A dual-channel PFC inductor

Abstract

This invention discloses a dual-path PFC inductor, comprising a magnetic core symmetrically assembled from two bases, a frame embedded in the magnetic core, and a stranded coil wound on the frame. The bases have a first main core and a second main core protruding from left to right, both of which are circular. A first side wing and a second side wing are respectively provided on both sides of the base, and a third side wing is provided between the first and second main cores. An opening slot is formed between the first, second, and third side wing. Magnetic pillars and epoxy board gaskets are arranged sequentially from top to bottom within the frame, and an epoxy base plate is provided at the bottom of the base. This dual-path PFC inductor, by setting two main cores on the base and I-shaped magnetic pillars inside the frame, achieves a large inductance under idle, light, or full load conditions, thus improving the working efficiency of the PFC inductor.

Description

Technical Field

[0001] This invention relates to the field of inductor technology, and more specifically to a dual-channel PFC inductor. Background Technology

[0002] PFC, or Power Factor Corrector, improves the utilization of mains power during AC-to-DC conversion, but it does not reduce energy loss during the conversion process. PFC is divided into active and passive types, and this is an important factor in determining its quality. The design of the PFC power inductor is particularly important, as it affects the inductor's operating efficiency.

[0003] Conventional PFC power inductors have low efficiency under idle or light load conditions and cannot achieve high efficiency under idle or light load conditions.

[0004] Based on the above, this invention proposes a dual-path PFC inductor, which can effectively solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a dual-path PFC inductor. The dual-path PFC inductor of this invention has a simple structure and is easy to use. By setting two main cores on the base and H-shaped magnetic pillars inside the frame, it can provide a large inductance under idle, light, or full load conditions, improving the working efficiency of the PFC inductor. Furthermore, the H-shaped magnetic pillars are segmented to even out the air gap, reducing eddy current losses in the nearby copper wires.

[0006] This invention is achieved through the following technical solution:

[0007] A dual-path PFC inductor includes a magnetic core symmetrically composed of two bases, a frame embedded in the magnetic core, and a stranded coil wound on the frame.

[0008] The base has a first main core and a second main core protruding from left to right. Both the first and second main cores are circular. The base has a first side wing and a second side wing on each side. A third side wing is located between the first and second main cores. An opening groove is formed between the first side wing, the second side wing and the third side wing. The frame has a magnetic column and an epoxy board gasket arranged from top to bottom. An epoxy base plate is located at the bottom of the base.

[0009] The purpose of this invention is to provide a dual-path PFC inductor. The dual-path PFC inductor of this invention has a simple structure and is easy to use. By setting two main cores on the base and H-shaped magnetic pillars inside the frame, it can provide a large inductance under idle, light, or full load conditions, improving the working efficiency of the PFC inductor. Furthermore, the H-shaped magnetic pillars are segmented to even out the air gap, reducing eddy current losses in the nearby copper wires.

[0010] Preferably, the magnetic column is I-shaped.

[0011] Preferably, the skeleton is cylindrical, and support plates are provided on both the upper and lower sides of the skeleton.

[0012] Preferably, the base has an inwardly recessed groove at the opening slot.

[0013] Preferably, the support plate is provided with a flange that matches the groove.

[0014] Preferably, the epoxy base plate has through holes.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0016] The purpose of this invention is to provide a dual-path PFC inductor. The dual-path PFC inductor of this invention has a simple structure and is easy to use. By setting two main cores on the base and H-shaped magnetic pillars inside the frame, it can provide a large inductance under idle, light, or full load conditions, improving the working efficiency of the PFC inductor. Furthermore, the H-shaped magnetic pillars are segmented to even out the air gap, reducing eddy current losses in the nearby copper wires. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention;

[0018] Figure 2 This is a schematic diagram of the exploded structure of the present invention. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solutions of the present invention, preferred embodiments of the present invention are described below in conjunction with specific examples. However, it should be understood that the accompanying drawings are for illustrative purposes only and should not be construed as limiting the present patent. For better illustration of this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable that some well-known structures and their descriptions may be omitted in the drawings for those skilled in the art. The positional relationships described in the drawings are for illustrative purposes only and should not be construed as limiting the present patent.

[0020] Example 1:

[0021] like Figures 1 to 2 As shown, a dual-path PFC inductor includes a magnetic core 1 symmetrically composed of two bases 11, a frame 2 embedded on the magnetic core 1, and a stranded coil 3, wherein the stranded coil 3 is wound on the frame 2.

[0022] The base 11 has a first main core 12 and a second main core 13 protruding from left to right. Both the first main core 12 and the second main core 13 are circular. The base 11 has a first side wing 14 and a second side wing 15 on both sides. A third side wing 16 is provided between the first main core 12 and the second main core 13. An opening groove 17 is formed between the first side wing 14, the second side wing 15 and the third side wing 16. The frame 2 has a magnetic column 4 and an epoxy board gasket 5 arranged from top to bottom. The bottom of the base 11 located below is provided with an epoxy base plate 6.

[0023] Example 2:

[0024] like Figures 1 to 2 As shown, a dual-path PFC inductor includes a magnetic core 1 symmetrically composed of two bases 11, a frame 2 embedded on the magnetic core 1, and a stranded coil 3, wherein the stranded coil 3 is wound on the frame 2.

[0025] The base 11 has a first main core 12 and a second main core 13 protruding from left to right. Both the first main core 12 and the second main core 13 are circular. The base 11 has a first side wing 14 and a second side wing 15 on both sides. A third side wing 16 is provided between the first main core 12 and the second main core 13. An opening groove 17 is formed between the first side wing 14, the second side wing 15 and the third side wing 16. The frame 2 has a magnetic column 4 and an epoxy board gasket 5 arranged from top to bottom. The bottom of the base 11 located below is provided with an epoxy base plate 6.

[0026] The stranded coil 3 uses 0.1*60P stranded wire, which reduces copper loss caused by the skin effect and improves product efficiency.

[0027] Furthermore, in another embodiment, the magnetic column 4 is in the shape of an I-beam.

[0028] The magnetic column 4 adopts an "I"-shaped magnetic column design. Under light load, the "I"-shaped magnetic column 4 is unsaturated and can provide a large inductance. However, under full load output, the middle part of the "I"-shaped magnetic column 4 saturates first, thereby increasing the magnetic resistance of the "I"-shaped magnetic column 4 and improving the anti-saturation capability. It is equivalent to the product having two air gaps under light load, while under full load, due to the saturation of the middle part of the "I"-shaped magnetic column and the increase in magnetic resistance, it is equivalent to having an additional air gap, that is, three air gaps under full load.

[0029] By using a segmented approach to average the air gap, the eddy current loss of the air gap on the nearby copper wires is reduced.

[0030] Furthermore, in another embodiment, the skeleton 2 is cylindrical, and support plates 21 are provided on both the upper and lower sides of the skeleton 2.

[0031] Furthermore, in another embodiment, the base 11 is provided with a groove 18 inwardly at the opening slot 17.

[0032] Setting the groove 18 can reduce the overall weight of the inductor and save materials.

[0033] Furthermore, in another embodiment, the support plate 21 is provided with a flange 211 that matches the groove 18.

[0034] The flange 211 is designed to facilitate the matching and installation of the frame 2 and the magnetic core 1.

[0035] Furthermore, in another embodiment, the epoxy base plate 6 has a through hole 61.

[0036] The through hole 61 facilitates the passage of the leads of the stranded coil 3 for connection to the outside.

[0037] Based on the description and accompanying drawings of this invention, those skilled in the art can readily manufacture or use the dual-channel PFC inductor of this invention and achieve the positive effects described herein.

[0038] Unless otherwise specified, in this invention, terms such as "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe orientation or positional relationships in this invention are for illustrative purposes only and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood in conjunction with the accompanying drawings and according to the specific circumstances.

[0039] Unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" in this invention should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0040] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A dual-channel PFC inductor, characterized in that: It includes a magnetic core composed of two symmetrically combined bases, a frame embedded in the magnetic core, and a stranded coil wound on the frame; The base has a first main core and a second main core protruding from left to right. Both the first and second main cores are circular. The base has a first side wing and a second side wing on each side. A third side wing is located between the first and second main cores. An opening groove is formed between the first side wing, the second side wing and the third side wing. The frame has a magnetic column and an epoxy board gasket arranged from top to bottom. The bottom of the base is provided with an epoxy base plate. The magnetic column is I-shaped; The frame is cylindrical, and support plates are provided on both the upper and lower sides of the frame. The base has an inward groove at the opening slot; The support plate is provided with a flange that matches the groove; The epoxy base plate has through holes.

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