon
particles per mm.sup.2 are sufficient to ensure a very homogeneous
gap G. The carbon particles are also non magnetic and badly
conductive and solid even at the temperature which develops in the
glue during hardening step, e.g. 180.degree. C. Specifically, the
spacer particles do not influence the magnetic flux and do not
produce any disturbing heating effect.
[0033] The core 1 according to the embodiment of FIG. 1 allows the
production of an inductor having excellent performance and
comparatively low losses in the desired frequency range, here 1
MHz. The total gap of the core of FIG. 1 is the sum of all gaps G
from where the magnetic field is dissipated only in a very small
area causing no additional losses in the winding. The winding
therefore can take the space very close to the core 1.
[0034] FIG. 2 shows a cross-section of a multi gap inductor core of
FIG. 1 in order to explain a corresponding manufacturing method
thereof.
[0035] As depicted in FIG. 2 the desired number of magnetic
lamination sheets 2a-2g is stacked on top of each other, wherein
between the pairs of adjacent magnetic lamination sheets the glue
layers 3a-3f are dispensed by appropriate dispensing means. The
glue layer is a premix of glue and the spherical carbon particles
4.
[0036] In order to obtain the favourable concentration of some
particles per mm.sup.2 the concentration of the particles in the
glue is typically between 0.1 and 3%, preferably 1%. If the volume
concentration is too high there would be the risk that the
particles stick together making the gap thickness d2 inhomogeneous.
On the other hand, if the volume concentration of the particles is
too low, the particles could be not evenly distributed over the
area between adjacent laminations and therefore also make the
thickness d2 inhomogeneous. Despite of these lower and upper
limitations which can normally be found very easily by experiments,
the range of applicable concentrations still stays broad.
[0037] When the stack with the desired number of laminations 2a-2g
and the intervening glue/spacer layers 3a-3f are completed, a
pressure P is applied on the stack such that the spherical carbon
particles 4 can exactly match and define the gap G with the
predetermined thickness d2 according to their own diameters d3.
Depending on the type of glue, e.g. epoxy glue, the hardening can
then be performed at room temperature or elevated temperatures,
while the application of pressure P is continued until the stack is
completely hardened.
[0038] FIG. 3, 4 are perspective views in order to explain the step
of separating individual multi gap inductor cores from the hardened
stack manufactured as explained in FIG. 2.
[0039] It should be mentioned that especially for small core
diameters, the dimensions of the stack orthogonal to the length
axis HA do not correspond to the dimensions of the finished
core.
[0040] In the example of FIG. 2, the dimensions of the hardened
stack 100 are 80 mm width, 50 mm depth, and 25 mm length.
[0041] In order to provide individual cores 1', the hardened stack
100 is cut by means of a wafer saw (i.e. diamond saw) or wire saw
into rows 100a and then into the cores 1', where the laminations
are labelled 2a'-2m' and the glue/spacer layers 3a'-3l'.
[0042] By using an appropriate sawing process arbitrary core shapes
may be obtained, for example, circular shapes as shown in FIG. 4
for the core 1'' including laminations 2a''-2n'' and glue/spacer
layers 3a''-3l''.
[0043] This manufacturing method allows an accuracy of typically 5%
of the inductance value and very small gaps. In a further example,
1.3 mm of gap were distributed among 65 ferrite sheets. The
tolerance accuracy can be improved by sorting out and assembling
together two or more partial core stacks in order to provide air
gaps with desired small tolerances.
[0044] FIG. 5a is a plain view of a first embodiment of an
insulated conductive flat band (also sometimes denoted in the art
as strip) used as a winding in connection with the multi gap
inductor core; and FIG. 5b,c are perspective views of the insulated
conductive flat band shown in FIG. 5a in order to illustrate a
first winding procedure.
[0045] The insulated conductive flat band 5 shown in FIG. 5a-c is
made of insulated conductive material such as copper or aluminum
and includes a first linear region SR, a second linear region SL
and a third linear region SM. The width b1 of the first linear
region SR is equal to the width b1 of the second linear region SL,
and the width b2 of the third linear region SM is 2.times.b1+S,
where S is a given distance. This means that the first and second
linear regions SR, SL are displaced by the distance S.
[0046] Moreover, the first and second linear regions SR, SL are
orthogonally connected to the third linear region SM and run in
anti-parallel directions as may be clearly obtained from FIG. 5a.
Virtual segments SR1-SR5 of the first linear region SR having a
length l are denoted in order to show the folding lines when
winding the insulated conductive flat band 5 around a core
according to an embodiment of the present invention occurs.
Analogously SL1-SL5 denote virtual segments of the second linear
region SL having all the length l which is a little bit larger than
the diameter of the core to be used.
[0047] As may be obtained from FIGS. 5b and 5c the first linear
region SR and the second linear region SL are wound in opposite
directions FU (clockwise) and FG (counter-clockwise) around the
third linear region SM in order to form the winding around the
core.
[0048] FIG. 6 is a perspective view of the first embodiment of
insuiated conductive flat band used as awinding in connection with
the multi gap inductor core after the first winding procedure is
finished.
[0049] A finished winding 5' made of an insulated conductive flat
band as shown in FIGS. 5a-c is shown in FIG. 6. As depicted, it is
preferred that the ends El, E2 of the finished winding 5' are
orthogonal to the length axis HA of the core to be inserted into
the finished winding 5'.
[0050] FIG. 7 shows a cross-section of a multi gap inductor having
the winding type of FIG. 6.
[0051] The finished inductor of FIG. 7 includes a multi gap core
1''' having 20 laminations with intervening glue/spacer layers as
explained in connection with FIGS. 1 and 2 and having a surrounding
winding 5'' in analogy to the winding 5' described with reference
to FIG. 6, however, having a larger number of winding turns.
[0052] As may be clearly obtained from FIG. 7, the gap .beta.
between the core 1''' and the winding 5'' can be made very small.
The section A of FIG. 7 is shown in enlarged form on the right-hand
side of FIG. 7 and also shows the space s which corresponds to the
distance S between the first and second linear regions SR, SL.
[0053] Reference sign V finally denotes a magnetic shielding which
surrounds the inductor according to this embodiment and closes the
magnetic field of the coil.
[0054] FIG. 8 shows a cross-section of a multi gap inductor having
a strand wire winding type.
[0055] In FIG. 8 the laminated core 1''' is surrounded by a strand
wire 50. All further details are the same as described above with
respect to FIG. 7.
[0056] FIG. 9a is a plain view of a second embodiment of an
insulated conductive flat band used as a winding in connection with
the multi gap inductor core; and FIG. 9b,c are perspective views of
multiple parallel windings of the insulated conductive flat band
shown in FIG. 9a in order to illustrate a second winding
procedure.
[0057] The insulated conductive flat band 25 shown in FIG. 9a
includes first linear region SU, a second linear region SO and a
third linear region SM'. As in the example of FIG. 5a, the third
linear region SM' is substantially orthogonally connected to the
first linear region SU and to said second linear region SO, wherein
the first linear region SU and the second linear region SO are
displaced by a distance S, however, in contrast to the example in
FIG. 5a run in parallel. The distance S arises from the difference
of the width b2 of the third linear region SM' and the sum of the
width b1 of the first and second linear regions SU, SO.
[0058] In these examples virtual segments SU1-5U5 of the first
linear region SU and virtual segments S01-505 of the second linear
region SO are depicted in order to clarify the folding lines when
the insulated conductive flat band 25 of FIG. 9a is wound to form a
winding around a core.
[0059] As shown in FIG. 9b a plurality of insulated conductive flat
bands of the 25, 25', 25'', 25''' of the type shown in FIG. 9a is
isolatedly stacked on top of each other. The isolation can be
achieved by using a foil, e.g. Kapton foil a resin or a native or
artificial oxide on the surface of the insulated conductive flat
bands 25, 25', 25'', 25'''.
[0060] As may be obtained from FIG. 9c, the stack of insulated
conductive flat bands 25,25',25'', 25''' shown in FIG. 9b is then
wound in opposite directions FU (clockwise) and FG (anti-clockwise)
around the third linear regions of the insulated conductive flat
bands 25, 25', 25'', 25''' in order to form the winding around a
core.
[0061] FIG. 10 is a perspective view of the second embodiment of
multiple parallel windings of insulated conductive flat band used
as a winding in connection with the multi gap inductor core after
the second winding procedure is finished.
[0062] The final winding shape is shown in FIG. 10, wherein the
ends E1', E2' are also bend orthogonal to the length axis HA of the
core in accordance with the embodiments of the present invention to
be inserted into the wound winding.
[0063] In the embodiment shown in FIG. 10 the outer flat band 25 on
one side becomes the inner flat band on the other side when wound
in opposite directions FU, FG. This contributes to counteract the
proximity effect which otherwise would tend to shift the
high-frequency current in the outermost flat band area. In
particular, the stack sequence change equalizes the induced voltage
along the bands in order to avoid a current along the bands.
[0064] FIG. 11a,b are plain views of the first embodiment of
insulated conductive flat band in form of a first and second
specially stacked flat bands used as a winding in connection with
the multi gap inductor core.
[0065] In the embodiment shown in FIG. 11 a winding around a core
in accordance with the embodiments described is made of two
insulated conductive flat bands 5a, 5b of the type shown in FIG. 5a
which are specially stacked on top of each other in an isolated
manner.
[0066] In the insulated conductive flat bands 5a, 5b shown in FIG.
11a SRa, SRb denote the corresponding first linear region of the
first and second flat band 5a, 5b and SLa, SLb denote the
corresponding second linear region of the flat bands 5a, 5b,
whereas SMa and SMb correspond to a respective third linear region
connecting the first and second linear regions of the flat bands
5a, 5b.
[0067] Before being wound the insulated conductive flat bands 5a,
5b shown in FIG. 11a are stacked isolatedly on each other such that
there is a crossover such that on one side the first linear region
SRa of the first insulated conductive flat band 5a lies above the
first linear region SRb of the second insulated conductive flat
band 5b, however, on the other side the second linear region SLa of
the first insulated conductive flat band 5a lies below the second
linear region SLb of the second insulated conductive flat band 5b.
In the crossover region there is a small lateral gap S'.times.S
between the insulated conductive flat bands 5a, 5b.
[0068] When winding the stacked arrangement of the first and second
insulated conductive flat bands 5a, 5b shown in FIG. 11b it also
becomes possible like in the embodiment shown in FIG. 10 that the
outer flat band on one side becomes the inner flat band on the
other side when wound in opposite directions FU, FG. This
contributes to counteract the proximity effect which otherwise
would tend to shift the high-frequency current in the outermost
flat band area.
[0069] FIG. 12 shows a partial cross-section of another multi gap
inductor core.
[0070] In this embodiment, spacer means 4' includes a
photolithgraphically structured Al.sub.2O.sub.3 layer having a
plurality of cube shape bumps 4' between which the hardended fixing
layers 3f etc. are provided. Here the fixing layer 3f is not made
of glue but of adhesive wax.
[0071] FIG. 13 shows a schematic view of a transformer including a
multi gap inductor core.
[0072] In FIG. 13 reference sign 1 denotes a multi gap inductor
core according to the embodiment of the present invention shown in
FIGS. 1, and W1, W2 denote a primary and secondary winding wound
around the core so as to form a transformer T.
[0073] Although the present invention has been described with
reference to particularly embodiments, various modifications can be
performed without departing from the scope of the present invention
as defined in the independent claims.
[0074] In particular, the spacer means is not restricted to the
specified carbon particles or Al.sub.2O.sub.3 bumps, but other
materials, e.g. sand particles or quartz particles, or spacer foils
or meshes may be used as well. Also the shape of the particles or
bumps is not restricted to the circular or square cube shape, but
can have various other shapes, such as polyedral shape, etc.,
however, it still is important that the diameter distribution is
narrow enough to achieve the desired homogeneity of the gap
thickness between the individual laminations.
[0075] Moreover, various materials can be used for the laminations,
the fixing material and the windings, and the invention is not
restricted to the materials and dimensions mentioned hereinbefore.
E.g. further examples of the fixing material are Teflon, resist and
grease which can be sufficiently hardenend.
* * * * *