Common mode differential mode filter inductor and method of making same

Abstract

The application discloses a common-mode differential-mode filtering inductor and a manufacturing method thereof, and comprises the following steps: step 1, manufacturing a hollow coil: the flat wire is spirally wound into a tensile spring through equipment; step 2, the hollow coil is spirally sleeved on a magnetic ring body to form a semi-finished product, and the hollow coil is arranged on the annular top surface, the inner annular surface, the annular bottom surface and the outer annular surface of the magnetic ring body along the annular extension direction of the magnetic ring body; and step 3, a round wire is wound on the magnetic ring body along the annular extension direction of the magnetic ring body, and the round wire is wound between the gaps between adjacent flat wires. The design difficulty that a large wire diameter and a small magnetic ring cannot realize winding is solved, the effective utilization of the product space of the small magnetic ring is realized, the high-power current thermal energy loss is reduced, the product use reliability is enhanced, the overall space of the product is smaller, and the two-coil arrangement can effectively suppress common-mode interference signals in the balanced line and has no influence on the normal transmission of differential-mode signals.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of high-power common-mode inductance, in particular to a common-mode differential-mode filter inductance and a manufacturing method thereof. BACKGROUND

[0002] The state has listed improving the reliability and energy saving of transformers as a key development project for transformers; the traditional high-power PFC vertical flat wire is formed by winding wire on a ring-shaped magnetic core through an automatic ring winding machine, and generally requires cutting the magnetic ring, which is troublesome and difficult to implement, and also causes a large space waste at the cutting gap, and further causes great design difficulties for product performance and magnetic leakage.

[0003] For the automatic ring winding machine for high-power PFC, winding large-diameter round wire on a large-size magnetic ring, when the heat energy loss of high-power current, the performance of electronic circuit is affected by the heat energy loss of the coil, and only the design of large-size magnetic ring and large-diameter round wire can be used to realize control, which causes a large space size waste. For example, CN 107146689 A discloses a new type of large current polygonal cross section magnetic ring vertical winding inductance, which comprises a ring-shaped magnetic core and a flat wire winding formed by vertically winding flat wire on the ring-shaped magnetic core through an automatic ring winding machine. If a small magnetic ring is selected, the automatic ring winding machine cannot realize the action of winding wire on the ring-shaped magnetic core, resulting in that the existing PFC inductance cannot solve the problem of small size and high power by using the traditional design.

[0004] Therefore, it is necessary to study a new technical solution to solve the above problems. SUMMARY

[0005] Therefore, the present application aims at the defects of the prior art, and the main purpose is to provide a common-mode differential-mode filter inductance and a manufacturing method thereof, which solves the design difficulty of large wire diameter and small magnetic ring that cannot realize winding, realizes effective utilization of the space of a small magnetic ring product, reduces the heat energy loss of high-power current, enhances the use reliability of the product, and the overall space of the product is smaller, and the two coils are arranged to realize that the common-mode inductance can effectively suppress common-mode interference signals in a balanced line without affecting the differential-mode signals normally transmitted by the line.

[0006] To achieve the above purpose, the present application adopts the following technical solution:

[0007] A common-mode differential-mode filter inductance comprises

[0008] A magnetic ring has a closed ring-shaped magnetic ring body; the surface of the magnetic ring body comprises a ring-shaped top surface, an inner ring surface, a ring-shaped bottom surface and an outer ring surface which are sequentially connected; and the magnetic ring body is surrounded to form an internal through hole;

[0009] The hollow coil is spirally wound by a device into a tensile spring shape, the radial section of the flat wire of the hollow coil is flat, the thickness value of the flat wire is less than the width value of the flat wire, and the thickness direction of the flat wire is arranged along the length direction of the hollow coil; both ends of the flat wire are respectively located at both ends of the length direction of the hollow coil to serve as a first connecting end and a second connecting end respectively; the hollow coil is spirally sleeved on the magnetic ring body to form a semi-finished product, and the hollow coil is arranged on the annular top surface, inner annular surface, annular bottom surface and outer annular surface of the magnetic ring body along the annular extension direction of the magnetic ring body;

[0010] The round wire is wound on the magnetic ring body of the semi-finished product; the round wire is wound between the gaps between adjacent flat wires along the annular extension direction of the magnetic ring body, and both ends of the round wire serve as a third connecting end and a fourth connecting end respectively.

[0011] As a preferred solution, the cross-sectional area of the round wire is the same as that of the flat wire.

[0012] As a preferred solution, the magnetic ring body is a nickel-zinc magnetic ring.

[0013] As a preferred solution, the flat wire and the round wire are both copper wires.

[0014] As a preferred solution, both ends of the length direction of the hollow coil are arranged adjacent to each other on the magnetic ring body, and the first connecting end and the second connecting end are arranged adjacent to each other on the magnetic ring body.

[0015] As a preferred solution, the third connecting end and the fourth connecting end are arranged adjacent to each other on the magnetic ring body.

[0016] As a preferred solution, the first connecting end, the second connecting end, the third connecting end and the fourth connecting end are arranged adjacent to each other on the magnetic ring body.

[0017] As a preferred solution, the outer diameter of the hollow coil is greater than the winding outer diameter of the round wire wound on the magnetic ring body.

[0018] A manufacturing method of a common-mode and differential-mode filtering inductor based on any one of the common-mode and differential-mode filtering inductors, comprising the following steps:

[0019] Step 1, manufacturing a hollow coil: spirally winding a flat wire into a tensile spring shape by a device;

[0020] Step 2, spirally sleeving the hollow coil on the magnetic ring body to form a semi-finished product, and arranging the hollow coil on the annular top surface, inner annular surface, annular bottom surface and outer annular surface of the magnetic ring body along the annular extension direction of the magnetic ring body;

[0021] Step 3, winding the round wire on the magnetic ring body along the annular extension direction of the magnetic ring body, and the round wire is wound between the gaps of adjacent flat wires.

[0022] Compared with the prior art, the present application has obvious advantages and beneficial effects. Specifically, from the above technical solution, it mainly adopts the hollow coil to be spirally sleeved on the magnetic ring body, and the round wire is wound on the magnetic ring body at the gap of the flat wire. It is suitable for large cross-sectional area wire diameter and small magnetic ring to control low value heat loss. It effectively solves the design difficulty that large wire diameter and small magnetic ring cannot be wound in the traditional technology. It realizes the effective use of small magnetic ring product space, reduces the heat loss of high-power current, enhances the product use reliability, the overall space of the product is smaller, and the two coil settings realize that the common mode inductance can effectively suppress the common mode interference signal in the balanced line, and has no effect on the differential mode signal of the normal transmission line.

[0023] To make the structure characteristics and effects of the present application clearer, the present application will be described in detail below in combination with the drawings and specific examples. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 is the exploded schematic view of the common mode and differential mode filter inductance of the embodiment of the present application (the state before the hollow coil is spirally sleeved on the magnetic ring body, and the round wire has not been wound on the magnetic ring body);

[0025] Figure 2 is the process state schematic view of the hollow coil spirally sleeved on the magnetic ring body of the embodiment of the present application;

[0026] Figure 3 is the completed state schematic view of the hollow coil spirally sleeved on the magnetic ring body of the embodiment of the present application (i.e. the semi-finished product diagram);

[0027] Figure 4 is the process state schematic view of the round wire wound on the semi-finished magnetic ring body of the embodiment of the present application;

[0028] Figure 5 is the completed state schematic view of the round wire wound on the semi-finished magnetic ring body of the embodiment of the present application (in order to show more clearly, Figure 5 the arrangement density of the hollow coil and the round wire on the magnetic ring body is shown to be relatively sparse in the middle);

[0029] Figure 6 is the completed state actual view of the round wire wound on the semi-finished magnetic ring body of the embodiment of the present application;

[0030] Figure 7 is the manufacturing process schematic view of the common mode and differential mode filter inductance of the embodiment of the present application.

[0031] The figure mark explanation: magnetic ring body 10, hollow coil 20, first connection end 21, second connection end 22, round wire 30, third connection end 31, fourth connection end 32, hollow coil outer diameter D1, winding outer diameter D2, flat wire 1, first coil A, second coil B. DETAILED DESCRIPTION

[0032] Please refer to Figures 1 to 7 The specific structure of the embodiment of the application is shown.

[0033] In the description of the application, it should be noted that the terms "upper", "lower", "left", "right" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the application.

[0034] A common mode and differential mode filtering inductor, comprising a magnetic ring, a hollow coil and a round wire.

[0035] The magnetic ring has a closed annular magnetic ring body 10, for example: the magnetic ring body 10 is circular, and the magnetic ring body 10 is a nickel-zinc magnetic ring. The surface of the magnetic ring body 10 includes annular top surface, inner annular surface, annular bottom surface and outer annular surface in turn, and the magnetic ring body 10 is surrounded by an internal through hole 16; The annular top surface and the inner annular surface of the magnetic ring body 10, the inner annular surface and the annular bottom surface, the annular bottom surface and the outer annular surface, and the outer annular surface and the annular top surface are all provided with rounded corner guide parts, so that the hollow coil is more smooth when it is spirally sleeved on the magnetic ring body 10. In addition, the surface of the magnetic ring body 10 is covered with an insulating layer, which completely covers the annular top surface, the inner annular surface, the annular bottom surface and the outer annular surface.

[0036] The hollow coil 20 is spirally wound into a stretch spring shape by the device, and has several adjacent spiral parts. During production, the flat wire is tightly wound into the hollow coil 20 by the device, so that the hollow coil 20 can be uniformly and tightly wound. In actual production, the hollow coil 20 can be uniformly and tightly wound, and the winding process is very mature. The gap and forming size precision of the spiral part of the hollow coil 20 are very good (for reference, the size precision of the stretch spring is very good in the existing technology). The flat wire can be copper wire, etc. The radial cross section of the flat wire of the hollow coil 20 is flat, and the radial cross section of the flat wire of the hollow coil 20 is rectangular. The thickness value of the flat wire is less than the width value of the flat wire, and the thickness direction of the flat wire is arranged along the length direction of the hollow coil; the two ends of the flat wire are respectively located at the two ends of the length direction of the hollow coil to serve as the first connecting end 21 and the second connecting end 22; the hollow coil 20 is spirally sleeved on the magnetic ring body 10 to form a semi-finished product, and the hollow coil 20 is arranged on the annular top surface, inner annular surface, annular bottom surface and outer annular surface of the magnetic ring body 10 along the annular extension direction of the magnetic ring body 10. The two ends of the length direction of the hollow coil 20 are arranged adjacent to each other on the magnetic ring body 10, and the first connecting end 21 and the second connecting end 22 are arranged adjacent to each other on the magnetic ring body 10.

[0037] The round wire 30 is wound on the magnetic ring body 10 of the semi-finished product; the round wire 30 is wound between the gaps between the adjacent flat wires along the annular extension direction of the magnetic ring body 10, and the two ends of the round wire 30 serve as the third connecting end 31 and the fourth connecting end 32, which are arranged adjacent to each other on the magnetic ring body 10. Preferably, the first connecting end 21, the second connecting end 22, the third connecting end 31 and the fourth connecting end 32 are arranged adjacent to each other on the magnetic ring body 10. The round wire 30 can also be made of copper wire, and the cross-sectional area of the round wire 30 is the same as that of the flat wire. The outer diameter D1 of the hollow coil is greater than the winding outer diameter D2 of the round wire 30 wound on the magnetic ring body 10.

[0038] Next, a manufacturing method of a common-mode and differential-mode filter inductor is introduced, which is based on the common-mode and differential-mode filter inductor described above, and includes the following steps:

[0039] Step 1, manufacturing the hollow coil 20: the flat wire 1 is spirally wound into a stretch spring shape by the device; since the manufacturing technology of the hollow coil 20 is mature, the gap and forming size precision of the spiral part of the hollow coil 20 are very good (for reference, the size precision of the stretch spring is very good in the existing technology).

[0040] Step 2, hollow coil 20 penetrates into the magnetic ring: the hollow coil 20 is spirally penetrated into the magnetic ring body 10 to form a semi-finished product, and the hollow coil 20 is arranged on the annular top surface, inner annular surface, annular bottom surface and outer annular surface of the magnetic ring body 20 along the annular extension direction of the magnetic ring body 10. When assembling, first hook one end of the hollow coil 20 into the magnetic ring body 10, then hold the other end of the hollow coil 20 and rotate, so that the spiral part of the hollow coil 20 is sequentially rotated into and sleeved on the magnetic ring body 10. In actual operation, the other end of the hollow coil 20 can be rotated by using an automatic machine or by manual operation, one hand holding the magnetic ring and the other hand holding the other end of the hollow coil 20 and rotating. The structure and operation mode are very simple, the product design is easier to control, the product assembly cost is low, the work efficiency is improved, and the product performance is better. The hollow coil 20 is spirally penetrated into the magnetic ring body 10, only the hollow coil 20 needs to be rotated (as shown in Figure 2 ), and the operation site is located outside the magnetic ring, which solves the design difficulty of the small size magnetic ring that cannot realize the vertical winding of the flat wire by the automatic annular winding machine. After penetrating and sleeving, as shown in Figure 3 , the gaps (also referred to as heat dissipation spaces) of the spiral part of the hollow coil 20 on the magnetic ring body are uniform after the spiral sleeving operation is completed, the traditional magnetic core window can be effectively utilized, the flat wire and the closed annular magnetic ring body are combined, the small size and large power design is realized, the loss can be effectively reduced, and it is beneficial to better meet the theme of "energy saving and environmental protection" advocated in the world.

[0041] Step 3, round wire 30 is wound on the magnetic ring body 10 of the semi-finished product: the round wire 30 is wound on the magnetic ring body 10 along the annular extension direction of the magnetic ring body 10, and the round wire 30 is wound between the gaps of adjacent flat wires. The hollow coil 20 is penetrated into the magnetic ring body 10 as a first coil A, and the round wire 30 is wound as a second coil B after the round wire 30 is wound. The two groups of coils (i.e. the first coil A and the second coil B) arranged at intervals have a considerable inductance when there is a common mode current, so that the magnetic flux in the magnetic ring is superimposed, thereby having a considerable inductance, which plays a role in inhibiting the common mode current. When the two coils pass through the differential mode current, the magnetic flux in the magnetic ring is cancelled, and there is almost no inductance, so the differential mode current can pass through without attenuation. Therefore, the common mode inductance can effectively suppress the common mode interference signal in the balanced line, and has no effect on the differential mode signal normally transmitted by the line. The common mode and differential mode filter inductor of the present application has a small leakage inductance, but a large capacitance value between the two groups, and a small difference between the inductance values of the two groups.

[0042] As shown in Figure 7 , it generally shows the manufacturing process diagram of the common mode and differential mode filter inductor of the embodiment of the present application. First, the flat wire 1 is vertically wound into a hollow coil 20, then the hollow coil 20 is spirally penetrated into the magnetic ring body 10, and then the round wire 30 is wound between the gaps of adjacent flat wires on the magnetic ring body 10.

[0043] In the present application, the outer diameter of the first coil is larger than that of the second coil, the cross-sectional area of the flat wire is large, the current passing through is large, the current runs on the surface, the density is 1.5 times that of round copper wire, and the copper loss of the flat wire is low, the resistance is small, and the temperature rise is low. The flat wire is first made into a hollow coil, and then the hollow coil 20 is spirally sleeved on the magnetic ring body 10, which ensures uniform winding, stable performance, good high-frequency effect, and the conduction residual at 200 kHz is twice that of ordinary magnetic rings. Closed loop magnetic circuit, small magnetic force leakage; effectively save the space utilization of the magnetic ring, and solve the difficult points of material and power supply design; also make the product appearance beautiful, high production capacity, flat winding, neat wire arrangement, no cross, perfect combination of subsequent base and coil, efficiency is 10 times that of magnetic ring, short delivery cycle.

[0044] The design focus of the present application is that it mainly adopts a hollow coil spirally sleeved on the magnetic ring body, and then a round wire is wound on the gap of the flat wire on the magnetic ring body. It is suitable for wire diameter with large cross-sectional area and small magnetic ring, to control the low value of heat loss, effectively solve the design difficulty of large wire diameter and small magnetic ring in traditional technology, realize the effective use of small magnetic ring product space, reduce the heat loss of high-power current, enhance the product use reliability, and the overall product space is smaller. Therefore, it has the advantages of high power, low temperature rise, low loss, small size, large current, etc.

[0045] Moreover, the two coils are arranged to effectively suppress common-mode interference signals in the balanced line without affecting the normal transmission of differential-mode signals.

[0046] In addition, the structure and production method are very simple, the product design is easy to control, the product assembly cost is low, the work efficiency is improved, and the product performance and reliability are better.

[0047] The above is only a preferred embodiment of the present application, and does not limit the technical scope of the present application. Any slight modification, equivalent change and modification of the above embodiment according to the technical essence of the present application still belongs to the scope of the technical solution of the present application.

Claims

1. A common mode differential mode filter inductor, characterized by: The magnetic ring has a closed annular magnetic ring body; the surface of the magnetic ring body comprises annular top surface, inner annular surface, annular bottom surface and outer annular surface in sequence, and the magnetic ring body is configured with an internal through hole; The hollow coil is spirally wound into a tensile spring shape by a device; the radial section of the flat wire of the hollow coil is flat; the thickness value of the flat wire is smaller than the width value of the flat wire, and the thickness direction of the flat wire is arranged along the length direction of the hollow coil; the two ends of the flat wire are respectively located at the two ends of the length direction of the hollow coil to serve as the first connecting end and the second connecting end respectively; the hollow coil is spirally sleeved on the magnetic ring body to form a semi-finished product, and the hollow coil is arranged on the annular top surface, the inner annular surface, the annular bottom surface and the outer annular surface of the magnetic ring body along the annular extension direction of the magnetic ring body; The round wire is wound on the magnetic ring body of the semi-finished product; the round wire is wound between the gaps between adjacent flat wires along the annular extension direction of the magnetic ring body, and the two ends of the round wire serve as the third connecting end and the fourth connecting end respectively. The magnetic ring body is a nickel-zinc magnetic ring.

2. The common mode differential mode filter inductor of claim 1, wherein: The flat wire and the round wire are copper wires.

3. The common mode differential mode filter inductor of claim 1, wherein: The two ends of the length direction of the hollow coil are arranged adjacent to each other on the magnetic ring body, and the first connecting end and the second connecting end are arranged adjacent to each other on the magnetic ring body.

4. The common mode differential mode filter inductor of claim 1, wherein: The third connecting end and the fourth connecting end are arranged adjacent to each other on the magnetic ring body.

5. The common mode differential mode filter inductor of claim 4, wherein: The first connecting end, the second connecting end, the third connecting end and the fourth connecting end are arranged adjacent to each other on the magnetic ring body.

6. The common mode differential mode filter inductor of claim 5, wherein: The outer diameter of the hollow coil is greater than the winding outer diameter of the round wire wound on the magnetic ring body.

7. The common mode - differential mode filter inductance of claim 1, wherein: The common mode and differential mode filtering inductor according to any one of claims 1 to 7 comprises the following steps:

8. A method of fabricating a common mode differential mode filter inductor, the method comprising: Step 1, manufacturing a hollow coil: spirally winding a flat wire into a tensile spring shape by a device; ​ Step 2, spirally sleeving the hollow coil on the magnetic ring body to form a semi-finished product, and arranging the hollow coil on the annular top surface, the inner annular surface, the annular bottom surface and the outer annular surface of the magnetic ring body along the annular extension direction of the magnetic ring body; Step 3, winding a round wire on the magnetic ring body along the annular extension direction of the magnetic ring body, and winding the round wire between the gaps between adjacent flat wires. ​

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