Winding device

Abstract

To achieve a winding device with reduced heat density in an insulating layer.SOLUTION: A winding device includes a winding (10) having a rectangular cylindrical shape, a winding heat transfer plate (20) connected to the winding, and a cooling mechanism connected to the winding heat transfer plate, the winding heat transfer plate is connected to the cooling mechanism and having a body part (21a, 22a) abutting on a first surface of the winding, and an extension portion (21b, 22b) extending from the body portion so as to abut on a second surface of the winding adjacent to the first surface.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] One aspect of the present disclosure relates to a winding machine. [Background technology]

[0002] Patent Document 1 discloses a transformer including an inner winding, an outer winding, and two heat sinks. In this transformer, a first cooling jacket for cooling the inner winding is connected to one heat sink. A second cooling jacket for cooling the outer winding is connected to the other heat sink. An insulating layer is formed on a surface of the first cooling jacket that contacts the inner winding and on a surface of the second cooling jacket that contacts the outer winding. Heat generated in the inner winding and the outer winding is efficiently transferred to the heat sink via the insulating layer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2023-14684 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the transformer of Patent Document 1, the rectangular cylindrical inner winding and outer winding have non-contact surfaces where the first cooling jacket and the second cooling jacket do not contact. Heat generated near the non-contact surfaces moves to the vicinity of the contact surfaces and is transferred from the contact surfaces to the heat sink via the insulating layer. This can cause the heat density in the insulating layer to increase.

[0005] One aspect of the present disclosure aims to provide a wound device in which the heat density in the insulating layer is reduced. [Means for solving the problem]

[0006] In order to solve the above problems, a winding device according to one embodiment of the present disclosure includes a winding having a rectangular cylindrical shape, a winding heat transfer plate connected to the winding, and a cooling mechanism connected to the winding heat transfer plate, wherein the winding heat transfer plate is connected to the cooling mechanism and has a main body portion abutting a first surface of the winding, and an extension portion extending from the main body portion so as to abut a second surface of the winding adjacent to the first surface. Effect of the Invention

[0007] According to one aspect of the present disclosure, a wound device having a reduced heat density in an insulating layer can be realized. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view illustrating an appearance of a transformer according to an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a plan view of a transformer according to an embodiment of the present disclosure, viewed vertically from above. [Diagram 3] 3 is a cross-sectional view taken along line III-III in FIG. 2. [Figure 4] FIG. 2 is a diagram showing the shapes of the inner winding and the outer winding. [Diagram 5] FIG. 4 is a diagram showing the shapes of a winding and a winding heat transfer plate. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the present disclosure will be described in detail below. In each drawing, two mutually orthogonal directions in a horizontal plane are defined as the X direction and the Y direction. The vertical direction is defined as the Z direction. In particular, the vertically upward direction is defined as the +Z direction.

[0010] (Transformer configuration) FIG. 1 is a perspective view showing the appearance of a transformer 1 according to an embodiment of the present disclosure. FIG. 2 is a plan view of the transformer 1 as viewed vertically from above. FIG. 3 is a cross-sectional view taken along line III-III in FIG. 2. The transformer 1 is an example of a winding device according to the present disclosure. However, the winding device according to the present disclosure is not particularly limited as long as it has a winding, an iron core, an iron core heat transfer plate, and a cooling mechanism. As shown in FIGS. 1 to 3, the transformer 1 includes a winding 10, a winding heat transfer plate 20, and a cooling mechanism 60. However, the cooling mechanism 60 is omitted in FIG. 2 for ease of visibility. The transformer 1 further includes an iron core 30, an iron core heat transfer plate 40, and a connection plate 45.

[0011] Cooling mechanism 60 dissipates heat conducted from winding heat transfer plate 20 and iron core heat transfer plate 40 to the outside. Cooling mechanism 60 may be a heat sink that has a plurality of heat dissipation fins and dissipates heat into the air, as shown in Fig. 1. Alternatively, cooling mechanism 60 may be a liquid cooling mechanism that dissipates heat into a liquid such as water. Cooling mechanism 60 may be disposed above and below winding 10 in the vertical direction.

[0012] The winding 10 is configured using, for example, a coated conductive wire such as a Litz wire. The winding 10 includes an inner winding 11 and an outer winding 12 wound around the outer side of the inner winding 11. In the transformer 1, one of the inner winding 11 and the outer winding 12 functions as a primary winding, and the other functions as a secondary winding.

[0013] The inner winding 11 may be sealed with a sealing resin 51. The outer winding 12 may be sealed with a sealing resin 52. The sealing resins 51 and 52 may contain a synthetic resin such as an epoxy resin and a filler such as alumina or silica. The sealing resins 51 and 52 may be formed by, for example, molding.

[0014] Fig. 4 is a diagram showing the shapes of the inner winding 11 and the outer winding 12. In Fig. 4, reference numeral 401 indicates a perspective view of the inner winding 11 and the outer winding 12. Reference numeral 402 indicates a plan view of the inner winding 11 and the outer winding 12 as viewed vertically from above.

[0015] As shown in Fig. 4, the inner winding 11 and the outer winding 12 each have a rectangular tubular shape. Therefore, the inner winding 11 and the outer winding 12 each have four regions that can be substantially regarded as surfaces on the inside and outside of the rectangular tubular shape. In the following description, the regions of the inner winding 11 and the outer winding 12 that can be substantially regarded as surfaces will be simply referred to as surfaces.

[0016] In the following description, one surface on the inside of the inner winding 11 and a surface not adjacent to that surface are each referred to as a first surface 11a. Two surfaces on either side of the first surface 11a that connect the ends of the first surface 11a are each referred to as a second surface 11b. Also, one surface on the outside of the outer winding 12 and a surface not adjacent to that surface are each referred to as a first surface 12a. Two surfaces on either side of the first surface 12a that connect the ends of the first surface 12a are each referred to as a second surface 12b.

[0017] The winding heat transfer plate 20 is connected to the cooling mechanism 60. In other words, the cooling mechanism 60 is connected to the winding heat transfer plate 20. The winding heat transfer plate 20 conducts heat generated by the winding 10 to the cooling mechanism 60. The winding heat transfer plate 20 may be a plate-shaped member formed of a metal having high thermal conductivity. Specific examples of the material of the winding heat transfer plate 20 include copper and aluminum. The winding heat transfer plate 20 includes an inner winding heat transfer plate 21 that conducts heat generated by the inner winding 11 to the cooling mechanism 60, and an outer winding heat transfer plate 22 that conducts heat generated by the outer winding 12 to the cooling mechanism 60.

[0018] A portion of the inner winding heat transfer plate 21 that contacts the inner winding 11 may be sealed together with the inner winding 11 with sealing resin 51. A portion of the outer winding heat transfer plate 22 that contacts the outer winding 12 may be sealed together with the outer winding 12 with sealing resin 52.

[0019] Fig. 5 is a diagram showing the shapes of the winding 10 and the winding heat transfer plate 20. In Fig. 5, reference numeral 501 indicates a perspective view of the winding 10 and the winding heat transfer plate 20. Reference numeral 502 indicates a plan view of the winding 10 and the winding heat transfer plate 20 as viewed vertically from above.

[0020] As shown in FIG. 5, the inner winding heat transfer plate 21 has a main body 21a and an extension 21b. The main body 21a abuts against the first surface 11a (see FIG. 4) of the inner winding 11. The main body 21a is connected to the cooling mechanism 60. The extension 21b extends from the main body 21a so as to abut against the second surface 11b (see FIG. 4) adjacent to the first surface 11a. Specifically, the extension 21b extends from the main body 21a so as to abut against one of the second surfaces 11b adjacent to both sides of the first surface 11a. Therefore, the inner winding heat transfer plate 21 abuts against two of the four surfaces that the inner winding 11 has on the inside. The inner winding heat transfer plate 21 has an "L" shape when viewed vertically.

[0021] In the inner winding heat transfer plate 21, the extension portion 21b is joined to the main body portion 21a. For example, the inner winding heat transfer plate 21 may be initially processed into an "L" shape when viewed in the vertical direction. In addition, in the inner winding heat transfer plate 21, a screw hole (not shown) may be formed in an end surface of the extension portion 21b facing the main body portion 21a, and a through hole (not shown) may be provided in a portion of the main body portion 21a corresponding to the screw hole. In this case, the extension portion 21b may be screwed to the main body portion 21a by a screw (not shown) inserted into the through hole of the main body portion 21a. However, the method of joining the extension portion 21b to the main body portion 21a is not limited to this, and the extension portion 21b may be bonded to the main body portion 21a by brazing, for example.

[0022] In this embodiment, the transformer 1 includes two inner winding heat transfer plates 21. The main body portions 21a of the two inner winding heat transfer plates 21 are in contact with the two first surfaces 11a of the inner winding 11, respectively. The extending portions 21b of the two inner winding heat transfer plates 21 are in contact with the two second surfaces 11b of the inner winding 11, respectively. Thus, one of the two inner winding heat transfer plates 21 is in contact with all four inner surfaces of the inner winding 11. However, the number of inner winding heat transfer plates 21 included in the transformer 1 is not limited to two, and it is sufficient that the transformer 1 includes at least two inner winding heat transfer plates 21.

[0023] As shown in FIG. 5, the outer winding heat transfer plate 22 has a main body 22a and an extension 22b. The main body 22a abuts against the first surface 12a (see FIG. 4) of the outer winding 12. The main body 22a is connected to the cooling mechanism 60. The extension 22b extends from the main body 22a so as to abut against the second surface 12b (see FIG. 4) adjacent to the first surface 12a. Specifically, the extension 22b extends from the main body 22a so as to abut against one of the second surfaces 12b adjacent to both sides of the first surface 12a. Therefore, the outer winding heat transfer plate 22 abuts against two of the four surfaces that the outer winding 12 has on the outside. The outer winding heat transfer plate 22 has an "L" shape when viewed vertically.

[0024] In the outer winding heat transfer plate 22, the extension portion 22b is joined to the main body portion 22a. The method for joining the extension portion 22b to the main body portion 22a may be the same as the method for joining the extension portion 21b to the main body portion 21a in the inner winding heat transfer plate 21 described above.

[0025] In this embodiment, the transformer 1 includes two outer winding heat transfer plates 22. The main body portions 22a of the two outer winding heat transfer plates 22 are in contact with the two first surfaces 12a of the outer winding 12, respectively. The extension portions 22b of the two outer winding heat transfer plates 22 are in contact with the two second surfaces 12b of the outer winding 12, respectively. Thus, one of the two outer winding heat transfer plates 22 is in contact with all four outer surfaces of the outer winding 12. However, the number of outer winding heat transfer plates 22 included in the transformer 1 is not limited to two, and it is sufficient that the transformer 1 includes at least two outer winding heat transfer plates 22.

[0026] In the transformer 1, the main body portion 21a and the main body portion 22a do not necessarily need to be directly connected to the cooling mechanism 60, but only need to be able to be regarded as being substantially connected to the cooling mechanism 60. For example, when the main body portion 21a and the main body portion 22a are connected to the cooling mechanism 60 via a plate-like member made of a material with sufficiently high thermal conductivity, such as a connection plate 45 described later, the main body portion 21a and the main body portion 22a can be regarded as being substantially connected to the cooling mechanism 60.

[0027] In the transformer 1, an insulating layer 21c is provided on a surface of the inner winding heat transfer plate 21 that abuts against the inner winding 11. The insulating layer 21c is provided on both the main body portion 21a and the extending portion 21b. Also, an insulating layer 22c is provided on a surface of the outer winding heat transfer plate 22 that abuts against the outer winding 12. The insulating layer 22c is provided on both the main body portion 22a and the extending portion 22b. The insulating layer 21c and the insulating layer 22c may be formed of a highly thermally conductive resin or a highly thermally conductive prepreg.

[0028] The main body 21a of the inner winding heat transfer plate 21 and the main body 22a of the outer winding heat transfer plate 22 may be connected to either one of the cooling mechanisms 60 provided above and below the winding 10. Here, the cooling mechanism 60 to which the main body 21a of the inner winding heat transfer plate 21 is connected and the cooling mechanism 60 to which the main body 22a of the outer winding heat transfer plate 22 is connected may be different from each other. In this case, the main body 21a of the inner winding heat transfer plate 21 and the main body 22a of the outer winding heat transfer plate 22 protrude in opposite directions from each other with respect to the winding 10 in the vertical direction.

[0029] A gap exists between one main body portion 21a of the inner winding heat transfer plate 21 and the other extension portion 21b of the inner winding heat transfer plate 21. Also, a gap exists between one main body portion 22a of the outer winding heat transfer plate 22 and the other extension portion 22b of the outer winding heat transfer plate 22. The existence of these gaps ensures an area for drawing out the ends of the respective wires constituting the inner winding 11 and the outer winding 12 to the outside.

[0030] The winding heat transfer plate 20 is disposed outside the space between the inner winding 11 and the outer winding 12. That is, the inner winding heat transfer plate 21 is disposed inside the inner winding 11. Moreover, the outer winding heat transfer plate 22 is disposed outside the outer winding 12. This makes it difficult for the magnetic field generated by the inner winding 11 and the outer winding 12 to link with the inner winding heat transfer plate 21 and the outer winding heat transfer plate 22. This makes it possible to reduce the generation of eddy currents caused by the magnetic field linking with the inner winding heat transfer plate 21 and the outer winding heat transfer plate 22, and the power loss in the transformer 1 caused by the eddy currents.

[0031] The iron core 30 is a core around which the winding 10 is wound. The iron core 30 may be made of a ferromagnetic material such as, for example, a silicon steel plate, ferrite, an amorphous alloy, or a nanocrystalline soft magnetic material.

[0032] The core 30 includes an upper core material 31 and a lower core material 32, and has a structure that can be separated into upper and lower parts. In the manufacturing process of the transformer 1, the winding 10 is wound around the core 30 by fitting the upper core material 31 from above and the lower core material 32 from below into the winding 10 that has been formed in advance into a rectangular tube shape. However, it is not essential that the core 30 has a structure that can be separated into upper and lower parts.

[0033] The iron core heat transfer plate 40 transfers heat generated in the iron core 30 to the cooling mechanism 60. The iron core heat transfer plate 40 may be a plate-shaped member made of a metal having high thermal conductivity. Specific examples of materials for the iron core heat transfer plate 40 include copper and aluminum.

[0034] 1 and other drawings, the transformer 1 may have two iron core heat transfer plates 40. The two iron core heat transfer plates 40 are arranged to sandwich the iron core 30. Each iron core heat transfer plate 40 is connected to both cooling mechanisms 60 arranged above and below the winding 10. However, the number of iron core heat transfer plates 40 included in the transformer 1 is not limited to two.

[0035] Each iron core heat transfer plate 40 may have a structure that can be separated into upper and lower parts, including an upper iron core heat transfer plate 41 in contact with the upper iron core material 31 and a lower iron core heat transfer plate 42 in contact with the lower iron core material 32. In this case, during the manufacturing process of the transformer 1, the upper iron core heat transfer plate 41 and the lower iron core heat transfer plate 42 can be fitted into the winding 10 that has been formed in advance into a rectangular tube shape, together with the upper iron core material 31 and the lower iron core material 32. However, it is not essential that each iron core heat transfer plate 40 has a structure that can be separated into upper and lower parts.

[0036] The connecting plate 45 is a plate member that assists in connecting the winding heat transfer plate 20 and the iron core heat transfer plate 40 to the cooling mechanism 60. The connecting plate 45 may be a plate-shaped member made of a metal having high thermal conductivity. Specific examples of the material of the connecting plate 45 include copper and aluminum.

[0037] An end of the winding heat transfer plate 20 or the iron core heat transfer plate 40 is connected to one surface of the connecting plate 45. Here, for the winding heat transfer plate 20, the main body portion 21a of the inner winding heat transfer plate 21 and the main body portion 22a of the outer winding heat transfer plate 22 are connected to the connecting plate 45. A cooling mechanism 60 is connected to the other surface of the connecting plate 45. That is, in the transformer 1, the winding heat transfer plate 20 is connected to the cooling mechanism 60 via the connecting plate 45.

[0038] Grease for improving thermal conductivity may be applied between each of the connection plates 45 and the cooling mechanism 60. This can improve the thermal conductivity from the winding heat transfer plate 20 and the iron core heat transfer plate 40 to the cooling mechanism 60.

[0039] When the winding heat transfer plate 20 and the iron core heat transfer plate 40 are disposed close to each other, the winding heat transfer plate 20 and the iron core heat transfer plate 40 may be connected to the same connecting plate 45. In Fig. 3, each of the inner winding heat transfer plates 21 is connected to the same connecting plate 45 as the adjacent iron core heat transfer plate 40.

[0040] An end face of the winding heat transfer plate 20 or the iron core heat transfer plate 40 is connected to each connecting plate 45. For example, when the end faces of the winding heat transfer plate 20 and the iron core heat transfer plate 40 are not flush with each other above the winding 10, the connecting plate 45 may be deformed as appropriate so that the face of the connecting plate 45 arranged above the winding 10 facing the cooling mechanism 60 is flush with the end faces of the winding heat transfer plate 20 and the iron core heat transfer plate 40 are not flush with each other below the winding 10. Also, when the end faces of the winding heat transfer plate 20 and the iron core heat transfer plate 40 are not flush with each other below the winding 10, the connecting plate 45 may be deformed as appropriate so that the face of the connecting plate 45 arranged below the winding 10 facing the cooling mechanism 60 is flush with the end faces of the winding heat transfer plate 20 and the iron core heat transfer plate 40 are not flush with each other below the winding 10.

[0041] Deforming connecting plate 45 in this manner is easier than shaping winding heat transfer plate 20 and iron core heat transfer plate 40 so that winding heat transfer plate 20 and iron core heat transfer plate 40 are positioned on the same plane, and assembling transformer 1. For this reason, by providing connecting plate 45 to transformer 1, the precision required for the shape and assembly of winding heat transfer plate 20 and iron core heat transfer plate 40 is lower than when winding heat transfer plate 20 and iron core heat transfer plate 40 are directly connected to cooling mechanism 60. In other words, manufacturing of transformer 1 becomes easier.

[0042] However, connecting plate 45 is not essential to transformer 1, and winding heat transfer plate 20 and core heat transfer plate 40 may be directly connected to cooling mechanism 60. In this case, compared to the case where transformer 1 includes connecting plate 45, the efficiency of heat conduction from winding heat transfer plate 20 and core heat transfer plate 40 to cooling mechanism 60 is improved.

[0043] (effect) As described above, in the transformer 1, the inner winding heat transfer plate 21 has the extension portion 21b in addition to the main body portion 21a. Moreover, the outer winding heat transfer plate 22 has the extension portion 22b in addition to the main body portion 22a. Therefore, the areas of the insulating layers 21c and 22c in contact with the winding 10 are larger than when the inner winding heat transfer plate 21 has only the main body portion 21a and the outer winding heat transfer plate 22 has only the main body portion 22a. Therefore, the heat density in the insulating layers 21c and 22c can be reduced.

[0044] In particular, the transformer 1 includes two inner winding heat transfer plates 21 and two outer winding heat transfer plates 22. The main body portions 21a of the two inner winding heat transfer plates 21 abut against the two first surfaces 11a of the inner winding 11, respectively, and the extension portions 21b abut against the two second surfaces 11b, respectively. The main body portions 22a of the two outer winding heat transfer plates 22 abut against the two first surfaces 12a of the outer winding 12, respectively, and the extension portions 22b abut against the two second surfaces 12b, respectively. This increases the area of ​​the region where the winding heat transfer plates 20 abut against the winding 10, thereby further reducing the heat density.

[0045] Furthermore, in the transformer 1, the cooling mechanism 60 to which the main body 21a of the inner winding heat transfer plate 21 is connected and the cooling mechanism 60 to which the main body 22a of the outer winding heat transfer plate 22 is connected are different from each other. This improves the efficiency of heat dissipation because the heat from the inner winding 11 and the heat from the outer winding 12 are dissipated by the separate cooling mechanisms 60. Furthermore, by equalizing the amount of heat dissipated to each cooling mechanism, it is possible to use cooling mechanisms of the same shape as the two cooling mechanisms 60, which is economical.

[0046] In general, the temperature rise can be reduced by making the insulating layer thinner. However, on the other hand, the electric field strength inside the insulating layer becomes stronger, so high insulating performance is required. In other words, there is a trade-off between the temperature rise and the insulating performance of the insulating layer.

[0047] In the transformer 1, as described above, the heat density in the insulating layers 21c and 22c can be reduced to reduce the temperature rise in the insulating layers 21c and 22c. For example, when the areas of the extensions 21b and 22b are equal to the areas of the main bodies 21a and 22a, respectively, the temperature rise in the insulating layers 21c and 22c can be reduced by half while maintaining the insulating performance of the inner winding heat transfer plate 21 and the outer winding heat transfer plate 22. This allows the transformer 1 to handle higher voltages than a conventional transformer that does not have the inner winding heat transfer plate 21 and the outer winding heat transfer plate 22.

[0048] As described above, in the transformer 1, the inner winding 11 and the outer winding 12 each have a rectangular tubular shape. Therefore, compared to a case where the inner winding 11 and the outer winding 12 have a cylindrical shape or the like, there is no need to bend the winding heat transfer plate 20 to fit the inner winding 11 and the outer winding 12, respectively. It is also easy to bring the winding heat transfer plate 20 into uniform contact with each portion of the inner winding 11 and the outer winding 12. It is also easy to connect the winding heat transfer plate 20 to the cooling mechanism 60. Therefore, the inner winding 11 and the outer winding 12 each have a rectangular tubular shape, which makes it easy to manufacture the transformer 1 with reduced heat density in the insulating layer 21c and the insulating layer 22c.

[0049] (Modification) The winding heat transfer plate 20 of the present disclosure may be applied to a transformer having a configuration different from that of the transformer 1 described above. For example, the winding heat transfer plate 20 may be applied to a transformer in which a primary winding and a secondary winding are arranged at different positions. Also, the winding heat transfer plate 20 may be applied to a transformer including an iron core having a structure in which a plurality of iron core materials are laminated.

[0050] The present disclosure is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present disclosure. [Explanation of symbols]

[0051] 1 Transformer 20 Winding heat transfer plate 21a, 21a, 22a, 22a Main body 21b, 21b, 22b, 22b extension 60 Cooling mechanism

Claims

1. A winding having a rectangular cylindrical shape; a winding heat transfer plate connected to the winding; a cooling mechanism connected to the winding heat transfer plate, The winding heat transfer plate is a main body portion connected to the cooling mechanism and in contact with a first surface of the winding; an extension portion extending from the body portion to abut a second surface of the winding adjacent the first surface.

2. At least two of the winding heat transfer plates are provided, The winding has two first surfaces and two second surfaces, The main body portions of the two winding heat transfer plates abut against the two first surfaces of the winding, respectively; The winding device according to claim 1 , wherein the extension portions of the two winding heat transfer plates abut against two second surfaces of the winding, respectively.

3. At least two of the cooling mechanisms are provided, The winding includes an inner winding and an outer winding wound around the inner winding, the winding heat transfer plate includes an inner winding heat transfer plate connected to the inner winding and an outer winding heat transfer plate connected to the outer winding, 2 . The winding device according to claim 1 , wherein the cooling mechanism to which the body portion of the inner winding heat transfer plate is connected and the cooling mechanism to which the body portion of the outer winding heat transfer plate is connected are different from each other.

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