Inductor with temperature detection

Abstract

The application discloses an inductor with temperature detection, which mainly comprises a magnetic core (1), a coil (2) and a temperature sensor (5). The magnetic core (1) is in a ring structure and is provided with two winding sections, at least one of which is provided with a groove. The coil (2) is wound around the winding section, and an expansion channel is formed between the inner side of the coil (2) and the groove on the winding section. The temperature sensor (5) comprises a sensing part (51) and a lead wire (52), and is arranged in the expansion channel. The sensing part (51) is in contact with the inner side of the coil (2) and is used for sensing the temperature of the coil (2) to generate a temperature signal. The lead wire (52) is connected with the sensing part (51) and is arranged along the expansion channel and is used for outputting the temperature signal.

Description

Technical Field

[0001] This application relates to the technical field of inductors, and more specifically to an inductor with temperature detection. Background Technology

[0002] In the design of high-power molded inductors, to achieve good heat dissipation of the inductor coil, the outer surface of the inductor coil can be completely exposed. Other methods include oil cooling, water cooling with the bottom or sides of the coil in close contact with a water-cooled plate, or potting with high thermal conductivity. These are all extremely important heat dissipation design methods. During operation, the heating of the inductor coil and internal magnetic core causes the overall temperature of the inductor to rise. To accurately detect and control the inductor's operating temperature, temperature sensing devices such as thermistors need to be installed on the surface of the inductor coil for temperature detection.

[0003] To accurately measure the surface temperature of an inductor coil, the temperature sensor must be installed in close contact with the heating element on the coil's surface. However, in practical applications, because inductors are made of multiple turns of enameled copper wire wound side-by-side, uneven pits exist between the copper wires on the coil surface. Conventional temperature sensors have air gaps at the contact surface with the coil. To achieve good thermal conductivity between the sensor and the coil surface, a highly thermally conductive gap material, such as a thermally conductive silicone sheet, needs to be filled between them. Currently, the assembly method of temperature sensors and inductors still has some problems, which may lead to inaccurate temperature sensing, and the use of excessive thermally conductive materials increases the difficulty of the process and manufacturing costs.

[0004] In some applications, such as in-vehicle applications in new energy vehicles, temperature sensors must also have good resistance to mechanical shock and vibration. In applications requiring oil cooling, the temperature sensor, thermally conductive silicone pads, and other materials must also have long-term resistance to ATF oil corrosion. Therefore, temperature sensors mounted on the coil surface require a complex and costly mounting structure, further complicating the structure of high-power inductors. Summary of the Invention

[0005] Technical issues

[0006] The main technical problem addressed in this application is how to improve the detection accuracy and reliability of temperature sensors in inductors.

[0007] Solution

[0008] To address the aforementioned technical problems, this application provides an inductor with temperature detection capabilities.

[0009] In one embodiment, the inductor with temperature detection includes a magnetic core, a coil, and a temperature sensor; the magnetic core has a ring-shaped structure and two winding sections, at least one of which has a groove; the coil is wound around the winding section, and an extended channel is formed between the inner surface of the coil and the groove on the winding section; the temperature sensor includes a sensing part and a lead wire, and the temperature sensor is disposed within the extended channel; wherein the sensing part contacts the inner surface of the coil and is used to sense the temperature of the coil to generate a temperature signal; the lead wire is connected to the sensing part and is arranged along the extended channel for outputting the temperature signal.

[0010] The inductor also includes a sensor base located within the expansion channel, the surface of which has a recess; a portion of the sensing part is engaged within the recess, and another portion of the sensing part protrudes from the recess and contacts the inner side of the coil.

[0011] The sensor base has a pipe or opening on one side leading to the recess, and the lead wire is connected to the sensing part in the recess through the pipe or the opening; the width of the pipe or the opening is smaller than the width of the recess, so that the sensing part cannot fall out of the pipe or the opening.

[0012] The inductor further includes a terminal block and a spring plate; the terminal block is disposed at the entrance of the expansion channel; one end of the spring plate is connected to the terminal block, and the other end of the spring plate is connected to the sensor base; the spring plate is used to adjust the position of the sensor base relative to the inner side of the coil by its own deformation, so that the sensor base can provide the sensing part with pressure that is always in contact with the inner side of the coil.

[0013] The terminal block is provided with at least one lead terminal; the lead is laid on the surface of the elastic plate and extends along the elastic plate to the terminal block, and the lead is connected to the lead terminal; the lead terminal is used to connect to an external signal line to transmit the temperature signal to the signal line.

[0014] The inductor further includes an external mounting base, on which at least one external terminal is provided for connecting the signal line; the external mounting base is detachably connected to the terminal block, and the external terminal is electrically connected to the lead terminal.

[0015] The magnetic core includes two first components and multiple second components; the two first components are arranged opposite each other, and each second component is arranged in two parallel columns between the two first components, and all the first components and second components are combined to form a ring structure of the magnetic core; the outer surface of the second component is used as the winding portion.

[0016] The inductor also includes multiple fixing brackets, which are fixed around the first component; the fixing brackets are provided with snap-fit ​​components, the inner side of which snaps into the second component, and the outer side of which supports the coil; the terminal block is fixed on the fixing brackets, and the elastic plate extends from the terminal block into the expansion channel.

[0017] The fixed bracket is provided with at least one hole, and the terminal block is provided with at least one pin; the pin and the hole are fitted together to fix the terminal block on the fixed bracket.

[0018] The inductor further includes an injection-molded body; an injection gap is formed between the inner side of the coil and the outer side of the second component, and the injection gap communicates with the expansion channel; the injection-molded body extends along the expansion channel to the surrounding injection gap and fills the expansion channel and the injection gap.

[0019] The injection-molded body encloses the first component and forms an assembly portion around the first component; the assembly portion is used to install and fix the integrated molded body composed of the injection-molded body, the magnetic core and the coil.

[0020] The assembly part is provided with a ribbon cable, which is connected to the tail terminal of the coil and is used to introduce or lead direct current into or out of the coil. Beneficial effects

[0021] The beneficial effects of this application are: An inductor with temperature detection according to the above embodiment mainly includes a magnetic core, a coil, and a temperature sensor; the magnetic core has a ring structure and is provided with two winding sections, at least one of which has a groove; the coil is wound around the winding section, and an extended channel is formed between the inner side of the coil and the groove on the winding section; the temperature sensor includes a sensing part and a lead wire, and the temperature sensor is disposed in the extended channel; wherein, the sensing part is in contact with the inner side of the coil and is used to sense the temperature of the coil to generate a temperature signal; the lead wire is connected to the sensing part and is arranged along the extended channel for outputting the temperature signal. On the one hand, the technical solution proposes a method of embedding the temperature sensor inside the inductor. This not only enables accurate measurement of the inductor coil temperature but also provides excellent resistance to high-intensity mechanical vibration and shock, as well as superior oil resistance, thereby effectively controlling the overall cost of fixing the temperature sensor on the inductor. On the other hand, the technical solution adopts an embedded approach, placing the sensor element inside the inductor and in close contact with the inner surface of the coil. This greatly improves the accuracy of temperature measurement and allows the sensor to be firmly embedded inside through an integrated injection molding process, achieving numerous positive effects such as low cost, high reliability, high precision, fast response, and high product quality. Attached Figure Description

[0022] Figure 1 This is an overall structural diagram of an inductor with temperature detection in one embodiment of this application; Figure 2 This is a disassembly diagram of an inductor; Figure 3 This is a schematic diagram of an inductor explosion. Figure 4 This is a schematic diagram of the assembly of the temperature sensor and the magnetic core. Figure 5 This is a structural diagram of the temperature sensor and its wiring. Figure 6 This is a schematic diagram showing the installation and assembly of the sensor mounting assembly and the coil. Detailed Implementation

[0023] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments. Similar elements in different embodiments are referred to by related similar element reference numerals. In the following embodiments, many details are described to facilitate a better understanding of the present application. However, those skilled in the art will readily recognize that some features may be omitted in different situations, or may be replaced by other elements, materials, or methods. In some cases, certain operations related to the present application are not shown or described in the specification. This is to avoid obscuring the core parts of the present application with excessive description. For those skilled in the art, detailed description of these related operations is not necessary; they can fully understand the related operations based on the description in the specification and general technical knowledge in the art.

[0024] Furthermore, the features, operations, or characteristics described in the specification can be combined in any suitable manner to form various embodiments. At the same time, the steps or actions in the method description can be rearranged or adjusted in a manner obvious to those skilled in the art. Therefore, the various orders in the specification and drawings are only for the clear description of a particular embodiment and do not imply a necessary order, unless otherwise stated that a particular order must be followed.

[0025] The serial numbers assigned to components in this document, such as "first" and "second," are used only to distinguish the described objects and have no sequential or technical meaning. The terms "connection" and "linkage" used in this application, unless otherwise specified, include both direct and indirect connections (linkages).

[0026] Please refer to Figures 1 to 6 This embodiment discloses an inductor with temperature detection, which mainly includes a magnetic core 1, a coil 2 and a temperature sensor 5, which are described below.

[0027] The magnetic core 1 has a ring-shaped structure with two winding sections, at least one of which has a groove. The ring-shaped structure of the magnetic core 1 can be a closed ring or a partially closed ring composed of multiple components. To facilitate winding on the winding sections, it is preferable to use at least one of the required components to form the winding sections. Furthermore, since each winding section needs to be surrounded by a coil 2, and the magnetic core 1 needs to generate an electromagnetic loop when the coil 2 is energized, it is preferable to have winding sections on opposite sides of the ring-shaped structure, thereby ensuring a uniform distribution of the generated electromagnetic loops.

[0028] The number of coils 2 is at least two, for example, a flat vertically wound coil. Each coil 2 is wound around a winding section, so an expansion channel can be formed between the inner side of the coil 2 and the groove on the winding section. The function of the expansion channel is to assemble the temperature sensor 5. Of course, in some cases, since the magnetic core 1 and coil 2 need to be integrated with the injection molding material, the expansion channel here can also be used to fill high-temperature plastic melts (such as high-temperature flowable melts of engineering plastics such as PPS, as well as PET, epoxy resin, nylon, etc.).

[0029] The temperature sensor 5 can employ a heat-sensitive element (such as an NTC thermistor) to sense temperature changes, and it may include a sensing part 51 and a lead wire 52. Here, the temperature sensor 5 is disposed within an extended channel; wherein, the sensing part 51 contacts the inner surface of the coil 2 to sense the temperature of the coil 2 and generate a temperature signal; the lead wire 52 is connected to the sensing part 51 and is arranged along the extended channel to output the temperature signal generated by the sensing part 51.

[0030] It should be noted that the temperature sensor 5 can be a spherically encapsulated thermistor temperature sensor element. Its sensing part 51 can be spherical, non-circular, elliptical, or even square, trapezoidal, or other shapes.

[0031] In one embodiment, for the two winding sections on the magnetic core 1, the grooves on the winding sections extend to at least one end of the winding section, exceeding the coverage area of ​​the coil on the winding section. This has two advantages: firstly, it facilitates the insertion of the temperature sensor along the groove into the extended channel between the coil and the winding section; secondly, it facilitates the smooth entry of the high-temperature molten plastic into the extended channel along the groove outside the coverage area during injection molding. It is understood that, generally, the grooves on the winding section only need to meet the assembly requirements of the temperature sensor 5 in terms of width and depth. For example, the grooves can extend vertically or curvedly on the winding section, and the cross-section of the grooves can be trapezoidal, arc-shaped, or square. However, if the grooves are to also accommodate injection molding filling, the grooves also need to meet certain width and depth requirements for smooth injection molding.

[0032] It should be noted that the grooves on the winding section inevitably alter the cross-sectional shape of the magnetic core, which will affect the magnetic flux density on the core. In order not to significantly change the inductance characteristics and magnetic flux density, the depth and width of the grooves can be limited. This ensures that the groove cross-section is as small as possible while also ensuring that injection molding is completed under relatively low injection pressure. For example, the groove depth can be set to a range of 1 to 5 mm, and the groove width can be set to a range of 3 to 15 mm. Furthermore, at any cross-section of the winding section, the preset percentage of the cross-sectional area of ​​the winding section is greater than the cross-sectional area of ​​all the grooves.

[0033] In one embodiment, see Figure 5 and Figure 6 To facilitate the mounting of the temperature sensor 5 within the expansion channel, the inductor also includes a sensor mounting assembly 6, which carries the temperature sensor 5 and places the carried temperature sensor 5 within the expansion channel, such that the temperature sensor 5 contacts the inner side of the coil 2.

[0034] In one specific embodiment, the sensor mounting assembly 6 includes a sensor base 61 disposed within an expansion channel, and the surface of the sensor base 61 has a recess 611 for mounting the temperature sensor 5. To ensure the temperature sensor 5 is securely mounted within the recess 611, a portion of the sensing part 51 of the temperature sensor 5 is snapped into the recess, while another portion of the sensing part 51 protrudes from the recess 611 and contacts the inner side of the coil 2. For example, the mounting depth of the sensing part 51 within the recess 611 is less than the height of the sensing part 51 but greater than half the height of the sensing part 51. This prevents the sensing part 51, with its core structure, from easily detaching after being placed in the recess 611.

[0035] Furthermore, one side of the sensor base 61 is provided with a conduit or opening leading to the recess 611. A conduit refers to a concealed pipe structure leading to the recess 611, while an opening refers to an open trench structure leading to 611, such as... Figure 5 The opening 612 in the recess. Then, the lead 52 of the temperature sensor 5 is connected to the sensing part 51 in the recess 611 through the pipe or opening. It can be understood that the width of the pipe or opening on the sensor base 61 should be smaller than the width of the recess 611 so that the sensing part 51 cannot fall off the pipe or opening.

[0036] In some cases, the recess 611 on the sensor base 61 can adopt a structure that is narrow at the top and tight at the bottom, thus ensuring that the lower part of the sensing part 51 can be firmly locked into the recess 611. Alternatively, adhesive can be used inside the recess 611 to bond the lower part of the sensing part 51 to the recess 611. For example, the recess 611 can be surrounded on three sides (left, right, and top), with the rear narrowing notch only slightly larger than the lead wire space and smaller than the spherical diameter of the sensing part 51, making it difficult for the temperature sensor 5 to escape from any direction after insertion.

[0037] In one specific embodiment, see Figure 5 and Figure 6 The sensor mounting assembly 6 includes not only the sensor base 61, but also a terminal block 63 and a spring plate 62. The terminal block 63 is located at the entrance of the expansion channel and is used to export the temperature signal output from the lead 52 of the temperature sensor 5 via the provided wiring terminals. One end of the spring plate 62 is connected to the terminal block 63, and the other end is connected to the sensor base 61. The spring plate 62 is used to adjust the position of the sensor base 61 relative to the inner surface of the coil 2 through its own deformation, so that the sensor base 61 can provide pressure to the sensing part 51 to always be in contact with the inner surface of the coil 2.

[0038] It should be noted that the elastic plate 62 can adopt a long thin plate structure, with the thickness of the thin plate being less than 1 / 10 of the length of the thin plate of the sensing part 51, so that the upper and lower sides can produce a certain deformation without breaking when subjected to force.

[0039] It is understandable that the coil is made of multiple turns of enameled copper wire wound side by side. Therefore, there are uneven pits between the copper wires on the inner side of the coil. When the sensor base 61 can provide some pressure to the sensing part 51, it can ensure that the sensing part 51 of the temperature sensor 5 is always in contact with the inner side of the coil, and also ensure that the sensing part 51 can accurately sense and measure the temperature of the coil 2. For example Figure 6The elastic plate 62 adjusts the position of the sensor base 61 relative to the inner side of the coil 22 by its own deformation, so that the sensor base 61 can provide pressure to the sensing part 51 that is always in contact with the inner side of the coil 22, thereby making the sensing part 51 of the temperature sensor 5 always in contact with the inner side of the coil 22.

[0040] It is understandable that the temperature sensor is placed inside the inductor using an internal method. This allows for accurate measurement of the inductor coil temperature, while the internal method also helps the temperature sensor to resist high-intensity mechanical vibration and shock, and has excellent oil resistance. This effectively controls the overall cost of fixing the temperature sensor on the inductor.

[0041] Furthermore, since the terminal block 63 is used to transmit the temperature signal output from the lead 52 of the temperature sensor 5 through the wiring terminals, the terminal block 63 should be equipped with at least one lead terminal, such as lead terminals 631 and 632. For details, please refer to [reference needed]. Figure 5 and Figure 6 Furthermore, the lead 52 of the temperature sensor 5 is laid on the surface of the elastic plate 62 and extends along the elastic plate 62 to the terminal block 63. Since the lead 52 can be divided into an inlet and an outlet, the inlet and outlet can be connected to the lead terminals 631 and 632 respectively. One lead terminal provides DC power to the inlet, and the other lead terminal provides the output path for the temperature signal to the outlet. It should be noted that the lead terminals 631 and 632 are used to connect to external signal lines, thereby transmitting the temperature signal output by the lead 52 to the external signal lines.

[0042] In one embodiment, see Figure 5 To facilitate external transmission of the temperature signal, the inductor also includes an external mounting base 71, a signal line 72, and a signal connector 73. The external mounting base 71 has at least one external terminal, such as external terminals 711 and 712, which are used to connect the signal line 72. The external mounting base 71 is detachably connected to the terminal block 63. The external terminals 711 and 712 are electrically connected to the lead terminals 631 and 632, for example, external terminal 711 is soldered to lead terminal 631, and external terminal 712 is soldered to lead terminal 632, thus ensuring the stability of the electrical connection. Since the temperature signal is very weak, the signal line 72 can be a shielded cable, which is then connected to the signal connector 73. The signal connector 73 can be a quick-pluggable connector for easy connection to communication circuit boards.

[0043] Furthermore, the external mounting base 71 also has a through hole 713 for engaging screws or bolts, with the purpose of fixing the external mounting base 71 to the outside of the inductor, such as fixing the external mounting base 71 to the assembly part 33 of the injection molding body 3.

[0044] In one embodiment, see Figures 1 to 5 The magnetic core 1 is designed as a ring structure composed of multiple components, which facilitates assembly. The magnetic core 1 may include two first components (as shown in the attached figures 11 and 12) and multiple second components (as shown in the attached figures 13 and 14). The two first components 11 and 12 are arranged opposite each other, and the two second components 13 and 14 are arranged in two parallel rows between the two first components 11 and 12. All the first and second components combine to form the ring structure of the magnetic core 1. It should be noted that the second components 13 and 14 can be used as winding sections, with coil 21 wound around second component 13 and coil 22 wound around second component 14. It can be understood that since the second components 13 and 14 serve as winding sections, grooves can be provided on one of them and temperature sensor 5 can be mounted thereon, or grooves can be provided on both and temperature sensor 5 can be mounted thereon.

[0045] For example, all the first and second components combine to form the ring structure of magnetic core 1, as detailed in the reference. Figure 5 The first components 11 and 12 each have U-shaped openings, and the second components (i.e., 13 and 14) are arranged in two parallel rows between the openings of the two first components, thus forming a ring-shaped arrangement of the first components 11, 14, 12, and 13. See also... Figure 4 and Figure 5 The second component 13 has a groove 131, which forms an extension channel with the coil 21. The second component 14 has a groove 141, which forms an extension channel with the coil 22. Therefore, it can be understood that, in one scenario, the temperature sensor 5 can be placed within the extension channel formed between the groove 141 and the coil 22, or within the extension channel formed between the groove 131 and the coil 21, or even two temperature sensors 5 can be deployed, each placed within a different extension channel.

[0046] It should be noted that for each of the second components 13 and 14, its outer surface includes one or more geometric surfaces, wherein several of these geometric surfaces are provided with grooves, and these grooves form an extended channel with the inner surface of the coil. Figure 4 Taking the magnetic core as an example, the second component 14 is a cuboid structure with six geometric surfaces. Two of these geometric surfaces need to be clearance-fitted with the openings of the first component 11 and the second component 12 and do not require coils. Therefore, grooves can be left on these two geometric surfaces. However, the remaining four geometric surfaces are used to surround the coils, so one or more grooves can be set on these four geometric surfaces respectively.

[0047] Furthermore, for each of the second components 13 and 14 forming the winding portion, the groove on the winding portion can extend to the outer surface of the first component, as detailed in [reference needed]. Figure 3 and Figure 4 The groove 131 on the second component 13 extends to the first components 11 and 12 to form grooves on the first components 11 and 12 respectively, and the groove 141 on the second component 14 extends to the first components 11 and 12 to form grooves on the first components 11 and 12 respectively. Therefore, after the first components 11 and 12 and the second components 13 and 14 are joined together, the grooves extending from all the components form a connected channel, facilitating the insertion of the temperature sensor 5 along this channel between the coil and the second component.

[0048] It should be noted that, for the ring structure of magnetic core 1, in order to achieve better inductance characteristics and magnetic flux density, the material of magnetic core 1 can be optimized. For example, the materials of the first components 11 and 12 and the second components 13 and 14 are all metal powders, and are made by pressing metal powders.

[0049] In one embodiment, since the magnetic core 1 is a ring-shaped structure formed by splicing the first components 11 and 12 and the second components 13 and 14, in order to achieve complete assembly between the components, the inductor device in this embodiment may further include multiple fixing brackets (as shown in reference numerals 41 and 42). Each fixing bracket is fixed around the corresponding first component, and the fixing bracket is provided with a snap-fit ​​component. The inner side of the snap-fit ​​component snaps into the second component, and the outer side of the snap-fit ​​component supports the coil. See also Figures 1 to 4 A fixing bracket 41 is fixed to the first component 11, and the fixing bracket 41 is provided with snap-fit ​​components 411 and 412. A fixing bracket 42 is fixed to the first component 12, and the fixing bracket 42 is provided with snap-fit ​​components 421 and 422. The inner sides of snap-fit ​​components 411 and 421 respectively snap-fit ​​the two ends of the second component 13, and the outer sides of snap-fit ​​components 411 and 421 respectively support the two ends of the coil 21, thereby fixing the second component 13 and the coil 21. The inner sides of snap-fit ​​components 412 and 422 respectively snap-fit ​​the two ends of the second component 14, and the outer sides of snap-fit ​​components 412 and 422 respectively support the two ends of the coil 22, thereby fixing the second component 14 and the coil 22.

[0050] It should be noted that the reference Figures 1 to 4Since the fixing bracket 41 can fix the second components 13 and 14 on the inside and the coils 21 and 22 on the outside, an injection gap can be formed between the inner side of coil 21 and the outer side of the second component 13, and also between the inner side of coil 22 and the outer side of the second component 14. The function of these injection gaps is to fill the injected molten plastic. Furthermore, to ensure smooth filling of the molten plastic within the injection gaps and to meet the requirement of minimizing the narrowness of the injection gaps, the gap distance can be set to a range of 0.5 to 3 mm.

[0051] In one embodiment, for each winding portion formed by the second component, a groove on the winding portion extends to the outer surface of the first component, forming an expansion inlet between the groove extending on the first component and the surrounding fixed bracket. This expansion inlet communicates with an expansion channel, through which a temperature sensor can be inserted into the expansion channel, and through which molten plastic can be injected into the expansion channel to form an injection-molded body. See details. Figures 1 to 4 The groove 141 on the second component 14 extends to the first component 11 to form a groove on the first component 11. An expansion inlet 142 will be formed between the groove formed on the first component 11 and the fixed bracket 41. The temperature sensor 5 can be inserted into the expansion channel along the expansion inlet 142.

[0052] In one embodiment, since an expansion inlet 142 is formed between the groove extending to the first component 11 and the fixing bracket 41, and the temperature sensor 5 is carried on the sensor mounting assembly 6, the terminal block 63 of the sensor mounting assembly 6 can be fixed to the fixing bracket 41, and the elastic plate 62 of the sensor mounting assembly 6 can enter through the expansion inlet 142 and extend from the terminal block 63 into the expansion channel. This completes the assembly of the sensor mounting assembly 6 and the temperature sensor 5 within the expansion channel.

[0053] In one specific embodiment, to facilitate fixing the terminal block 63 on the fixed bracket 41, at least one hole, such as hole 413 or 414, can be provided on the fixed bracket 41, and at least one pin, such as pin 633 or 634, can be provided on the terminal block 63. Then, pins 633 and 634 are connected to holes 413 and 414 respectively through transition fits, thereby fixing the terminal block 63 on the fixed bracket 41.

[0054] For example, pins 633 and 634 can both be cylindrical pins. After being assembled onto the mounting bracket 41, the pins fit tightly into the holes, and the pins always maintain a relatively stable height relative to the inner plane of the inductor coil. For details, please refer to... Figure 6Furthermore, the upper surface of the sensing part 51 of the temperature sensor 5 is at the same height as the inner plane of the coil 22, or slightly higher than the inner plane of the coil 22, so that the sensing part 51 is in close contact with the inner surface of the coil 22.

[0055] In one embodiment, to facilitate the protection and installation of the inductor, the inductor also includes an injection-molded body 3, which, together with the magnetic core 1, coil 2, mounting bracket 4, temperature sensor 5, and sensor mounting assembly 6, forms an integrated molded body. This integrated molded body can minimize the spatial distance between the coil 2 and the magnetic core 1 to ensure good electrical insulation. The extremely thin insulation distance also improves the outward thermal conductivity of the magnetic core 1, and the dense injection molding effect ensures the overall resistance of the inductor to mechanical vibration and shock. Of course, in addition to the body filling the space between the coil 2 and the magnetic core 1, the injection-molded body 3 can also include a body wrapping around the outside of the magnetic core 1.

[0056] for example Figures 1 to 3 The injection-molded body 3 not only fills the gaps between the magnetic core 1 and coils 21 and 22 along the expansion channel, forming filling portions 31 and 32 (these filling portions 31 and 32 are the result of the plastic melt filling the expansion channel and injection gap), but also wraps around the first components 11 and 12, forming assembly portions 33 and 34 on the periphery of the first components 11 and 12. These assembly portions 33 and 34 are the result of the plastic melt filling in the injection mold and are mainly used to install and fix the integrated molded body composed of the injection-molded body 3, the magnetic core 1, and the coils 21 and 22. For example, multiple through holes 331 and 332 are provided on the assembly portions 33 and 34, which are used to pass through screws or bolts for installation and fixing. It can be understood that screws or bolts passing through the through holes 331 and 332 can fix the inductor device to some power supply equipment.

[0057] Further, see Figure 1 and Figure 2 The assembly part 34 is also equipped with ribbon cables 211 and 221. Ribbon cable 211 is connected to the tail terminal of coil 21 for introducing or drawing direct current into or out of coil 21, and ribbon cable 221 is connected to the tail terminal of coil 22 for introducing or drawing direct current into or out of coil 22. To fix ribbon cables 211 and 221, the assembly part 34 can also be provided with multiple screw holes 341 and 342, which are used to fix ribbon cables 211 and 221 respectively. Thus, ribbon cable 211 can be fixed to the assembly part 34 with the cooperation of screw 343 and screw hole 341, and ribbon cable 221 can be fixed to the assembly part 34 with the cooperation of screw 344 and screw hole 342.

[0058] It should be noted that high-power inductors primarily employ oil or water cooling to dissipate heat, thereby reducing size and cost. Therefore, in the inductor design of this application, the outer surface of the coil, the hottest part, needs to be fully exposed after injection molding. Conducting heat through the exposed coil surface is one of the most effective means to improve heat dissipation and reduce inductor size. To achieve this exposed coil, the integrally molded plastic injection port needs to be located on one or both sides of the inductor coil. Depending on the product requirements, the injection port can be single-sided or both sides. The magnetic core, coil, temperature sensor, and sensor mounting assembly are assembled using mounting brackets on both sides of the coil and placed into the injection mold beforehand. During injection molding, the high-temperature PPS molten plastic is injected through the injection port outside the coil mounting bracket, flowing rapidly along the injection channel inside the coil and filling the gap between the magnetic core and the coil, thus completing the integral injection molding process.

[0059] Understandably, the technical solution adopts an embedded approach, placing the sensor element inside the inductor and in close contact with the inner side of the coil, which greatly improves the accuracy of temperature measurement. Moreover, the sensor can be firmly embedded inside through an integrated injection molding process, achieving many positive effects such as low cost, high reliability, high precision, fast response, and high product quality.

[0060] The above examples illustrate this application only to aid in understanding its technical solution and are not intended to limit its scope. Those skilled in the art can make various simple deductions, modifications, or substitutions based on the ideas presented in this application.

Claims

1. An inductor with temperature detection, characterized in that, Includes magnetic core, coil, and temperature sensor; The magnetic core has a ring structure and is provided with two winding sections, and at least one of the winding sections is provided with a groove; The coil is wound around the winding portion, and an extended channel is formed between the inner side of the coil and the groove on the winding portion; The temperature sensor includes a sensing element and leads, and the temperature sensor is disposed within the expansion channel; The sensing element contacts the inner surface of the coil to sense the temperature of the coil and generate a temperature signal; the lead wire is connected to the sensing element and is laid along the extended channel to output the temperature signal. The inductor also includes a sensor base located within the expansion channel, and the surface of the sensor base is provided with a recess; a portion of the sensing part is snapped into the recess, and another portion of the sensing part protrudes from the recess and contacts the inner side of the coil; The inductor also includes a terminal block and a spring plate; The terminal block is located at the entrance of the expansion channel; One end of the elastic plate is connected to the terminal block, and the other end of the elastic plate is connected to the sensor base; The elastic plate is used to adjust the position of the sensor base relative to the inner side of the coil by its own deformation, so that the sensor base can provide the sensing part with pressure that is always in contact with the inner side of the coil.

2. The inductor as described in claim 1, characterized in that, The sensor base has a pipe or opening on one side leading to the recess, and the lead wire is connected to the sensing part in the recess through the pipe or the opening; The width of the pipe or the opening is smaller than the width of the recess, so that the sensing element cannot fall off the pipe or the opening.

3. The inductor as described in claim 1, characterized in that, The terminal block is provided with at least one lead terminal; The lead wire is laid on the surface of the elastic plate and extends along the elastic plate to the terminal block, and the lead wire is connected to the lead wire terminal. The lead terminal is used to connect to an external signal line to transmit the temperature signal to the signal line.

4. The inductor as described in claim 3, characterized in that, It also includes an external mounting base, which has at least one external terminal for connecting the signal line; The external mounting base is detachably connected to the terminal mounting base, and the external terminal is electrically connected to the lead terminal.

5. The inductor as described in claim 1, characterized in that, The magnetic core includes two first components and multiple second components; Two first components are arranged opposite each other, and each second component is arranged in two parallel columns between the two first components. All the first components and the second components are combined to form the ring structure of the magnetic core. The outer surface of the second component is used as the winding portion.

6. The inductor as described in claim 5, characterized in that, It also includes multiple fixing brackets, which are fixed around the first component; The fixed bracket is provided with a snap-fit ​​assembly, the inner side of which snaps into the second assembly, and the outer side of which supports the coil. The terminal block is fixed to the fixed bracket, and the elastic plate extends from the terminal block into the expansion channel.

7. The inductor as described in claim 6, characterized in that, The fixed bracket is provided with at least one hole, and the terminal block is provided with at least one pin; the pin and the hole are fitted together to fix the terminal block on the fixed bracket.

8. The inductor as claimed in claim 6, characterized in that, It also includes the injection molded body; An injection gap is formed between the inner side of the coil and the outer side of the second component, and the injection gap communicates with the expansion channel; The injection body extends along the expansion channel to the surrounding injection gap and fills the expansion channel and the injection gap.

9. The inductor as claimed in claim 8, characterized in that, The injection-molded body encloses the first component and forms an assembly portion on the periphery of the first component; The assembly part is used to install and fix the injection-molded body, the magnetic core and the coil as an integrated molded body.

10. The inductor as claimed in claim 9, characterized in that, The assembly part is provided with a ribbon cable, which is connected to the tail terminal of the coil for introducing or drawing direct current into or out of the coil.

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