Induction device

• US 9,666,353 B2
• Filed: 04/03/2015
• Issued: 05/30/2017
• Est. Priority Date: 04/10/2014
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toyota Jidoshokki
• Original Assignee: Kabushiki Kaisha Toyota Jidoshokki
• Inventors: Moiseev, Sergey
• Primary Examiner(s): Lian, Mangtin
• Application Number:
  US14/678,423
• Publication Number:
  US 20150294782A1
• Time in Patent Office: 788 Days
• Field of Search: 336221, 336 61, 336206, 336232, 336220
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/2866 Combination of wires and sheets

Abstract

There is provided an induction device including a first coil formed by winding a plurality of times a conductive wire that is covered with an insulating layer, a second coil formed of a metal pattern, and a coil support member disposed between the first coil and the second coil. The first coil and the second coil are magnetically connected to each other. There is also provided a transformer including a primary coil formed by winding a plurality of times a conductive wire that is covered with an insulating layer, a secondary coil formed of a metal pattern, and an insulating sheet that is disposed between the primary coil and the secondary coil. The primary coil and the secondary coil are magnetically connected to each other.

Claims

1. An induction device comprising:

a first coil formed by winding an insulated conductive wire a plurality of times, the conductive wire being covered with an insulating layer;

a second coil being a metallic sheet having a pattern; and

a coil support member disposed between the first coil and the second coil,

wherein the coil support member is a first insulating substrate,

wherein the first coil is supported by the first insulating substrate,

wherein a winding start and a winding end of the first coil are connected to the first insulating substrate,

wherein the conductive wire forming the first coil is a single continuous wire,

wherein the first coil and the second coil are magnetically connected to each other,

wherein the first coil is supported by the first insulating substrate and the second coil is supported by a second insulating substrate,

wherein a radiator plate, formed of a metal pattern, is supported on one side of the second insulating substrate that is opposite from the second coil and is fixed to a heat sink, and

wherein the heat sink, an insulating sheet, the first coil, the first insulating substrate, the second coil, the second insulating substrate and the radiator plate are aligned in an axial direction of the first coil.

2. The induction device according to claim 1, wherein the first coil is disposed only on one side of the coil support member.

3. The induction device according to claim 1, wherein the first coil and the second coil are disposed on opposite sides of the coil support member.

4. The induction device according to claim 1, wherein the first coil, the second coil, and the coil support member are encased by a first core and a second core, and

wherein the first core is larger than the second core.

5. The induction device according to claim 1, wherein the second coil is disposed between the first insulating substrate and a radiator plate.

6. A transformer comprising:

a primary coil formed by winding an insulated conductive wire a plurality of times, the conductive wire being covered with an insulating layer;

a secondary coil being a metallic sheet having a pattern; and

a coil support member disposed between the primary coil and the secondary coil,

wherein the coil support member is a first insulating substrate,

wherein the primary coil is supported by the first insulating substrate,

wherein a winding start and a winding end of the primary coil are connected to the first insulating substrate,

wherein the conductive wire forming the primary coil is a single continuous wire,

wherein the primary coil and the secondary coil are magnetically connected to each other,

wherein the primary coil is supported by the first insulating substrate and the secondary coil is supported by a second insulating substrate,

wherein a radiator plate, formed of a metal pattern, is supported on one side of the second insulating substrate that is opposite from the secondary coil and is fixed to a heat sink, and

wherein the heat sink, an insulating sheet, the primary coil, the first insulating substrate, the secondary coil, the second insulating substrate and the radiator plate are aligned in an axial direction of the primary coil.

7. The transformer according to claim 6, wherein the primary coil is mounted on the first insulating substrate and the secondary coil is mounted on a second insulating substrate,

wherein the primary coil is provided on one side of the first insulating substrate that is opposite from the second insulating substrate,

wherein the secondary coil is provided on one side of the second insulating substrate that is opposite from the first insulating substrate and the primary coil and the secondary coil are disposed in overlapping relation to each other.