THERMAL CONDUCTIVE BOBBIN FOR A MAGNETIC POWER UNIT

1 . A thermal conductive bobbin for a magnetic power unit, wherein the thermal conductive bobbin has a magnetic field closed around, generated with or without a core, and the thermal conductive bobbin is made of an injectable and polymerizable thermoplastic composition comprising:

a plastic polymer in an amount of between 5% and 15% by weight with respect to the total weight of the composition;

an aluminium nanoparticles dispersion in mineral oil in an amount of between 25% and 55% by weight with respect to the total weight of the composition;

silicon carbide microparticles between 20% and 45% by weight with respect to the total weight of the composition; and

additives up to 10% by weight with respect to the total weight of the composition,

so that the thermal conductive bobbin has a dielectric rigidity higher than 5 kV/mm.

2 . The thermal conductive bobbin according to claim 1 , wherein the plastic polymer is selected from the group consisting of polybutylene terephthalate, polycaprolactam, poly(hexamethylene adipamide), polyethylene terephthalate, polyether ether ketone and polyimide.

3 . The thermal conductive bobbin according to claim 1 , wherein the additives are dispersants, lubricants, flame retardants or combinations thereof.

4 . The thermal conductive bobbin according to claim 3 , wherein the dispersant is a condensation product of polyethyleneimine and polycarbonylalkylenoxy.

5 . The thermal conductive bobbin according to claim 3 , wherein the lubricant is oil.

6 . The thermal conductive bobbin according to claim 3 , wherein the flame retardant is Aluminium Hydroxide.

7 . The thermal conductive bobbin according to claim 1 , wherein the aluminium nanoparticles have a D50 equal to or lower than 100 nm.

8 . The thermal conductive bobbin according to claim 1 , wherein the silicon carbide microparticles have a D50 equal to or lower than 10 μm.

9 . An inductive unit comprising a thermal conductive bobbin and at least one magnetic core, the thermal conductive bobbin being made of an injectable and polymerizable thermoplastic composition comprising:

a plastic polymer in an amount of between 5% and 15% by weight with respect to the total weight of the composition;

an aluminium nanoparticles dispersion in mineral oil in an amount of between 25% and 55% by weight with respect to the total weight of the composition;

silicon carbide microparticles between 20% and 45% by weight with respect to the total weight of the composition; and

additives up to 10% by weight with respect to the total weight of the composition,

so that the thermal conductive bobbin has a dielectric rigidity higher than 5 kV/mm.

10 . The inductive unit according to claim 9 , wherein the plastic polymer is selected from the group consisting of polybutylene terephthalate, polycaprolactam, poly(hexamethylene adipamide), polyethylene terephthalate, polyether ether ketone and polyimide.

11 . The inductive unit according to claim 9 , wherein the aluminium nanoparticles have a D50 equal to or lower than 100 nm; and/or the silicon carbide microparticles have a D50 equal to or lower than 10 μm.

12 . The inductive unit according to claim 9 , wherein the additives are:

dispersants or dispersants made of a condensation product of polyethyleneimine and polycarbonylalkylenoxy;

lubricants, or lubricant made of silicon oil;

flame retardants or flame retardant made of Aluminium Hydroxide;

or combinations thereof.

13 . An inductive assembly including several inductive units, each inductive unit including a thermal conductive bobbin and at least one magnetic core, the inductive assembly constituting a transformer, each thermal conductive bobbin being made of an injectable and polymerizable thermoplastic composition comprising:

a plastic polymer in an amount of between 5% and 15% by weight with respect to the total weight of the composition;

an aluminium nanoparticles dispersion in mineral oil in an amount of between 25% and 55% by weight with respect to the total weight of the composition;

silicon carbide microparticles between 20% and 45% by weight with respect to the total weight of the composition; and

additives up to 10% by weight with respect to the total weight of the composition,

so that the thermal conductive bobbin has a dielectric rigidity higher than 5 kV/mm.

14 . The inductive assembly according to claim 13 , wherein the plastic polymer is selected from the group consisting of polybutylene terephthalate, polycaprolactam, poly(hexamethylene adipamide), polyethylene terephthalate, polyether ether ketone and polyimide.

15 . The inductive assembly according to claim 13 , wherein the aluminium nanoparticles have a D50 equal to or lower than 100 nm.

16 . The inductive assembly according to claim 13 , wherein the silicon carbide microparticles have a D50 equal to or lower than 10 μm.

17 . The inductive assembly according to claim 13 , wherein the additives are:

dispersants or dispersants made of a condensation product of polyethyleneimine and polycarbonylalkylenoxy;

lubricants, or lubricant made of silicon oil;

flame retardants or flame retardants made of Aluminium Hydroxide;

or combinations thereof.

18 . The inductive assembly according to claim 13 , wherein the inductive assembly is configured to operate under a switching frequency of at least 400 KHz.

19 . The inductive assembly according to claim 13 , wherein the several inductive units are encased in a one-piece thermally conductive case made of aluminium with a number of housings, each housing containing at least one inductive unit.

20 . The inductive assembly according to claim 19 , wherein the case is filled with polyimide insulants having a thermal conductivity higher than 0.8 W/mk.