A high thermal conductivity automotive power inductor and its assembly method

Abstract

The application discloses a high-heat-conductivity power inductor for vehicle, which comprises magnetic cores, coils arranged between the two magnetic cores, and heat-conducting sheets arranged on the ground of the coils and the magnetic cores. The coils are in flat spiral structure, and the coil cable is in flat structure. In the application, the coils are arranged in flat spiral structure, the upper and lower surfaces of the coils have a large number of plane areas, the heat-conducting sheets are arranged on the ground of the coils and the magnetic cores, the heat-dissipating capacity of the surface of the magnetic cores is fully utilized, the surface of the magnetic cores is attached to the radiator of the vehicle body, the heat-dissipating capacity of the product is further improved, the current density of the coil section is improved under the condition of constant temperature rise, the conductor section area is small, and the product volume is reduced. When the product is in horizontal structure, the gravity center is low, the stress of the product connecting point is reduced, when the product is in vertical structure, the product occupies a small area, and the space utilization rate of the vehicle body is improved.

Description

Technical Field

[0001] This invention relates to a high thermal conductivity automotive power inductor and its assembly method. Background Technology

[0002] Because automotive products have long service life and operate in harsh environments (vibration, temperature, humidity, salt spray, altitude, etc.), they have stringent safety and reliability requirements. In addition, with the increasing informatization and intelligence of automobiles, more and more system assemblies need to be installed in a limited space. This requires our components to have a lower center of gravity, stronger heat dissipation performance, and smaller installation space.

[0003] The heat generated by existing horizontal and vertical power inductors mainly comes from the conductor coil. There is air between the coil and the magnetic core. Both air and the plastic base have poor thermal conductivity. The heat generated by the coil is conducted to the PCB board and the enclosed heat radiation through the conductor, resulting in poor heat dissipation. In order to ensure that the product's operating temperature is within the specified range, it is difficult to achieve a high conductor length, which makes it difficult to reduce the cross-sectional area of ​​the product, thus making it difficult to reduce the product's size and weight. Moreover, with one layer of coil winding, the coil height is high, the product height is high, and the product's center of gravity is high. In the automotive environment, the pins are easily damaged, resulting in low product reliability. In addition, the product has a large installation area and occupies a lot of PCB installation space. Summary of the Invention

[0004] The purpose of this invention is to provide a high thermal conductivity automotive power inductor and its assembly method, which solves the problem of poor heat dissipation performance of existing inductors.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A high thermal conductivity automotive power inductor includes two magnetic cores, with a coil disposed between the two magnetic cores. The coil has a flat helical structure, and the coil cable has a flat structure.

[0007] As a further description of the above technical solution:

[0008] A heat-conducting plate is embedded on the inner side of one of the two magnetic cores that is in contact with the external heat sink. No heat-conducting plate is provided in the inductor with low coil operating current and low power loss. A through slot is opened at the center of the heat-conducting plate.

[0009] As a further description of the above technical solution:

[0010] Each magnetic core has a slot on the side near the coil, and a cylindrical limiting post is fixedly connected to the magnetic core at the middle position of the slot. The limiting post is slidably fitted with the heat-conducting sheet and the coil.

[0011] As a further description of the above technical solution:

[0012] When the inductor is a vertical power inductor, the two free ends of the coil are arranged vertically, and a base that is fixedly connected to the magnetic core is provided below the coil.

[0013] As a further description of the above technical solution:

[0014] When the inductor is a horizontal power inductor, the two free ends of the coil are bent vertically downwards.

[0015] As a further description of the above technical solution:

[0016] A method for assembling a high thermal conductivity automotive power inductor includes the following steps:

[0017] Step 1: Manufacturing flat coils with flat wire;

[0018] A) Winding a tower-shaped flat wire coil;

[0019] B) Pressing and shaping into flat wire flat coils;

[0020] Step Two: Assembly of Horizontal Structure Products;

[0021] A) Install the heat-conducting plate into the slot of the magnetic core;

[0022] B) Spot adhesive;

[0023] C) Install the flat wire coil into the slot of the magnetic core;

[0024] D) Press the upper magnetic core with the heat-conducting plate onto the magnetic core with the coil installed;

[0025] E) Clamp the magnetic core and cure;

[0026] Step 3: Assemble the vertical structure product;

[0027] A) Install the heat-conducting plate into the slot of the magnetic core;

[0028] B) Spot adhesive;

[0029] C) Install the flat wire coil into the slot of the magnetic core;

[0030] D) Press the upper magnetic core with the heat-conducting plate onto the magnetic core with the coil, and install the base.

[0031] E) Clamp the magnetic core and cure it.

[0032] As a further description of the above technical solution:

[0033] If the paint film is damaged during the molding process in step one, it shall be repaired in the following ways;

[0034] a) During the pressing, shaping and feeding process, self-adhesive sheets can be inserted between the layers of the tower-shaped coil. The self-adhesive sheets can be hot-melt self-adhesive sheets or alcohol-soluble self-adhesive sheets to increase the insulation between the layers and prevent the springback gap between the layers from being too large.

[0035] b) Repair the insulation layer by dipping the coil in insulating varnish and then baking it dry;

[0036] c) Coil coating is performed using either hot-melt film coating or adhesive film coating.

[0037] As a further description of the above technical solution:

[0038] The heat-conducting sheet is made of thermally conductive silicone sheet, thermally conductive phase change sheet, or thermally conductive paste.

[0039] As a further description of the above technical solution:

[0040] If there is excess adhesive after the magnetic core is installed in steps two and three, it must be cleaned thoroughly.

[0041] As a further description of the above technical solution:

[0042] In steps two and three, the curing method is determined by the adhesive properties and can be baking, room temperature moisture absorption curing, or solvent evaporation curing.

[0043] The present invention has at least the following beneficial effects:

[0044] By setting the coil into a flat spiral structure, the upper and lower surfaces of the coil have a large amount of planar area. Combined with the heat-conducting sheet between the coil and the magnetic core ground, the heat dissipation capacity of the magnetic core surface is fully utilized. The magnetic core surface is attached to the radiator of the vehicle body, which further improves the heat dissipation performance of the product. Under the condition of a certain temperature rise, the current density of the coil cross section is increased, thereby achieving a smaller conductor cross-sectional area and reducing the product volume.

[0045] By using flat wire and flat coils, the height of the coil is reduced. When the product adopts a horizontal structure, the center of gravity is lower. In the complex working environment of the vehicle body, the stress on the product connection points is reduced, improving durability. When the product adopts a vertical structure, the assembly area is smaller, increasing the space utilization rate inside the vehicle body.

[0046] The product adopts a flat structure with a smaller magnetic leakage window, which reduces electromagnetic interference to surrounding components. Attached Figure Description

[0047] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0048] Figure 1 An exploded view of a horizontal inductor provided according to an embodiment of the present invention is shown;

[0049] Figure 2 An exploded view of a vertical inductor provided according to an embodiment of the present invention is shown;

[0050] Figure 3 A diagram of a tower-shaped coil structure according to an embodiment of the present invention is shown;

[0051] Figure 4 A diagram of a flat coil structure provided according to an embodiment of the present invention is shown;

[0052] Figure 5 A dispensing location diagram according to an embodiment of the present invention is shown.

[0053] In the diagram: 1. Coil; 2. Magnetic core; 201. Limiting post; 3. Heat-conducting plate; 301. Through slot; 4. Slot; 5. Base. Detailed Implementation

[0054] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0055] Example 1

[0056] Reference Figure 1-5 A high thermal conductivity automotive power inductor includes a magnetic core 2, of which two magnetic cores 2 are provided. A coil 1 is provided between the two magnetic cores 2. The coil 1 has a flat spiral structure and the coil 1 cable has a flat structure. A heat-conducting plate 3 is embedded on the inner side of one of the two magnetic cores 2 that is in contact with an external heat sink. In an inductor with low operating current and low power loss of coil 1, no heat-conducting plate 3 is provided. A through slot 301 is opened at the center of the heat-conducting plate 3. A slot 4 is opened on the side of the magnetic core 2 near the coil 1. A cylindrical limiting post 201 is fixedly connected to the magnetic core 2 at the middle position of the slot 4. The limiting post 201 slides into the heat-conducting plate 3 and the coil 1. When the inductor is a vertical power inductor, the two free ends of the coil 1 are vertically arranged, and a base 5 fixedly connected to the magnetic core 2 is provided below the coil 1.

[0057] A method for assembling a high thermal conductivity automotive power inductor includes the following steps:

[0058] Step 1: Manufacturing flat coils with flat wire;

[0059] A) Winding a tower-shaped flat wire coil, the tower-shaped flat wire coil as follows: Figure 3 As shown;

[0060] B) Pressing and shaping into a flat wire coil. After pressing, the coil is inserted... Figure 4 As shown;

[0061] If the paint film is damaged during the molding process, it can be repaired in the following ways;

[0062] a. When pressing, shaping and feeding, self-adhesive sheets can be inserted between the layers of the tower-shaped coil. The self-adhesive sheets are hot-melt self-adhesive sheets or alcohol-soluble self-adhesive sheets to increase the insulation between the layers and prevent the springback gap between the layers from being too large.

[0063] b. After impregnating the coil with insulating varnish, bake it dry to repair the insulation layer;

[0064] c. Coil coating is performed using either film hot-melt coating or adhesive film bonding.

[0065] Step Two: Assemble the vertical structure product;

[0066] A) Install the heat-conducting sheet into the slot of the magnetic core. The heat-conducting sheet is made of thermally conductive silicone sheet, thermally conductive phase change sheet or thermally conductive paste.

[0067] B) Apply adhesive, the application location is as follows: Figure 5 ;

[0068] C) Install the flat wire coil into the slot of the magnetic core;

[0069] D) Press the upper magnetic core with the heat-conducting plate onto the magnetic core with the coil, and install the base. If there is excess glue, clean it thoroughly.

[0070] E) Clamp the magnetic core and cure it. Depending on the properties of the adhesive, use baking, room temperature moisture absorption curing or solvent evaporation curing methods.

[0071] Example 2

[0072] Reference Figure 1-5 A high thermal conductivity automotive power inductor includes a magnetic core 2, of which two magnetic cores 2 are provided. A coil 1 is provided between the two magnetic cores 2. The coil 1 has a flat spiral structure and the coil 1 cable has a flat structure. A heat-conducting plate 3 is embedded on the inner side of one of the two magnetic cores 2 that is in contact with an external heat sink. In an inductor with low operating current and low power loss of coil 1, the heat-conducting plate 3 is not provided. A through slot 301 is opened at the center of the heat-conducting plate 3. A slot 4 is opened on the side of the magnetic core 2 near the coil 1. A cylindrical limiting post 201 is fixedly connected to the magnetic core 2 at the middle position of the slot 4. The limiting post 201 slides and engages with the heat-conducting plate 3 and the coil 1. When the inductor is a horizontal power inductor, the two free ends of the coil 1 are bent vertically downward.

[0073] A method for assembling a high thermal conductivity automotive power inductor includes the following steps:

[0074] Step 1: Manufacturing flat coils with flat wire;

[0075] A) Winding a tower-shaped flat wire coil, the tower-shaped flat wire coil as follows: Figure 3 As shown;

[0076] B) Pressing and shaping into a flat wire coil. After pressing, the coil is inserted... Figure 4 As shown;

[0077] If the paint film is damaged during the first step of the molding process, it can be repaired in the following ways;

[0078] a. When pressing, shaping and feeding, self-adhesive sheets can be inserted between the layers of the tower-shaped coil. The self-adhesive sheets are hot-melt self-adhesive sheets or alcohol-soluble self-adhesive sheets to increase the insulation between the layers and prevent the springback gap between the layers from being too large.

[0079] b. After impregnating the coil with insulating varnish, bake it dry to repair the insulation layer;

[0080] c. Coil coating: Step 2: Assembly of horizontal structure products is carried out by using thin film hot melt coating or adhesive film coating.

[0081] A) Install the heat-conducting sheet into the slot of the magnetic core. The heat-conducting sheet is made of thermally conductive silicone sheet, thermally conductive phase change sheet or thermally conductive paste.

[0082] B) Apply adhesive, the application location is as follows: Figure 5 ;

[0083] C) Install the flat wire coil into the slot of the magnetic core;

[0084] D) Press the upper magnetic core with the heat-conducting plate onto the magnetic core with the coil. If there is excess glue after installation, it needs to be cleaned.

[0085] E) Clamp the magnetic core and cure it. Depending on the properties of the adhesive, use baking, room temperature moisture absorption curing or solvent evaporation curing methods.

[0086] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A high heat conductive performance power inductor for vehicle, comprising magnetic cores (2), the magnetic cores (2) are provided with two, characterized in that, Two said magnetic core (2) between the coil (1) is provided with, the coil (1) is flat spiral structure, and the coil (1) cable is flat structure; One of the two said magnetic core (2) is inlaid with a heat conduction sheet (3) on the inner side adhered to the external heat sink, the coil (1) is not provided with a heat conduction sheet (3), and a through hole (301) is formed in the center position of the heat conduction sheet (3); The assembling method of the vehicle power inductor comprises the following steps: Step one: flat wire flat coil manufacturing: A), winding tower-shaped flat wire coil; B), pressing and forming flat wire flat coil; Step two: horizontal structure product assembly: A), the heat conduction sheet is installed in the clamping groove of the magnetic core; B), point bonding glue; C), the flat wire flat coil is installed in the clamping groove of the magnetic core; D), the magnetic core with the heat conduction sheet is pressed on the magnetic core with the coil; E), clamp the magnetic core and solidify; Or vertical structure product assembly: A), the heat conduction sheet is installed in the clamping groove of the magnetic core; B), point bonding glue; C), the flat wire flat coil is installed in the clamping groove of the magnetic core; D), the magnetic core with the heat conduction sheet is pressed on the magnetic core with the coil, and the base is installed; E), clamp the magnetic core and solidify; When pressing and shaping, a self-adhesive sheet is inserted between the layers of the tower-shaped coil, the self-adhesive sheet is a hot melt self-adhesive sheet or an alcohol-soluble self-adhesive sheet, the insulation between the layers is increased, and the rebound gap between the layers is prevented from being too large.

2. The high thermal conductivity power inductor for vehicle according to claim 1, wherein The clamping groove (4) is formed in the side of the magnetic core (2) close to the coil (1), the middle position of the clamping groove (4) is fixedly connected with a cylindrical limiting column (201) of the magnetic core (2), and the limiting column (201) is slidably embedded with the heat conduction sheet (3) and the coil (1).

3. The high thermal conductivity power inductor for automotive use according to claim 1, characterized in that, When the inductor is a vertical power inductor, the two free ends of the coil (1) are vertically arranged, and a base (5) fixedly connected with the magnetic core (2) is arranged below the coil (1).

4. The high thermal conductivity power inductor for automotive use according to claim 1, characterized in that, When the inductor is a horizontal power inductor, the two free ends of the coil (1) are vertically downward curved.

5. The high thermal conductivity power inductor for automotive use according to claim 1, characterized in that, The heat conduction sheet is made of heat conduction silica gel sheet, heat conduction phase change sheet or heat conduction paste material.

6. The high thermal conductivity power inductor for automotive use according to claim 1, characterized in that, When there is overflow glue after the magnetic core is installed in step two, it needs to be cleaned.

7. The high thermal conductivity power inductor for automotive use according to claim 1, characterized in that, In step two, the solidification method is selected according to the characteristics of the glue, such as baking, normal temperature moisture curing or solvent evaporation curing.

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