Inductive component
By using a non-circular winding wire with a large and small transverse dimension and orienting it obliquely or parallel to the air gap's central longitudinal axis, the inductive component reduces magnetic field line penetration and heating, addressing the issue of increased losses during rapid current fluctuations.
Patent Information
- Application Number
- PCT/EP2024/081651
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-11-13
- Filing Date
- 2024-11-08
- Publication Date
- 2025-05-22
AI Technical Summary
Inductive components with cores and air gaps in magnetic circuits suffer from increased losses due to magnetic field line penetration into the winding wire, especially during rapid current fluctuations, leading to heating and reduced efficiency.
The winding wire is arranged to have a non-circular cross-section with a large and small transverse dimension, and is oriented such that the large transverse dimension is obliquely or parallel to the central longitudinal axis of the air gap, reducing magnetic field line penetration and heating.
This configuration significantly reduces losses in the inductive component by minimizing magnetic field line penetration into the winding wire, thereby maintaining efficiency even during rapid current fluctuations.
Smart Images
Figure EP2024081651_22052025_PF_FP_ABST
Abstract
Description
[0001] Inductive component
[0002] The invention relates to an inductive component having a core and at least one winding on the core, wherein the core defines an air gap in a magnetic circuit, wherein a winding wire of the winding has a non-circular cross-section with a large transverse dimension and a small transverse dimension relative to the large transverse dimension, in particular a rectangular, parallelogram-shaped or trapezoidal cross-section.
[0003] The invention aims to improve an inductive component.
[0004] According to the invention, an inductive component having the features of claim 1 is provided for this purpose. Advantageous developments of the invention are mentioned in the subclaims.
[0005] An inductive component comprises a core and at least one winding on the core, wherein the core defines an air gap in a magnetic circuit. A winding wire of the winding has a non-circular cross-section with a large transverse dimension and a small transverse dimension relative to the large transverse dimension. In particular, the winding wire has a rectangular, parallelogram-shaped, or trapezoidal cross-section. The winding wire surrounds a first core section and / or the air gap in a first winding section, and in the first winding section, the large transverse dimension of the winding wire is arranged obliquely or parallel to a central longitudinal axis of the first core section and / or the air gap.
[0006] In inductive components with a core, the magnetic field lines also run across the air gap. In the area of the air gap, the magnetic field lines take up more space than within the magnetic core. In other words, the magnetic field lines deform compared to their course in the core and typically bulge in the area of the air gap. If the magnetic field lines penetrate the winding at least partially in the area of the air gap, this leads to losses because the winding wire heats up. This effect is particularly pronounced during rapid current fluctuations, a so-called "ripple current." The heating of the winding wire reduces the efficiency of the inductive component. The advantages achieved by a rectangular winding wire are thus partially lost. On the other hand, if the winding ends before the air gap, the space surrounding the air gap cannot be used.By surrounding the winding wire in a first winding section, a first core section and / or the air gap, and by arranging the large transverse dimension of the winding wire in the first winding section obliquely or parallel to a central longitudinal axis of the first core section and / or the air gap, the winding wire can be arranged such that the magnetic field lines in the region of the air gap do not penetrate the winding wire or penetrate it to a significantly lesser extent. The losses of the inductive component can thus be significantly reduced.The oblique or parallel arrangement of the large transverse dimension of the winding wire to a central longitudinal axis of the first core section and / or the air gap thus makes it possible to at least partially use a space surrounding the air gap to accommodate winding wire and at the same time to prevent or largely prevent the magnetic field lines in the region of the air gap from penetrating the winding wire and thereby heating it.
[0007] In a further development of the invention, a second winding section surrounds a second core section, wherein in the second winding section the large transverse dimension of the cross section of the winding wire is arranged perpendicular to a central longitudinal axis of the second core section and wherein in the region of the air gap the large transverse dimension of the winding wire is arranged obliquely or parallel to the central longitudinal axis of the air gap.
[0008] The angle formed by the large transverse dimension of the winding wire's cross-section relative to the core's central longitudinal axis thus changes in the air gap region. For example, the large transverse dimension of the winding wire is initially arranged at an angle at the beginning of the air gap, then approximately in the middle of the air gap, parallel to the central longitudinal axis of the air gap, and then again at an angle to the central longitudinal axis of the air gap near the end of the air gap.
[0009] In a further development of the invention, an orientation of the large transverse dimension of the cross section of the winding wire changes relative to a central longitudinal axis of the air gap.
[0010] In this way, a gradual transition can be realized, for example over the length of a winding from an orientation of the large transverse dimension perpendicular to the central longitudinal axis of the air gap to an orientation parallel to the central longitudinal axis of the air gap and back again to an orientation perpendicular to the central longitudinal axis of the air gap.
[0011] In a further development of the invention, in the region of the air gap, the orientation of the large transverse dimension of the cross section of the winding wire changes from a first oblique orientation relative to a central longitudinal axis of the air gap to a parallel orientation and again to a second oblique orientation.
[0012] In a further development of the invention, the first oblique orientation relative to the central longitudinal axis has a first angle and the second oblique orientation relative to the central longitudinal axis of the air gap has a second angle, wherein the first and the second angles have the same amount but different signs.
[0013] Further features and advantages of the invention emerge from the claims and the following description of preferred embodiments of the invention in conjunction with the drawings. Individual features of the various illustrated and / or described embodiments can be combined with one another in any way without exceeding the scope of the invention. This also applies to the combination of individual features without other individual features with which they are illustrated and / or described in connection. In the drawings:
[0014] Fig. 1 is a front view of an inductive component according to a first
[0015] Embodiment of the invention,
[0016] Fig. 2 is a sectional view of the inductive component of Fig. 1,
[0017] Fig. 3 is a side view of the winding of the inductive component of Fig. 1,
[0018] Fig. 4 is a sectional view of the winding of Fig. 3,
[0019] Fig. 5 is a front view of an inductive component according to a second
[0020] Embodiment of the invention,
[0021] Fig. 6 is a sectional view of the inductive component of Fig. 5,
[0022] Fig. 7 is a view of the winding of the inductive component of Fig. 5 from an angle above,
[0023] Fig. 8 is a side view of the winding of the inductive component of Fig. 5,
[0024] Fig. 9 is a view of an inductive component according to a third embodiment of the
[0025] Invention from the front, Fig. 10 a sectional view of the inductive component of Fig. 9 and
[0026] Fig. 11 is a sectional view of the winding of the inductive component of Fig. 9.
[0027] Fig. 1 shows an inductive component 10 with a winding 12 and a core 14. The core is constructed in two parts, with a first E-shaped part 16 and a second, identical E-shaped part 18. The winding 12 is wound from winding wire with a rectangular cross-section. The rectangular cross-section consequently has a large transverse dimension, corresponding to the width of the winding wire, and a small transverse dimension, corresponding to the height of the winding wire. The winding has a first winding section 20, a second winding section 22, and a third winding section 24. Not visible in Fig. 1 are a first and a second core section, which are cylindrical and extend into the winding 12 from a respective base of the core parts 16, 18. This corresponds to the known structure of a so-called E-core.The free ends of the first core portion and the second core portion are spaced apart from each other so that a magnetic circuit formed by the core 14 has an air gap.
[0028] It can already be seen in Fig. 1 that in the first winding section 22, the large transverse dimension of the winding wire is arranged perpendicular to an imaginary central longitudinal axis 26 of the air gap. The central longitudinal axis 26 of the air gap coincides with the central longitudinal axis of the first core section and the second core section. In the first winding section 20, which surrounds the air gap, however, the orientation of the large transverse dimension of the winding wire to the central longitudinal axis 26 changes. It can be seen that the large transverse dimension is initially arranged at an increasingly oblique angle, up to an orientation parallel to the central longitudinal axis 26 halfway along the length of the air gap, and that the orientation of the large transverse dimension then changes again from the parallel orientation via oblique orientations to the vertical orientation in the third winding section 24.In the first winding section 20, the orientation of the large transverse dimension of the cross-section of the winding wire thus gradually changes from a first oblique orientation relative to the central longitudinal axis 26 of the air gap to a parallel orientation and from the parallel orientation gradually again to a second oblique orientation. The first oblique orientation relative to the central longitudinal axis of the air gap has a first angle at any point in the first winding section before half the length of the air gap, and the second oblique orientation relative to the central longitudinal axis 26 of the air gap, symmetrical to half the length of the air gap, has a second angle, wherein the first and second angles have the same magnitude but different signs. Fig. 2 shows a sectional view of the inductive component 10 of Fig. 1. The core 14 with the two parts 16, 18 can be seen, each of which has an E-shaped cross-section.An air gap 34 is formed between a first core section 30 of the first part 16 and a second core section 32 of the second part 18. The sectional view in Fig. 2 shows how the angle of the large transverse dimension of the cross section of the winding wire changes from the vertical orientation in the second winding section 22 to the vertical orientation in the first winding section 20. The change of the angle back to the vertical orientation in the third winding section 24 is not shown in Fig. 2, but occurs analogously.
[0029] It is very important that in the area of the air gap 34 the radial distance of the winding wire to the air gap between the two core sections 30, 32 is greater than in the area of the first core section 30 and in the area of the second core section 32. Magnetic field lines 36 in the area of the air gap 34 bulge, so that the magnetic field in the area of the air gap 34 takes up more space because the field lines 36 bulge radially than in the area of the first core section 30 and the second core section 32. By arranging the large transverse dimension of the winding wire in the area of the air gap 34 initially obliquely, then parallel and then again obliquely to the central longitudinal axis 26 of the air gap, it is possible to prevent the magnetic field lines 36 in the area of the air gap 34 from penetrating the winding wire. This can prevent or even slow down heating of the winding wire.can be largely avoided and the losses of the inductive component 10 are significantly reduced.
[0030] For clarification, magnetic field lines 36 are drawn in the area of the air gap 34, which are intended to show the qualitative typical course of magnetic field lines 36 in the area of an air gap.
[0031] Fig. 3 shows the winding wire 12 of the inductive component of Fig. 1 in a side view, without the core 14. The gradual transition from the vertical orientation of the winding wire to the central longitudinal axis from the vertical orientation in the second winding section 22 to the first oblique, then parallel and then again oblique orientation in the first winding section 20 and to the again vertical orientation in the third winding section 24 can be seen.
[0032] Fig. 4 shows a sectional view of the winding 12 of Fig. 3. It can be seen that the winding wire has a rectangular cross-section and the large transverse dimension 40 of the winding wire, which corresponds to the width of the winding wire, is approximately eight times as large as the small transverse dimension 42, which corresponds to the height of the winding wire. Fig. 5 shows a front view of an inductive component 50 according to a further embodiment of the invention. The inductive component 50 is constructed very similarly to the inductive component 10 of Fig. 1, so that only the differences from the inductive component 10 will be explained. In particular, the core 14 of the inductive component 50 is constructed identically to the core 14 of the inductive component 10 and has a first part 16 and a second part 18, each of which has an E-shape. A winding 52 of the inductive component 50 is, like the winding 12 of the inductive component 10, made of winding wire with a rectangular cross-section.In the second winding section 22, wherein the second winding section 22 surrounds the first core section 30, the large transverse dimension of the cross section of the winding wire is oriented perpendicular to the central longitudinal axis 26 of the air gap 34, and in the third winding section 24, the large transverse dimension of the winding wire is also oriented perpendicular to the central longitudinal axis 26. In the region of the air gap 34 and consequently in the first winding section 20, however, the large transverse dimension of the winding wire is oriented parallel to the central longitudinal axis 26. Here, the winding wire runs essentially parallel to the central longitudinal axis 26 over the entire length of the air gap 34.In the region of the air gap 34 and thus in the first winding section 20, not only is the orientation of the large transverse dimension of the winding wire changed, but the winding wire changes its direction and no longer runs in the circumferential direction to the central longitudinal axis 26 as in the second winding section 22 and in the third winding section 24, but parallel to the central longitudinal axis 26.
[0033] Fig. 6 shows a sectional view of the inductive component 50 of Fig. 5. It can be seen that in the region of the air gap 34, in which the magnetic field lines run analogously to the illustration in Fig. 2, the winding wire is spaced very far apart from the air gap 34 in the radial direction. As a result, there is no fear that the magnetic field lines in the region of the air gap 34 will penetrate the winding wire and thereby cause losses.
[0034] Fig. 7 shows a view of the winding 52 of the inductive component 50 of Fig. 5 without the core. Fig. 8 shows a side view of the winding 52 of Fig. 7.
[0035] Fig. 9 shows an inductive component 60 according to another embodiment of the invention. The inductive component 60 has a winding 62 and a core 64. The core 64 is constructed in two parts and has a first part 66 in an E-shaped form and a second part 68 in the form of a base plate.
[0036] The winding 62 is wound from winding wire with a rectangular cross-section. The core 64 defines a magnetic circuit with an air gap not visible in Fig. 9. Fig. 10 shows a sectional view of the inductive component 60 of Fig. 9. The sectional plane in Fig. 9 runs from bottom left to top right and thus also through the openings in the first part 66 of the core 64. It can be seen that the core 64 has a first core section 68 on the first part 66, which is cylindrical and whose free end is arranged at a distance from the second part 68. This defines an air gap 70 between the free end of the first core section 68 and the top side of the second part 68. The course of some exemplary magnetic field lines 72 is shown in the air gap 64.It can be seen that the field lines 72, starting from the free end of the first core section 68, curve radially away from the central longitudinal axis 26. As the distance from the free end of the first core section 68 increases, the diameter of the space occupied by the magnetic field lines 72 increases.
[0037] To prevent the magnetic field lines 72 from penetrating the winding wire of winding 62, the winding wire of winding 62, which has a rectangular cross-section, is arranged obliquely to the central longitudinal axis 26 of the air gap 70. The angle formed by the large transverse dimension of the winding wire of winding 62 is pivoted downward from the vertical position. The angle between the central longitudinal axis 26 and a respective top or bottom side of the winding wire is approximately 120° in the illustrated embodiment.
[0038] Due to the oblique arrangement of the winding wire, the large transverse dimension of the winding wire can be increased, while maintaining the same core dimensions, compared to an arrangement in which the large transverse dimension is perpendicular to the central longitudinal axis 26. In other words, a wider winding wire can be used. A winding wire with a parallelogram-shaped cross-section can also be used. If necessary, the installation space within the core 60 can be optimally utilized in this way.
[0039] Because the oblique orientation of the large transverse dimension of the cross section of the winding wire of the winding 62 prevents the magnetic field lines 72 in the air gap 70 from penetrating the winding wire, losses of the inductive component 60 can be significantly reduced.
[0040] Fig. 11 shows a sectional view of the winding 62 of the inductive component of Figs. 9 and 10. The oblique arrangement of the large transverse dimension 40 of the cross section of the winding wire of the winding 62 to the central longitudinal axis 26 is clearly visible. Due to the rectangular cross section of the winding wire, the small transverse dimension 42 is also arranged obliquely to the central longitudinal axis 26.
Claims
Patent claims 1. Inductive component with a core and at least one winding on the core, wherein the core defines an air gap in a magnetic circuit, wherein a winding wire of the winding has a non-circular cross-section with a large transverse dimension and a small transverse dimension relative to the large transverse dimension, in particular a rectangular, parallelogram-shaped or trapezoidal cross-section, characterized in that the winding wire surrounds a first core section and / or the air gap in a first winding section and that in the first winding section the large transverse dimension of the winding wire is arranged obliquely or parallel to a central longitudinal axis of the first core section and / or the air gap.
2. Inductive component according to claim 1, characterized in that a second winding section surrounds a second core section and that in the second winding section the large transverse dimension of the cross section of the winding wire is arranged perpendicular to a central longitudinal axis of the second core section and that in the region of the air gap the large transverse dimension of the winding wire is arranged obliquely or parallel to the central longitudinal axis of the air gap.
3. Inductive component according to claim 1 or 2, characterized in that in the region of the air gap an orientation of the large transverse dimension of the cross section of the winding wire changes relative to a central longitudinal axis of the air gap.
4. Inductive component according to claim 3, characterized in that in the region of the air gap the orientation of the large transverse dimension of the cross section of the winding wire changes from a first oblique orientation relative to a central longitudinal axis of the air gap to a parallel orientation and again to a second oblique orientation.
5. Inductive component according to claim 4, characterized in that the first oblique orientation relative to the central longitudinal axis of the air gap has a first angle and the second oblique orientation relative to the central longitudinal axis of the air gap has a second angle, wherein the first and the second angles have the same amount but different signs.
Citation Information
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