Integrally-designed high-power two-path power inductor and processing method thereof

Abstract

The invention relates to the technical field of integrated inductors, and discloses an integrated high-power two-path power inductor and a processing mode thereof, the integrated high-power two-path power inductor comprises at least two inductance coils arranged in a magnetic core main body, and the at least two inductance coils share a middle column of the magnetic core main body; the magnetic core body is provided with an air gap acting on the inductance coils, the inductance coils comprise the first inductance coil and the second inductance coil, the first inductance coil is arranged on the first side column, the second inductance coil is arranged on the second side column, and the directions of magnetic circuit loops corresponding to the first inductance coil and the second inductance coil are the same. According to the high-power two-path power inductor with the integrated design and the processing mode thereof, the coil of the integrated inductor scheme of the structure is of a semi-open structure, the direct contact area with air in the surrounding space is large, heat dissipation is facilitated, therefore, the problem of coil heat dissipation can be effectively solved, the two side columns are synchronously processed, the consistency of air gaps of magnetic cores during batch production can be guaranteed, and the production efficiency is improved. And the problem of consistency of inductance parameters of two paths of inductors can be further solved.

Description

Technical Field

[0001] The present invention relates to a technical field, and in particular to an integrated high-power two-way power inductor and a processing method thereof. Background Art

[0002] In a DCDC power supply system that uses a resonant cavity circuit architecture, such as LLC and LCC architectures, two resonant cavities are often connected in parallel to achieve high power output. In this case, each resonant cavity needs to be equipped with a power inductor device.

[0003] In existing product designs, each power inductor is often designed as an independent device, and the traditional EE-type magnetic core combination is often used. The inductor has a simple structure and is easy to design. However, there are also shortcomings in engineering applications: First, most of the coil is surrounded by the magnetic core, which is not conducive to the heat dissipation of the coil, resulting in a large margin in the coil design; second, the two power inductors are independent of each other, and the inconsistency of their inductance parameters in engineering is the key factor that causes the power distribution imbalance of each parallel resonant cavity, which directly affects the long-term operation reliability of the system; third, high-power inductors are often large in size due to thermal design requirements and anti-saturation design requirements. Compared with the integrated design of other modules, the independent inductor design will significantly increase the space occupied by the inductor in the system and reduce the overall power density; fourth, each inductor needs to be installed independently, which will complicate the assembly process and increase costs. Summary of the invention

[0004] In view of the problems existing in the above-mentioned existing integrated high-power two-way power inductor, the present invention is proposed.

[0005] Therefore, the purpose of the present invention is to provide an integrated high-power two-way power inductor, which aims to effectively solve the problem of coil heat dissipation of the high-power inductor and consistency of inductance parameters of the two-way resonant inductors.

[0006] In order to solve the above technical problems, the present invention provides the following technical solution: comprising at least two inductance coils arranged in a magnetic core body, and at least two of the inductance coils share a middle column of the magnetic core body;

[0007] An air gap is arranged on the magnetic core body to act on the inductor coil.

[0008] As a preferred solution of the integrated high-power two-way power inductor described in the present invention, the magnetic core body is composed of a magnetic core body, a middle column arranged on the outer surface of the magnetic core body, and a first side column and a second side column respectively located on both sides of the middle column and arranged at both ends of the magnetic core body.

[0009] As a preferred solution of the integrated high-power two-way power inductor described in the present invention, gaps are provided on both the first side column and the second side column, the magnetic core body is combined and connected by symmetrical magnetic core bodies, and the gaps on the two first side columns and the second side columns are connected and combined into an air gap.

[0010] As a preferred solution of the integrated high-power two-way power inductor described in the present invention, the inductor coil includes a first inductor coil and a second inductor coil, the first inductor coil is arranged on the first side column, and the second inductor coil is arranged on the second side column.

[0011] As a preferred solution of the integrated high-power two-way power inductor of the present invention, the first magnetic circuit loop of the first inductor coil and the first magnetic circuit loop of the second inductor coil have the same direction as each other.

[0012] As a preferred solution of the integrated high-power two-way power inductor of the present invention, the first inductor coil corresponds to the first magnetic circuit loop direction which is clockwise, and the second inductor coil corresponds to the first magnetic circuit loop direction which is clockwise.

[0013] As a preferred solution of the integrated high-power two-way power inductor of the present invention, the middle column is shared by the first inductor coil and the second inductor coil, and the magnetic fluxes of the middle column cancel each other out.

[0014] As a preferred solution of the integrated high-power two-way power inductor of the present invention, the distance between the first inductor coil and the middle column is greater than the distance between the first inductor coil and the first side column.

[0015] As a preferred solution of the integrated high-power two-way power inductor of the present invention, the distance of the second inductor coil close to the middle column is greater than the distance close to the second side column.

[0016] In view of the problems existing in the above-mentioned existing integrated high-power two-way power inductor, the present invention is proposed.

[0017] Therefore, the purpose of the present invention is to provide an integrated design of a high-power two-way power inductor processing method, the purpose of which is to effectively solve the problem of coil heat dissipation of the high-power inductor and the consistency of the inductance parameters of the two-way resonant inductor.

[0018] In order to solve the above technical problems, the present invention provides the following technical solutions: comprising:

[0019] The magnetic core body is processed into a semi-open structure by a magnetic core body, a middle column, a first side column and a second side column that are symmetrical up and down;

[0020] At the same time, the first side column and the second side column are processed simultaneously during the inductor air gap processing to ensure the consistency of the core air gap during mass production;

[0021] Among them, the first inductor coil and the second inductor coil have the same direction of corresponding magnetic circuit loops, the first inductor coil corresponds to the first magnetic circuit loop direction is clockwise, the second inductor coil corresponds to the first magnetic circuit loop direction is clockwise, and the first inductor coil and the second inductor coil share a middle column, the magnetic flux of the middle column cancel each other out, reducing the width and volume of the middle column.

[0022] Beneficial effects of the present invention: the integrated inductor coil of the structure is a semi-open structure, with a large direct contact area with the surrounding air, which is convenient for heat dissipation, thus effectively solving the heat dissipation problem of the coil, and the two side columns are processed synchronously to ensure the consistency of the core air gap during mass production, which can further solve the consistency problem of the inductance parameters of the two inductors. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. Among them:

[0024] Figure 1 The overall structural diagram of the high-power two-way power inductor integratedly designed by the present invention and its processing method.

[0025] Figure 2 A schematic structural diagram of the first side column and the second side column of the high-power two-way power inductor integratedly designed for the present invention and its processing method.

[0026] Figure 3 A schematic diagram of the main structure of the magnetic core of the high-power two-way power inductor integratedly designed by the present invention and its processing method.

[0027] Figure 4 The overall front cross-sectional structural schematic diagram of the high-power two-way power inductor integratedly designed by the present invention and its processing method.

[0028] Figure 5 A schematic diagram of the magnetic circuit loop structure of the high-power two-way power inductor integratedly designed by the present invention and its processing method.

[0029] Figure 6 It is a schematic diagram of the inductor structure of the prior art. DETAILED DESCRIPTION

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0031] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0032] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0033] Secondly, the present invention is described in detail with reference to the schematic diagram. When describing the embodiments of the present invention in detail, for the sake of convenience, the cross-sectional diagrams showing the device structure will not be partially enlarged according to the general scale, and the schematic diagrams are only examples, which should not limit the scope of protection of the present invention. In addition, in actual production, the three-dimensional dimensions of length, width and depth should be included.

[0034] Example 1

[0035] Reference Figure 1 to Figure 4 , which is the first embodiment of the present invention, provides an integrated high-power two-way power inductor, the device includes a magnetic core body 100 and an inductor coil 200.

[0036] At least two inductors 200 are disposed in the magnetic core body 100 , and at least two inductors 200 share a central column 102 of the magnetic core body 100 . An air gap F is disposed on the magnetic core body 100 to act on the inductors 200 .

[0037] During use, the magnetic core body 100 comprises a magnetic core body 101 , a middle column 102 disposed on the outer surface of the magnetic core body 101 , and a first side column 103 and a second side column 104 respectively located on both sides of the middle column 102 and disposed at both ends of the magnetic core body 101 .

[0038] The magnetic core body 101 is composed of a main body, a first side column 103 and a second side column 104 arranged at two ends, and a middle column 102 arranged in the middle. The magnetic core body 100 is composed of two magnetic core bodies 101 with symmetrical upper and lower structures.

[0039] Gaps D are provided on the first side column 103 and the second side column 104 . The magnetic core body 100 is formed by combining and docking symmetrical magnetic core bodies 101 . The gaps D on the two first side columns 103 and the second side columns 104 are docked with each other to form an air gap F.

[0040] The inductor coil 200 is wound around the first side column 103 and the second side column 104 respectively, and is shared by the two inductors through the middle column 102, and the gaps D on the two first side columns 103 and the second side columns 104 are connected to each other to form an air gap F, so that the air gaps of the two inductors are respectively on the first side column 103 and the second side column 104, forming Figure 4 .

[0041] Example 2

[0042] Reference Figures 1 to 6 , which is the second embodiment of the present invention. This embodiment is different from the first embodiment in that: the inductor 200 includes a first inductor 201 and a second inductor 202, the first inductor 201 is arranged on the first side column 103, and the second inductor 202 is arranged on the second side column 104.

[0043] The first inductor 201 is wound around the first side pole 103 , and the second inductor 202 is wound around the second side pole 104 . Meanwhile, the first inductor 201 and the second inductor 202 share the middle pole 102 to form two inductors.

[0044] Compared with Example 1, further, the first magnetic circuit loop A of the first inductor 201 and the first magnetic circuit loop B of the second inductor 202 have the same magnetic circuit loop direction, and the two inductors are symmetrically integrated with the magnetic core body 100, which can ensure the consistency of the magnetic material properties of the two inductors corresponding to the magnetic circuits. By sharing the middle column structure, the volume of the magnetic core can be reduced, and the direction of the current of the first inductor 201 and the second inductor 202 can be controlled to achieve the magnetic circuit loop and direction as shown in FIG. Figure 5 As shown, the first inductor 201 corresponds to the first magnetic circuit loop A in a clockwise direction, and the second inductor 202 corresponds to the first magnetic circuit loop B in a clockwise direction.

[0045] Since the two power inductors are independent of each other, the deviation of their inductance parameters depends on the control of the inductance tolerance of the magnetic parts supplier during mass production. In general, since the magnetic core of power inductors needs to have an air gap, the deviation of the inductance of different inductors mainly depends on the precise control of the air gap size. Taking into account the process level and cost, the tolerance of the inductance parameters that the existing magnetic parts manufacturers can provide is 10% to 20%. This deviation can obviously cause the current imbalance problem of the two resonant circuits.

[0046] refer to Figure 6In engineering applications, the problems faced by high-power inductors mainly include increased coil design margins due to heat dissipation difficulties, parameter inconsistencies between independent inductors affecting power distribution and system reliability, large volume reducing power density, and complex assembly processes and increased costs due to independent installation. The middle column 102 of the present invention is shared by the first inductor coil 201 and the second inductor coil 202. The magnetic fluxes of the middle column 102 cancel each other out. The distance between the first inductor coil 201 and the middle column 102 is greater than the distance between the first side column 103 and the second inductor coil 202 is greater than the distance between the second side column 104. The magnetic fluxes of the middle column 102 cancel each other out, which can reduce the width of the middle column 102 and further reduce the volume of the overall magnetic core 100. At the same time, the solution to the coil heat dissipation problem is conducive to reducing the size of the coil winding window. In the actual application of a medical power supply with a single-channel resonant cavity carrying 30kW, the overall volume of the integrated inductor solution can save about 20% of the space compared to the total volume of two traditional independent inductors.

[0047] The remaining structures are the same as those of Example 1.

[0048] Example 3

[0049] Reference Figure 1 , which is the third embodiment of the present invention, and this embodiment is different from the second embodiment in: processing method.

[0050] Compared with Example 2, the magnetic core body 100 is further processed into a semi-open structure by the upper and lower symmetrical magnetic core body 101, the middle column 102, the first side column 103 and the second side column 104, which has a large direct contact area with the surrounding air and is convenient for heat dissipation, thereby effectively solving the coil heat dissipation problem.

[0051] Taking the traditional inductor solution as an example, the following are the electrical parameters of the inductor during actual operation:

[0052]

[0053] When the core has a large vertical depth, most of the coil is wrapped by the core. When the coil is densely wound, heat is easily accumulated in the area of ​​the coil wrapped by the core, making it difficult to dissipate heat.

[0054] At the same time, the first side column 103 and the second side column 104 are processed simultaneously during the processing of the inductor air gap. The integrated inductor solution formed has two inductors that are symmetrical and integrated in structure based on the magnetic core body 100, which can ensure the consistency of the magnetic material properties of the corresponding magnetic circuits of the two inductors, and also ensure the consistency of the magnetic core air gap during mass production, which can further solve the problem of consistency of the inductance parameters of the two inductors.

[0055] The overall integrated structure can effectively reduce the volume of the two-way power inductor after the integrated design. Comparing the total volume of two traditional inductors with the volume of an integrated inductor solution, the volume of the latter can be reduced by about 20% compared with the former.

[0056] Among them, the first inductor 201 and the second inductor 202 have the same direction of corresponding magnetic circuit loops, the first inductor 201 corresponds to the first magnetic circuit loop A in a clockwise direction, and the second inductor 202 corresponds to the first magnetic circuit loop B in a clockwise direction, and the first inductor 201 and the second inductor 202 share a middle column 102, the magnetic fluxes of the middle column 102 cancel each other out, reducing the width and volume of the middle column 102, and through optimized design, the size of the magnetic core and the coil can be reduced.

[0057] The remaining structure is the same as that of Example 2.

[0058] Importantly, it should be noted that the construction and arrangement of the present application shown in a plurality of different exemplary embodiments are only exemplary. Although only a few embodiments are described in detail in this disclosure, it should be readily understood by those who refer to this disclosure that many modifications are possible (e.g., the size, scale, structure, shape and proportion of various elements, and parameter values ​​(e.g., temperature, pressure, etc.), installation arrangement, use of materials, color, directional changes, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in the application. For example, the element shown as integrally formed can be composed of multiple parts or elements, the position of the element can be inverted or otherwise changed, and the nature or number or position of the discrete element can be changed or changed. Therefore, all such modifications are intended to be included in the scope of the present invention. The order or sequence of any process or method steps can be changed or reordered according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure of performing the function described herein, and is not only structurally equivalent but also equivalent structure. Without departing from the scope of the present invention, other replacements, modifications, changes and omissions can be made in the design, operating conditions and arrangement of the exemplary embodiments. Therefore, the invention is not limited to a specific embodiment, but extends to numerous modifications still falling within the scope of the appended claims.

[0059] Additionally, in order to provide a concise description of exemplary embodiments, all features of an actual embodiment (ie, those features that are not relevant to the best mode presently contemplated for carrying out the invention or those that are not relevant to implementing the invention) may not be described.

[0060] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. An integrated high-power two-way power inductor, characterized by: include, At least two inductance coils (200) are arranged in the magnetic core body (100), and at least two of the inductance coils (200) share a central column (102) of the magnetic core body (100); An air gap (F) is provided on the magnetic core body (100) to act on the inductor coil (200).

2. The integrated high-power two-way power inductor according to claim 1 is characterized in that: The magnetic core body (100) comprises a magnetic core body (101), a middle column (102) arranged on the outer surface of the magnetic core body (101), and a first side column (103) and a second side column (104) respectively located on both sides of the middle column (102) and arranged at both ends of the magnetic core body (101).

3. The integrated high-power two-way power inductor according to claim 2 is characterized in that: Gaps (D) are provided on the first side column (103) and the second side column (104); the magnetic core body (100) is composed of symmetrical magnetic core bodies (101) combined and connected; the gaps (D) on the two first side columns (103) and the second side columns (104) are connected and combined into an air gap (F).

4. The integrated high-power two-way power inductor according to claim 2 or 3, characterized in that: The inductor (200) comprises a first inductor (201) and a second inductor (202); the first inductor (201) is arranged on a first side column (103), and the second inductor (202) is arranged on a second side column (104).

5. The integrated high-power two-way power inductor according to claim 4 is characterized in that: The magnetic circuit loop directions corresponding to the first magnetic circuit loop (A) of the first inductor (201) and the first magnetic circuit loop (B) of the second inductor (202) are the same.

6. The integrated high-power two-way power inductor according to claim 5 is characterized in that: The direction of the first inductor (201) corresponding to the first magnetic circuit loop (A) is clockwise, and the direction of the second inductor (202) corresponding to the first magnetic circuit loop (B) is clockwise.

7. The integrated high-power two-way power inductor according to claim 5 or 6, characterized in that: The middle column (102) is shared by the first inductor coil (201) and the second inductor coil (202), and the magnetic fluxes of the middle column (102) cancel each other out.

8. The integrated high-power two-way power inductor according to claim 7 is characterized in that: The distance of the first inductor coil (201) close to the middle column (102) is greater than the distance of the first inductor coil (201) close to the first side column (103).

9. The integrated high-power two-way power inductor according to claim 8, characterized in that: The distance of the second inductor coil (202) close to the middle column (102) is greater than the distance of the second inductor coil (202) close to the second side column (104).

10. An integrated high-power two-way power inductor processing method, characterized by: The high-power two-way power inductor with integrated design as claimed in any one of claims 8 or 9 also includes: The magnetic core body (100) is manufactured into a semi-open structure by processing a magnetic core body (101) that is symmetrical in top and bottom, a middle column (102), a first side column (103) and a second side column (104); At the same time, when processing the inductor air gap, the first side column (103) and the second side column (104) are processed simultaneously to ensure the consistency of the magnetic core air gap during mass production; The first inductor (201) and the second inductor (202) have the same direction of corresponding magnetic circuit loops, the first inductor (201) corresponds to the first magnetic circuit loop (A) in a clockwise direction, and the second inductor (202) corresponds to the first magnetic circuit loop (B) in a clockwise direction, and the first inductor (201) and the second inductor (202) share a middle column (102), the magnetic fluxes of the middle column (102) cancel each other out, and the width and volume of the middle column (102) are reduced.

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