Three-phase transformer for isolated voltage converter

Abstract

Three-phase transformer (15) for an insulated voltage converter (12), comprising: - a magnetic circuit (22), comprising a first part and a second part, each part comprising: a base (26) of substantially triangular outline, and three pads (27) each extending towards the base of the other part of the magnetic circuit, - three supports (30) for electrical conductors (31, 32), each support (30) being mounted on two facing pads (27) belonging respectively to one and the other of the parts of the magnetic circuit, each support (30) for electrical conductors carrying two electrical windings in inductive coupling with each other via the magnetic circuit, - a housing (50) in which the supports (30) for electrical conductors, the electrical windings and the magnetic circuit (22) are arranged, and - a connection terminal block (45), in particular fixed to the housing (50),and defining six terminals (60) for the connection of the three-phase transformer to the rest of the isolated voltage converter, the six terminals (60) being distributed between two distinct zones (Z1, Z2) at a distance from each other around the perimeter of the magnetic circuit (22). Abstract figure: Fig.22,

Description

Title of the invention: Three-phase transformer for isolated voltage converter

[0001] The present invention relates to a three-phase transformer for an isolated voltage converter, such a voltage converter being for example integrated into a component for the electrical power supply of a vehicle electrical energy storage unit, also called a "charger" of this electrical energy storage unit. The electrical energy storage unit is for example a battery, which may have a nominal voltage greater than 60V, for example greater than or equal to 300V, 400V, 800V, or even 1000V. The voltage converter receives for example an alternating voltage from an electrical network and supplies the battery with a direct voltage. This converter can convey a power greater than 5kW, for example greater than 7kW, for example greater than 1kW, in particular 22kW or more.

[0002] It is known to connect the transformer to the rest of the converter's electrical circuit to make a direct connection to an electronic card arranged above the transformer. This results in space problems in arranging the card precisely above the transformer, and the need to carry out wave soldering in the assembled converter.

[0003] Application CN 110 223 831 discloses a transformer with a magnetic circuit having legs extending continuously between two Y-shaped bases.

[0004] There is a need to overcome the aforementioned drawbacks. The invention aims to meet this need and achieves this, according to one of its aspects, by means of a three-phase transformer for an isolated voltage converter, comprising:

[0005] - a magnetic circuit, comprising a first part and a second part, each part comprising: a base of substantially triangular outline, and three pads each extending towards the base of the other part of the magnetic circuit,

[0006] - three electrical conductor supports, each support being mounted on two pads opposite belonging respectively to one and the other of the parts of the magnetic circuit, each support of electrical conductors carrying two electrical windings in inductive coupling with each other via the magnetic circuit,

[0007] - a housing in which the supports of electrical conductors, the windings electrical and magnetic circuit are arranged, and

[0008] - a connection terminal block, in particular fixed to the housing, and defining six terminals for the connection of the three-phase transformer to the rest of the isolated voltage converter, the six terminals being distributed between two separate areas and at a distance from each other on the perimeter of the magnetic circuit.

[0009] According to the invention, the connection terminal block with two separate areas for the connection terminals allows a less constrained environment for connecting the transformer to the rest of the voltage converter. Furthermore, the fact of not concentrating the six or more connection terminals in the same place of the transformer makes it possible to limit heating linked to the presence in a constrained environment of capacitors to which these terminals are connected on the rest of the voltage converter side.

[0010] The terminal block can extend around the entire perimeter of the magnetic circuit.

[0011] Each terminal of the terminal block is respectively connected to one of the electrical conductors.

[0012] Each area of ​​the terminal block can define exactly three terminals for the connection of the three-phase transformer to the rest of the isolated voltage converter. One of the areas of the terminal block corresponds, for example, to the terminals for the connection on the primary side of the transformer, while the other area of ​​the terminal block corresponds to the terminals for the connection on the secondary side of the transformer. The primary and secondary side connections are thus grouped on different sides of the transformer.

[0013] Each base of the magnetic circuit having a substantially triangular contour, this contour has for example only three sides, except where appropriate at the level of the vertices of the triangle which can be defined by a rounding.

[0014] Each area of ​​the terminal block containing terminals may be arranged opposite a vertex of one of the bases of the magnetic circuit. Where appropriate, each vertex of a base is rounded and the inner contour of the terminal block matches these rounded edges. Within an area containing the terminals, the distance between two consecutive terminals may not remain constant.

[0015] The terminal block may comprise a body and a plurality of electrically conductive bars, each terminal being defined by a portion of a bar. Each electrically conductive bar has, for example, a portion, opposite the portion defining the terminal, which is electrically connected to one of the electrical conductors, for example via a hollow sleeve inside which the conductor is inserted and fixed by crimping or soldering.

[0016] Each portion of a bar defining a terminal is for example a flat portion, capable of coming into contact with an electrical track of an electronic card for connecting the transformer to the rest of the voltage converter.

[0017] Each electrically conductive bar may locally comprise a hole and the fixing of this electrically conductive bar on the body is carried out by means of a screw received in this hole.

[0018] According to an exemplary implementation, the body may comprise a plurality of housings, each housing cooperating with an electrically conductive bar for fixing the latter to the body, the fixing screw of the bar being received in the housing. In this implementation example, the bar is fixed directly to the body using a screw, without any intermediate piece.

[0019] According to another exemplary implementation, the body may comprise a plurality of housings, each housing comprising an insert forming a hole, each insert cooperating with an electrically conductive bar for fixing the latter on the body, the screw for fixing the bar being received in an insert hole. In this other exemplary implementation, the fixing of the bar on the body is done via the screw and the insert received in the housing. Such fixing via an insert may be more robust.

[0020] When inserts are present, each insert may define a positioning relief for the portion of the electrically conductive bar defining the hole. Such an insert may, in addition to the aforementioned robustness, also assist in positioning the portion of the electrically conductive bar on the body of the terminal block.

[0021] The aforementioned screws can allow the fixing of the electrically conductive bars on the electronic card with which the connection of the transformer to the rest of the voltage converter is made, in addition to allowing the fixing of these electrically conductive bars on the body of the terminal block.

[0022] Regardless of whether or not an insert is present, the outer wall of each housing may provide a recess capable of accommodating an end portion of the electrically conductive bar, in order to ensure correct positioning of this bar.

[0023] In all of the above, the body of the terminal block may be made of plastic, for example plastic such as polybutylene terephthalate (PBT), or polyamide (PA).

[0024] Each insert may be made of metal, in particular steel. Alternatively, each insert may be made of composite material. Six inserts are provided, for example, and all of these inserts may have the same shape and / or the same dimensions.

[0025] Each terminal may be defined by a portion of an electrically conductive bar carried by a first surface of the terminal block body, and the terminal block body may carry, on a second surface opposite the first surface, a relief for fixing to the transformer housing. The transformer housing may contain the support for electrical conductors, the electrical windings and the magnetic circuit. The transformer housing may comprise a housing body and a cover closing this body. The housing body comprises for example a bottom wall and a side wall extending from the bottom wall and interposed between the bottom wall and the cover. The cover may have a plate shape. The fixing relief of the second surface of the terminal block body cooperates for example with a complementary relief carried by the upper end of the side wall of the housing body.The fixing relief of the terminal block body is for example of the male type such as a pin, in which case the fixing relief of the housing body is of the female type such as a . housing for the pin. The opposite is possible, namely a female type fixing relief for the terminal block body and a male type for the housing body.

[0026] The body of the housing may be filled with a resin capable of being polymerized to harden and immobilize the elements arranged inside the body ("potting" in English).

[0027] Each pad may have its portion extending from the base of the part of the magnetic circuit which is made in one piece with this base of the part of the magnetic circuit.

[0028] From one part of the magnetic circuit to the other, the pads may extend towards the base of the other part of the magnetic circuit over the same height. In other words, the height of the pads carried by one part of the magnetic circuit from its base may be equal to the height of the pads carried by the other part of the magnetic circuit from its base.

[0029] Two pads belonging respectively to a part of the magnetic circuit and facing each other can define a leg of the magnetic circuit and this leg can have at least three air gaps, in particular exactly three air gaps.

[0030] Each electrical conductor support may comprise:

[0031] - a wall around which the electrical windings are arranged, this wall defining in particular a hollow cylinder of circular cross-section, and

[0032] - three edges offset along the longitudinal axis of the support, so that one of the one of the electrical windings is arranged between the first and second rims and the other of the electrical windings is arranged between the second and third rims.

[0033] The electrical conductor supports can be arranged relative to each other so that the axes of their walls are parallel.

[0034] The gap between two consecutive edges can be constant or vary.

[0035] In other words, the two electrical windings carried by a support of electrical conductors can follow one another along this support, without overlapping along planes perpendicular to the longitudinal axis of this support.

[0036] For the purposes of this application:

[0037] - "axially" or "longitudinally" or the term "height" means "the along the axis of the support wall around which the electrical windings are arranged”,

[0038] - “angularly” or “circumferentially” means “moving around this axis of the support wall”, and

[0039] - “radially” means “in a plane perpendicular to this axis, along a straight line intersecting this axis” when this wall defines a hollow cylinder of circular cross-section.

[0040] The body of the terminal block may comprise two walls extending along the axis of the wall of the support beyond this support, these two walls being offset and defining between them a guide channel receiving at least one of the electrical conductors outside the electrical winding that it defines. The body of the terminal block can thus define a guide piece for all or part of the electrical conductors of the transformer. This guide piece is here separate from the support of the electrical conductors.

[0041] Each electrical conductor of the transformer is for example guided between the two walls of the terminal block body outside the electrical winding that it defines. In this case, the terminal block body defines a common guide piece for all the electrical windings of the transformer. This guidance can then only be carried out on one side, axially speaking, of the transformer.

[0042] The two walls carried by the body of the terminal block may extend over all or part of the perimeter of the magnetic circuit, and each zone of the terminal block defining terminals may form a radially external protrusion relative to these two walls. Each zone of the terminal block defines, for example, an ear relative to the space delimited externally by the two walls.

[0043] In all of the above, the body of the terminal block can be made of plastic. The body of the terminal block is for example made in a single piece. When this body of the terminal block also serves as a guide piece for the electrical conductors outside the windings, it is possible, when this body of the terminal block is in a single piece, to ensure the guidance and the electrical connection to the outside of the transformer using a single piece.

[0044] In all of the above, the three electrical conductor supports may be arranged to define a geometric pattern being an equilateral triangle. This arrangement of the three electrical conductor supports according to an equilateral triangle may make it possible to ensure a balance between the electrical parameters such as the inductances of the electrical windings and reduce the magnetic volume.

[0045] The housing may have a substantially triangular outline, in particular an equilateral triangle.

[0046] The transformer may be devoid of a cooling circuit internal to the housing implementing a circulation of liquid, in particular oil, in the housing.

[0047] The invention also relates, according to another of its aspects, to a component for the electrical power supply of a vehicle electrical energy storage unit, comprising the transformer defined above. The electrical energy storage unit is for example a battery which may have one of the nominal voltages above.

[0048] The invention may be better understood by reading the following description of non-limiting examples of its implementation and by examining the attached drawing in which:

[0049] The invention may be better understood by reading the following description. non-limiting examples of its implementation:

[0050] - [Fig.l] schematically represents a part of the electrical circuit of a component for the power supply of a vehicle electrical energy storage unit

[0051] - [Fig.2] shows in elevation an example of a three-phase transformer which can be used in the circuit of [Fig.l],

[0052] - [Fig.3] represents in isolation the magnetic circuit of the three-phase transformer of [Fig.2],

[0053] - [Fig.4] partially represents the three-phase transformer of figures 2 and 3 when the case cover is removed

[0054] - [Fig.5] represents a detail of an example of a system for holding the cover of the transformer housing on the bracket,

[0055] - [Fig.6] represents the cover of the housing of [Fig.4],

[0056] - [Fig.7] represents in isolation the body of the terminal block visible in [Fig.2],

[0057] - [Fig.8] represents the body of [Fig.7] in which inserts are arranged,

[0058] - [Fig.9] represents the terminal block of figures 7 and 8 with electrically connected bar driver and screw,

[0059] - [Fig. 10] represents the face of the transformer opposite to that shown on the [Fig.4],

[0060] - [Fig. 11] is a view of the transformer's electrical conductor support from the same side as [Fig. 10], and shows the support holding system on the magnetic circuit and the support holding system on the transformer housing body carried by this support

[0061] - [Fig. 12] represents the body of the transformer housing on which the support of electrical conductors of [Fig. 11],

[0062] - [Fig. 13] is a view similar to [Fig. 11] and also shows ribs allowing the distance of this support from the portion of the magnetic circuit on which it is mounted,

[0063] - [Fig. 14], [Fig. 15] and [Fig. 16] are views similar to that of [Fig. 13], when the electrical conductor support is mounted on the portion of the magnetic circuit,

[0064] - [Fig. 17] is a side sectional view of [Fig. 16],

[0065] - [Fig. 18] represents three supports of electrical conductors of the transformer and their electrical conductors, in the absence of the magnetic circuit,

[0066] - [Fig. 19] represents in isolation one of the three supports of electrical conductors of [Fig. 18] with its electrical conductors,

[0067] - [Fig.20] represents the support of electrical conductors of [Fig. 19] without its electrical conductors,

[0068] - [Fig.21] represents, in a similar way to [Fig.2], another example of trans- three-phase trainer differing among other things in the way in which the cover is held,

[0069] - [Fig.22] represents, in a similar manner to [Fig.2], a three-phase transformer according to an example of implementation of the invention,

[0070] - [Fig.23] represents the transformer of [Fig.22] with the housing shown,

[0071] - [Fig.24] shows in isolation the guide piece and the supports electrical winding of the transformer of figures 22 and 23,

[0072] - [Fig.25] shows in isolated top view the guide part of the [Fig.24],

[0073] - [Fig.26] shows a bottom view of the guide part of [Fig.25],

[0074] - [Fig.27] represents in isolation an electrical winding support of the trans trainer of figures 22 and 23, and

[0075] - [Fig.28] is another view of the electrical winding support of [Fig.27].

[0076] [Fig.l] shows a part of the electrical circuit 1 of a component for the electrical power supply of a vehicle electrical energy storage unit. This component is also called a “charger”. The electrical energy storage unit, not shown in this [Fig.l], is for example a battery, which may have a nominal voltage greater than 60V, for example greater than or equal to 300V, 400V, 800V, or even 1000V.

[0077] The circuit 1 receives as input an alternating voltage from a network (not shown) which is three-phase here. A rectifier for converting this alternating voltage into a direct voltage, and also performing a power factor correction function (in English), if necessary, is arranged upstream of a direct bus 11. Downstream of this direct bus, from the electrical network, is arranged an isolated voltage converter 12, here being a DC / DC. This converter 12 comprises, in a known manner, an inverter 14, a three-phase transformer 15, and a rectifier 16 supplying the vehicle with a direct voltage isolated from the electrical network. As can be seen in [Fig.l], the three-phase transformer 15 is connected to each of the rectifier 16 and the inverter 14 by an inductor block 17 and a capacitor block 18, so as to define a CLLLC structure.Other structures are of course possible, such as an LLC, CLLC, LC or even CL structure.

[0078] As can be seen in [Fig.l], each phase has a primary winding 20 and a secondary winding 21 in inductive coupling with each other, and the primary windings 20 are connected in star and the secondary windings 21 are also connected in star.

[0079] The three-phase transformer 15 comprises in the example considered a magnetic circuit 22, comprising a first part 23 and a second part 24. Each part 23, 24 comprises: a base 26 of substantially triangular outline, and three pads 27 each extending in the direction of the base 26 of the other part of the magnetic circuit- genetic 22. Each base 26 here has an outline defining an equilateral triangle.

[0080] The transformer 15 also comprises three supports 30 of electrical conductors 31, 32, each support 30 being here mounted on two facing pads 27 belonging respectively to one and the other of the parts 23, 24 of the magnetic circuit. Two electrical conductors 31, 32 associated with the same support 30 respectively have a portion defining a primary winding 20 and a portion defining a secondary winding 21. These electrical conductors 31, 32 are for example Litz wire.

[0081] As can be seen in [Fig.2], the three supports 30 of electrical conductors 31, 32 are positioned so as to define an equilateral triangle.

[0082] The transformer 15 further comprises a housing 50 comprising a body 51 closed by a cover 52, which are visible in FIGS. 4, 6 and 21. This body 51 and this cover 52 are for example made of metal, for example aluminum. The supports 30 and the magnetic circuit 22 are arranged inside the housing 50. The body 51 is filled with a resin capable of being polymerized to harden and immobilize the components arranged inside the body (“potting” in English).

[0083] As can be seen in Figures 4, 6 and 21, the housing 50 also has a triangular outline, being more precisely here an equilateral triangle. The housing is in the example considered exclusively formed by the body 51 and the cover 52, but the invention is not limited to a housing 50 consisting of two parts.

[0084] As can be seen in [Fig.3], each pad 27 defines its own air gap 28, for example via an area of ​​the pad 27 filled with non-magnetic material such as a fiberglass-reinforced epoxy resin composite (FR4) or ceramic. This area occupied by this non-magnetic material defines, for example, an entire slice of the pad. Several sections are, for example, assembled with this area of ​​the pad 27 to constitute this pad 27.

[0085] As can be seen in [Fig.3], an additional air gap 29 is present between the opposite ends of two pads 27 belonging respectively to different parts 23, 24 of the magnetic circuit 22. Thus, in the example of magnetic circuit 22 considered, each magnetic field allowing the inductive coupling between a primary winding 20 and a secondary winding 21 crosses exactly three air gaps.

[0086] Still in [Fig.3], it can be seen that the magnetic circuit 22 of the example considered comprises a central leg 40 carried by one of the parts 23, 24 of the magnetic circuit 22. This central leg 40 is here made in a single piece with the part 23 of the magnetic circuit 22 which carries it.

[0087] It can be seen in [Fig. 3] that the central leg 40 extends in this example continuously between two ends each being in contact with one of the bases 26 of the magnetic circuit 22, so that no air gap is provided in the central leg 40.

[0088] It can also be seen in [Fig. 3] or in [Fig. 16] that the central leg 40 has a core 41 and three protrusions 42 extending from this core 41, each protrusion 42 extending between two neighboring pads 27 carried by the same part of the magnetic circuit.

[0089] As can be seen in [Fig.3], in the example considered, each pad 27 has a circular external contour, and each protrusion 42 of the central leg 40 here has a wall opposite the pads 27 of rounded shape.

[0090] As can be seen in [Fig.2], the three-phase transformer 15 comprises a connection terminal block 45. The terminal block 45 here defines six terminals 60 for connecting the three-phase transformer 15 to the rest of the electrical circuit 1, these terminals 60 being shown schematically in [Fig.l]. These terminals 60 here come into contact with electrical tracks of an electronic card not shown. In [Fig.2], and according to an arrangement which is not covered by the claims but useful for understanding the invention, the connection terminal block 45 is fixed to one side of the housing 50 of the three-phase transformer 15 and it has an elongated shape. In this arrangement which is not covered, the six terminals 60 are arranged in a row.

[0091] The various elements of the terminal block 45 according to this example will now be described with reference to Figures 7 to 9.

[0092] The terminal block 45 here comprises a body 61 and a plurality of electrically conductive bars 62, each terminal 60 being defined by a portion 63 of a bar. Each portion 63 is here planar, so as to come into contact with an electrical track of the electronic card mentioned above. The body 61 can be made of plastic, for example PBT, PA, etc.

[0093] Each electrically conductive bar 62 has for example a portion 65, opposite the portion 63 defining the terminal, which is electrically connected to one of the electrical conductors 31, 32, here via a hollow sleeve 66 inside which the conductor 31, 32 is inserted, for example fixed by crimping or welding.

[0094] Each electrically conductive bar 62 locally comprises a hole 67 and the fixing of this electrically conductive bar 62 on the body 61 is carried out by means of a screw 68 received in this hole 67. The body 61 here comprises six housings 69, and each of these housings receives an insert 70 forming a hole 71, the aforementioned screw 68 being received in an insert hole 71. Thus, the fixing of the electrically conductive bar 62 on the body 61 is carried out via the screw 68 and the insert 70 received in the housing 69. Each insert 70 can be made of metal, in particular steel. Alternatively, each insert is made of composite material. Six inserts are for example provided, and all these inserts 70 have in the example considered the same shape and the same dimensions. Each screw 68 can, in addition to ensuring the fixing of an electrically conductive bar 62 on the body 61, also ensure the fixing of the electrically conductive bar 62 on the electronic card not shown.

[0095] As can be seen in [Fig.8], each insert 70 can define a positioning relief 73 of the portion 63 of the electrically conductive bar defining the hole 67. This positioning relief 73 is for example a circular-shaped flat.

[0096] As can be seen in Figures 2, 7 and 8, the outer wall of each housing 69 can provide a recess 75 capable of receiving an end portion 64 of the electrically conductive bar 62, in order to ensure correct positioning of this bar on the body 61 and to avoid any relative rotation between this bar and this body.

[0097] In another example of implementation not shown, the body 61 comprises a plurality of housings 69 which directly receive the screws 68, in the absence of insert 70. In this other example of implementation, the fixing of the electrically conductive bar 62 on the body 61 is done directly via the screw 68, without an intermediate part.

[0098] As can be seen in Figures 4 and 5, each support 30 for electrical conductors can integrate a system 80 for holding the cover 52 on this support 30.

[0099] Each support 30 comprises, for example, a single pin 81 projecting relative to the rest of the support 30 along the longitudinal axis of the latter. As a variant, only two of the three supports of the transformer 15 comprise a pin 81, the third support 30 being devoid of one.

[0100] [Fig.5] shows in detail a pin 81, the latter being able to have a section perpendicular to the longitudinal axis of the support which is cruciform. Each pin 81 of a support 30 of electrical conductors is in the example considered force-fitted into an opening made in the cover 52, as can be seen in [Fig.4]. The relative arrangement of the pins 81 of the supports 30 makes it possible to immobilize the cover 52.

[0101] As can be seen in [Fig. 5], the holding system 80 of the cover 52 on the support 30 can extend along the longitudinal axis of the support 30 on the same side of the support 30 as a guiding system 85 of electrical conductors which will be described with reference to FIGS. 18 to 20.

[0102] In these figures 18 to 20, the holding system 80 is not shown, the guidance system 85 being able to be present without necessarily the holding system 80 being there.

[0103] As can be seen in [Fig.18], each electrical conductor 31, 32 carried by a support 30 of the transformer 15 can be guided outside the winding 20, 21 which it defines.

[0104] In the example considered, each of these conductors 31, 32 is guided by the system guide 85 beyond each of the ends of the electrical winding 20, 21 which it defines. As already mentioned previously, the first ends of the electrical conductors may constitute an output to the electrical circuit 10 outside the transformer 15, and three of the second ends of the electrical conductors may lead to a common point via a star connection to the primary, and three other of these second ends of the electrical conductors may lead to a common point via another star connection to the secondary.

[0105] The support 30 of the two electrical windings 31, 32 comprises:

[0106] - a wall 90 around which the electrical windings 20, 21, and this wall 90 defines in the example considered but in a non-limiting manner a hollow cylinder of circular cross-section, and

[0107] - three edges 92, 93, 94 offset along the longitudinal axis of the support, so that one of the electrical windings 31 is arranged between the first 92 and the second rim 92 and that the other of the electrical windings 32 is arranged between the second 93 and the third 94 rim, as is clearly visible in [Fig.2] for example. The gap between two consecutive rims 92, 93 and 93, 94 remains constant in the example considered.

[0108] The guidance system 85 acts on the electrical conductors on the one hand via clamps 97 and 98, and on the other hand via additional walls 105 and 106.

[0109] In the example of Figures 18 to 20, the guidance system 85 comprises, for each electrical conductor 31, 32, on the one hand a first clamp 97 cooperating with this electrical conductor 31, 32 beyond the first end of the electrical winding 20, 21 that it defines. Such a clamp 97 has for example two arms 99 curved so as to match an area of ​​the contour of this end of the electrical conductor, as shown in [Fig. 18] or 20. This is a circular contour. Each clamp 97 is for example, but in a non-limiting manner, made in a single piece with the rest of the support 30 of electrical conductors. As already explained, each first clamp 97 cooperates for example with a portion of electrical conductor 31, 32 on the way to a connection terminal 60.

[0110] The guidance system 85 further comprises a second clamp 98 cooperating with the electrical conductor beyond the second end of the electrical winding that it defines, these first 97 and second 98 clamps succeeding one another along one of the first 92, second 93 and third 94 edges. As already explained, each second clamp 98 cooperates for example with a portion of electrical conductor 31, 32 on the way to a common point of a star connection.

[0111] More precisely, in the example considered:

[0112] - the first rim 92 comprises two first clamps 97 which each cooperate respectively with one of the electrical conductors 31, 32 beyond the first end of the electrical winding 20, 21 which it defines, and two second clamps 98 which each cooperate respectively with an electrical conductor beyond the second end of this electrical winding 20, 21, and

[0113] - the second rim 93 comprises a first clamp 97, arranged under a first clamp 97 of the first rim 92, and a second clamp 98, arranged under a second clamp 98 of the first rim. The clamps carried by the second rim 94 make it possible to guide the electrical conductor 32 outside the electrical winding arranged between the second rim 93 and the third rim 94.

[0114] It can be seen in Figures 18 to 20 that, along the edge 92, there are two pairs of clamps each formed of a first clamp 97 and a second clamp 98, and that the distance between two pairs of clamps is greater than the distance between two clamps of the same pair.

[0115] It can also be seen in these figures 19 and 20 that the clamps 97, 98 carried by the second rim 93 are aligned along the axis of the cylindrical wall 90 with clamps 97, 98 carried by the first rim 92.

[0116] The two additional walls 105 and 106 of the guidance system 85 will now be described. These two additional walls 105 and 106 are here offset so as to define between them a guidance channel 108 receiving in a stacked manner the electrical conductors 31, 32 outside the windings 20, 21 that they define. The channel 108 here has a constant dimension. These additional walls extend in the example considered on either side of an arcuate portion of the first rim 92, projecting axially beyond this first rim 92. In the overlapping zone of this first rim 92, the additional walls 105 and 106 each define an arcuate portion, the wall 106 having a radius greater than the wall 105, as is also visible in [Fig. 17].

[0117] It can be seen in Figures 18 to 20 that the wall 106 comprises first openings 110 for the passage of the electrical conductors 31, 32 towards the electrical winding 20, 21 that it defines, and second openings 111 in which no electrical winding passes. It can be seen that the first openings 110 are arranged radially opposite a clamp 97, 98.

[0118] In the example of Figures 10 to 12, each support 30 of electrical conductors 31, 32 also integrates a holding system 120 on the body 51 of the housing 50. This holding system 120 here comprises a pin 121, having in this example a section perpendicular to the longitudinal axis of the support which is cruciform. This pin 121 extends axially away from the rest of the support 30 from the third rim 94. As can be seen in Figures 10 and 12, each pin 121 is force-received in an opening 122 formed in the body 51 of the housing 50. This holding system can ensure immobilization of the magnetic circuit 22 on the body 51 of the housing before polymerization of the resin contained in this housing 50.

[0119] When such holding systems 120 exist, they may or may not be combined with the aforementioned holding systems 80 and guide systems 85. As can be seen in FIGS. 10 to 12, each holding system 120 may then extend axially on one side of the support 30 while the holding system 80 and the guide system 85 extend axially on the opposite side of the support 30.

[0120] We will now describe with reference to Figures 13 to 15, a functionality that can be integrated into all or part of the supports 30 of electrical conductors 31, 32. A system 130 for holding the support 30 of electrical conductors 31, 32 on the magnetic circuit 22 is thus provided. This holding system 130 is in the form of two pads 132 projecting relative to the rest of the support 30. When the holding system 120 is provided, these systems 130 and 120 can extend axially on the same side of the support, the pin 121 and a pad 132 being arranged in particular side by side as can be seen in the example of [Fig. 11].

[0121] Each pad 132 here defines a surface 135 coming into contact with a surface 136 of a base 26 of the magnetic circuit 22. The surfaces 135 and 136 are here flat. Each pad 132 is for example supported by a reinforcement 133, as visible in [Fig.11].

[0122] As can be deduced from [Fig. 15], the cooperation between the two pads 132 of a support 30 and the base 26 can ensure rotational immobilization of the support 30 on the magnetic circuit 22.

[0123] We will now describe with reference to figures 13 to 16 another functionality that can be integrated into all or part of the supports 30 of electrical conductors 31, 32. It can be seen in these figures that the cylindrical wall 90 of the support 30 comprises ribs 142 extending away from the wall 90 in the direction of the pad 27 on which this support is mounted.

[0124] In the example considered, six ribs 142 are provided, but the invention is not limited to a precise number of ribs 142. These six ribs 142 thus constitute a spacing system 140 of the cylindrical wall 90, and therefore of the electrical windings 20, 21 which it carries, from the pad 27.

[0125] It can be seen in Figures 13 to 16 that all the ribs 142 can have the same shape and be distributed uniformly around the pad 27.

[0126] It can also be seen in these figures that each rib 142 can extend continuously along the axis of the support 30 from the first rim 92 to the third rim 94.

[0127] In a variant not shown, all or part of the ribs extend discontinuously along the axis of the support 30.

[0128] As can be seen in [Fig. 16], each rib 142 does not extend for example not up to the pad 27 on which the support 30 is mounted. An empty space ensuring easy mounting thus remains present between each end of a rib opposite the pad 27 and this pad 27.

[0129] As already mentioned, each support 30 of electrical conductors 31, 32 can be made from a single piece.

[0130] When this support 30 integrates:

[0131] - the ribs 142, and / or

[0132] - the holding system 80 of the cover 52 on the support, and / or

[0133] - the guidance system 85 of electrical conductors, and / or

[0134] - the holding system 120 of the support on the body 51 of the housing, and / or

[0135] - the system 130 for holding the support on the magnetic circuit 22,

[0136] all these systems can be made in one piece or not with the rest of the support 30. In a particular example, the support 30 is thus in one piece and has all or part of the aforementioned functionalities.

[0137] In the example of [Fig.21], the cover 52 is held directly on the body 51 of the housing 50 by means of screws 56 received in a shoulder 57 of the wall of the body 51. The cover 52, which is shown transparently in this [Fig.21], can close the body 51, thus ensuring EMC shielding of the housing 50.

[0138] It can be seen in this [Fig.21] that the wall 105 of the guide system 85 can have additional projections 115, received in openings made in the cover 52. These additional projections 115 define for example two notches per side of the transformer 15, and they can facilitate the introduction of the magnetic circuit 22 provided with the supports 30 inside the body 51 of the housing 50.

[0139] We will now describe with reference to figures 22 to 28 a transformer 15 according to an exemplary implementation of the invention.

[0140] As can be seen, this transformer 15 differs from that which has been previously described with reference to FIGS. 2 to 21 by the fact that the terminal block 45 is no longer arranged on a single side of the housing 50 but extends over the entire periphery of the magnetic circuit 22. The terminal block 45 also differs from that which has been previously described by the non-limiting fact that the body of the terminal block 86 carries the walls 105, 106 defining the guide channel 108 for the electrical conductors beyond the electrical winding 20, 21 which they define. Thus, the terminal block 45 here defines via its body 86 a guide part which is distinct, physically speaking, from the support 30 of the electrical windings, which is notably visible in [Fig. 24].

[0141] Similar to what has been described with reference to figures 18 to 20, the wall 106 of the terminal block body 86 comprises first openings 110 for the passage of the electrical conductors 31, 32 towards the electrical winding 20, 21 which it defines. The wall 105 is here devoid of openings. The wall 106 does not comprise in the implementation example describes openings 111 in which no electrical winding passes but it could in a variant include some.

[0142] Similar to what has been described with reference to figures 18 to 20, first openings 110 are arranged radially opposite a clamp 97, 98. Clamps 97, 98 are also provided here on the first rim 92 and the second rim 93.

[0143] The body of the terminal block 86 is shown in isolation in Figures 25 and 26. It can be seen that it extends here around the entire perimeter of the magnetic circuit 22. As shown in these Figures 25 and 26, the body of the terminal block 86 has a first surface which carries connection terminals 60 for connecting the transformer 15 to the rest of the electrical circuit of the converter 12. Each terminal 60 is here directly carried by the body of the terminal block 86. The terminal block 45 also comprises electrically conductive bars 62, a portion 63 of which defines a terminal 60, similarly to what has been described with reference to Figures 7 to 9.

[0144] As described with reference to Figures 7 to 9, the fixing of each electrically conductive bar 62 on the body of the terminal block 86 can be carried out by means of a screw 68 received in a hole 67 of the bar 62, either by direct cooperation between this screw 68 and a housing 69 of the guide part 86, or via an interposed insert 70.

[0145] As can be seen in Figures 22 to 26, the terminal block according to this example of implementation is different from that described with reference to Figures 2 to 21.

[0146] Indeed, in the example of figures 22 to 28, the six terminals 60 are distributed between two distinct zones Z1 and Z2 and at a distance from each other on the periphery of the magnetic circuit 22. It can be seen in [Fig.22] that each zone Z1, Z2 defines exactly three terminals for the connection of the three-phase transformer 15 to the rest of the isolated voltage converter 12. One of the zones Z1 corresponds for example to the terminals for the connection on the primary side of the transformer 15 while the other zone Z2 corresponds to the terminals for the connection on the secondary side of the transformer.

[0147] It can also be seen in [Fig.22] that each zone Z1, Z2 can be arranged opposite a respective vertex of one of the bases 26 of the magnetic circuit 22. In the example considered, the vertices in question are rounded and each zone Z1, Z2 follows the external shape of one of these rounded shapes.

[0148] Still in [Fig.22], we see that, within a zone Zl, Z2, the gap between two consecutive terminals 60 is not constant.

[0149] Each zone Z1, Z2 defining limits here forms a radially external protrusion relative to the walls 105, 106. More precisely in the example considered, each zone Z1, Z2 defines an ear relative to the space delimited externally by the two walls 105 and 106.

[0150] As shown in [Fig.26], the second surface of the body of the terminal block 86, opposite that carrying the connection terminals 60, carries in the example described fixing reliefs 87 on the body 51 of the housing 50. Two fixing reliefs 87, each being a pin, may be provided. Each fixing relief 87 is for example provided in the second surface of the body of the terminal block 86, at the level of a zone Z1, Z2.

[0151] The body of the terminal block 86 which has just been described with reference to figures 22 to 26 can be used with three electrical winding supports as described with reference to figures 2 to 21, except where applicable with regard to the presence of the walls 105, 106. Such supports 30 then comprise for example all or part:

[0152] - ribs 142 of figures 13 to 17, and / or

[0153] - of the holding system 80 of the cover 52 on the support of figures 4 and 5, and / or

[0154] - of the holding system 120 of the support on the body 51 of the housing of figures 10 to 12, and / or

[0155] - of the holding system 130 of the support on the magnetic circuit 22 of figures 10 to 15.

[0156] Alternatively, the guide piece 86 cooperates with three electrical conductor supports 30 which are each such as that shown in Figures 24, 27 and 28.

[0157] This support 30 always has a wall 90 around which the electrical windings 20, 21 are arranged, and which here defines a hollow cylinder of circular cross-section, and three edges 92, 93, 94 offset along the longitudinal axis of the support. The presence of the clamps 97 and 98 is always noted on the first edge 92 and the second edge 93.

[0158] It can also be seen in [Fig.28] that the ribs 142 are still present, although having a reduced height and not extending to the first edge 92 and / or to the third edge 94.

[0159] As shown in [Fig.27], the support 30 here has a wall 90 comprising a plurality of openings 91. The openings 91 are here provided throughout the thickness of the wall 90.

[0160] The openings 91 are distributed between:

[0161] - a first series of openings following one another around the perimeter of the support 30 between the first report 92 and the second edge 93, and

[0162] - a second series of openings following one another around the perimeter of the support 30 between the second ledge 93 and third ledge 94.

[0163] Each series of openings comprises for example three or four openings 91.

[0164] Each opening 91 here has a substantially rectangular closed contour. It can be seen in Figures 27 and 28 that two consecutive openings 91 of the same series can have different dimensions, their circumferential dimension varying for example while their axial dimension remains constant.

[0165] It can also be seen in Figures 27 and 28 that two openings 91 belonging to two different series and succeeding each other axially can have the same dimensions.

[0166] In [Fig.28], it can be seen that steps 95 are provided on the outer surface of the first rim 92 furthest from the rest of the support 30, leading to a local reduction in the height of the first rim 92. More precisely, several steps 95 are here provided around the periphery of the first rim 92. It can be seen in [Fig.28] that these steps 95 are concentrated in a given angular sector of the first rim 92. This angular sector measures for example less than 120°, or even less than 90°, when measured from the axis of the support 30.

[0167] Each step 95 is for example identical. Each step 95 has for example, when moving radially towards the outside of the support 30, two successive surfaces 96, 97 of different shapes, inclined relative to each other, which are here flat surfaces. In a variant not shown, each step 95 could have a rounded or more generally curved profile.

[0168] The invention is not limited to the example which has just been described.

[0169] The body of the terminal block 86 does not necessarily carry the walls 105, 106 in a single piece.

[0170] For example, in a variant, the terminal block still defines two distinct zones Z1 and Z2 at a distance from each other, as in FIGS. 22 to 26, but the walls 105 and 106 are integrated into the different supports 30 of electrical windings, being in particular made in a single piece with the respective supports 30. The terminal block 45 can then cooperate with supports similar to those described with reference to FIGS. 2 to 21.

Claims

Claims

1. Three-phase transformer (15) for an isolated voltage converter (12), comprising: - a magnetic circuit (22), comprising a first part and a second part, each part comprising: a base (26) of substantially triangular outline, and three pads (27) each extending towards the base of the other part of the magnetic circuit, - three supports (30) for electrical conductors (31, 32), each support (30) being mounted on two facing pads (27) belonging respectively to one and the other of the parts of the magnetic circuit, each support (30) for electrical conductors carrying two electrical windings (20, 21) in inductive coupling with each other via the magnetic circuit (22), - a housing (50) in which the supports (30) for electrical conductors, the electrical windings and the magnetic circuit (22) are arranged, and - a connection terminal block (45),in particular fixed on the housing (50) and defining six terminals (60) for the connection of the three-phase transformer (15) to the rest of the isolated voltage converter (12), the six terminals (60) being distributed between two distinct zones (Zl, Z2) and at a distance from each other on the periphery of the magnetic circuit (22).,

2. Transformer according to claim 1, the terminal block (45) extending around the entire perimeter of the magnetic circuit (22).

3. A transformer according to claim 1 or 2, each zone (Zl, Z2) of the terminal block defining exactly three terminals (60) for the connection of the three-phase transformer (15) to the remainder of the isolated voltage converter (12).

4. Transformer according to claim 3, each zone (Z1, Z2) of the terminal block being arranged opposite a top of one of the bases (26) of the magnetic circuit (22).

5. Transformer according to claim 3 or 4, the gap between two consecutive terminals (60) within a zone (Zl, Z2) of the terminal block (45) not being constant.

6. A transformer according to any preceding claim, the terminal block (45) comprising a body (86) and a plurality of electrically conductive bars (62), each terminal (60) being defined by a portion (63) of a bar (62).

7. Transformer according to claim 6, each electrically conductive bar (62) locally comprising a hole (67) and the fixing of this electrically conductive bar (62) on the body (86) of the terminal block (45) being carried out by means of a screw (68) received in this hole (67).

8. Transformer according to claim 7, the body (86) comprising a plurality of housings (69), each housing (69) cooperating with an electrically conductive bar (62) for fixing the latter on the body (61), the screw (68) for fixing the bar being received in the housing (69), or each housing (69) comprising an insert (70) forming a hole (71), each insert (70) cooperating with an electrically conductive bar (62) for fixing the latter on the body (61), the screw (68) for fixing the bar (62) being received in a hole (71) of the insert (70).

9. Transformer according to any one of the preceding claims, each support (30) of electrical conductors comprising: - a wall (90) around which the electrical windings (20, 21) are arranged, this wall defining in particular a hollow cylinder of circular cross-section, and - three flanges (92, 93, 94) offset along the axis of the wall (90) of the support, so that one of the electrical windings (20, 21) is arranged between the first (92) and the second flange (93) and the other of the electrical windings (20, 21) is arranged between the second (93) and the third (94) flange, the body (86) of the terminal block comprising two walls (105, 106) extending along the axis of the wall (90) of the support beyond this support (30), these two walls (105, 106) being offset and defining between them a guide channel (108) receiving at least one of the electrical conductors (31, 32) outside the electrical winding which it defines.

10. Transformer according to claim 9, each electrical conductor (31, 32) being guided between the two walls (105, 106) outside the electrical winding which it defines.

11. Transformer according to claim 9 or 10, the two walls (105, 106) carried by the body of the terminal block (86) extending over all or part of the periphery of the magnetic circuit (22), and each zone (Z1, Z2) of the terminal block defining terminals (60) forming a radially external protrusion relative to these two walls (105, 106).

12. Transformer according to any one of the preceding claims, the body (86) of the terminal block (45) being made of plastic.

13. Transformer according to any one of the preceding claims, the body (86) of the terminal block being in one piece.

14. Component for the electrical supply of a vehicle electrical energy storage unit, comprising the transformer (15) according to any one of the preceding claims.

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