Bus bar winding choke

Abstract

To make a choke as small as possible for a heavy-current DC network.SOLUTION: A choke of the present invention includes a core (4) and a first power supply conductor (10). The first power supply conductor (10) comprises a first coil winding (11) having at least one complete turn (12) around the core (4). The least one turn (12) of the first coil winding (11) comprises a first rigid bus bar member (1) and a second rigid bus bar member (2).SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates in particular to chokes for vehicle DC networks and / or interference suppression, in particular current-compensated chokes.

Background Art

[0002] Chokes, such as current-compensated chokes, are important components of interference suppression solutions in DC networks. The volume and weight of a choke generally increase in proportion to the inductance and maximum current of the choke. In general, especially when applied to automobiles, there is concern that the volume and weight of the choke be kept as low as possible. At the same time, the current flowing through the DC network of an electric vehicle is very large, and the choke is assumed to have a high inductance.

[0003] The power of a choke depends on its inductance. The power and / or inductance depend on the core and the number of turns. The greater the number of turns, the greater the inductance and the greater the output. This becomes a problem in applications involving large currents. These applications generally require very thick power conductors, typically in the form of busbars or special cables. For currents from 2.5 amperes (A) to 5 amperes, a busbar cross-section on the order of 1 mm 2 or more is correspondingly braided, and thus a bendable cable is required. Therefore, for a 125 A application, the cross-sectional area of the busbar needs to be 25 mm 2 to 50 mm 2 . This type of busbar can no longer be bent around the core.

[0004] Therefore, for this type of high-current choke, a half-wound choke is generally preferred. In other words, a straight busbar is enclosed within an annular core. Therefore, the inductance depends only on the material and dimensions of the annular core. As a result, this type of choke for high inductance, and thus for interference suppression applications including a high level of interference suppression, is often exceptionally large and heavy.

[0005] Instead, for special applications, chokes with current windings are also used, and the power conductors are composed of very heavy gauge stranded copper cables that are finely braided. However, these chokes are complex to manufacture and have a large volume because the stranded copper cables do not adhere closely to the core. Furthermore, this type of stranded copper cable requires a larger cross-sectional area than equivalent busbars.

[0006] Patent Document 1 and Patent Document 2 therefore propose providing a busbar wound around a core. This is done by connecting two pre-bent busbar members. However, since busbar coil windings require a lot of space, these solutions have only one turn. This is due to the large width of the busbar required by the cross-sectional requirements described above and the screw connection between the two busbar members forming one turn. The screw connection is also troublesome to close due to its position. The screw connection shown in Patent Document 2 is even less suitable for use in vehicles because vibrations in the vehicle tend to open such screw connections over time.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0008] An object of the present invention is to identify a choke for high currents with the smallest possible volume and weight, especially for a DC network and especially for a vehicle.

Means for Solving the Problems

[0009] According to the present invention, this object is satisfied by the choke of claim 1.

[0010] Since at least one turn of the coil winding comprises at least one rigid first busbar member and a rigid second busbar member, the turns of the coil winding around the core can be realized in the form of a busbar. As a result, the busbar can be brought into close contact with the core, and at the same time, the busbar can achieve a conductor cross-sectional area smaller than that possible with a stranded copper cable. A choke of equal inductance can thus be assumed to be substantially more compact and often lighter in construction. At the same time, the manufacture of this type of coil can be automated more easily, contrary to the winding of a weight-gauge stranded copper cable. Since one turn or each turn consists of (at least) two connected busbar members, the three-dimensional shape of the busbar winding can be achieved by connecting busbar members cut out from (two-dimensional) sheet material.

[0011] According to the present invention, this object is achieved by a vehicle and / or a DC voltage network having a choke of this type.

[0012] According to the present invention, this object is achieved by a method of manufacturing a choke of this type. The method comprises the following steps. Arranging at least one first busbar member of a first coil winding of a first power conductor. Arranging a core relative to the at least one first busbar member. Connecting at least one half busbar member of the first coil winding of the first power conductor to the at least one first busbar member such that the at least one first busbar member and the at least one half busbar member constitute the first coil winding of the first power conductor around the core.

[0013] Further advantageous configurations are described in the dependent claims.

[0014] In an exemplary embodiment, the core is annular and includes a first opening side, a second opening side disposed opposite the first opening side, an outer lateral surface, and an inner lateral surface.

[0015] In realizing this product form, a series of problems arising with respect to effective manufacturing, sensitivity to vibration, and heat exhaust are solved as follows by the housing and structural elements described below.

[0016] In an exemplary embodiment, the choke comprises a housing.

[0017] In an exemplary embodiment, the housing comprises at least one protrusion, and at each of the at least one protrusion, one turn of a first busbar member of a first coil winding is arranged. This is advantageous in that during assembly the first busbar is fixed in the correct position by the protrusion, especially in that the core is arranged within the first busbar member. Thereby, the assembly of the choke is simplified and the assembly time is shortened. At the same time, the clearance between the core and the first busbar member with respect to the housing wall is minimized, and accordingly heat exhaust is optimized. Especially in combination with encapsulation, this form of structure minimizes the amount of the molded composite and thus the weight of the choke.

[0018] In an exemplary embodiment, the housing covers a first opening side portion and an outer lateral surface of the core, and at least one protrusion within the housing is arranged on the first opening side portion and / or the outer lateral surface.

[0019] In an exemplary embodiment, the shape of the housing of the first opening side portion coincides with the shape of the core of the first opening side portion (interrupted by at least one protrusion), and / or the shape of the housing of the outer lateral surface coincides with the shape of the outer lateral surface of the core (interrupted by at least one protrusion). Due to these characteristics, the first busbar member can be arranged at the correct winding angle and / or upright with respect to the toroidal core.

[0020] In an exemplary embodiment, the housing comprises an inner housing portion that covers the inner lateral surface of the core. The inner housing portion preferably comprises a separation element extending into the core, and the first busbar member and / or the second busbar member of the turns of the first coil winding are arranged between two adjacent separation elements, and / or the separation elements are arranged so as to be disposed between two adjacent turns of the first coil winding. The housing on the inner lateral surface of the core can thus additionally perform a positioning or insulating function for the first and / or second busbar members. The inner housing portion is preferably hollow. This reduces the weight, especially in the location where the housing is enclosed. The hollow inner housing portion preferably communicates with the second opening side portion so that air exchange occurs between the hollow housing portion and the outside. This improves the discharge of heat from the inner lateral surface of the core and the turn portion disposed thereon.

[0021] In an exemplary embodiment, the choke comprises an electrical insulation structural element disposed at the second opening side of the core between the second opening side portion and at least one second busbar member. This structural element enables insulating the second opening side of the core from the second busbar member, mutually insulating the second busbar members, and / or accurately positioning the busbar members. The structural element preferably covers the second opening side portion of the core, at least in the region of the second busbar member. The structural element preferably incorporates a separation structure between two adjacent second busbar members. The separation structure preferably comprises a separation element extending in the direction of the inner housing portion, and in combination with one of the separation elements of the inner housing portion, insulates two adjacent turns from each other.

[0022] In an exemplary embodiment, the housing encloses the core and the first power conductor. This eliminates the ingress of insulating air and prevents the dissipation of heat and vibration. The housing is preferably filled with a molding composite such that all conductive parts of the choke (except the terminals) are covered by the molding composite and are thus insulated from the outside. The housing is preferably configured in a cup shape with an upper cup rim, and the cup rim (at the deepest point) is disposed above the core and the first and second busbar members (except the terminals), and the housing is filled with the molding composite to a level below the cup rim.

[0023] In an exemplary embodiment, the first busbar member has a first end and a second end, the second busbar member has a first end and a second end, the second end of the first busbar member is connected to the first end of the second busbar member, and the connected first and second busbar members form the turns of a first coil winding with a rigid busbar from the first end to the second end of the first busbar member. Thus, despite the large diameter and high rigidity of the busbar members, a multi-turn coil winding in close contact with the core can be realized.

[0024] In an exemplary embodiment, the first end of the first busbar member is connected to an adjacent turn of the first coil winding or the first terminal of the first coil winding, and / or the second end of the second busbar member is connected to another adjacent turn of the first coil winding or the second terminal of the first coil winding.

[0025] There is no solution satisfying the prior art that enables good current conduction, secure holding, and rapid assembly for electrically connecting the first busbar member to the second busbar member. Due to space constraints and the arrangement of the first and second busbar members around the core, conventional solutions for busbar connection including threaded through-bolts and mating nuts are not applicable in this case.

[0026] In an exemplary embodiment, the second end of the first bus bar member incorporates a fixing recess having a thread, and the first end of the second bus bar member incorporates a through hole. It extends through the through hole and is screwed into the thread of the fixing recess, and the bolt head of the screwed bolt presses the first end of the second bus bar member against the second end of the first bus bar member. By this solution, the necessary contact pressure between the first and second bus bar members is achieved to ensure a good conductive connection between the first and second bus bar members. Since the threaded bolt is screwed into the first bus bar member, a mating nut is not required. At the same time, since a good connection is provided through the thread flank and the bolt head, the current flows through the bolt and does not reduce the bus bar diameter.

[0027] The threaded bolt is preferably a self-tapping threaded bolt, and the thread is configured in a form defined by screwing the self-tapping threaded bolt into the fixing recess. According to this, there is an advantage that the manufacture of the first bus bar member is greatly simplified because there is no need to additionally cut or form the thread, and it is formed by screwing. The contact surface area between the threaded bolt and the first bus bar member is also larger in the case of a self-tapping threaded bolt than in the case of a metric bolt. Self-tapping threaded bolts having self-tapping threads with a flank angle of 30° to 36° have proven to be particularly suitable for this application.

[0028] In an alternative exemplary embodiment, the second end of the first bus bar member is connected to the first end of the second bus bar member by a solder paste. After applying and positioning the solder paste at both ends, it is heated for induction soldering. This process further simplifies the connection between the two bus bar members.

[0029] Even more advantageous, exemplary embodiments are described below.

[0030] In an exemplary embodiment, the first bus bar member of the first coil winding is disposed at the first opening side portion of the core, and the second bus bar member is disposed at the second opening side portion of the core.

[0031] In an exemplary embodiment, the first bus bar member has a U-shaped configuration disposed around the core, and / or the second bus bar member has an I-shaped configuration. The U-shaped configuration has the advantage of extending around the core and enabling the core to be arranged in a U-shape. Further, this combination of the U-shaped configuration and the I-shaped configuration is particularly advantageous because the first end portion of the second bus bar member can be more easily connected to the second end portion of the first bus bar member by using other configurations, for example, two U-shaped configurations. The combination of the U-shaped configuration and the I-shaped configuration can both be cut from sheet metal of the same thickness, but as a result of the angle of the U-shaped configuration with respect to the I-shaped configuration, it further has the advantage that there is no reduction in the cross-section in the connection region. Accordingly, the second bus bar member preferably has a thickness incorporated in the regions of its first and second end portions.

[0032] In one embodiment, the main cross-sectional shape of the first bus bar member and the second bus bar member is such that its first width in the first direction is between 0.5 (half) and 1.5 (one and a half) times the size of its second width in the second direction (perpendicular to the first direction), preferably between 0.7 and 1.4, between 0.8 and 1.2, and preferably between 0.9 and 1.1. Compared with the flat bus bars used in the prior art, a lot of bus space is saved and it is not necessary to increase the core 4. In addition, it enables the distal end portion of the first bus bar member to be fixed to the second bus bar portion, which was not possible with the conventional flat bus bars in the prior art.

[0033] The first coil winding and the further coil windings preferably comprise at least two turns.

[0034] In an exemplary embodiment, the choke comprises a second power conductor, the second power conductor comprising a second coil winding having at least one complete turn around the (same) core, at least one turn of the second coil winding comprising a rigid first busbar member and a rigid second busbar member.

[0035] In an exemplary embodiment, the first and second coil windings are wound around the core such that the magnetic fluxes induced in the core by the normal mode currents in the first and second power conductors cancel each other out, whereby a current compensation choke is configured accordingly.

[0036] In an exemplary embodiment, the core is shaped as a hollow cylinder and preferably has a circular cross-section perpendicular to the cylinder axis. This shape provides the maximum volume for the toroidal core and allows the use of simply shaped turns.

[0037] In an exemplary embodiment, the choke is configured for a DC network.

[0038] In an exemplary embodiment, the choke is rated for a nominal or maximum current of more than 30 A, preferably more than 50 A.

[0039] In an exemplary embodiment, the first and / or second power conductors of the choke each have a minimum conductor cross-sectional area of more than 10 mm 2 greater, preferably more than 15 mm 2 greater.

[0040] In an exemplary embodiment, the choke is a current compensation type choke.

[0041] In an exemplary embodiment, the vehicle includes a DC network in which the choke is incorporated.

[0042] In an exemplary embodiment, at least one first busbar member is arranged at a protrusion of the housing before the core fits into at least one (preferably U-shaped) first busbar member.

[0043] In an exemplary embodiment, the threaded bolt is screwed through the first end portion of the second bus bar member into the second end portion of the first bus bar member, and preferably, in order to connect the first bus bar member to the second bus bar member, is a self-tapping threaded bolt that cuts or screws a screw into the second end portion of the first bus bar member.

[0044] In an exemplary embodiment, a solder paste is applied between the first end portion of the second bus bar member and the second end portion of the first bus bar member and then soldered. Preferably, soldering is performed by induction heating of the solder paste.

[0045] The exemplary embodiments described are particularly advantageous in combination, but also advantageous individually.

[0046] The present invention will be described in more detail with reference to the following accompanying drawings.

Brief Description of the Drawings

[0047]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Mode for Carrying Out the Invention

[0048] The choke of the present invention is preferably a noise suppression choke. The choke is preferably a noise suppression filter or is employed in a noise suppression filter. However, the choke may also be used for other applications. The choke is preferably connected in series with the main power line. However, the choke may be connected in parallel with the main power line or in another configuration. The choke is preferably used in a direct current voltage network (also referred to as a DC network). However, this type of choke may also be used in an alternating current voltage network (single-phase or three-phase). The choke is preferably rated for a maximum or nominal current greater than 30A, preferably greater than 40A, preferably greater than 50A, preferably greater than 60A, preferably greater than 70A. The choke is preferably a current compensation choke, i.e., at least two of its coil windings are wound around the core such that the magnetic fields generated within the core by differential mode currents (useful currents and / or differential mode interference currents) in at least two core windings cancel each other out. Thus, the current compensation choke presents a low inductance to differential mode currents and a high inductance to common mode currents. However, the choke described may also be used in other applications, for example, for differential mode chokes. The above-described choke was developed for use in (motor) vehicles, particularly vehicles driven by electric motors such as hybrid or electric vehicles, because the voltage network frequently carries very high currents. However, the choke described may also be used for other applications.

[0049] Figures 1 through 6 show a first exemplary embodiment of this type of choke. The choke includes a core 4, a first power conductor 10, and a second power conductor 20. The illustrated choke is a current compensated choke rated for a maximum or nominal current of 125A, but the following description applies to at least one of other chokes and other maximum or nominal currents.

[0050] Core 4 is a coil core. In this case, core 4 is annular. However, in other embodiments of the choke, core 4 may be of a different shape, such as bar-shaped. In this case, core 4 forms a closed loop without voids. However, in other exemplary embodiments, the term "annular" also includes an annular core 4 having a void. The annular core 4 has an opening. The two sides of the annular core 4 having the opening are described as the first opening side and the second opening side. The opening sides are preferably perpendicular to the opening axis of the annular core 4. The annular core 4 preferably forms a circular ring. However, the annular core 4 may be configured as a triangular, rectangular, polygonal, elliptical ring, or a ring of other shapes. Here, the shape of the ring refers to the surrounding shape, that is, the outer, inner, and / or central surrounding shape of the ring. The outer-facing side between the two opening sides is defined as the outer lateral surface. The inner-facing side between the two opening sides is defined as the inner lateral surface. The inner lateral surface and / or the outer lateral surface are preferably arranged parallel to the opening axis of the ring. The annular bead preferably has a rectangular cross-section such that core 4 is configured as a straight hollow cylinder (a straight cylinder in the case of a circular ring). Also, the rectangular cross-section includes a square cross-section. A rectangular cross-section or a cross-section having a different number of angles must also include rounded corners or edges. However, the cross-section of the annular bead may be circular (in the case of an annular, circular ring), elliptical, or of other shapes. However, the rectangular cross-sections of the annular bead and / or the annular ring are particularly advantageous. By combining these two shapes, core 4 can be made into a particularly advantageous shape as a straight hollow cylinder where the two bottom surfaces of the cylinder correspond to the first opening side and the second opening side, the outer lateral surface corresponds to the outer shell surface, and the inner lateral surface corresponds to the inner shell surface. In this case, the opening axis corresponds to the axis of the hollow cylinder.

[0051] The material of core 4 is preferably a material having a high magnetic permeability in the desired frequency range, and is a ferromagnetic material, preferably, for example, ferrite, nanocrystalline material, etc.

[0052] The first power conductor 10 comprises a first coil winding 11. The coil winding 11 comprises at least one (complete) turn 12, preferably two or more turns 12, arranged around a core 4 (in this case, the annular bead of the core 4). The first coil winding 11 and / or the first power conductor 10 is constituted by a bus bar. The bus bar is formed of a solid conductive material. The conductive material is preferably a metal, preferably copper. The bus bar is rigid, i.e., it cannot be bent.

[0053] The first power conductor 10 preferably comprises a first terminal 13 and / or a second terminal 14. The first terminal 13 and / or the second terminal 14 are configured to connect to a power conductor, such as a bus bar or a cable. The first terminal 13 and / or the second terminal 14 are preferably configured as rigid bus bars. The first terminal 13 and / or the second terminal 14 comprise coil connection means and external connection means. The coil connection means of the first terminal 13 are configured to connect to the first end of the coil winding 11, the first turn 12 of the coil winding 11, and / or the first end of the first bus bar member 1 of the first turn 12 of the coil winding 11. The coil connection means of the second terminal 14 are configured to connect to the second end of the coil winding 11, the last winding 11 of the coil turn 12, and / or the second end of the first bus bar member 1 of the last winding 11 of the coil turn 12. The external connection means of the first terminal 13 and / or the second terminal 14 are configured to connect to a power conductor. The shape of the first and / or second terminal 13 and / or 14 extends away from the first opening side portion, in the opening axis direction with respect to the second opening side portion, or at a right angle. The external connection means thus protrude from a formed composite body (see below).

[0054] At least one turn 12, preferably most of the turns 12, preferably each turn 12, comprises a first busbar member 1 and a second busbar member 2. Preferably, the first busbar member 1 and the second busbar member 2 constitute each turn 12. However, one or more of the turns 12 may each comprise more than two busbar members. The first busbar member 1 and the second busbar member 2 are formed and connected in combination (and, where applicable, one or more busbar members) so as to form the turn 12 around the core 4. Preferably, the shape of the turn 12 basically corresponds to the cross-sectional shape of the core 4, in other words, in the case of the annular core 4, to the cross-sectional shape of an (only slightly larger) annular bead. Preferably, the main cross-sectional shape of the first busbar member 1 and the second busbar member 2 is such that its first width in the first direction is between 0.5 (half) and 1.5 (one and a half), preferably between 0.7 and 1.3, preferably between 0.8 and 1.2, preferably between 0.9 and 1.1 times the size of its second width in the second direction. It provides more windings through the opening of the core 4 without the need to increase the core 4 as compared to the flat busbars used in the prior art. In addition, the distal end of the first busbar member 1 can be fixed to a portion of the second bus member 2, which was not possible with the conventional flat busbars of the prior art. The main cross-sectional shape of the first busbar member 1 and the second busbar member 2 is preferably rectangular, preferably square. However, other shapes are possible. The main cross-sectional shape of the first busbar member 1 and the second busbar member 2 is mainly the cross-sectional shape of the first busbar member 1 and the second busbar member 2 used along the length of the first busbar member 1 and the second busbar member 2, preferably along at least 50%, preferably at least 70%, preferably at least 80% of the length of the first busbar member 1 and the second busbar member 2 respectively.

[0055] Preferably, the first bus bar member 1 has a shape extending along the inner lateral surface, the first opening side portion, and the outer lateral surface of the core 4. Preferably, the inner shape of the first bus bar member 1 coincides with the outer shape of the inner lateral surface, the first opening side portion, and the outer lateral surface of the core 4. Preferably, the first bus bar member 1 is U-shaped. Thus, the U-shaped first bus bar member 1 extends along at least a part of the inner lateral surface and / or at least a part of the outer lateral surface of the core 4. As a result, the core 4 may be fitted / concavely provided in the first bus bar member 1. Preferably, the first bus bar member 1 extends along the entire inner lateral surface and / or outer lateral surface of the core 4, and preferably, extends slightly beyond the core 4. At least one of both ends of the first bus bar member 1 is connected (parallel to the second opening side portion) to the first bus bar member 1 of the next turn 12 and / or the first bus bar member 1 of the further next turn 12 by the linear second bus bar member 2. Thereby, a simpler configuration of the second bus bar member 2 and / or a simpler connection between the first bus bar member and the second bus bar member can be achieved. However, the first bus bar member 1 may not extend beyond the outer lateral surface and / or the inner lateral surface, or may extend only partially. In this case, the first bus bar member 1 may be, for example, a (shorter) U-shape, an L-shape, or an I-shape, or an (asymmetric) U-shape having two U-shaped legs with different lengths. The main cross-sectional shape of the first bus bar member 1 is preferably rectangular (e.g., a quadrilateral). However, other shapes may also be possible. The first bus bar member 1 has a first end portion and a second end portion. The first bus bar member 1 has a longitudinal axis extending along the direction of current flow within the first bus bar member 1. The U-shaped first bus bar member 1 has a longitudinal axis that is U-shaped. The first bus bar member 1 has at least one side surface substantially parallel to the longitudinal axis and two distal side portions at both ends of the first bus bar member 1 that penetrate the longitudinal axis of the first bus bar member 1. Preferably, the two distal sides are perpendicular to the longitudinal axis. The at least one lateral surface preferably has four lateral portions. The distal side portions are preferably flat.

[0056] Preferably, the second bus bar member 2 has a shape along the second opening side of the core 4. Preferably, the internal shape of the second bus bar member 2 coincides with the outer shape of the second opening side portion of the core 4. Preferably, the first bus bar member 1 is in an I shape (in the case of the U-shaped first bus bar member 1 extending along the entire inner and outer lateral surfaces of the core 4). The main cross-sectional shape of the second bus bar member 2 is preferably rectangular (for example, a quadrilateral). However, other shapes may also be used. The second bus bar member 2 may be, for example, an L shape (for example, when the first bus bar member 1 is an asymmetric U shape having one U-shaped leg extending along the entire inner or outer lateral surface of the core 4 and the other U-shaped leg extending only along a part of the other side of the side surface, or when the first bus bar member 1 is an L shape). The second bus bar member 2 may be, for example, a U shape (for example, when the first bus bar member 1 is a U shape and the U-shaped legs extend only along a part of the inner and outer lateral surfaces of the core 4). The second bus bar member 2 has a longitudinal axis extending along the current flow direction within the second bus bar member 2. For the I-shaped second bus bar member 2, the longitudinal axis will be a straight line. The second bus bar member 2 has at least two lateral surfaces that are substantially parallel to the longitudinal axis (and the two distal end sides at both ends of the second bus bar member 2 that penetrate the longitudinal axis of the second bus bar member 2). At least one of the at least two lateral surfaces of the second bus bar member 2 is preferably flat. Preferably, those at least two lateral surfaces have four lateral surfaces. Preferably, the second bus bar member 2 is expanded at the connection region with the first bus bar member 1 and / or at both ends. This expansion is arranged on the (parallel) plane of the second opening side portion. This expansion is configured such that the expansion region covers the entire conductor cross-section of the end of the first bus bar member 1 connected to the expansion. The second bus bar member 2 has a first end and a second end.

[0057] The second end of the first bus bar member 1 is connected to the first end of the second bus bar member 2. The connection part is configured so that a conductive connection and / or a mechanically rigid / non-flexible and / or stable connection can be made between the first bus bar member 1 and the second bus bar member 2 for each turn 12. By connecting the second end of the first bus bar member 1 to the first end of the second bus bar member 2, each turn 12 of the first coil winding 11 is configured as a rigid bus bar (preferably entirely) from the first end of the first bus bar member 1 to the second end of the second bus bar member 2. Preferably, the distal side part of the second end of the first bus bar member 1 is connected to the first end of the second bus bar member 2. Thereby, the gap between the first bus bar member 1 and the second bus bar member 2 becomes smaller. In one embodiment, the distal side part of the second end of the first bus bar member 1 is connected to the lateral side surface (assumed in the case of the second bus bar member 2 of I-shaped or L-shaped) of the first end of the second bus bar member 2. In one embodiment, the distal side part of the second end of the first bus bar member 1 is connected to the distal side part of the first end of the second bus bar member 2 (assumed in the case of the second bus bar member 2 of U-shaped or L-shaped). Preferably, the first end of the first bus bar member 1, the first end of this turn 12 of the first coil winding 11 and / or the second end of the second bus bar member 2 provide the second end of this turn 12. Preferably, the first end of the first bus bar member 1 is connected to an adjacent turn 12 (the second end) of the first coil winding 11, or to the first terminal 13 of the first coil winding 11. Preferably, the second end of the second bus bar member 2 is connected to another adjacent turn 12 (the first end). Therefore, by connecting various turns 12 in series or by alternately connecting the first bus bar member 1 and the second bus bar member 2, the first coil winding 11 is composed of a rigid bus bar. Preferably, most (preferably) of the first bus bar member 1 of the first coil winding 11 (and any further coil windings 21) has the same design. Preferably, most (preferably the whole bar) of the second bus bar member 2 of the first coil winding 11 (and any further coil windings 21) has the same design. Preferably, the second bus bar member of the last turn 12 of the first coil winding 11 is constituted by the second terminal 14.However, the second bus bar member of the final turn 12 may be configured in the same manner as the other turns 12, and the second terminal 14 may be connected to the second end of the second bus bar member 2. The first coil winding 11 is preferably such that the (one or more) first bus bar members 1 are basically oriented radially with respect to the opening axis, and / or such that most of the second bus bar members 2 are oriented along a connecting line between two radial lines (such that the second end of the first bus bar member 1 is connected to the first end of the second bus bar member 2). The last (or first) second bus bar member 2 of the coil winding 11 is configured here as the terminal 14 for illustrative purposes and is preferably oriented substantially radially with respect to the opening axis of the core 4.

[0058] There can be various connection methods for the connection between one end of the first bus bar member 1 and one end of the second bus bar member 2 (or the connection between one end of the bus bar member 1 or 2 and one of the coil connection means of the terminals 13 or 14). This connection may be made by screws, welding (resistance welding, laser welding, etc.), soldering, press fitting, etc. However, considering the number of connection points and / or the importance of a good electrical connection, the connection technique here is extremely important to be fast, to obtain good conductivity, and / or to be mechanically stable. Otherwise, if the connection quality is not sufficient, the manufacturing will become overly complicated and / or hot spots will occur on the connection points. The following two connection techniques have proven to be particularly suitable. These connection techniques are particularly advantageous for connecting the distal side portion of the first bus bar member 1 to the second bus bar member 2 (the side portion or the distal side portion thereof). The prior art does not provide a fast, robust, and good conductivity connection technique for connecting the distal side portion of the bus bar.

[0059] According to the first connection technique, the second end portion of the first bus bar member 1 incorporates a fixing recess with a female thread. Preferably, the fixing recess is provided on the distal surface of the second end portion of the first bus bar member 1. Preferably, the fixing recess is a blind hole. Preferably, the fixing recess extends parallel to the longitudinal axis of the first bus bar member 1 at its second end portion. The first end portion of the second bus bar member 2 incorporates a through opening. The through opening preferably extends through at least one lateral side surface of the second bus bar member 2 at its first end portion. In one embodiment, it passes through two lateral side surfaces of the second bus bar member 2 (in the case of an I-shaped or a part of an L-shaped second bus bar member 2). In one embodiment, it passes through one lateral side surface and one distal side surface of the second bus bar member 2 (in the case of a U-shaped or a part of an L-shaped second bus bar member 2). A threaded bolt 5 is inserted into this through hole and screwed into the female thread of the fixing recess. In one embodiment, the through opening does not have a female thread. In another embodiment, the through opening also has a female thread. Preferably, the longitudinal axis of the fixing recess at the second end portion of the first bus bar member 1, the longitudinal axis of the through opening at the first end portion of the second bus bar member 2, and / or the longitudinal axis of the threaded ball 5 extend parallel to the longitudinal axis of the second end portion of the first bus bar member 1. This means that the threaded bolt 5 is screwed in the direction of the U-shaped leg portion or the longitudinal axis direction of the first bus bar member 1. Thus, the connection depth of the threaded bolt 5 is much higher, similar to a flat bus bar screwed in together with a flat lateral side surface. This provides a more robust and better connection. In addition, the threaded bolt 5 can be screwed in from one opening side of the core 4 so that the manufacturing can be performed easily and quickly. As a result, the bolt head of the threaded bolt 5 presses the end of the second busbar member against the end of the first busbar member 1. Particularly advantageously, a self-tapping threaded bolt 5 (also called self-piercing) is employed, and this self-tapping screw cuts or penetrates the thread in the fixing recess by itself during the screwing process. This reduces the manufacturing complexity and at the same time improves the holding and electrical connection between the connected busbar members. The self-tapping threaded bolt 5 is provided with a screw (see FIG. 5). The screw preferably has a thread flank angle of 30° to 36°, in this case 33°. The overall flank angle is formed between the upper flank surface 51 and the lower flank surface 52 of the screw. The upper flank surface 51 is the flank surface of the screw facing the bolt head, and the lower flank surface 52 is the flank surface of the screw departing from the bolt head. Preferably, the upper flank angle is larger than the lower flank angle. The upper flank angle is formed between the upper flank 51 and a plane perpendicular to the screwing direction. The lower flank angle is formed between the lower flank 52 and a plane perpendicular to the screwing direction. The upper flank angle is preferably 20° to 24°, preferably 22°. The lower flank angle is preferably 10° to 12°, preferably 11°.

[0060] In the second connection technique, one end of the first busbar member 1 is connected to one end (or terminals 13, 14) of the second busbar member 2 with solder paste, and preferably, this is soldered by induction heating. Preferably, the distal side part of the second end of the first busbar member 1 is soldered to the first end (side surface or distal side part) of the second busbar member 2 with solder paste. Since it is difficult to reach the connection surface between the distal side part of the first busbar member 1 and the second busbar member 2 (distal side part or lateral side surface), this technique is suitable for simple and rapid processing.

[0061] The description of the turn 12 having the first busbar member 1 and the second busbar member 2 is similarly applicable to some, preferably all, of the turns 12 of the coil winding 11 of the first power conductor 10.

[0062] The first power conductor 10, coil winding 11, turn 12, first busbar member 1, second busbar member 2, first terminal 13 and / or second terminal 14 have a conductor cross-section (minimum value) selected based on the nominal or maximum current of the choke. Preferably (depending on the material of the first power conductor 10, coil winding 11, turn 12, first busbar member 1, second busbar member 2, first terminal 13 and / or second terminal 14), 1 mm 2 is provided for every 2.5 A to 5 A. Preferably, the above (minimum value) conductor cross-sectional area is greater than 10 mm 2 more preferably greater than 15 mm 2 more preferably greater than 20 mm 2 more preferably greater than 30 mm 2 or more preferably greater than.

[0063] The second power conductor 20 includes a second coil winding 21. The second coil winding 21 includes at least one (complete) turn 22, preferably two or more turns 22, arranged around the core 4 (in this case, the annular bead of the core 4). Preferably, the second power conductor 20 includes a first terminal 23 and / or a second terminal 24. At least one of the turns 22, preferably most of the plurality of turns 22, preferably each turn 22 includes the first busbar member 1 and the second busbar member 2. The plurality of characteristics of the second power conductor 20, second coil winding 21, single or multiple turns 22, first terminal 23, and second terminal 24 are, individually or in combination, the corresponding characteristics of the first power conductor 10, first coil winding 11, single or multiple turns 12, first terminal 13, and second terminal 14, but their description will not be repeated here. Preferably, the first coil winding 11 is arranged mirror-symmetrically with respect to the second coil winding 21 (with respect to the plane passing through the opening axis).

[0064] In other exemplary embodiments, the choke may be provided with only one power conductor and thus only one coil winding, or may be provided with three or more power conductors and thus three or more coil windings. Each of these power conductors and coil windings preferably has a design similar to that of the first power conductor and the first coil winding.

[0065] The choke preferably comprises a housing 30 in which the core and coil windings 11 and 12 are accommodated. The housing wall of the housing 30 at the first opening side of the core 4 is preferably also described as the first opening side of the housing 30. The side of the housing 30 at the second opening side of the core 4 is preferably also described as the second opening side of the housing 30. The housing wall of the housing 30 at the outer lateral surface of the core 4 is preferably also described as the outer lateral surface of the housing 30. The housing 30 is preferably designed in a cup shape or a pot shape so that the core and the coil windings 11 and 12 can be encapsulated (potted) in combination. This means that the housing 30 is closed at the first opening side and the outer lateral side. Conversely, the housing 30 is open at the second opening side so that the core 4 and the coil windings 11 and 12, or elements thereof, can be inserted into the housing 30 from the second opening side and / or the housing 30 can be filled with a molding composite. The housing walls at the first opening side and the outer lateral side are thus closed (in a leak-proof manner) so that fluid, specifically a molding compound, does not leak from the housing at the first opening side and the outer lateral side when injected into the housing.

[0066] The housing 30 preferably comprises an inner housing part 31 extending through the opening of the annular core 4. Preferably, the inner housing part 31 is constituted by the housing wall at the inner lateral surface of the core 4. This inner housing part 31 preferably opens at the first or second opening side, and preferably at the first opening side. This improves heat dissipation. However, the inner housing part 31 may be a closed hollow structure and may be filled with a molding composite 6.

[0067] The housing 30, specifically its first opening side portion, its outer lateral surface and / or its inner lateral surface, is shaped such that the first bus bar member 1 (and further, if applicable, the second bus bar member 2) and / or the core 4 are fixed, positioned and / or oriented by the housing 30. Thereby, simple, reproducible and rapid assembly of the choke is made possible. For this reason, the first bus bar member 1 is fitted into the housing 30 and fixed in the correct position by the housing. Then, the core 4 may be inserted into the housing 30 (and the first bus bar member 1). Since the housing 30 functions to correctly position the core 4 and the first bus bar member 1, the assembly is very simple.

[0068] The housing 30 preferably has protrusions 32 on the first opening side portion and / or the outer lateral surface for the first bus bar member 1. By means of these protrusions 32, the first bus bar member 1 is fixed in a predetermined position. Preferably, the basic shape of the first opening side portion and / or the outer lateral surface of the housing 30 preferably coincides with the corresponding shape of the core 4, preferably parallel to the core 4. The gap between the housing wall of this basic shape and the core 4 is preferably greater than 1 mm, preferably greater than 3 mm, preferably greater than 5 mm. The gap between the housing wall of this basic shape and the core 4 is preferably less than 10 mm, preferably less than 7 mm, preferably less than 5 mm, preferably less than 3 mm. This basic shape is preferably a straight circular cylinder, preferably a hollow circular cylinder. The basic shape is interrupted by the above-described protrusions. The protrusions are preferably arranged in a radial plane (with a slight deviation) from the opening axis. Preferably, each protrusion is configured to hold only the first bus bar member 1. In a first exemplary embodiment, a common protrusion 32 is provided at the first (alternatively last) turn 12 of the first coil winding 11 and the first (alternatively last) turn 22 of the second coil winding 21, at the first (or last) winding 21. The protrusion 32 first performs the above-described positioning of the first bus bar member 1. However, the protrusion 32 has further advantages, namely that heat from the first bus bar member 1 can be directly dissipated through the protrusion 32 and / or heat from the core 4 can be quickly dissipated from the outer side surface of the housing 30 through the basic shape, and the required heat dissipation path is short. The gap between the housing wall of the protrusion 32 and the first bus bar member 1 is preferably greater than 1 mm, preferably greater than 3 mm, preferably greater than 5 mm. The gap between the receiving wall of the protrusion 32 and the first bus bar member 1 is preferably less than 10 mm, preferably less than 7 mm, preferably less than 5 mm, preferably less than 3 mm. The shape of the housing 30 having the basic shape 33 and the protrusion 32, as described thus, also has the further advantage that the amount of the molding composite 6 is minimized when the choke 1 is enclosed, thereby enabling weight reduction.Preferably, the housing 30 incorporates a blade 35 for holding the first busbar member 1 in a predetermined position on the inner lateral surface of the housing 30 or on the inner side of the inner housing portion 31 (facing the core 4). Preferably, the blade 35 extends inside the housing 30 in the radial direction of the opening axis of the core 4. Preferably, one such blade 35 is arranged in each case between two adjacent first or second busbar members 1, 2 and / or between two adjacent turns 12, 22. Preferably (a plurality of, most, all) the first or second busbar members 1, 2 and / or the adjacent turns 12, 22 are delimited and / or held by the blade 35 at either side of both sides.

[0069] The housing 30 is provided with a blade 34 on the inner side of the outer lateral surface and / or is provided with a blade 35 for maintaining the core 4 in a predetermined position on the inner side of the inner lateral surface (facing the core 4). The blade 35 is preferably the same one that holds or separates the busbar members 1, 2 and / or the turns 12, 22. Thereby, the vibration of the completed choke is reduced and the accurate positioning of the core 4 is facilitated. Preferably, the blade 34 and / or 35 is configured in a slight rust shape (where the clearance from the blade 34, 35 to the first opening side is narrower than the clearance to the second opening side), the core 4 can be easily inserted from the second opening side, and the core 4 can be guided to an accurate position on the second opening side. Preferably, the clearance from the blade 34 and 35 to the first opening side is slightly narrower than the width of the core 4 (specifically its annular bead), and the core 4 is press-fitted between the blade 34 and 35. The blade 34 is preferably formed inside the basic shape of the outer side wall (and extends radially inside the housing 30). The blade 34 is preferably configured inside the inner housing portion 31 (and extends radially inside the housing 30).

[0070] The busbar members 1, 2 and / or turns 12, 22 of the coil windings 11, 21 are close to the opening of the core 4, and it is necessary to provide effective insulation therebetween. Preferably, the housing 30, particularly its inner lateral surface and / or its first opening side portion, is formed such that the adjacent busbar members 1, 2 and / or turns 12, 22 of the coil windings 11, 21 are insulated from each other. This is preferably achieved by blades 35 extending from the inner housing portion 22 (preferably radially) towards the inside of the housing 11 (i.e., outwardly with respect to the opening axis) between the corresponding adjacent busbar members 1, 2 and / or windings 30, 12 of the coil windings 35, 31. These blades are preferably the same blades 35 for positioning the core 4. However, they may be configured separately such that blades are provided for positioning the core and other blades are provided for insulation. The protrusions 32 and / or blades 35 thus provide most of the insulation between the adjacent busbar members 1, 2 and / or turns 12, 22 of the coil windings 11, 21 without involving additional steps related to the assembly of the choke.

[0071] The above-mentioned housing 30 is preferably of an integral structure and / or composed of a single material. However, it may also be configured as a multi-component structure. The material of the housing 30 is preferably electrically insulating, preferably plastic.

[0072] The choke preferably includes a structural element 40. The structural element 40 is disposed between the core 4, specifically its second opening side, and the second busbar member 2 or turns 12, 22, and / or between adjacent second busbar members 2 or adjacent turns 12, 22. The structural element 40 is shaped to engage with the second opening side portion of the core 4, and the second busbar member 2 (terminals 13, 14, 23, 24 when applicable) can be easily positioned by the structural element 40. Also, the structural member 40 is shaped to engage with the second opening side of the core 4, and the second busbar member 2 (terminals 13, 14, 23, 24 when applicable) can be easily positioned by the structural member 40, and the structural member 40 and the housing 30 are shaped such that the structural member 40 can be adopted only at one location within the housing 30.

[0073] The structural element 40 preferably includes a covering element 41 disposed between the core 4, specifically its second opening side portion, and the second busbar member 2 or turns 12, 22. The covering element 41 preferably covers at least a part of the second opening side portion of the core 4. Specifically, at least a part of the covered portion of the covering element 41 includes the region of the second opening side portion of the core 4 and is covered by the second busbar member 2 so as to insulate the core 4 from the second busbar member 2. Preferably, the covering element is annular so as to completely cover the second opening side portion of the core 4. The covering element 41 extends in the plane of the second opening side portion of the core 4 or perpendicular to the opening axis.

[0074] The structural element 40 preferably comprises a partition 42 which extends in the opening direction from the second opening side portion of the core 4 or from the covering element 41 (preferably at a right angle thereto) and / or is arranged to be oriented along the side wall of the second busbar member 2. Preferably, one or each second busbar member 2 is delimited on both sides by such a partition (arranged at a right angle to the second opening side of the core 4). The partition 42 is oriented parallel to the second busbar member 2 such that the partition defines the position of the second busbar member 2. The partition is preferably at approximately the same height as the second busbar member 2 and preferably higher than the second busbar member 2 such that the partition 42 projects above the second busbar member 2. Thereby, in particular in the internal region where a plurality of second busbar members 2 are close to each other, the insulation between two adjacent second busbar members 2 is improved. The partition 42 preferably extends from the inner edge to the outer edge of the structural element 40 or the core 4. To improve stability, two adjacent partitions 42 of adjacent second busbar members 2 are connected by a connecting wall to form a separation structure. The connecting wall is preferably oriented along the inner and outer edge portions of the structural element 40 or the core 4. The separation structure is open at its upper side, such that the latter can be filled with a molding composite. Thereby, the discharge of heat from the side wall of the second busbar member 2 and from the second opening side of the core 4 is improved.

[0075] The structural element 40 preferably further comprises a separation element 43 which extends from the (inner edge portion) of the structural element 40 or from the core 4 to the opening of the core 4. These separation elements 43 are preferably implemented in the form of a continuous one of two partitions 12 around the second busbar member 2. The separation element 43 insulates adjacent busbar members 1, 2 or turns 11, 22 in the opening region of the core 4. Preferably, a plurality of or each separation element 35, in combination with the blade 35, functions here as a separation element and forms a closed partition or insulation between adjacent busbar members 1, 2 or turns 12, 22.

[0076] Preferably, at least one of the partition portions 44 is disposed between the two terminals 14, 24 of the different coil windings 11, 21 and / or is raised so as to project from the molded composite body 6. Thereby, the insulation between the two terminals 14, 24 outside the molded composite body 6 is improved.

[0077] The above-described component 40 is preferably composed of an integral structure and / or a single material. However, the structural element 40 may also be configured as a multi-component structure. The material of the structural element 40 is preferably electrically insulating and is preferably plastic.

[0078] When the second bus bar member 2 and the terminals 13, 14, 23, 24 are appropriately arranged on the structural element 40, the latter only requires connection to the corresponding first bus bar member 1 (see the above description).

[0079] Preferably, the housing 30 and / or the structural element 40 is encapsulated in the molded composite body 6 together with the core 4 and at least one coil winding 11, 21. The molded composite body 6 is applied to the height within the housing 30 such that all conductive parts (excluding the terminals 13, 14, 23, 24) are encapsulated in the molded composite body 6 or covered by the molded composite body 6. The molded composite body 6 suppresses vibration and effectively discharges heat. Specifically, in combination with the housing 30 described above, an effective compromise is achieved among weight reduction, effective heat exhaust, and low vibration.

[0080] Figures 7 to 10 represent a second exemplary embodiment of this type of choke. The illustrated choke is a current compensation type choke designed for a maximum or nominal current of 80A. The foregoing also applies to this choke.

[0081] Figures 11 to 14 represent a third exemplary embodiment of this type of choke. The illustrated choke is a current compensation type choke designed for a maximum or nominal current of 200A. The foregoing also applies to this choke.

Description of the reference numerals

[0082] 1 First bus bar member 2 Second bus bar member 4 Core 5 Screwed bolt 6 Molded composite 10 First power conductor 11 First coil winding 12 Turn 13 First terminal 14 Second terminal 20 Second power conductor 22 Turn 23 First terminal 24 Second terminal 30 Housing 31 Inner housing part 34 Blade 35 Blade, separating element 40 Structural element 41 Coating element 42 Partition part 43 Separating element 51 Upper flange angle 52 Lower flange angle

Claims

1. A choke comprising a core (4) and a first power conductor (10), wherein the first power conductor (10) comprises a first coil winding (11) having at least one complete turn (12) around the core (4), at least one of the at least one complete turn (12) of the first coil winding (11) comprises a rigid first busbar member (1) and a rigid second busbar member (2), the choke comprises a housing (30), the core (4) and the first coil winding (11) are disposed within the housing (30), the housing (30) is configured to include at least one protrusion (32) for receiving the rigid first busbar member (1) of the one complete turn (12), and the rigid first busbar member (1) of the complete turn (12) of the first coil winding (11) is received within each of the at least one protrusion (32), Choke.

2. The choke according to claim 1, wherein the rigid first busbar member (1) is U-shaped and is configured around the core.

3. The rigid first busbar member (1) comprises a first end and a second end, the rigid second busbar member (2) comprises a first end and a second end, the rigid first busbar member (1) comprises a first distal side at the first end of the rigid first busbar member (1), a second distal side at the second end of the rigid first busbar member (1), and at least one lateral surface between the first distal side of the rigid first busbar member (1) and the second distal side of the rigid first busbar member (1), the rigid second busbar member (2) comprises at least one lateral surface between the first end of the rigid second busbar member (2) and the second end of the rigid second busbar (2), the second end of the rigid first busbar member (1) is connected to the first end of the rigid second busbar member (2) with the second distal side of the rigid first busbar member (1), and the connected rigid first busbar member (1) and the rigid second busbar member (2) form the complete turn (12) of the first coil winding (11) formed from a rigid busbar. The choke according to claim 1.

4. The second end of the rigid first busbar member (1) incorporates a fixing recess having a menage at the second distal side. The first end of the rigid second bus bar member (2) incorporates a through-hole portion that penetrates at least one of the at least one lateral surface of the rigid second bus bar member (2). The threaded bolt (5) extends through the through-hole portion and is threaded into the female thread of the fixing recess, and the bolt head of the threaded bolt (5) presses the first end of the rigid second bus bar member (2) against the second end of the rigid first bus bar member (1). The choke according to claim 3.

5. The threaded bolt (5) is a self-tapping threaded bolt, and the female thread is configured in a shape determined by threading the self-tapping threaded bolt (5) into the fixing recess. The choke according to claim 4.

6. The self-tapping threaded bolt (5) has an angle on the side surface of the thread that is a value between 30 degrees and 36 degrees. The angle on the side surface of the thread is provided between an upper flank (51) facing the bolt head and a lower flank (52) extending therefrom from the bolt head, and the angle of the upper flank is larger than the angle of the lower flank. The choke according to claim 5.

7. The rigid first bus bar member (1) has a first distal side portion at the first end of the rigid first bus bar member (1), a second distal end portion at the second end of the rigid first bus bar member (1), and at least one lateral surface between the first distal side portion of the rigid first bus bar member (1) and the second distal side portion of the rigid first bus bar member (1). and comprises The rigid second bus bar member (2) has at least one lateral surface between the first distal side portion of the rigid second bus bar member (2) and the second distal side portion of the rigid second bus bar member (2). The second distal side portion of the rigid first bus bar member (1) is connected to the first end of the rigid second bus bar member (2) by solder paste, and the solder paste is configured to be solderable by induction heating. The choke according to claim 1 or 2.

8. The core (4) is annular and comprises a first opening side portion, a second opening side portion in the opposite direction to the first opening side portion, an external lateral surface, and an internal lateral surface. The housing (30) covers the first opening side portion and the external lateral surface of the core (4). At least one of the protruding portions (32) of the housing (30) is provided on at least one of the first opening side portion and the outer lateral surface, and is the choke according to claim 1.

9. The shape of the housing (30) on at least one of the first opening side portion and the outer lateral surface conforms to the shape of the core (4) on at least one of the first opening side portion and the outer lateral surface blocked by at least one of the protruding portions (32), and is the choke according to claim 8.

10. The housing (30) includes an inner housing portion (31) that covers the inner lateral surface of the core (4), and is the choke according to claim 8 or 9.

11. The inner housing portion (31) includes a separating element (35) extending to the core (4), and at least one of the rigid first bus bar member (1) and the rigid second bus bar member (2) of the complete turn (12) of the first coil winding (11) is provided between two adjacent separating elements (35), and is the choke according to claim 10, where at least one of the separating elements (35) is provided between two adjacent complete turns (12) of the first coil winding (11).

12. The inner housing portion (31) is hollow and opens toward the first opening side portion or the second opening side portion, and is the choke according to claim 10 or 11.

13. The housing (30) is surrounded by the core (4) and the first power conductor (10), and the second opening side portion is covered by a molded composite (6) together with at least one of the rigid second bus bar members (2), and is the choke according to any one of claims 8 to 12.

14. The housing (30) has a cup shape, the outer lateral surface of the housing protrudes above the conductive portion of the first power conductor (10), and the molded composite (6) injected into the cup-shaped housing (30) covers the conductive portion of the first power conductor (10) so as to insulate it except for the protruding terminals (13, 14), and is the choke according to claim 13.

15. The choke according to any one of claims 8 to 14 includes an electrically insulating structural element (40) provided between the second opening side portion of the core (4) and at least one of the rigid second bus bar members (2).

16. The structural element (40) covers the second opening side portion of the core (4), and is at least one of a separated configuration or at least one partition portion (42) being incorporated between two adjacent rigid second bus bar members (2). The choke according to claim 15.

17. The separated configuration or at least one partition portion (42) includes a separation element (43) extending in the direction of the inner housing portion (31), and in combination with one of the separation elements (35) of the inner housing portion (31), insulates two adjacent complete turns (12) from each other. The choke according to claim 16, which quotes claim 15, which quotes claim 10.

18. The choke includes a second power conductor (20), and the second power conductor (20) includes a second coil winding (21) having at least one complete turn (22) around the core (4). At least one of at least one of the complete turns (22) of the second coil winding (21) includes the rigid first bus bar member (1) and the rigid second bus bar member (2). The choke according to any one of claims 1 to 17.

19. The first coil winding (11) and the second coil winding (21) are wound around the core (4), and the magnetic fluxes induced in the core (4) by the differential mode currents of the first power conductor (10) and the second power conductor (20) cancel each other out, thus creating a current compensation choke. The choke according to claim 18.

20. The core (4) is formed as a hollow cylindrical body. The choke according to any one of claims 1 to 19.

21. At least one of the first power conductor (10) and the second power conductor (20) of the choke has a minimum conductor cross-sectional area surface area larger than 10 mm ２ or larger than 20 mm ２ The choke according to any one of claim 18, claim 19, and claim 20 that cites claim 18 or 19, having a minimum conductor cross-sectional area surface area larger than 10 mm

22. A vehicle having a DC network, wherein the DC network includes the choke according to any one of claims 1 to 21.

23. The separated configuration or at least one partition portion (42) includes a separation element (43) extending in the direction of the inner housing portion (31), and in combination with one of the separation elements (35) of the inner housing portion (31), insulates two adjacent complete turns (12) from each other. The choke according to claim 16, which quotes claim 15, which quotes claim 13, which quotes any one of claims 10, 11, and 12. Claim 24: The separated configuration or at least one partition (42) comprises a separation element (43) extending in the direction of the inner housing part (31), and in combination with one of the separation elements (35) of the inner housing part (31), insulates two adjacent said complete turns (12) from each other. A claim 16 for a choke, which cites claim 15, which cites claim 14, which cites claim 13, which cites any one of claims 10, 11, and 12.

Images