Current-Compensated Inductor, Filter, High-Voltage On-Board Electrical System and Motor Vehicle

Abstract

A current-compensated inductor for filtering interference signals which are transmitted between two high-voltage components of a high-voltage on-board electrical system of a motor vehicle, includes a toroidal, in particular circular ring-shaped or oval ring-shaped, magnet core which surrounds an inner opening, and has at least two busbars for electrically connecting the two high-voltage components. The busbars are routed axially through the inner opening of the magnet core and are arranged at a distance from one another in the inner opening so as to form an air gap. An inner side of the magnet core, which inner side faces the inner opening, and regions of outer sides of the busbars, which regions face the inner side of the magnet core, have shapes which correspond to one another.

Claims

1.-10. (canceled)

11. A current-compensated inductor for filtering interference signals transmitted between two high-voltage components of a high-voltage on-board power system of a motor vehicle, comprising: a toroidal magnetic core which surrounds an inner opening; and at least two busbars for electrically connecting the two high-voltage components, wherein the two busbars are guided axially through the inner opening in the magnetic core and are arranged spaced apart from one another in the inner opening while forming an airgap, and an inner side, facing the inner opening, of the magnetic core and areas, facing the inner side of the magnetic core, of outer sides of the busbars have shapes which correspond to one another.

12. The current-compensated inductor according to claim 11, wherein the inner side of the magnetic core is formed from an electrically insulating material, and the areas, facing the inner side of the magnetic core, of the outer sides of the busbars are arranged bearing over an entire surface on the inner side of the magnetic core.

13. The current-compensated inductor according to claim 11, wherein the inner side of the magnetic core has at least in certain sections a concave shape, and the areas, facing the concavely shaped inner side of the magnetic core, of the outer sides of the busbars have a convex shape in order to bear over an entire surface on the inner side of the magnetic core, wherein the concavely shaped inner side of the magnetic core and the convexly shaped areas of the outer sides of the busbars have a same radius of curvature.

14. The current-compensated inductor according to claim 13, wherein in order to form the concavely shaped inner side, the magnetic core has a circular-ring-shaped cross section which surrounds the inner opening in a circular shape, and the inductor has precisely two busbars which have circular-segment-shaped cross sections in order to form the convexly shaped areas of the outer side and are arranged in the inner opening while forming a strip-shaped airgap.

15. The current-compensated inductor according to claim 13, wherein in order to form the concavely shaped inner side, the magnetic core has a circular-ring-shaped cross section which surrounds the inner opening in a circular shape, and the inductor has three busbars which have circular-sector-shaped cross sections in order to form the convexly shaped areas of the outer side and which are arranged in the inner opening while forming a star-shaped airgap.

16. The current-compensated inductor according to claim 13, wherein in order to form the concavely shaped inner side, the magnetic core has an oval-ring-shaped cross section which surrounds the inner opening in an oval shape and has two circular-arc-shaped sections lying opposite one another and two straight element sections lying opposite one another, and the inductor has precisely two busbars which have circular-segment-shaped cross-sectional areas for forming the convexly shaped areas of the outer side, and are arranged on the circular-arc sections of the inner side of the magnetic core, forming a strip-shaped airgap.

17. The current-compensated inductor according to claim 13, wherein in order to form the concavely shaped inner side, the magnetic core has an oval-ring-shaped cross section which surrounds the inner opening in an oval fashion and has two circular-arc-shaped sections lying opposite one another and two straight element sections lying opposite one another, the inductor has three busbars which are arranged spaced apart from one another along the straight element sections, forming two strip-shaped airgaps, and in order to form the convexly shaped areas of the outer side, the two busbars lying on the outside have circular-segment-shaped cross-sectional areas, and the inner busbar has a rectangular-shaped cross section.

18. A filter for a high-voltage on-board power system of a motor vehicle comprising a current-compensated inductor according to claim 11.

19. A high-voltage on-board power system for a motor vehicle which is driven electrically, comprising: at least two high-voltage components; and a filter according to claim 18, wherein the two high-voltage components are electrically connected to one another via the busbars of the inductor.

20. A motor vehicle comprising a high-voltage on-board power system according to claim 19.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1a to FIG. 1d are schematic cross-sectional illustrations of current-compensated inductors according to the prior art.

[0025] FIG. 2 is a schematic illustration of an embodiment of a high-voltage on-board power system according to the invention.

[0026] FIG. 3a to FIG. 3c are schematic cross-sectional illustrations of embodiments of current-compensated inductors according to the invention.

[0027] In the figures, identical and functionally identical elements are provided with the same reference symbols.

DETAILED DESCRIPTION OF THE DRAWINGS

[0028] FIG. 2 shows a high-voltage on-board power system 7 for a motor vehicle (not shown) which can be driven electrically. The high-voltage on-board power system 7 has two high-voltage components 8, 9 which are electrically connected to one another. The high-voltage component 8 can be, for example, a traction battery of the motor vehicle which can be driven electrically, and the high-voltage component 9 can be, for example, an inverter of the motor vehicle. The high-voltage components 8, 9 are electrically coupled to one another via a filter 10 which is configured at least to damp interference signals which are transmitted between the high-voltage components 8, 9. The filter 10 has at least one current-compensated inductor 11.

[0029] In FIG. 3a to FIG. 3c, cross-sectional illustrations of different embodiments of a current-compensated inductor 11 according to the invention are shown. The inductor 11 has a magnetic core 12 which is extruded in the axial direction (into the plane of the drawing). Busbars 14 which also extend in the axial direction are arranged within an inner opening 13 of the magnetic core 12. A section of the busbars 14 is surrounded by the magnetic core 12 here along the axial direction. The magnetic core 12 is therefore plugged onto the busbars 14. An inner side 15, facing the inner opening 13, of the magnetic core 12 and first areas 16a of outer sides 16 of the busbars 14 which face the inner side 15 of the magnetic core 12 have shapes which correspond to one another. The inner side 15 of the magnetic core 12 can be formed, for example, from an electrically insulated material so that the first areas 16a of the outer side 16 of the busbars 14 bear over an entire surface on the inner side 15 of the magnetic core 12 here.

[0030] Second areas 16b of the outer sides 16 of the busbars 14 face an airgap 17 or an electrically insulating area between the busbars 14. The inner side 15 of the magnetic core 12 is shaped concavely, at least in certain areas, here, while the first areas 16a of the busbars 14 are shaped concavely, at least in certain areas, so as to fit the latter.

[0031] In the embodiment of the inductor 11 according to FIG. 3a, the magnetic core 12 has a circular-ring-shaped cross section 18, so that the inner opening 13 is embodied in a circular fashion. Furthermore, the inductor 11 according to FIG. 3a has three busbars 14 which have circular-sector-shaped cross sections 19. The convexly shaped first areas 16a of the outer side 16 and the concavely shaped inner side 15 of the magnetic core 12 have the same radius of curvature here, so that the first areas 16a of the busbars can be positioned over an entire surface on the inner side 15 of the magnetic core 12. The three circular-sector-shaped cross sections 19 of the busbars 14 have here, in particular, areas of equal size. The airgap 17 between the circular-sector-shaped cross sections 19 of the busbars 14 is embodied in a star shape here. Given the same inductivity, a quantity of material of such an inductor 11 according to FIG. 3a is smaller, approximately by a factor of 2.5, than a quantity of material of the inductor 1 according to FIG. 1b in which the busbars 4 have rectangular cross sections. A depth of the magnetic core 2 of the inductor 1 according to FIG. 1b in the axial direction must therefore be larger approximately by a factor of 2.5 in order to set the same inductivity as the inductor 11 according to FIG. 3a.

[0032] In the embodiment of the inductor 11 according to FIG. 3b, the magnetic core 12 has an oval-ring-shaped cross section 20 with two circular-arc sections 21 lying opposite one another and two straight element sections 22 lying opposite one another. As a result, the inner opening 15 is embodied in an oval fashion. The inductor 11 according to FIG. 3b also has three busbars 14, wherein two outer busbars 14 are arranged in the region of the circular arc sections 21, and a central busbar 14 is arranged in the region of the straight element sections 22. The two outer busbars 14 each have a circular-segment-shaped cross-sectional area 23 and a rectangular cross-sectional area 24, wherein the convexly shaped form of the first area 16a of the outer side 16 of the busbar 14 is formed by the circular-segment-shaped cross-sectional area 23. The middle busbar 14 has a rectangular cross section 25. The first area 16a of the outer side 16 of the middle busbar 14 therefore has straight edges facing the straight element sections 22. A volume of the inner opening 13 is utilized here to a significantly greater extent than the internal volume of the inner opening 3 of the inductor 1 according to FIG. 1c in which the busbars 4 have rectangular cross sections.

[0033] In the embodiment of the inductor 11 according to FIG. 3c, the magnetic core 12 also has an oval-ring-shaped cross section 20, but the straight element sections 22 are shorter than the straight element sections 22 of the inductor 11 according to FIG. 3b. The inductor 11 according to FIG. 3c has two busbars 14 which have circular-segment-shaped cross sections 26 in order to form the convex shape. The circular-segment-shaped cross sections 26 are arranged spaced apart from one another here in the region of the circular-arc sections 21 of the magnetic core 12, forming a strip-shaped airgap 17.

LIST OF REFERENCE NUMBERS

[0034] 1 Inductor [0035] 2 Magnetic core [0036] 3 Inner opening [0037] 4 Busbars [0038] 5 Inner side [0039] 6 Outer side [0040] 7 High-voltage on-board power system [0041] 8, 9 High-voltage components [0042] 10 Filter [0043] 11 Inductor [0044] 12 Magnetic core [0045] 13 Inner opening [0046] 14 Busbar [0047] 15 Inner side [0048] 16 Outer side [0049] 16a, 16b Areas of the outer side [0050] 17 Airgap [0051] 18 Circular-ring-shaped cross section [0052] 19 Circular-sector-shaped cross section [0053] 20 Oval-ring-shaped cross section [0054] 21 Circular-arc sections [0055] 22 Straight element sections [0056] 23 Circular-segment-shaped cross-sectional area [0057] 24 Rectangular cross-sectional area [0058] 25 Rectangular cross section [0059] 26 Circular-segment-shaped cross section