ELECTRICAL COMPONENT, ESPECIALLY TRANSFORMER OR INDUCTOR

Abstract

An electrical component includes a ferromagnetic core with a first and a second leg; a primary winding with a first primary winding portion arranged around the first leg of the ferromagnetic core and a second primary winding portion arranged around the second leg of the ferromagnetic core; wherein the first primary winding portion and the second primary winding portion each include parallel connectable conductors arranged around the ferromagnetic core in a cross section with the conductors being radially displaced with respect to each other at radial row positions, wherein the number of conductors of the first primary winding portion is equal the number of conductors of the second primary winding portion.

Claims

1. An electrical component, comprising: a ferromagnetic core with a first and a second leg; a primary winding with a first primary winding portion arranged around the first leg of the ferromagnetic core and a second primary winding portion arranged around the second leg of the ferromagnetic core; wherein the first primary winding portion and the second primary winding portion each comprise a plurality of conductors connectable in parallel and arranged around the ferromagnetic core in a cross section with the conductors being radially displaced with respect to each other at radial row positions, wherein the number of conductors of the first primary winding portion is equal the number of conductors of the second primary winding portion and each of the conductors of the first primary winding portion is connected in series with one corresponding conductor of the second primary winding portion, wherein a conductor of a radially outer row of the first primary winding portion is connected in series with a conductor of a radially inner row of the second primary winding portion, thereby reducing the sum of the magnetic flux between parallel connectable conductors of the first primary winding portion and parallel connectable conductors of the second primary winding portion.

2. The electrical component according to claim 1, wherein the electrical component is an inductor.

3. The electrical component according to claim 1, wherein the electrical component is a transformer and further comprises a secondary winding with a first secondary winding portion arranged around the first leg of the ferromagnetic core and a second secondary winding portion arranged around the second leg of the ferromagnetic core.

4. The electrical component according to claim 1, wherein the first and second primary winding portions are arranged around the ferromagnetic core in a cross section comprising M rows of conductors, each row being arranged at a radial row position, with the radially innermost row position being row position number 1 and the radially outermost row position being row position number M, wherein each conductor in the m.sup.th row position of the first primary winding portion with 1≤m≤M is in series connected with a conductor in the (M+1−m).sup.th row position of the second primary winding portion.

5. The electrical component according to claim 3, wherein the secondary winding is a low voltage winding and the primary winding is a high voltage winding.

6. The electrical component according to claim 1, wherein the first primary winding portion and the second primary winding portion each comprise at least 3, preferably at least 4, conductors.

7. The electrical component according to claim 1, wherein in an operational state of the electrical component, a current of at least 20 A, especially at least 100 A, flows through the primary winding.

8. The electrical component according to claim 1, wherein the electrical component comprises a first external electrical connector in series connected with the conductors of the first primary winding portion and a second external electrical connector in series connected with the conductors of the second primary winding portion, wherein the first and second primary winding portions are located between the first and second external electrical connector.

9. The electrical component according to claim 1, wherein the first primary winding portion and the second primary winding portion each comprise a cable formed of a group of litz wires and wherein the plurality of parallel connectable conductors are a plurality of parallel connectable litz wires.

10. The electrical component according to claim 9, wherein the cable comprises 4 litz wires and wherein the litz wires of the first and second primary winding portions are arranged around the ferromagnetic core in a cross section comprising 2 radial rows and 2 axial rows, wherein an axial direction defines an axial top row and an axial bottom row, wherein a litz wire of a top row of the first primary winding portion is connected in series with a litz wire of a top row of the second primary winding portion and a litz wire of a bottom row of the first primary winding portion is connected in series with a litz wire of a bottom row of the second primary winding portion.

11. The electrical component according to claim 9, wherein the litz wires of the first and second primary winding portions are arranged around the ferromagnetic core in a cross section comprising K≥3 axial rows of litz wires, each row being arranged at an axial row position, wherein an axial end row position is row position number 1 and an opposite axial end row position is row position number K, wherein each litz wire in the k.sup.th row position of the first primary winding portion with 1≤k≤K is in series connected with a litz wire in the (K+1−k).sup.th row position of the second primary winding portions, thereby reducing the sum of the magnetic flux between parallel connectable litz wires of the first primary winding portion and parallel connectable litz wires of the second primary winding portion.

12. The electrical component according to claim 11, wherein the cable comprises 6 litz wires, wherein the litz wires of the first and second primary winding portions are arranged around the ferromagnetic core in a cross section comprising 2 radial rows and 3 axial rows.

13. The electrical component according to claim 1, wherein the conductors of the first and second primary winding portions are foils.

14. The electrical component according to claim 3 wherein the first secondary winding portion and the second secondary winding portion are parallel connectable.

15. The electrical component according to claim 3 wherein the first secondary winding portion and the second secondary winding portion are connected in series.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments. The accompanying drawings relate to embodiments of the disclosure and are described in the following:

[0036] FIG. 1 shows a schematic view of an electrical component, especially a transformer, according to embodiments described herein;

[0037] FIG. 2 shows a detailed schematic sectional view of a primary winding portion in a cross section according to embodiments described herein;

[0038] FIG. 3 shows a detailed schematic sectional view of a primary winding portion in a cross section according to another embodiment;

[0039] FIGS. 4A and 4B show different embodiments of primary and secondary winding portions around a leg of a ferromagnetic core according to the present disclosure;

[0040] FIGS. 5A and 5B show a schematic diagram of the flux in a primary winding portion and the series connection of conductors of the first and second primary winding portion according to an embodiment; and

[0041] FIGS. 6A and 6B show another schematic diagram of the flux in a primary winding portion and the series connection of conductors of the first and second primary winding portion according to another embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

[0042] Reference will now be made in detail to the various embodiments, one or more examples of which are illustrated in each figure. Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment can be used on or in conjunction with any other embodiment to yield yet a further embodiment. It is intended that the present disclosure includes such modifications and variations.

[0043] Within the following description of the drawings, the same reference numbers refer to the same or to similar components. Generally, only the differences with respect to the individual embodiments are described. Unless specified otherwise, the description of a part or aspect in one embodiment can apply to a corresponding part or aspect in another embodiment as well.

[0044] With exemplary reference to FIG. 1, an electrical component is shown. The electrical component of FIG. 1 is a transformer according to an embodiment, which can be combined with other embodiments described herein. Especially according to other embodiments, the electrical component can be an inductor. The electrical component comprises: a ferromagnetic core 10 with a first and a second leg 11, 12; a primary winding 20 with a first primary winding portion 21 arranged around the first leg 11 of the ferromagnetic core and a second primary winding portion 22 arranged around the second leg 12 of the ferromagnetic core;

[0045] wherein the first primary winding portion 21 and the second primary winding portion 22 each comprise a plurality of parallel connectable conductors 1, 2, 3, 4, 5, 6 arranged around the ferromagnetic core in a cross section with the conductors being radially displaced with respect to each other at radial row positions, wherein the number of conductors 1, 2, 3, 4, 5, 6 of the first primary winding portion 21 is equal the number of conductors 1, 2, 3, 4, 5, 6 of the second primary winding portion 22 and each of the conductors 1, 2, 3, 4, 5, 6 of the first primary winding portion 21 is connected in series with one corresponding conductor 1, 2, 3, 4, 5, 6 of the second primary winding portion 22, whereby a conductor 1, 2, 3, 4, 5, 6 of a radially outer row of the first primary winding portion 21 is connected in series with a conductor 1, 2, 3, 4, 5, 6 of a radially inner row of the second primary winding portion 22, thereby reducing the sum of the magnetic flux between parallel connectable conductors 1, 2, 3, 4, 5, 6 of the first primary winding portion 21 and parallel connectable conductors 1, 2, 3, 4, 5, 6 of the second primary winding portion 22.

[0046] The electrical component of FIG. 1 is a transformer and further comprises a secondary winding 30 with a first secondary winding portion 31 arranged around the first leg 11 of the ferromagnetic core and a second secondary winding portion 32 arranged around the second leg 12 of the ferromagnetic core. Primary and secondary winding are separated by an insulation.

[0047] Because of insulation, the primary winding portions 21/22 are kept at larger distances from the secondary winding portions 31/32 and the ferromagnetic core 10 than the distance between secondary winding portions 31/32 and ferromagnetic core 10. The insulation distances are schematically shown in FIG. 1. This reduces the height of the primary winding portions 21/22 compared to that of the secondary winding portions 31/32. Given the reduced height, the radial thickness of the primary winding 20 must be greater than that of the secondary winding 30 to provide sufficient conductor cross-section. Therefore, each primary winding portion 21, 22 has two or more rows of conductors radially displaced with respect to each.

[0048] The ferromagnetic core 10 is adapted for a core type transformer. The shape of the ferromagnetic core 10 can comprise, for example, a C-C, U-U, U-I or an L-L shape, wherein the two components form a ring with an “O”-shape. The ferromagnetic core has at least two legs 11, 12, wherein the legs 11, 12 do not have to be necessary parallel to each other, although it is preferred. Each leg 11, 12 define a separate space for a first primary winding portion 21 and a second primary winding portion 22, so that first and second primary winding portions 21, 22 do spatially not overlap.

[0049] According to yet another embodiment, the electrical component can also be an inductor. Typically, inductors only have a primary winding 20. A secondary winding 30 is not needed.

[0050] The electrical component can comprise a first external electrical connector 41 in series connected with the conductors 1, 2, 3, 4, 5, 6 of the first primary winding portion 21 and a second external electrical connector 41 in series connected with the conductors 1, 2, 3, 4, 5, 6 of the second primary winding portion 22, wherein the first and second primary winding portions 21, 22 are located between the first and second external electrical connector 41, 42 as shown in FIG. 1. All conductors 1, 2, 3, 4, 5, 6 can be connected in series with the external electrical connector 41, 42, thereby creating a parallel circuit of the conductors 1, 2, 3, 4, 5, 6.

[0051] In FIG. 1, the first and second primary winding portions 21, 22 are arranged as outer windings and the first and second secondary winding portions 31, 32 are arranged as inner windings. Preferably, first and second primary winding portions 21, 22 are both either inner or outer windings. Symmetry of first and second primary winding portions 21, 22 is preferred because the magnetic flux cancels each other best if the magnetic flux norm is equal and if the magnetic flux points in the opposite direction.

[0052] According to an embodiment, primary winding 20 is an outer winding and a HV winding. The secondary winding 30 is an inner winding and a LV winding.

[0053] FIGS. 2 and 3 show two different embodiments of parallel connectable conductors arranged in a cross section. A cross section of the first or second primary winding portion 21, 22 is shown. Typically, first and second primary winding portion 21, 22 have the same structure. FIGS. 2 and 3 show a more detailed structure of, for example, the left part of the first primary winding portion 21 shown in FIG. 1.

[0054] In FIG. 2, the conductors 1, 2, 3, 4 are foils. The foils 1, 2, 3, 4 are arranged in a cross section. In the embodiment of FIG. 2, the primary winding portion 21 comprises 2 turns, therefore, the cross section is shown two times. The radial position of the foils 1, 2, 3, 4 in the two cross sections is identical.

[0055] According to another embodiment shown in FIG. 3, the, conductors 1, 2, 3, 4 are litz wires. The litz wires 1, 2, 3, 4 are arranged in a cable formed of a group of litz wires. The cable has a cross section as shown in FIG. 3. The first primary winding portion 21 comprises several turns of the cable arranged as a spiral. The cross section is essential identical in each turn, especially, radial and axial position of each litz wire is 1, 2, 3, 4 is identical in each cross section. There is no transposition of conductors 1, 2, 3, 4 within a primary winding portion 21, 22. The series connection of conductors 1, 2, 3, 4 of the first and second primary winding portion 21, 22 is further described in FIGS. 5A to 6B.

[0056] In the embodiment of FIG. 3, the first primary winding portion 21 comprises several turns of the litz wires arranged as a spiral. According to other embodiments, the first primary winding portion 21 can comprise one or more further radial turns of the cable forming an inner and outer spiral or several spirals radially displaced within each other. Accordingly, the second primary winding portion 22 can have the same structure.

[0057] FIGS. 4A and 4B show different embodiments of the first primary and secondary winding portions 21, 31 arranged around a leg 11 of a ferromagnetic core 10 according to embodiments. The electrical component in this embodiment is a transformer and further comprises a secondary winding 30 with a first secondary winding portion 31 arranged around the first leg 11 of the ferromagnetic core and a second secondary winding portion 32 arranged around the second leg 12 of the ferromagnetic core (not shown). In FIG. 4A, primary winding 20 is an outer winding and secondary winding 30 is an inner winding. Accordingly, first secondary winding portion 31 is arranged radially closer to the first leg 11 of the ferromagnetic core 10 than first primary winding portion 21, which is arranged around the first secondary winding portion 31.

[0058] In FIGS. 4A and 4B first primary winding portion 21 comprises schematically 2 turns to keep the figure simple. However, first and primary winding portion 21, 22 can comprise several turns, for example between 10 and 20.

[0059] In FIG. 4B, primary winding 20 is an inner winding and secondary winding 30 is an outer winding. Therefore, first primary winding portion 21 is arranged radially closer to the first leg 11 of the ferromagnetic core 10 than first secondary winding portion 31. However, independent of which winding 20, 30 is an inner winding, usually first and second primary winding portions 21, 22 are equal, namely either both inner or both outer winding portions.

[0060] Between primary and secondary winding 20, 30, there is a magnetic stray field, pointing in axial direction of the windings 20, 30, which is perpendicular to the shown cross sectional view in FIG. 4B. According to Ampere's law, the field increases from zero outside the windings 20, 30 to a maximum between the windings 20, 30. Within the inner winding, it increases in radial direction from zero to the maximum. Within the outer winding, it decreases back to zero. Moving radially outward in the inner winding, there is a normalized field strength of 1 after the first foil 1, of 2 after the second foil 2, etc. According to the present invention, the foils are transposed between the first and second primary winding portion 21, 22 such that the magnetic flux through loops formed by the parallel connectable foils 1, 2, 3 cancel or is at least significantly reduced.

[0061] In the embodiment of FIGS. 4A/4B, foil 1 is the radially innermost foil, foil 3 is the radially outermost foil, and foil 2 is located in between. In general, a conductor 1, 2, 3, 4, 5, 6 of a radially outer row of the first primary winding portion 21 is connected in series with a conductor 1, 2, 3, 4, 5, 6 of a radially inner row of the second primary winding portion 22. Therefore at least two foils have to be transposed.

[0062] According to an embodiment, first and second primary winding portions 21, 22 are arranged around the ferromagnetic core in a cross section comprising M rows of conductors 1, 2, 3, 4, 5, 6, each row being arranged at a radial row position, with the radially innermost row position being row position number 1 and the radially outermost row position being row position number M, wherein each conductor 1, 2, 3, 4, 5, 6 in the m row position of the first primary winding portion with 1≤m≤M is in series connected with a conductor 1, 2, 3, 4, 5, 6 in the M+1−m row position of the second primary winding portion. According to the numbering in FIG. 4A/4B, foils 1 and 3; 2 and 2; and 3 and 1 of the first and second primary winding portions 21, 22, respectively, are connected in series.

[0063] According to an embodiment, first primary winding portion 21 and the second primary winding portion 22 each comprise a cable formed of a group of litz wires 1, 2, 3, 4, 5, 6.

[0064] FIG. 5A shows the magnetic flux in the first and second primary winding portion 21, 22. The axial direction (z) is shown in FIG. 5A from bottom to the top and the radial direction (r) is shown from left to right. The flux has an axial component (Hz) and a radial component (Hr). Axial flux occurs because of a difference in radial distance to the ferromagnetic core 10 and the first and second secondary winding portions 31, 32. In FIG. 5A, the flux is shown upside down so that it points in the same direction. The conductors 1, 2, 3, 4 are arranged in a helix and form first and second primary winding portions 21, 22.

[0065] FIG. 5B illustrates the magnetic flux in axial and radial component between parallel connectable conductors of the first and second primary winding portion 21, 22. As illustrated, the magnetic flux points in different directions indicated as plus and minus. The magnetic flux is anti-symmetric. FIG. 5B also shows the connection of the conductors 1, 2, 3, 4 between first and second primary winding portion 21, 22.

[0066] In this embodiment, the litz wires 1, 2, 3, 4 of the first and second primary winding portion 21, 22 are connected such that wires 1 and 4 exchange position, and wires 2 and 3 exchange position as shown in FIGS. 5A/5B with the litz wires 1 and 2 being at inner row positions and litz wires 3 and 4 being at outer row positions. The exchange of position between radially inner and outer litz wires 1, 2, 3, 4 does not necessarily include an exchange between top and bottom litz wires 1, 2, 3, 4. In other words, wires 1 and 4 are at the bottom in both primary windings portions 21, 22, while wires 2 and 3 are at the top in both primary windings portions. This serial connection leads to a complete cancellation of axial and radial magnetic flux between all loops formed by the 4 parallel litz wires 1, 2, 3, 4. Therefore, circulating currents due to such fluxes are eliminated.

[0067] FIGS. 6A and 6B show another embodiment, wherein the primary winding comprises six conductors 1, 2, 3, 4, 5, 6. Compared to the embodiment of FIG. 5A, the embodiment of FIG. 6A comprises two additional conductors 5, 6. The conductors 1, 2, 3, 4, 5, 6 are arranged in a cross section with two radial rows and three axial rows. Conductors 1, 2 and 3 are located at radially inner positions and conductors 4, 5 and 6 are located at radially outer positions in the cross section of conductors. The compensation of axial fluxes works like in FIGS. 5A and 5B. The compensation of radial fluxes doesn't work perfectly anymore, if there is no transposition in axial direction. This is because the magnitude of radial flux decreases in axial direction from the end of the primary winding towards the middle. The flux is sketched in FIGS. 6A. The right side of FIG. 6A is shown upside down analog to FIG. 5A. For example, at the bottom of the first primary winding portion 21, the radial flux between litz wires {1, 6} and litz wires {2, 5} is larger than the radial flux between litz wires {2, 5} and litz wires {3, 4}. This is indicated by the change of angle of the H-field vector.

[0068] According to this embodiment, the cross section of conductors comprises K≥3 axial rows of litz wires 1, 2, 3, 4, 5, 6 as shown in FIG. 6A. Each row is arranged at an axial row position, wherein an axial end row position is row position number 1 and an opposite axial end row position is row position number K, wherein each litz wire 1, 2, 3, 4, 5, 6 in the k row position of the first primary winding portion 21 with 1≤k≤K is in series connected with a litz wire 1, 2, 3, 4, 5, 6 in the K+1−k row position of the second primary winding portions 22, thereby reducing the sum of the magnetic flux between parallel connectable litz wires 1, 2, 3, 4, 5, 6 of the first and second primary winding portions 21, 22.

[0069] FIG. 6B shows the serial connection of the conductors 1, 2, 3, 4, 5, 6 of the first and second primary winding portion 21, 22.

REFERENCE NUMBERS

[0070] 1 conductor

[0071] 2 conductor

[0072] 3 conductor

[0073] 4 conductor

[0074] 5 conductor

[0075] 6 conductor

[0076] 10 ferromagnetic core

[0077] 11 first leg

[0078] 12 second leg

[0079] 20 primary winding

[0080] 21 first primary winding portion

[0081] 22 second primary winding portion

[0082] 30 secondary winding

[0083] 31 first secondary winding portion

[0084] 32 second secondary winding portion

[0085] 41 first external electrical connector

[0086] 42 second external electrical connector