A semi-potted combined inductor

Abstract

This invention discloses a semi-encapsulated combined inductor, specifically relating to the field of electronic component technology. It includes a fixed housing, on the top of which a differential mode inductor body is mounted. The differential mode inductor body is semi-encapsulated and positioned on top of the fixed housing. The interior of the fixed housing, outside the extension portion of the differential mode inductor body, is filled with potting compound. The differential mode inductor body consists of three sets of double-ring wound differential mode inductors and one set of double-ring wound auxiliary inductors. Both the differential mode inductors and the auxiliary inductors include a magnetic core, the outer surface of which is wound with circular enameled wire. This invention has excellent scalability and widespread applicability, effectively solving the problems of large size, low efficiency, high cost, poor heat dissipation, and poor EMI filtering effect of combined inductors. Simulation experiments and laboratory tests demonstrate that it achieves the expected results, exhibiting strong innovation, practicality, and scalability, with extremely high market value.

Description

Technical Field

[0001] This invention relates to the field of electronic components technology, and more specifically, to a semi-encapsulated composite inductor. Background Technology

[0002] Since the beginning of the 21st century, clean energy has made great strides, with global photovoltaic installations growing rapidly. In the future, countries around the world will continue to implement their photovoltaic policies and support. In particular, in recent years, the construction and development of smart grids have greatly promoted the popularization of distributed photovoltaic and microgrid technologies.

[0003] In the field of new energy electronic components, switching converters are crucial components, and their energy storage, electrical isolation, and energy conversion mainly depend on transformers and inductors. Therefore, the selection and design of magnetic materials directly determine the performance and efficiency of micro-inverters. Nowadays, high-performance, high-efficiency, and small-size switching power supplies are increasingly favored. With the increase in frequency, the heating problem of magnetic components becomes increasingly serious. Magnetic materials are sensitive to temperature, and high temperatures lead to increased magnetic losses. In terms of power loss, magnetic component losses include copper losses (heat loss generated by the current flowing through the winding) and iron losses (core losses, such as hysteresis losses, eddy current losses, and residual losses). For magnetic component manufacturers, it is very important to understand the basic characteristics of magnetic components and the physics of core losses. The selection of magnetic materials directly determines the performance of the final design. There are many factors to consider when designing reasonable, efficient, and applicable magnetic components, such as the shape and material of the core, core losses, and the influence of the air gap.

[0004] In the prior art, utility model patent CN215815497U discloses a potted inductor, including a shell, an inductor body, a heat dissipation filling unit, and potting compound. The shell includes a cavity with an opening, and the inductor body is disposed within the cavity of the shell. The heat dissipation filling unit includes at least one heat dissipation filling block, which fills the gap between the inductor body and the cavity of the shell. The potting compound is poured into the cavity from the opening to completely fill the cavity. This patent has good heat dissipation performance.

[0005] As power electronic devices move towards higher frequencies, the electronic components within these devices generate electromagnetic interference. Traditional chokes are insufficient to suppress noise, and the usual approach is to add differential-mode inductors to suppress noise. However, this increases the size and weight of the devices, limiting the miniaturization of EMI filters. In recent years, in emerging fields such as photovoltaic power generation, photovoltaic energy storage and charging, combined inductors have sprung up like mushrooms after rain, but they also bring many problems, such as large size, low efficiency, high cost, poor heat dissipation, and poor EMI filtering effect. Summary of the Invention

[0006] The present invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different solution. To overcome the aforementioned deficiencies of existing technologies, the present invention provides a semi-encapsulated composite inductor.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a semi-encapsulated combined inductor, comprising a fixed shell, a differential mode inductor body mounted on the top of the fixed shell, the differential mode inductor body being placed on the top of the fixed shell and semi-encapsulated, and the interior of the fixed shell being filled with potting compound outside the extension portion of the differential mode inductor body. The differential mode inductor body consists of two parts: three sets of differential mode inductors wound in parallel with double rings and one set of auxiliary inductors wound in parallel with double rings. Both the differential mode inductor and the auxiliary inductor include a magnetic core. The magnetic core is wound with circular enameled wire, and both the differential mode inductor and the auxiliary inductor are provided with an insulating shell between the outer surface and the potting compound.

[0008] As a further improvement to the technical solution of the present invention, mounting feet are provided at the bottom of the fixed shell near the four corners, and each mounting foot is provided with a through hole for connection and fixation.

[0009] As a further improvement to the technical solution of the present invention, both the fixing shell and the mounting base are made of aluminum metal, and the fixing shell is a one-piece molded aluminum shell. The interior of the fixing shell is provided with a groove for mounting the differential mode inductor body.

[0010] As a further improvement to the technical solution of the present invention, both the differential mode inductor and the auxiliary inductor are connected to electronic connecting wires, and the outer side of the electronic connecting wires near the differential mode inductor and the auxiliary inductor is wrapped with insulating tape.

[0011] As a further improvement to the technical solution of the present invention, the magnetic core is a structure formed by bonding two customized modified iron-silicon-aluminum magnetic rings together, and the customized modified iron-silicon-aluminum magnetic rings have 30% higher power than the original iron-silicon-aluminum magnetic rings.

[0012] As a further improvement to the technical solution of the present invention, the diameter of the circular enameled wire is 2.3 mm, and the circular enameled wire is wound around the outside of the magnetic core using a butterfly winding method.

[0013] Many factors influence the EMC (Electromagnetic Compatibility) of inductors, such as the core material, winding method, winding structure, inductor design, potting compound quality, and manufacturing process. At a fixed frequency, inductive reactance and inductance have a linear relationship; the larger the inductance, the greater the impedance. Compared with traditional design and manufacturing processes, this invention has significant technical advantages: 1. Customized magnetic cores result in lower magnetic loss than standard products, significantly improving work efficiency; 2. The one-piece molded aluminum shell provides excellent anti-penetration performance and heat dissipation. 3. The thick wire diameter allows for high current carrying capacity and high inductance, making it suitable for the needs of new energy development; 4. Compared to traditional designs, efficiency is increased by 3-5 times while maintaining the same volume; and volume is reduced by 50-80% while maintaining the same efficiency. 5. Under high temperature conditions of 150℃, the size of the inductor air gap was adjusted, resulting in high impedance characteristics, a large resonant frequency, and good inductor EMI characteristics, thereby eliminating the EMI interference source of the inductor body at the source.

[0014] In summary, the semi-encapsulated combined inductor designed in this invention has the characteristics of small size, low cost, high efficiency, good heat dissipation, good EMI effect, and long life. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention.

[0016] Figure 2 This is a schematic diagram of the winding structure of the circular enameled wire on the modified iron-silicon-aluminum magnetic ring in this invention.

[0017] Figure 3 This is a schematic diagram of the structure of the double-ring magnetic core and the circular enameled wire assembled in this invention.

[0018] The attached diagram is labeled as follows: 1. Fixing shell; 2. Mounting feet; 3. Insulating shell; 4. Magnetic core; 5. Circular enameled wire; 6. Electronic connecting wire; 7. Insulating tape; 8. Potting compound. Detailed Implementation

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

[0020] As attached Figure 1-3 The semi-encapsulated composite inductor shown includes a fixed shell 1, a differential mode inductor body is mounted on the top of the fixed shell 1, the differential mode inductor body is placed on the top of the fixed shell 1 and is semi-encapsulated, and the interior of the fixed shell 1 is filled with potting compound 8 outside the extension of the differential mode inductor body. The differential mode inductor body consists of two parts: three sets of differential mode inductors wound in parallel with double rings and one set of auxiliary inductors wound in parallel with double rings. Both the differential mode inductor and the auxiliary inductor include a magnetic core 4. The magnetic core 4 is wound with a circular enameled wire 5. Both the differential mode inductor and the auxiliary inductor are provided with an insulating shell 3 between their exteriors and the potting compound 8.

[0021] Three sets of differential mode inductors wound in parallel with double rings and one set of auxiliary inductors wound in parallel with double rings are formed by bonding customized modified iron-silicon-aluminum (with a 30% increase in power compared to the original iron-silicon-aluminum magnetic ring) rings in double rings, and winding them with thick-diameter (2.3 mm in diameter) round enameled wire 5 that can handle large currents. They are then connected by electronic connection wires 6 to form the main body of the differential mode inductor. The main body of the differential mode inductor is placed in a fixed shell 1 for semi-encapsulation, and an insulating shell 3 is set between the inductor coil on the main body of the differential mode inductor and the potting compound 8, which can better dissipate heat, reduce magnetic loss, and improve product working efficiency and lifespan. To ensure waterproof and corrosion-resistant performance, the mounting shell is manufactured using a one-piece molding method, abandoning the traditional welding method and eliminating the possibility of shell penetration. It is also made of aluminum. The coil winding method has been optimized by using a unique butterfly winding method, which maximizes the improvement of the inductor's impedance characteristics and eliminates EMI interference from the inductor itself at the source. The properties of the potting compound (such as density, material, thermal conductivity, etc.) have been optimized, reducing the impact of the potting compound on the parasitic capacitance and dielectric constant of the inductor body, and also improving the inductor impedance characteristics, thus significantly improving the overall performance of the product.

[0022] By integrating magnetic structures, magnetic rings with a single unit capacity of 12.5KW are stacked together, increasing the electrical power to 100KW. This breaks through the low power limitation of traditional coil inductors. Currently, no similar products have been found at home and abroad, making it a distinctive and innovative high-efficiency combined inductor.

[0023] Working principle: This invention designs a semi-encapsulated combined inductor, the specific structure of which is shown in the attached instruction manual. Figure 1-3 As shown, this technical solution utilizes a magnetically integrated structure of a differential-mode inductor, consisting of a magnetic core 4, circular enameled wire 5, insulating tape 7, insulating cover 3, potting compound 8, fixing shell 1, and electronic connection wire 6. A mathematical model of the insertion loss of the differential-mode inductor is established. By using three differential-mode inductors and one auxiliary inductor, the problem of the coupling coefficient of the magnetically integrated differential-mode inductor affecting the noise suppression capability of the filter is solved. Simultaneously, the filter size is effectively reduced. This solution is suitable for the miniaturization, high efficiency, and low emission needs of photovoltaic inverters, wind power, electric vehicle charging piles, and distributed photovoltaic power generation. It has excellent potential for widespread adoption and effectively solves the problems of large size, low efficiency, high cost, poor heat dissipation, and poor EMI filtering effect of combined inductors. Simulation experiments and laboratory tests demonstrate that it achieves the expected results, exhibiting strong innovation, practicality, and scalability, with extremely high market value.

[0024] In the accompanying drawings of the embodiments disclosed in this invention, only the structures involved in the embodiments of this disclosure are shown. Other structures can be referred to with general designs. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other. In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A semi-encapsulated composite inductor, characterized in that: Includes a fixed shell (1), on the top of the fixed shell (1) a differential mode inductor body is installed, the differential mode inductor body is placed on the top of the fixed shell (1) and is installed in a semi-encapsulated manner, and the interior of the fixed shell (1) is filled with potting compound (8) outside the extension of the differential mode inductor body. The differential mode inductor body consists of two parts: three sets of differential mode inductors with double rings wound in parallel and one set of auxiliary inductors with double rings wound in parallel. Both the differential mode inductor and the auxiliary inductor include a magnetic core (4). The magnetic core (4) is wound with a circular enameled wire (5), and an insulating shell (3) is provided between the differential mode inductor and the potting compound (8). The bottom of the fixed shell (1) is provided with mounting feet (2) near the four corners, and each mounting foot (2) has a through hole for connection and fixing. The fixed shell (1) and the mounting base (2) are both made of aluminum metal, and the fixed shell (1) is a one-piece molded aluminum shell. The interior of the fixed shell (1) is provided with a groove for mounting the differential mode inductor body. Both the differential mode inductor and the auxiliary inductor are connected to electronic connection lines (6), and the outer side of the electronic connection lines (6) near the differential mode inductor and the auxiliary inductor is wrapped with insulating tape (7). The magnetic core (4) is a structure made of two customized modified iron-silicon-aluminum magnetic rings bonded together; The circular enameled wire (5) is wound around the outside of the magnetic core (4) using a butterfly winding method.

2. The semi-encapsulated composite inductor according to claim 1, characterized in that: The diameter of the circular enameled wire (5) is 2.3 mm.

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