reactor

Abstract

The application discloses an electric reactor. The electric reactor comprises a shell, a prefabricated magnetic core, a coil and an injection molded magnetic core. The shell comprises a containing cavity. The prefabricated magnetic core is arranged in the containing cavity and connected with the shell. The coil comprises a winding part, and the winding part is arranged in the containing cavity and positioned by the prefabricated magnetic core. The injection molded magnetic core is filled in the containing cavity and connected with the prefabricated magnetic core and the winding part in a solidified state. The electric reactor according to the embodiment of the application does not need to set an additional clamp for the coil in the manufacturing process, and the clamp does not need to be removed, so that the convenience of manufacturing the electric reactor is improved, and the heat dissipation performance of the electric reactor is stronger.

Description

Technical Field

[0001] This application relates to the field of electromagnetic devices, and in particular to a reactor. Background Technology

[0002] A reactor consists of a magnetic core and a coil. In related technologies, when manufacturing a one-piece reactor, the coil needs to be fixed in the housing using an additional clamp. Then, magnetic powder adhesive is injected into the housing, and the adhesive cures to form the magnetic core. After the adhesive cures, the clamp is removed. The above-mentioned reactor manufacturing process requires additional clamps, and the clamps need to be removed after the reactor is completed, making the reactor manufacturing process quite cumbersome. Utility Model Content

[0003] This application provides a reactor that improves the ease of manufacturing reactors.

[0004] This application provides a reactor, which includes: a housing with a receiving cavity; a prefabricated magnetic core disposed in the receiving cavity and connected to the housing; a coil with a winding portion disposed in the receiving cavity and limited by the prefabricated magnetic core; and an injection-molded magnetic core filled in the receiving cavity and connected to the prefabricated magnetic core and the winding portion in a cured state.

[0005] According to the foregoing embodiments of this application, the prefabricated magnetic core includes a radial limiting portion, which limits the radial position of the winding portion.

[0006] According to any of the foregoing embodiments of this application, the prefabricated magnetic core includes an axial limiting portion, which limits the axial position of the winding portion.

[0007] According to any of the foregoing embodiments of this application, the radial limiting portion is located at the bottom of the winding portion, and the surface of the radial limiting portion facing the winding portion matches a portion of the outer peripheral surface of the winding portion.

[0008] According to any of the foregoing embodiments of this application, the prefabricated magnetic core further includes a first axial limiting portion and a second axial limiting portion disposed opposite to each other, the first axial limiting portion and the second axial limiting portion being disposed at opposite ends of the winding portion along the axial direction, and the first axial limiting portion and the second axial limiting portion abutting against the winding portion.

[0009] According to any of the foregoing embodiments of this application, the first axial limiting portion and the second axial limiting portion are integrally disposed with the radial limiting portion; or, the first axial limiting portion and the second axial limiting portion are integrally formed with the radial limiting portion.

[0010] According to any of the foregoing embodiments of this application, the inner wall of the bottom of the housing is provided with a recess, and the prefabricated magnetic core is installed in the recess.

[0011] According to any of the foregoing embodiments of this application, the prefabricated magnetic core is bonded to the housing.

[0012] According to any of the foregoing embodiments of this application, the coil includes a conductor and a first insulating layer wrapped around the outer periphery of the conductor at least at the winding portion, and the reactor further includes a second insulating layer covering the surface of the first insulating layer.

[0013] According to any of the foregoing embodiments of this application, the reactor further includes: a plurality of heat dissipation teeth disposed on the outer surface of the housing, wherein the positions of the heat dissipation teeth correspond to the positions of the prefabricated magnetic core.

[0014] According to an embodiment of this application, the reactor includes a housing, a coil, a prefabricated magnetic core, and an injection-molded magnetic core. The housing includes a receiving cavity, within which the prefabricated magnetic core and the winding portion of the coil are disposed. The prefabricated magnetic core is connected to the housing and limits the position of the winding portion within the receiving cavity. During reactor fabrication, when the receiving cavity is filled with magnetic powder adhesive used to form the injection-molded magnetic core, the prefabricated magnetic core provides support and limits the coil, reducing or even preventing positional displacement of the coil during magnetic powder adhesive filling. The injection-molded magnetic core is filled into the receiving cavity and, in a cured state, is integrally connected with the prefabricated magnetic core and the winding portion. The reactor of this embodiment eliminates the need for additional clamps for the coil during fabrication and also eliminates the need to remove existing clamps, thus improving the convenience of reactor fabrication. In the reactor of this application embodiment, the magnetic core includes a prefabricated magnetic core and an injection-molded magnetic core connected as one piece. The thermal conductivity of the prefabricated magnetic core is significantly higher than that of the injection-molded magnetic core. Compared with the reactor in which the magnetic core is composed of an injection-molded magnetic core, the reactor of this application embodiment has stronger overall thermal conductivity of the magnetic core and stronger heat dissipation performance. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0016] Figure 1 This is a perspective view of one embodiment of the reactor in this application; Figure 2 This is a top view schematic diagram of one embodiment of the reactor in this application; Figure 3 for Figure 2Schematic diagram of the cross section along the AA direction; Figure 4 for Figure 2 Schematic diagram of the cross section in the BB direction.

[0017] Explanation of reference numerals in the attached figures: 110 Housing; 111 Receiving cavity; 120 Prefabricated magnetic core; 121 Radial limiting part; 123 First axial limiting part; 124 Second axial limiting part; 130 Coil; 131 Winding section; 132 Electrical connection section; 140 injection molded magnetic core; 150 heat dissipation teeth.

[0018] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and the accompanying drawings. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0020] It should be noted that all directional indications in the embodiments of this application, such as up, down, left, right, front, back, etc., are only used to explain the relative positional relationship and movement of the components in a specific posture as shown in the attached figure. If the specific posture changes, the directional indication will also change accordingly.

[0021] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0022] This application provides an embodiment of a reactor. The reactor is, for example, an inductor comprising a magnetic core and a coil. Figure 1 , Figure 2 This is a perspective view and a top view of one embodiment of the reactor in this application. Figure 3 for Figure 2 Schematic diagram of the cross section along the AA direction. Figure 4 for Figure 2 A cross-sectional schematic diagram along the BB direction. The reactor includes a housing 110, a prefabricated magnetic core 120, a coil 130, and an injection-molded magnetic core 140. To clearly show some of the internal structures of the reactor housing 110, Figure 1 , Figure 2 The Lieutenant General's injection-molded magnetic core 140 is shown in transparent form.

[0023] The housing 110 includes a receiving cavity 111. The housing 110 may be made of metal, such as aluminum or aluminum alloy.

[0024] A prefabricated magnetic core 120 is disposed within the receiving cavity 111 and connected to the housing 110. In some embodiments, the prefabricated magnetic core 120 is connected to the bottom of the receiving cavity 111, and in some embodiments, the prefabricated magnetic core 120 is connected to the side of the receiving cavity 111. In this embodiment, the example of the prefabricated magnetic core 120 being connected to the bottom of the receiving cavity 111 of the housing 110 will be described.

[0025] The coil 130 includes a winding portion 131 disposed within a receiving cavity 111 and limited by a prefabricated magnetic core 120. In some embodiments, the coil 130 further includes an electrical connection portion 132 electrically connected to the winding portion 131 and at least partially located outside the receiving cavity 111. There may be two electrical connection portions 132, connected to both ends of the winding portion 131.

[0026] The injection-molded magnetic core 140 is filled into the receiving cavity 111 and, in the cured state, is connected to the pre-made magnetic core 120 and the winding part 131 as a whole.

[0027] The injection-molded magnetic core 140 is obtained by curing magnetic powder adhesive, which is a mixture of fluid magnetic powder and glue. The magnetic powder is preferably spherical alloy soft magnetic powder, which has high fluidity, high filling density, and higher permeability. In other embodiments, the permeability and saturation magnetic induction density of the injection-molded magnetic core 140 can be adjusted according to application requirements by modifying the type and filling ratio of the magnetic powder.

[0028] The thermal conductivity of injection-molded magnetic core 140 is significantly higher than that of injection-molded magnetic core 140, which is around 7 W / (m·K) while that of injection-molded magnetic core 140 is around 3 W / (m·K).

[0029] According to an embodiment of this application, the reactor includes a housing 110, a coil 130, a prefabricated magnetic core 120, and an injection-molded magnetic core 140. The housing 110 includes a receiving cavity 111, within which the prefabricated magnetic core 120 and the winding portion 131 of the coil 130 are disposed. The prefabricated magnetic core 120 is connected to the housing 110 and limits the winding portion 131, restricting its positional movement within the receiving cavity 111. During reactor fabrication, when the receiving cavity 111 is filled with magnetic powder adhesive used to form the injection-molded magnetic core 140, the prefabricated magnetic core 120 provides support and limits the coil 130, reducing or even preventing positional displacement of the coil 130 during magnetic powder adhesive filling. The injection-molded magnetic core 140 is filled into the receiving cavity 111 and, in a cured state, is integrally connected to the prefabricated magnetic core 120 and the winding portion 131. In the reactor of this embodiment, no additional clamps are required for the coil 130 during manufacturing, nor is it necessary to remove the clamps, thus improving the convenience of reactor manufacturing. In the reactor of this embodiment, the magnetic core includes a prefabricated magnetic core 120 and an injection-molded magnetic core 140 connected as a single unit. The thermal conductivity of the prefabricated magnetic core 120 is significantly higher than that of the injection-molded magnetic core 140. Therefore, compared to a reactor where the entire magnetic core is composed of the injection-molded magnetic core 140, the reactor of this embodiment has stronger overall thermal conductivity and better heat dissipation performance.

[0030] The prefabricated magnetic core 120 can be prepared using powder molding technology. The prefabricated magnetic core 120 can be an alloy magnetic powder core, a metal strip wound core, or a ferrite core, and the appropriate core type can be selected according to performance requirements. In some embodiments, the prefabricated magnetic core 120 has a smooth surface and a density of 7 g / cm³ or higher, giving it high structural strength and enabling effective support and containment of the coil 130.

[0031] In some embodiments, the surface of the preformed magnetic core 120 may be polished. For example, in one example, the surface of the preformed magnetic core 120 may be polished with a 150-mesh polishing material to enhance the bonding strength between the preformed magnetic core 120 and the coil 130 after contact.

[0032] like Figure 3 , Figure 4 In some embodiments, the prefabricated magnetic core 120 includes a radial limiting portion 121, which limits the radial position of the winding portion 131. During the fabrication of the reactor, when the receiving cavity 111 is filled with magnetic powder adhesive for forming the injection-molded magnetic core 140, the radial limiting portion 121 can reduce the positional displacement of the coil 130 in the radial position during the filling of the magnetic powder adhesive, thus ensuring the quality stability of the reactor.

[0033] In some embodiments, the prefabricated magnetic core 120 includes an axial limiting portion that limits the axial position of the winding portion 131. During the manufacture of the reactor, when the receiving cavity 111 is filled with magnetic powder adhesive for forming the injection-molded magnetic core 140, the axial limiting portion can reduce the positional displacement of the coil 130 in the axial position during the filling of the magnetic powder adhesive, thus ensuring the quality stability of the reactor.

[0034] like Figure 3 , Figure 4 In some embodiments, the radial limiting portion 121 is located at the bottom of the winding portion 131, and the surface of the radial limiting portion 121 facing the winding portion 131 matches a portion of the outer peripheral surface of the winding portion 131. In one example, the surface of the radial limiting portion 121 facing the winding portion 131 is a curved surface corresponding to the outer peripheral surface of the winding portion 131. During the fabrication of the reactor, when the receiving cavity 111 is filled with magnetic powder adhesive, the radial limiting portion 121 radially limits the coil 130.

[0035] like Figure 3 , Figure 4 In some embodiments, the prefabricated magnetic core 120 further includes a first axial limiting portion 123 and a second axial limiting portion 124 disposed opposite to each other. That is, in some embodiments, the axial limiting portion of the prefabricated magnetic core 120 includes a first axial limiting portion 123 and a second axial limiting portion 124. The first axial limiting portion 123 and the second axial limiting portion 124 are respectively disposed at opposite ends of the winding portion 131 along the axial direction, and the first axial limiting portion 123 and the second axial limiting portion 124 abut against the winding portion 131. During the fabrication of the reactor, when the magnetic powder adhesive is filled into the receiving cavity 111, the opposite ends of the coil 130 along the axial direction abut against the first axial limiting portion 123 and the second axial limiting portion 124 respectively, thereby limiting the axial position of the coil 130.

[0036] In this embodiment, the first axial limiting part 123 and the second axial limiting part 124 are separately provided with the radial limiting part 121, so that the first axial limiting part 123, the second axial limiting part 124, and the radial limiting part 121 can be prefabricated separately, reducing the molding difficulty of the prefabricated magnetic core 120 and facilitating the improvement of the production efficiency of the prefabricated magnetic core 120.

[0037] In some other embodiments, the first axial limiting portion 123 and the second axial limiting portion 124 can be integrally formed with the radial limiting portion 121, thereby further improving the limiting accuracy.

[0038] In some embodiments, the inner wall of the bottom of the housing 110 is provided with a recess, and the prefabricated magnetic core 120 is installed in the recess. This ensures a stable connection between the prefabricated magnetic core 120 and the housing 110 while improving the convenience of installing the prefabricated magnetic core 120 into the housing 110. In some embodiments, the recess depth is 1 mm or more. In some embodiments, the recess is formed by stamping the inner wall of the housing 110, and the wall thickness of the housing 110 at the recess is less than the wall thickness of the housing 110 at other locations other than the recess.

[0039] In other embodiments, the prefabricated magnetic core 120 may be bonded to the housing 110. In one example, the prefabricated magnetic core 120 and the housing 110 are bonded together with a high-temperature adhesive to achieve connection and fixation between the prefabricated magnetic core 120 and the housing 110.

[0040] In some embodiments, the coil 130 includes a conductor and a first insulating layer wrapped around the outer periphery of the conductor at least at the winding portion 131, and the reactor further includes a second insulating layer covering the surface of the first insulating layer.

[0041] In some embodiments, the coil 130 includes a conductor and a first insulating layer wrapped around the outer periphery of the conductor at least at the winding portion 131, for example, the conductor of the coil 130 is enameled wire. In this embodiment, the reactor also includes a second insulating layer covering the surface of the first insulating layer, which enhances the insulation performance of the winding portion 131, enabling the reactor to be used in higher voltage applications.

[0042] The second insulating layer is either insulating tape or an insulating powder coating. In one example, the second insulating layer is insulating tape, for example, high-temperature resistant insulating tape is wrapped around the surface of coil 130 with a wrapping factor greater than or equal to 0.65. In another example, the second insulating layer is an insulating powder coating; specifically, a non-porous second insulating layer is formed on the surface of coil 130 using a powder coating method.

[0043] like Figure 1 In some embodiments, the reactor further includes a plurality of heat dissipation teeth 150 disposed on the outer surface of the housing 110, wherein the positions of the heat dissipation teeth 150 correspond to the positions of the prefabricated magnetic core 120. Since the thermal conductivity of the prefabricated magnetic core 120 is higher than that of the injection-molded magnetic core 140, the correspondence between the positions of the heat dissipation teeth 150 and the prefabricated magnetic core 120 allows heat generated at the windings to be conducted to the heat dissipation teeth 150 more efficiently, further improving the reactor's heat dissipation performance.

[0044] The following describes the manufacturing process of a reactor according to an embodiment of this application: First, a pre-fabricated magnetic core 120 is prepared. In one example, magnetic powder with a permeability of 20 H / m is used, and the pre-fabricated magnetic core 120 is obtained by a pressing process. The surface of the pre-fabricated magnetic core 120 is polished. The pre-fabricated magnetic core 120 is placed in the receiving cavity 111 of the housing 110, so that the pre-fabricated magnetic core 120 is connected to the housing 110. For example, the pre-fabricated magnetic core 120 is placed in a recess in the inner wall of the bottom of the housing 110. A second insulating layer is formed on the surface of the coil 130. For example, the coil 130 is wrapped with high-temperature insulating tape, the overlay factor is, for example, 0.65, and the winding portion 131 has, for example, 20 turns. The winding portion 131 of the coil 130 with the second insulating layer is placed in the pre-fabricated magnetic core 120, so that the pre-fabricated magnetic core 120 limits the winding portion 131. Magnetic powder adhesive is injected into the receiving cavity 111. After the magnetic powder adhesive is filled, the semi-finished reactor is placed in a drying oven and heated to cure. The magnetic powder adhesive is cured into an injection-molded magnetic core 140. The injection-molded magnetic core 140 is connected to the pre-made magnetic core 120 and the winding part 131 in the cured state to obtain the reactor.

[0045] A temperature rise test was conducted on the example reactor obtained through the above-described fabrication process. With an inductance value of 140uH, and operating under a DC current of 20kHz, 1V, and 150A, the temperature rise was measured to be 144℃. For comparison, a comparative example was also tested using the same temperature rise method. The comparative example reactor, except for its core structure, had the same overall structure as the reactor in the above embodiment. In the comparative example, the entire core of the reactor was a molded core 140. With the same inductance value and operating under the same current, the temperature rise was measured to be 152℃. It is evident that the reactor of this embodiment, compared to the reactor with a core composed entirely of a molded core 140, has a stronger overall thermal conductivity and better heat dissipation performance.

[0046] The above description is merely a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural transformations made based on the concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A reactor, characterized in that, include: The housing includes a receiving cavity; A prefabricated magnetic core is disposed within the receiving cavity and connected to the housing; A coil, including a winding portion, the winding portion being disposed within the receiving cavity and limited by the prefabricated magnetic core; The injection-molded magnetic core is filled into the cavity and, in a cured state, is integrated with the pre-made magnetic core and the winding section.

2. The reactor as described in claim 1, characterized in that, The prefabricated magnetic core includes a radial limiting portion, which limits the radial position of the winding portion.

3. The reactor as described in claim 1 or 2, characterized in that, The prefabricated magnetic core includes an axial limiting part, which limits the axial position of the winding part.

4. The reactor as described in claim 2, characterized in that, The radial limiting part is located at the bottom of the winding part, and the surface of the radial limiting part facing the winding part matches a portion of the outer peripheral surface of the winding part.

5. The reactor as described in claim 4, characterized in that, The prefabricated magnetic core further includes a first axial limiting part and a second axial limiting part disposed opposite to each other. The first axial limiting part and the second axial limiting part are disposed at opposite ends of the winding part along the axial direction, and the first axial limiting part and the second axial limiting part abut against the winding part.

6. The reactor as described in claim 5, characterized in that, The first axial limiting portion and the second axial limiting portion are integrally disposed with the radial limiting portion; or, the first axial limiting portion and the second axial limiting portion are integrally formed with the radial limiting portion.

7. The reactor as described in claim 1, characterized in that, The inner wall at the bottom of the housing has a recess, and the prefabricated magnetic core is installed in the recess.

8. The reactor as described in claim 1, characterized in that, The prefabricated magnetic core is bonded to the housing.

9. The reactor as described in claim 1, characterized in that, The coil includes a conductor and a first insulating layer wrapped around the outer periphery of the conductor at least at the winding portion, and the reactor further includes a second insulating layer covering the surface of the first insulating layer.

10. The reactor as claimed in claim 1, characterized in that, Also includes: Multiple heat dissipation teeth are disposed on the outer surface of the housing, wherein the positions of the heat dissipation teeth correspond to the positions of the prefabricated magnetic core.

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