EP3561824A1 - Coil assembly for a resonance converter - Google Patents

Abstract

The invention relates to a coil arrangement (10) for a resonant converter, comprising: - at least one winding (12) having an electrical conductor (14) comprising a plurality of individual conductors which are electrically insulated from one another and arranged in the manner of a high-frequency strand, two electrical connections (16, 18), wherein respective conductor ends of the individual conductors are connected to a respective one of the electrical connections (16, 18), so that the respective individual conductors are connected in parallel, and a cooling unit (20) for cooling the at least one winding ( 12), the at least one electrical conductor (14) forming at least two winding elements (22, 24) arranged coaxially and axially spaced from one another, the electrical conductor (14) in each of the at least two winding elements (22, 24) at least one Winding of the at least one winding (12) is formed.

Description

The present invention relates to a coil assembly for a resonant converter, comprising at least one winding comprising an electrical conductor comprising a plurality of single conductors electrically insulated from each other, which are arranged in the manner of a high-frequency strand to each other, and two electrical terminals, wherein respective conductor ends of the individual conductors are connected to a respective one of the electrical connections, so that the respective individual conductors are connected in parallel. Furthermore, the invention also relates to a winding module. Moreover, the invention relates to a method for producing a coil arrangement for a resonant converter, wherein at least one winding is formed from an electrical conductor comprising a plurality of electrically insulated individual conductors which are arranged in the manner of a high-frequency strand to each other, and respective conductor ends of the individual conductors be connected to a respective one of two electrical terminals of the at least one winding to parallel the respective individual conductors. Finally, the invention also relates to a method for producing a winding module for a coil arrangement.

Coil arrangements for resonant converters, in particular for resonant converters with a resonant circuit subjected to high electrical power, are well-known in the prior art, so that there is no further need for a separate printed documentary proof in this regard. Generic resonant converters are used as clocked energy converters for a variety of energy conversion functions in electrical engineering. Such energy converters are used, for example, in high-voltage generators, which are used inter alia in X-ray machines. However, resonant converters are also used in many other technical energy conversion functionalities, for example, in induction heaters and / or the like.

In particular, in X-ray devices, a high voltage generator is required, which is able to generate a suitable high voltage for the intended operation of an X-ray tube of the X-ray machine. Such a high voltage may be, for example, in a voltage range of about 40 kV to about 150 kV. Depending on the design of the X-ray device, deviating voltage values may also be provided here, which may be either less than 40 kV or even greater than 150 kV. The aforementioned voltage range is used inter alia in medical X-ray devices.

In general, for the vast majority of applications the required high voltages by means of energy converters, preferably resonant energy converters, also called resonant converters, from a low voltage, such as the low voltage of the public grid, generated. For normal applications in the industrial and / or household sector, this usually provides an alternating voltage of 230V at about 50 Hz by means of a public power supply network. The term "low voltage" in the present disclosure means in particular a voltage according to Directive 2014/35 / EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of the Member States relating to the provision of electrical equipment for use within certain voltage limits the market (Low Voltage Directive).

Resonant energy converters, also called resonance converters, use at least one resonant circuit which is operated essentially in the region of its resonant frequency in order to be able to provide the desired energy conversion and thus a desired high voltage. The resonant circuit usually has for this purpose an electrical capacitor, which is interconnected with a coil arrangement to form a resonant circuit is. Depending on the type of interconnection may be a series resonant circuit or a parallel resonant circuit. The electrotechnical basics with regard to resonant circuits are known to the person skilled in the art, so that further relevant interpretations are essentially dispensed with.

In order to achieve the most favorable energy conversion, the resonant converter is usually operated at a resonant frequency of the resonant circuit, which is in such energy converters usually well above 1kHz. In particular, for use in X-ray devices as well as in induction heaters, the range of application with respect to the resonant frequency is, for example, in a range from about 20 kHz to about 200 kHz or even more. The resonant circuit is designed appropriately for this operating frequency, that is to say the capacitor and the coil arrangement provide corresponding values with regard to the electrical capacitance or the electrical inductance.

In particular, with regard to the coil arrangement, which comprises at least one single electronic coil or throttle, there are special requirements that have to be considered for the construction of the coil arrangement. Due to the comparatively high operating frequency, it should be noted in the coil arrangement that due to conductivity losses, electrical losses due to the skin effect, the proximity effect and possibly losses of a ferromagnetic material, a significant amount of power loss arises for which appropriate measures are taken , For this reason, it is generally provided that the coil arrangement comprises a cooling unit, with which a suitable dissipation of the heat generated by the power loss can be dissipated. As a rule, provision is made for the cooling unit to provide at least one cooling channel for a cooling fluid, which as a rule is air. The cooling fluid flows through suitable areas of the coil assembly to thereby absorb heat and out of the coil assembly dissipate. The cooling fluid can then be correspondingly cooled and reused via a suitable heat exchanger. If air is used as cooling fluid, a heat exchanger does not need to be provided.

The cooling of the coil arrangement is to be interpreted such that a high temperature for the coil arrangement, in particular for the electrical conductor, which is greater than a rated temperature, can be largely avoided. Namely, if the operating temperature of the coil assembly is greater than the rated temperature, it must be expected that damage to the coil assembly, even if it occurs only selectively, the coil assembly at least partially damaged or even completely destroyed.

In the prior art, it has also been customary to construct chokes which consist of ferrite cores in standard designs and matching standard winding carriers and a high-frequency strand as an electrical conductor. In this case, a tight winding, for example, in layers, is usually provided, which proves to be unfavorable especially with respect to a heat transfer from the inside to the outside. In addition, it should be noted that these constructions often have external air gaps in the ferromagnetic material, which can in particular also lead to larger stray fields around the coil arrangement and thus also with respect to the resonant converter, so that in part also undesired heating of electrically conductive substances arranged in the vicinity the result can be. In addition, there are also unfavorable properties in terms of electromagnetic compatibility.

Furthermore, it proves to be disadvantageous that an electromechanical connection of the coil arrangement takes place via an extension of the high-frequency strand, which takes place, for example, with crimped or soldered cable lugs. In this area, the flexibility is very low, so the assembly is difficult. In addition, this is suitable Construction hardly to allow flexibility in terms of different power and resonance frequencies. Rather, it is necessary to construct a new coil arrangement for each operating situation. This is very expensive.

The invention has for its object to provide an improved coil assembly.

As a solution, the invention proposes a coil arrangement, a winding module, a method for producing the coil arrangement and a method for producing the winding module.

Advantageous developments emerge by features of the dependent claims.

With regard to a generic coil arrangement, it is in particular proposed that the at least one electrical conductor form at least two winding elements which are arranged coaxially and axially spaced from one another, wherein the electrical conductor forms at least one turn of the at least one winding in each of the at least two winding elements.

In addition, a winding module for the coil assembly is proposed.

With regard to a generic method for producing the coil arrangement, it is in particular proposed that at least two winding elements be formed from the at least one electrical conductor so that the electrical conductor in each of the at least two winding elements forms at least one turn of the at least one winding, and the at least two winding elements coaxially and axially spaced from each other.

With regard to a generic method for producing a winding module, it is in particular proposed that at least two winding elements be formed from at least one electrical conductor for forming the winding module, so that the electrical conductor in each of the at least two winding elements forms at least one turn of at least one winding of the coil arrangement the at least one electrical conductor comprises a plurality of individual conductors which are electrically insulated from one another and which are arranged in the manner of a high-frequency strand, and the at least two winding elements are arranged coaxially and axially spaced from one another.

The invention is based on the idea that an improved coil arrangement can be provided in that the winding is improved by winding elements, wherein due to the spaced arrangement of the winding elements, a significantly improved cooling effect can be achieved by the cooling unit. As a result, not only a simpler design of the coil arrangement over the prior art, but also an increased load capacity can be achieved. Preferably, a winding element may comprise a disk-like part-winding, which extends substantially radially, so that an outer radius of the winding element is preferably greater than an axial extent of the winding element. The winding element may have a suitable geometric shape, which allows to arrange the winding elements in the simplest possible way to each other. The geometric shape may, for example, be angular, round, for example circular, elliptical and / or the like. This can be provided in particular for an outer contour of the winding element. In addition, the winding element can of course also have a passage opening, which is preferably formed centrally and which may be formed accordingly. The contour of the passage opening need not be identical to the outer contour. It may also be chosen differently. Due to the structure of the coil arrangement by winding elements, the structure of the coil arrangement depending on If desired, they can be varied in a simple manner in order to be able to realize the most diverse requirements with regard to the electrical properties. This gives great flexibility in terms of usability. The customary in the prior art new design of a coil assembly for a different application can thus be largely avoided.

Of course, the coil assembly does not need to have a single winding. Of course, it can also have two or more windings, which are preferably all constructed according to the invention. As a result, the advantage according to the invention can be used for the entire coil arrangement, even if it has more than one single winding.

The electrical conductor of the winding has a plurality of individual conductors which are insulated from one another electrically. The individual conductors can be formed from a good electrically conductive material such as copper, aluminum, alloys thereof and / or the like. In order for the individual conductors to be electrically insulated from one another, they preferably have an insulating layer at their outer circumference, that is, transversely to their longitudinal extension. This can be realized by a lacquer layer, a plastic, an oxide layer and / or the like.

So that the individual conductors are applied as uniformly as possible with electric current and thus a favorable for the entire electrical conductor Funktonalität can be achieved, the individual conductors are arranged in the manner of a high-frequency strand to each other. For this purpose, specific arrangement modalities are provided with respect to the individual conductors, so that they also provide, as far as possible, a substantially equal inductance in addition to a substantially equal length and a substantially identical conductor cross-section. This can be achieved by suitable arrangement methods for the individual conductors within the electrical conductor. For this purpose it can be provided that the individual conductors are suitably twisted together. For a conductor diameter of a respective single conductor, for example, a diameter may be provided in a range of about 0.2 mm or less, for example about 0.1 mm, preferably about 0.05 mm.

The winding comprises two electrical connections, wherein respective conductor ends of the individual conductors are connected to a respective one of the electrical connections, so that the respective individual conductors are connected in parallel. The connection, preferably realized immediately, can be realized by bonding, soldering, crimping and / or the like. The individual conductors are preferably connected to the electrical connections in such a way that the current loading of the individual conductors continues to be as uniform as possible. The electrical connections of the winding can be formed by suitable conductor lugs, for example in the manner of a strip conductor or the like, which allow the winding to be electrically connected to an electronic circuit of the resonance converter. However, solder terminals, crimp terminals, terminal connections, screw terminals and / or the like may also be provided.

Characterized in that the winding elements on the one hand coaxial and on the other hand also axially spaced from each other, a space between adjacent arranged winding elements are formed, which allows for improved cooling, for example by this space by means of the cooling unit, a corresponding cooling fluid, for example air, is supplied. This makes it possible to significantly improve the cooling function with respect to the winding over the prior art. The usually occurring in the art heat accumulation just in the center of the winding can be significantly reduced. This makes it possible to realize a significantly more compact winding with the same performance. Additionally or alternatively, the winding can also be used for a higher load capacity.

Each winding element comprises at least one turn of the at least one winding. Preferably, however, the winding elements comprise the same number of turns. As a result, standardized winding elements can be formed, which make it possible to adapt the winding in a highly flexible manner.

It is further proposed that at least two windings are arranged at least partially radially one above the other in at least one of the two winding elements. As a result, winding elements can be realized with a comparatively small axial extent. At the same time, it is possible to provide a plurality of turns for a respective one of the winding elements with small axial dimensions.

Preferably, the windings are arranged in the manner of an Archimedean coil. In particular, it can be provided that each of the winding elements is designed in the manner of an Archimedean coil. An Archimedean coil is characterized in that the partial winding, which is formed by the winding element, extends substantially radially from the inside to the outside. It is possible that only a single layer, for example by the electrical conductor wound in a plane, is provided by this partial winding. Depending on requirements, however, two or more layers may be arranged axially adjacent to each other.

Preferably, the winding elements comprise two radially spaced winding element terminals, wherein respective conductor ends of the electrical conductor of the winding elements are connected to a respective one of the winding element terminals. As a result, each of the winding elements can be provided as a component that can be handled separately, so that the coil arrangement or the winding can be realized in a simple manner by suitably assembling the winding elements. At the same time it is possible, in this way, an interconnection of the winding elements with each other in suitable to be able to set flexibly, for example a parallel connection, a series connection, combinations thereof and / or the like. The flexibility with regard to the production of the winding or of the coil arrangement can thereby be further improved.

According to a further development, it is proposed that the winding element terminals which are electrically connected to one another in the case of adjacently arranged winding elements be arranged opposite one another in their radial position relative to one another. In this way, a particularly simple connection of the winding elements can be achieved with each other, if these are individually manageable components. It then only needs to be made a respective electrical connection between the to be connected and opposite winding element terminals. It is particularly advantageous if the winding element connections are already designed in such a way that they can be connected directly to one another. This makes it possible to further improve the production of the coil arrangement or the winding.

In order to further improve the handling of individual winding elements, it can be provided that at least one of the at least two winding elements has a winding element carrier. The winding element carrier is preferably formed of an electrically insulating material such as plastic, ceramic or the like and in particular makes it possible to handle the respective winding element better. In addition, the winding element carrier can also serve to enable an improved arrangement of the electrical conductor of the winding element. Overall, the production of the coil arrangement or the winding can be further improved.

The winding element carrier preferably grips the electrical conductor of the winding element at least partially radially. In particular, when the partial winding of the winding element extends radially far outward, thereby a improved stability of the winding element can be achieved. This is advantageous not only for the production of the coil arrangement or the winding but also for the intended operation. In addition, of course, can also be provided that the winding element carrier provides a radially inner support for an innermost turn of the electrical conductor of the winding element.

It is preferably provided that the coil arrangement has a cooling unit. The cooling unit is preferably designed to guide a cooling fluid into a space formed by the spaced-apart winding elements. The cooling fluid may be a suitable gas or a suitable liquid with which heat can be removed from the winding. Preferably, the cooling fluid is air. The cooling unit may have a corresponding conveying means for the cooling fluid, for example a pump, a blower and / or the like. In addition, the cooling unit may also include one or more cooling channels in order to be able to guide the cooling fluid in a suitable manner to predetermined positions of the coil arrangement or the winding. This allows a particularly favorable cooling of the coil assembly or the winding can be achieved. The cooling unit may be formed integrally with the coil arrangement.

It is further proposed that the coil arrangement has a modular construction of at least two winding modules, which are arranged coaxially and adjacent to one another, wherein a respective one of the winding modules comprises at least two winding elements. This allows a particularly favorable modular design can be achieved, which allows to produce the coil assembly in the manner of a modular principle. The winding module can be used as an individually manageable and preferably tested structural unit in order to be able to realize coil arrangements with great flexibility in a very simple manner. It is therefore possible with the invention to be able to produce almost any coil arrangements without great design effort.

It can be provided that the winding modules have corresponding mechanical connecting elements, which allow the winding modules to arrange in the manner of a stack and preferably to connect to each other. Overall, even an automated highly flexible production of the coil arrangement or the winding can be achieved thereby. The winding modules can be arranged immediately adjacent, preferably directly adjacent to each other. Particularly advantageously, it can be provided that the cooling unit is designed to act on each of the winding modules with the cooling fluid, in particular by the cooling fluid is applied to the space between the winding elements of a respective one of the winding modules.

It is also proposed that the winding module has at least two module connections projecting radially outwards. With the module connections, the module winding provided by the winding elements can be connected. The winding modules can be connected by means of the module connections at will in series or in parallel. Of course, combinations thereof may be provided. The module terminals may be formed by electrical terminal lugs, such as electrical conductors in the manner of a strip conductor or the like and having corresponding connection means at their ends to realize, for example, a screw, a clamp connection, a solder joint, combinations thereof or the like. The winding modules can be standardized, so that a simple production of the winding can be realized.

The winding module preferably has a central opening for arranging a spool core. Preferably, the opening is a passage opening, which is formed in particular for the winding modules of a specific coil arrangement or specific winding substantially equal in terms of geometry. The bobbin may serve to suitably wind the winding modules coaxially with one another to arrange. In addition, it can also have ferromagnetic properties in order to be able to achieve a suitable guidance of the magnetic field in a predefined manner and thereby be able to achieve a predefinable inductance. The coil core can preferably be formed at least partially from a ferrite, preferably in such a way that eddy current formation can be largely suppressed. For this purpose, the ferrite preferably has the smallest possible electrical conductivity. In addition, the coil core may at least partially also be formed by suitable ferromagnetic sheets, which are arranged electrically insulated from one another. Combinations of the aforementioned possibilities can also be provided.

The coil core preferably comprises a non-magnetic gap, in particular an air gap. Due to the non-magnetic gap, in particular if it is an air gap, it is possible to guide the magnetic flux of the coil arrangement in a predeterminable manner and thereby to be able to achieve specific properties of the coil arrangement. This can serve to be able to adjust the electrical inductance of the coil arrangement in a suitable manner. In addition, by providing the non-magnetic gap in the coil core, it is possible to achieve a reduction in the leakage flux generated thereby with respect to its effect outside the coil arrangement. As a result, not only can the electronic components surrounding the action on the coil arrangement be reduced, but it is also possible to achieve an improved functionality with respect to the electromagnetic compatibility.

According to one embodiment, it is proposed that the non-magnetic gap is formed by at least two individual gaps, which are arranged axially spaced from each other. This makes it possible to design the non-magnetic gap to be particularly small and to distribute the effect of the non-magnetic gap axially over a longitudinal extension of the coil core. Overall, this can improve functionality be achieved. Particularly advantageous may be provided that a separate non-magnetic gap is provided for each winding module. At the same time, this also makes it possible to automatically provide a corresponding air gap in a flexible configuration of the coil arrangement by means of winding modules. As the number of converter modules increases, the air gap can thus also increase. It need not be provided for separate constructions.

It proves to be particularly advantageous if the non-magnetic gap is at least partially formed by the winding element carrier. The winding element carrier, which can also be the carrier for the winding module at the same time, can at the same time be designed such that it comprises a module-specific spool core section which comprises at least one module-specific air gap and a module-specific ferromagnetic core. As a result, by stacking the winding modules automated without special additional measures, a suitable air gap and a suitable guidance of the magnetic flux can be achieved. Overall, this can further improve the production of the coil arrangement or the winding.

Overall, the invention makes it possible to realize a two-layer, in particular at least partially spiral, winding structure. In this case, the electrical conductor can wind in a first position from the outside inwards to form a first winding element, to then be guided in one turn inside in a second adjacent winding element, and then wind in the second winding element from the inside to the outside , In this way, it is easily possible to form a clearance between the two winding elements, which allows the cooling fluid, in particular air to lead to the winding can.

In addition, a coil core of, for example, outer U-shaped ferrite cores with an opening in the center a bottom of the ferrite cores and formed as a coil core inside layered, perforated ferrite disks and spacers. As a result, an internal magnetic air gap can be generated. Outside then no explicit magnetic air gap needs to be realized.

The winding element carrier, which can also be designed as a module carrier at the same time, can consist of two nested elements. On the one hand, an internal coil carrier can be provided with cast-on spiral projections in the center and, on the other hand, an external frame can be provided by means of which requirements with regard to electrical safety, in particular with regard to creepage distances and clearances, can be realized.

The individual turns can be fixed by gluing or impregnating with an epoxy resin in a corresponding position. A mechanical attachment of the overall structure can be realized via the central opening by means of the coil core, for example in the form of ferrite cores and a bobbin.

By means of the invention, scalability of the coil arrangement is possible such that a plurality of winding modules and, if appropriate, coil cores can be combined with one another in a suitable manner. This allows in a first variant to realize a parallel connection of the winding modules, wherein the winding modules are magnetically coupled. In a second variant, the winding modules can also be operated as independent coils or chokes by means of suitable partial energy converters of the resonant converter.

A connection of the coil arrangement or the throttle to the resonant converter can be done for example by means of copper bars. The electrical conductor or the Hochfrequenzlitze can be soldered directly to the copper bars for this purpose. In addition, a parallel connection of winding modules via the corresponding soldering the Winding module connections to be realized with the copper rail. The copper rail can be provided with a press-in nut or with a threaded bolt, which can be connected for example directly to a circuit board of the resonant converter. The copper bars can thereby be shaped and already mounted in the production so that they can be easily electrically coupled at an assembly with the resonant converter at the desired location.

The advantages and effects given for the coil arrangement according to the invention apply equally to the winding module of the invention as well as to the methods for producing the coil arrangement and the winding module and vice versa. In particular, method features and vice versa can thus be formulated for device features.

Further advantages and features will become apparent from the following description of embodiments with reference to the accompanying figures. In the figures, like reference numerals designate like features and functions.

FIG 1

in einer schematischen perspektivischen Seitenansicht eine Spulenanordnung gemäß der Erfindung; und

FIG 2

in einer schematisch aufgeschnittenen perspektivischen Darstellung die Spulenanordnung gemäß FIG 1.

Show it:

FIG. 1

in a schematic perspective side view of a coil assembly according to the invention; and

FIG. 2

in a schematic cutaway perspective view of the coil assembly according to FIG. 1 ,

FIG. 1 shows a schematic perspective view of a coil assembly 10 for a resonant converter, not shown. The coil arrangement 10 has a winding 12, which has an electrical conductor 14. It is not apparent from the figures that the electrical conductor 14 comprises a plurality of individual conductors, which are electrically insulated from one another and are not further illustrated, which are arranged in the manner of a high-frequency strand to one another.

The coil assembly 10 further includes two formed as a bolt electrical connections 16, 18, by means of which the coil assembly 10 can be electrically connected to a printed circuit board, not shown, of the resonant converter by the bolts inserted into corresponding through holes of the circuit board and fastened there. The electrical function of the coil assembly 10 in the resonant converter is known to the person skilled in the art, which is why in this respect apart from more detailed explanations.

Respective conductor ends of the individual conductors of the electrical conductor 14 are connected to a respective one of the electrical connections 16, 18, so that the respective individual conductors are connected in parallel.

The coil assembly 10 further includes a cooling unit 20 for cooling the winding 12, which in FIG FIG. 1 is shown only schematically. In alternative embodiments, the cooling unit 20 may also be formed and arranged separately from the coil arrangement 10. The cooling unit 20 comprises a fan, by means of which air is conveyed as cooling fluid to the winding 12 in order to cool it in a predeterminable manner.

Out FIG. 1 It can also be seen that two U-shaped ferrite elements 46 are arranged adjacent to each other, so that they form a cavity for receiving the winding 12. The ferrite elements 46 form in this way a magnetic inference. The ferrite elements 46 have a central passage opening 36 (FIG. FIG. 2 ), which serves to record a spool core which will be described below.

Out FIG. 1 It can be seen that the coil assembly 10 has a modular construction of two winding modules 28, 30, which are arranged coaxially and immediately adjacent to each other. A respective one of the winding modules 28, 30 comprises at least two winding elements 22, 24 (FIG. FIG. 2 ).

The winding elements 22, 24 of a respective one of the winding modules 28, 30 are formed by the electrical conductor 14. The winding elements 22, 24 of a respective one of the winding modules 28, 30 are arranged coaxially and axially spaced from one another. The electrical conductor 14 forms in each of the two winding elements 22, 24 of a respective one of the winding modules 28, 30 a winding having a predetermined, unspecified number of turns of the winding 12. In the present embodiment, it is provided that the turns of a respective one of the two winding elements 22, 24 are arranged radially one above the other, in the manner of an Archimedean coil.

The two winding elements 22, 24 are electrically connected to each other in a radially inner region via winding element terminals not shown. In the present case, the winding elements 22, 24 have the same winding sense, so that when they are connected in series as in this embodiment, they are traversed by the same current and the respective magnetic fluxes add up. In addition, it is provided in the present case that a number of turns for the two winding elements 22, 24 is the same.

In the present case, the winding elements 22, 24 of a respective one of the winding modules 28, 30 are arranged on a common winding element carrier 42, which at the same time also represents a carrier for the winding module 28 or 30. The winding element carrier 42 holds the winding elements 22, 24 radially. In addition, the winding element carrier 42 also provides a substantially cylindrical bearing surface for the winding elements 22, 24 or the central windings of the winding elements 22, 24 in the radially central region. In the present case, although an outer diameter of the respective one of the winding elements is round, in particular approximately circular, another contour may also be provided here, for example angled or the like.

Between the winding elements 22, 24, a space 26 is formed, which is flowed through by the cooling fluid. This makes it possible in normal operation, the electrical conductor 14 of the winding elements 22, 24 to apply in the radially central region with cooling fluid and thereby achieve improved cooling. The cooling fluid is present air. Overall, a radial temperature gradient in the winding elements can thereby be reduced. The cooling unit 20 is designed accordingly so that the cooling air can be guided into the space formed by the spaced-apart winding elements 22, 24.

Each of the winding modules 28, 30 has two radially outwardly projecting module connections 32, 34. The module terminals 32, 34 serve to contact corresponding copper bars 48, 50, on which the respective terminals 16, 18 are arranged. As a result, the winding modules 28, 30 can be electrically coupled to the terminals 16, 18. In the present case, it is provided that the module connections 32, 34 are soldered to the copper bars 48, 50. At the module terminals 32, 34 then a respective end of the electrical conductor 14 is connected.

The winding element carrier 42 are presently designed as a coil carrier made of a plastic material and have a circular cylindrical outer circumference. They are essentially formed by two circular disks connected by a central cylinder.

The winding modules 28, 30 comprise a respective module housing 44, which is substantially rectangular in shape and has a substantially rectangular receiving space for the respective winding element carrier 42 with the winding elements 22, 24 holds. As a result, the winding modules 28, 30 can be handled as individually manageable components at will to form the coil assembly 10. The construction of the coil assembly 10 allows to provide almost any number of winding modules 28, 30 to in this way, the coil assembly 10 can be adjusted as needed with great flexibility.

Fig. 2 shows in a schematic perspective sectional view of the coil assembly 10 according to FIG. 1 , Out FIG. 2 is also apparent that in the central passage opening 36 more cylindrical ferrite disks 52 are arranged. Between immediately adjacent ferrite disks 52 spacers 40 formed from a plastic are arranged, which form non-magnetic gaps. Thereby, in a central region of the coil assembly 10, there is provided a distributed non-magnetic gap gap arrangement providing functionality comparable to that of an air gap. This embodiment has the advantage that stray magnetic field effects can be reduced.

In addition, is off FIG. 2 it can be seen that a further central passage opening 38 is provided by the ferrite elements 52 and the plastic disks 40 and the ferrite elements 46. This central passage opening 38 can be used for mounting purposes to produce the coil assembly 10. Thus, it is possible, for example, to assemble the coil assembly 10 on a central mandrel in a desired manner and subsequently to remove the coil assembly 10 from this mandrel. In addition, it is possible to pass through the passage opening 38 a connecting element, which not only the individual elements of the coil assembly 10 centered in the radial direction, but at the same time provides a connection of all elements of the coil assembly 10 in the axial direction. As a result, a compact high-performance coil arrangement 10 can be achieved in a simple manner.

The construction of the coil arrangement 10 according to the invention makes it possible to create the coil arrangement 10 almost arbitrarily by winding modules 28, 30. In addition, the coil arrangement 10 according to the invention makes it possible to connect the individual winding modules 28, 30 with each other almost as desired, in order to be able to realize in this way a wide variety of electrical functionalities of the coil assembly 10. Thus, the winding modules 28, 30, as shown in the figures, for example, be connected in parallel. Alternatively or additionally, however, a series connection or series connection can also be provided. Of course, with a suitable number of winding modules 28, 30, other combinations of the interconnection of the winding modules 28, 30 may be provided, in particular a mixed interconnection. This makes it possible to easily adapt the coil assembly 10 for a wide variety of applications. In addition, of course, the coil assembly 10 is particularly suitable for automated production in that the winding modules 28, 30 can be suitably selected and combined with each other.

The single winding module can also be manufactured in a single operation, namely by first electrically winding the electrical conductor 14 from a predetermined outside diameter to form the first winding element 22. In the radially inner region, the electrical conductor is then guided axially into the region of the second winding element 24 and wound up from the inside to form the second winding element 24. In this way, a winding module 28, 30 can be produced by simple means.

Alternatively, it can of course also be provided that both winding elements 22, 24 are wound simultaneously from radially inward to radially outward, for example by providing two winding devices which wind the electrical conductor 14 in opposite directions. As a result, reliable production of the winding elements 22, 24 and thus also of the winding module 28, 30 can be achieved at a high processing speed.

The embodiment is solely illustrative of the invention and is not intended to limit this. Of course, the invention is basically also applicable when the electrical conductor is not formed by a high-frequency strand but instead by an electrical conductor made of a solid material.

Claims (17)

Coil assembly (10) for a resonant converter, comprising: - At least one winding (12) having an electrical conductor (14) comprising a plurality of mutually electrically insulated individual conductors, which are arranged in the manner of a high-frequency strand to each other, and - Two electrical terminals (16, 18), wherein respective conductor ends of the individual conductors are connected to a respective one of the electrical connections (16, 18), so that the respective individual conductors are connected in parallel, characterized in that
the at least one electrical conductor (14) forming at least two winding elements (22, 24) arranged coaxially and axially spaced from one another, the electrical conductor (14) in each of the at least two winding elements (22, 24) comprising at least one turn of the at least forms a winding (12). Coil arrangement according to claim 1,
characterized in that
at least in one of the two winding elements (22, 24) at least two windings are at least partially arranged radially one above the other. Coil arrangement according to Claim 2,
characterized in that
the turns are arranged in the manner of an Archimedean coil. Coil arrangement according to one of the preceding claims,
characterized in that
the winding elements (22, 24) comprise two radially spaced winding element terminals, wherein respective conductor ends of the electrical conductor of the winding elements (22, 24) are connected to a respective one of the winding element terminals. Coil arrangement according to one of the preceding claims,
characterized in that
the adjacent winding elements (22, 24) are connected to each other winding element terminals electrically connected to each other in their radial position. Coil arrangement according to one of the preceding claims,
characterized in that
at least one of the at least two winding elements (22, 24) has a winding element carrier (42). Coil arrangement according to Claim 6,
characterized in that
the winding element carrier (42) at least partially radially surrounds the electrical conductor of the winding element (22, 24). Coil arrangement according to one of the preceding claims,
characterized in that
the cooling unit (20) is adapted to guide a cooling fluid into a space (26) formed by the spaced-apart winding elements (22, 24). Coil arrangement according to one of the preceding claims,
marked by
a modular construction of at least two winding modules (28, 30) arranged coaxially and adjacent to one another, wherein a respective one of the winding modules (28, 30) comprises at least two winding elements (22, 24). Coil arrangement according to Claim 9,
characterized in that
the winding module (28, 30) has at least two module connections (32, 34) projecting radially outwards. Coil arrangement according to Claim 9 or 10.
characterized in that
the winding module (28, 30) has a central opening (36) for arranging a spool core (38). Coil arrangement according to Claim 11,
characterized in that
the coil core (38) in the axial direction has a non-magnetic gap, in particular an air gap. Coil arrangement according to Claim 12,
characterized in that
the non-magnetic gap is formed by at least two individual gaps (40) arranged axially spaced from one another. Coil arrangement according to Claim 12 or 13, characterized
characterized in that
the non-magnetic gap is at least partially formed by the winding element carrier (42). Winding module (28, 30) of the coil arrangement (10) according to one of the preceding claims. Method for producing a coil arrangement (10) for a resonant converter, in which: - At least one winding (12) of an electrical conductor (14) is formed, which comprises a plurality of mutually electrically insulated individual conductors, which are arranged in the manner of a high-frequency strand to each other, and the respective conductor ends of the individual conductors are connected to a respective one of two electrical connections (16, 18) of the at least one winding (12) in order to connect the respective individual conductors in parallel, characterized in that - From the at least one electrical conductor (14) at least two winding elements (24, 26) are formed, so that the electrical conductor (14) in each of the at least two winding elements (24, 26) at least one turn of the at least one winding (12) is formed , and - The at least two winding elements (24, 26) coaxially and axially spaced from each other are arranged. Method for producing a winding module (28, 30) for a modular coil arrangement (10) according to one of Claims 1 to 14,
characterized in that
for forming the winding module (28, 30) - At least one electrical conductor (14) at least two winding elements (24, 26) are formed, so that the electrical conductor (14) in each of the at least two winding elements (24, 26) at least one turn of at least one winding (12) of the coil assembly (10), wherein the at least one electrical conductor (14) comprises a plurality of individual conductors which are electrically insulated from one another and which are arranged in the manner of a high-frequency strand,
and - The at least two winding elements (24, 26) coaxially and axially spaced from each other are arranged.

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