Inductive component with improved heat dissipation

Abstract

The invention relates to an inductive component (1) with a winding (20) which is wound around a winding axis (22) and has a winding opening (21) in which a magnetic core (50) sits, and with a heat dissipation device which is provided to dissipate power loss, occurring during operation of the inductive component (1), towards a wall part (61) of the inductive component (1). The invention is characterised by the following features: - the winding axis (22) is parallel to the wall part (61), - the heat dissipation device has, on both sides of the winding opening (21), heat dissipation elements (70) which project at least partially into the winding opening (21), and - the heat dissipation elements (70) are at least partially coupled to the wall part (61) in a thermally conductive manner.

Description

[0001] Inductive component with improved all-clear signal

[0002] The invention relates to an inductive component according to the features of the preamble of claim 1.

[0003] Such an inductive component is known, for example, from EP 2 801 987 B1. The inductive component has at least one winding which is thermally coupled to a cooling element via a thermally conductive insulator. The insulator is provided in this case in a jacket-like manner and at least partially encloses the winding in a surface-fitting manner. The cooling element is designed as a housing which accommodates the at least one winding and has an interior space, the inner contour of the interior space of the housing being adapted to the outer contour of the insulator. The housing, which is preferably made of metal, therefore conforms closely to the thermally conductive insulators and thus ensures good heat dissipation and absorption of the power loss of the inductive component.

[0004] Another inductive component, designed as a transformer, is known from DE 10 2011 082 046 A1. For efficient cooling of this known choke, a flat cooling element is provided, which is thermally coupled to the surface of the winding facing away from the magnetic core. For this purpose, a heat-conducting electrical insulator in the form of an electrically insulating heat-conducting foil is provided between this cooling element and the winding.

[0005] Finally, EP 1 501 1056 B1 describes an inductive component, namely a choke, with a segmented magnetic core that can be provided with a heat sink to achieve high power density. Both the winding and the magnetic core of this known choke offer sufficient contact surface for an externally applied passive heat sink.

[0006] For electrical and electronic components that process relatively high levels of power during operation, it is important to ensure good heat dissipation of the power loss that occurs. This problem is exacerbated by the constant demand for ever smaller installation space for these components. This requirement is particularly problematic for power components such as inductive components, which have to be operated at high frequencies due to the ever higher demands on the power to be processed in ever smaller installation space. Such inductive components become relatively hot during power operation and can even overheat and become damaged or cause damage if their performance limit is exceeded.

[0007] This is where the present invention comes in.

[0008] The present invention aims to provide an inductive component that can process high power at a relatively high frequency while at the same time requiring reduced installation space.

[0009] This object is achieved by an inductive component having the features of claim 1.

[0010] Further developments of such an inductive component are the subject of the subclaims.

[0011] The inductive component according to the invention, such as a choke or a transformer, accordingly has a winding which is wound around a winding axis, and a winding opening in which a magnetic or soft magnetic or permanent magnetic core is located. In the following, even when only a magnetic core is mentioned, a permanent magnetic or soft magnetic core is always referred to. The component additionally has a heat dissipation device which is provided for dissipating power losses arising during operation of the inductive component in the direction of a wall part of the inductive component. The wall part can be, for example, a base or side part or cover part of a housing of the component and can preferably be made of metal in order to ensure optimal heat dissipation.

[0012] According to the invention, the inductive component

[0013] - the winding axis is arranged parallel to the wall part,

[0014] - the heat dissipation device has heat dissipation elements on both sides of the winding opening, which protrude at least partially into the winding opening, and

[0015] - the heat dissipation elements are at least partially thermally coupled to the wall section.

[0016] Preferably, said wall part is designed as a cooling part or as a wall part sitting on a cooling part.

[0017] In contrast to conventional cooling devices for inductive components, the present invention provides a cooling device in which cooling elements, preferably consisting of metallic plates, engage in the winding opening on the left and right. This is particularly preferred because such cooling elements allow the power loss already generated inside the component to be optimally dissipated to the outside, toward the wall part of the housing.

[0018] In a further development of the invention, the winding body has at least one U-shaped metal plate with two spaced-apart and at least approximately parallel longitudinal legs, which are preferably connected to a transverse leg in one piece. Support legs projecting beyond the U-shaped metal plate on both sides are arranged at the free ends of the transverse leg. The support legs are provided with fastening means for mounting on a metallic housing of the inductive component. Such an arrangement improves the dissipation of power loss and ensures optimum heat dissipation if the entire winding body is made of metal, such as copper, aluminium or the like.The metallic winding body, with its U-shaped metal plate, engages under the winding on the one hand, and is optimally thermally coupled to the housing for heat dissipation by means of the preferably integrally formed support legs, which are also preferably L-shaped. For example, by the support legs resting flat against the housing or, preferably, being suitably screwed or clamped there.

[0019] For fastening to the housing, the support legs expediently have at least one opening for receiving fastening means, e.g. screws or the like.

[0020] It is also advantageous if two opposing, U-shaped plates, particularly metal plates, are provided with supporting bodies on which the winding sits. Extension plates can be arranged between the opposing U-shaped plates to extend the winding body, if necessary.

[0021] In a further development of the inductive component according to the invention, it is provided that it is arranged encapsulated in the housing.

[0022] Another development of the invention provides that the magnetic core is formed by at least two opposing cores, in particular E-cores or U-cores, which engage with at least one leg, in particular their middle leg, in the winding opening of the winding.

[0023] To further improve the dissipation of power loss, it is provided that heat dissipation elements in the form of preferably E-shaped or U-shaped metal plates are applied to at least one of the cores, preferably to all cores, on both end faces. Each heat dissipation element can have an L-shaped bevel, which at least partially encompasses the rear side of each associated core.

[0024] To further optimize heat dissipation, the heat dissipation elements and the U-shaped metal plates of the winding body are thermally coupled. In particular, they are thermally connected to one another via a wall section or are screwed together via the wall section. The soft magnetic core can, for example, rest on a wall section of the housing designed as a metallic base plate.

[0025] The invention is explained in more detail below using a specific embodiment. Figure 1 shows a perspective view of an embodiment of an inductive component in an exploded view.

[0026] Figure 2 shows a part of a winding body used in Figure 1 in perspective view,

[0027] Figure 3 shows the inductive component of Figure 1 in the assembled state within a housing, also in perspective view,

[0028] Figure 4 shows the inductive component with housing of Figure 3 in plan view from above into the housing interior of the inductive component, and

[0029] Figure 5 is a view similar to Figure 4 from above into the interior of a housing of an inductive component according to a second embodiment.

[0030] In the following figures, unless otherwise stated, like reference symbols designate like parts with like meaning.

[0031] Figure 1 shows a first embodiment of an inductive component according to the invention. The inductive component is designated by the reference numeral 1. The inductive component 1 has a winding 20 which has a winding opening 21. This winding opening 21 is wound around a winding axis 22. In the illustrated embodiment, the winding 20 is not rotationally symmetrical, but has an approximately rectangular winding opening 21 which extends from left to right through the winding 20. This winding opening 21 spans a plane which is perpendicular to the winding axis 22. The winding 20 therefore has an upper, relatively long side and a relatively long, lower side lying parallel thereto, as well as two narrow sides, one of which faces the viewer in Figure 1. The opposite narrow side, however, is hidden.

[0032] The winding 20 sits on a winding body 30, which is explained in more detail in connection with Figure 2. This winding body 30 consists of two identical or similar parts. One of these parts is shown in Figure 2. The part of the winding body 30 shown in Figure 2 consists, for example, of metal, preferably copper or aluminum, or a plastic or ceramic or a mixture of these materials and is preferably designed in one piece. The part has a first longitudinal leg 31 and a second longitudinal leg 32 extending parallel thereto, which are connected to one another by means of a transverse leg 33. Support legs adjoin the transverse leg 33 on the right and left, namely a first support leg 35 and a second support leg 36, which project significantly beyond the two longitudinal legs 31, 32.As can be seen from Figure 2, the support legs 35, 36 are L-shaped and have a central fastening opening 38 for fastening, in particular screwing, the winding body to the housing of the inductive component 1. As can also be seen from Figure 2, the surface of the transverse leg 33 and the support legs 35, 36 lie in one plane.

[0033] To form a winding body 30, two identical or similar parts, as shown in Figure 2, are placed together in such a way that the upward-facing edges of the longitudinal limbs 31, 32 of two identical parts, as shown in Figure 2, are adjacent to one another or flush with one another. The result is a winding body 30 consisting of two parts, as shown in Figure 1.

[0034] The winding 20 can then be wound onto this winding body 30.

[0035] If necessary, the length of the winding body 30 can be extended by inserting extension plates 21 between the free ends of two opposing parts, as shown in Figure 2.

[0036] Returning to Figure 1, it can be seen that several E-shaped magnetic cores 50 are inserted into the winding opening 21 of the winding 20 on the left and right. In the present example, three E-cores 50 are inserted into the winding opening 21 of the winding 20 on the left, and three similar E-cores 50 are also inserted into the opposite winding opening 21. The E-cores 50 are designed such that their central leg 52 engages as precisely as possible in the opening 21 of the winding 20 and their outer legs 51, 53 engage under or over the winding 20. It is important to ensure that the magnetic cores 50 fill the winding opening 21 as optimally and completely as possible and that they overlap or underlie the winding 20 as optimally and completely as possible.

[0037] As can also be seen from Figure 1, the magnetic cores 50 are placed at a slight distance from one another in their respective row. This is necessary so that heat dissipation elements 70 can optimally at least partially encompass the magnetic cores 50. Ideally, each magnetic core 50 is at least partially encompassed by at least one heat dissipation element 70. The heat dissipation elements 70 are adapted to the outer contour of the magnetic cores 50. In the present case, the heat dissipation elements 70 have side walls which are adapted to the lateral contour of the magnetic cores 50. This means that the walls of the heat dissipation elements 70 are designed as E-shaped metal plates which follow the contour of the E-cores of the magnetic cores 50. On their rear side, these E-shaped metal plates have an L-shaped bend 74 which is adapted to the cuboidal structure of the magnetic cores 50.The E-shaped metal plates have a lower leg 71, a middle leg 72 and an upper leg 73. Two such E-shaped metal plates, which are joined together in a mirror image with their L-shaped fold 74, each form a heat dissipation element 70. Each heat dissipation element 70 can, for example, be made of copper or aluminum or another metal or material with good heat conduction, such as ceramic. Each of these heat dissipation elements 70 is pushed over one of the magnetic cores 50, so that the heat dissipation elements 70, when the inductive component 1 is in the assembled state, engage with their legs 71, 72, 73 in the winding opening 21 of the winding 20, or engage under or over the winding 20.

[0038] As clearly seen in Figure 1, effective heat dissipation from the interior of the inductive component 1 is possible due to the engagement of the heat dissipation elements 70 in the winding opening 21, or above and below the winding 70, as well as the metallic construction of the winding body 30. This heat dissipation is further improved by the fact that both the heat dissipation elements 70 and the winding body 30 are thermally coupled to at least one metallic plate or wall of the housing of the inductive component.

[0039] While in Figure 1 only a base plate 61 of the inductive component 1 is indicated, Figure 3 shows the installation of the inductive component 1 in the preferably metallic housing 60. The housing 60 of Figure 3 has a base plate 61, two elongated side walls 62, 63 and two shorter side walls 64, 65. A cover part has been omitted in Figure 3 for the sake of clarity. The fastening openings 38 of the support legs 35, 36 of the winding body 30, already explained in connection with Figures 1 and 2, are aligned with fastening openings 81 of the housing 60, so that the housing 60 can be fastened, in particular screwed, to the winding body 30 of the inductive component 1. This tightening of the preferably metallic side walls 62, 63 of the housing 60 ensures optimal two-sided heat dissipation from the inductive component 1 to the base plate 61 of the housing 60.Since the heat dissipation elements 70 rest flat against the side walls 62, 63 of the housing 60, optimal heat dissipation from both sides of the inductive component 1 can be ensured. The side parts 62, 63 are expediently connected to a thermal sink, e.g., the base part and / or a cooling part, which may be connected to the base part of the housing 60. Alternatively, the base part can also rest on a cooling part or cooling element.

[0040] Figure 4 shows the housing of Figure 3 with a view from above of the inductive component. Here, the support legs 35, 36 are designed as cuboid-shaped structures. Unlike in the previous exemplary embodiments, these support legs 35, 36 are now preferably designed as one piece or, in particular, as structures positively connected to the housing 60, so that the transverse leg(s) 33 of the winding body 30 are connected, in particular screwed or soldered, to this support leg 35, 36.

[0041] Figure 5 shows a view similar to Figure 4, but a housing variant in which the corners of the housing 60 fit directly against the projection of the winding 20, which projects from the magnetic cores 50 on the left and right. The arrangement essentially corresponds to the arrangement in Figure 4, although the cuboid-shaped support legs 35, 36 shown there have been omitted. Such a housing structure can, for example, be produced from a flat metal plate with a suitable cut and suitable bending lines. Otherwise, the structure in Figure 5 corresponds to that explained in connection with Figures 1 to 4.

[0042] Reference symbol list

[0043] 1 Inductive component

[0044] 20 windings

[0045] 21 Winding opening

[0046] 22 Winding axis

[0047] 30 winding bodies

[0048] 31 first longitudinal leg

[0049] 32 second longitudinal leg

[0050] 33 cross legs

[0051] 35 first support leg

[0052] 36 second support leg

[0053] 38 Mounting hole

[0054] 40 extension plate

[0055] 50 E-core, magnetic core

[0056] 51 lower leg

[0057] 52 middle thigh

[0058] 53 upper thigh

[0059] 60 metallic housing

[0060] 61 Wall part, in particular metallic floor part

[0061] 62 side panel

[0062] 63 side panel

[0063] 64 70 Heat dissipation element, E-shaped metal plate

[0064] 71 lower leg

[0065] 72 middle thigh

[0066] 73 upper thigh

[0067] 74 L-shaped bend

[0068] 81 Mounting hole

Claims

Patent claims 1. Inductive component (1) with a winding (20) which is wound around a winding axis (22) and has a winding opening (21) in which a soft magnetic or magnetic core (50) is located, and with a heat dissipation device which is provided for dissipating power losses arising during operation of the inductive component (1) in the direction of a wall part (61) of the inductive component (1), characterized by the following features: - the winding axis (22) is arranged parallel to a wall part (61), - the heat dissipation device has heat dissipation elements (70) on both sides of the winding opening (21), which protrude at least partially into the winding opening (21), and - the heat dissipation elements (70) are at least partially thermally conductively coupled to the wall part (61).

2. Inductive component (1) according to claim 1, characterized in that the wall part (61) is a preferably metallic bottom part or side part of the inductive component (1).

3. Inductive component (1) according to claim 1 or 2, characterized in that - the winding body (30) has at least one U-shaped metal plate with two spaced-apart and at least approximately parallel longitudinal legs (31, 32), which are preferably connected in one piece to a transverse leg (33), - supporting legs (35, 36) projecting beyond the U-shaped metal plate on both sides are arranged on the free edges of the transverse leg (33), and - the support legs (35, 36) are provided with fastening means (38) for mounting on a metallic housing (60) of the inductive component (1).

4. Inductive component (1) according to claim 3, characterized in that the support legs (35, 36) are L-shaped.

5. Inductive component (1) according to claim 3 or 4, characterized in that the Support legs (35, 36) are integrally formed onto the U-shaped metal plate.

6. Inductive component (1) according to claim 3, 4 or 5, characterized in that the support legs (35, 36) have at least one opening for receiving fastening means.

7. Inductive component (1) according to one of the preceding claims, characterized in that two opposing, U-shaped plates, in particular metal plates, are provided with supporting bodies (35, 36) on which the winding (20) sits.

8. Inductive component (1) according to claim 7, characterized in that extension plates (40???) are arranged between the opposing U-shaped plates.

9. Inductive component (1) according to one of the preceding claims, characterized in that the U-shaped metal plate is formed from copper or aluminum.

10. Inductive component (1) according to one of the preceding claims, characterized in that the inductive component is arranged encapsulated in the housing (60).

11. Inductive component (1) according to one of the preceding claims or according to the preamble of claim 1, characterized in that the magnetic core (50) is formed by at least two opposing cores, in particular E-cores or U-cores, which engage with at least one leg, in particular their middle leg (50), in the winding opening (21) of the winding (20).

12. Inductive component (1) according to claim 11, characterized in that on at least one of the cores (50), preferably on all cores (50), in each case on the two end faces, heat dissipation elements (70) in the form of preferably E-shaped metal plates (70) are applied.

13. Inductive component (1) according to claim 12, characterized in that each heat dissipation element (70) has an L-shaped bevel (74) which surrounds a rear side of each associated core (50).

14. Inductive component (1) according to claim 12 or 13, characterized in that the Heat dissipation elements (70) and the U-shaped metal plates of the winding body (30) are thermally coupled and in particular lie touching one another.

15. Inductive component (1) according to one of the preceding claims, characterized in that the magnetic core (50) sits on the wall part (61) designed as a metallic base plate.

16. Inductive component (1) according to one of the preceding claims, characterized in that several E-cores (50) or U-cores are inserted in pairs next to one another into the winding opening (21) of the winding (20).

17. Inductive component (1) according to one of the preceding claims Claims, characterized in that the winding (20) sits on a winding body (30).

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