Integrated magnetic component winding structure and winding method thereof

Abstract

The invention discloses an integrated magnetic component winding structure and a winding method thereof, and relates to the technical field of magnetic component winding structures.The integrated magnetic component winding structure comprises an iron core and two coil windings, each coil winding comprises at least two sub-windings and is used for generating magnetic flux in the iron core when an electric signal is input, and the two sub-windings are connected with the iron core. The sub-windings in each coil winding are wound on the iron core in a mutually staggered manner, and the staggered winding means that after each coil winding is nested on the iron core, the sub-windings in other coil windings are arranged between the sub-windings in each coil winding. On the premise that the product cost is reduced, the coupling degree is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic component winding structures, and in particular to an integrated magnetic component winding structure and a winding method thereof. Background Art

[0002] With the development of electric vehicles, slow charging of electric vehicles has become one of the main factors restricting the development of electric vehicles. In order to solve the problem of difficult charging of electric vehicles, the most effective method at present is to increase the output power of the AC-DC module in the charging pile.

[0003] At present, in AC-DC modules, an autotransformer is generally required to cooperate with a power factor correction inductor to achieve power factor correction.

[0004] However, in the existing autotransformer, due to the leakage inductance phenomenon, the magnetic flux in the two windings of the autotransformer cannot be completely offset, resulting in the leakage inductance magnetic flux superimposed on the excitation magnetic flux, resulting in saturation problems and increased losses. In order to solve the leakage inductance problem of the autotransformer, the existing solution is to provide a larger magnetic core flux area or more coil turns, which not only increases the cost of the product, but also causes the volume of the autotransformer to increase, which is not conducive to the installation of the autotransformer in increasingly miniaturized electronic devices. Summary of the invention

[0005] The present application provides an integrated magnetic component winding structure and a winding method thereof, which has the effect of improving coupling degree while reducing product cost.

[0006] The present application provides an integrated magnetic component winding structure and a winding method thereof, which adopts the following technical solutions: An integrated magnetic component winding structure and a winding method thereof, the integrated magnetic component winding structure, comprising an iron core and two coil windings, each of the coil windings comprising at least two sub-windings for generating magnetic flux in the iron core when an electrical signal is passed, the sub-windings in each of the coil windings being wound on the iron core in an interlaced manner, and the interlaced winding means that after each coil winding is nested on the iron core, there are sub-windings in other coil windings between the sub-windings in each coil winding.

[0007] By adopting the above technical solution, by staggered winding of sub-windings, each sub-winding can have more opportunities to share magnetic flux with other sub-windings, thereby effectively reducing leakage inductance; on the iron core, different sub-windings of the coil are staggered, that is, when the sub-winding of a coil is inlaid, the laying position of the subsequent sub-windings must be considered, so that the relative position of each sub-winding can maximize overlap, thereby improving the coupling degree while reducing product costs.

[0008] Preferably, the iron core comprises a base, and a first core body is arranged on the base.

[0009] By adopting the above technical solution, the design of the base effectively isolates the first core from the external environment, thereby enhancing the electrical insulation and safety during operation; in addition, the structure with the base provides stable support, which not only simplifies the assembly and installation process, but also facilitates integration with other electronic components.

[0010] Preferably, the first core is one of a U-shape, an E-shape, a U-shape and a C-shape.

[0011] By adopting the above technical solutions, specific shape designs such as U-shaped, E-shaped, U-shaped and C-shaped can effectively reduce magnetic flux leakage and ensure that more magnetic flux is concentrated in the iron core, thereby improving the surge current capacity of the coil and the efficiency of the transformer.

[0012] Preferably, a second core body matching the first core body is disposed on the first core body, and the second core body is detachably arranged from the first core body.

[0013] By adopting the above technical solution, the design is easy to maintain and replace, and provides flexibility to adapt to diverse working conditions and applications with different magnetic properties; thus, users can adjust or replace the second core according to actual needs to meet different working environments and performance requirements, which also effectively reduces maintenance costs.

[0014] Preferably, the second core is one of an inverted U-shape, an inverted E-shape, an inverted U-shape, and an inverted C-shape.

[0015] By adopting the above technical solution, the shape of the second core effectively supplements the magnetic circuit of the first core, forming a more complete magnetic flux path; through the combination of the upper and lower parts, the overall magnetic permeability can be improved, and the concentration and stability of the magnetic field can be enhanced.

[0016] Preferably, a slot matching the first core is provided at the bottom of the second core.

[0017] By adopting the above technical solution, the purpose of the slot design is to enable the second core to be accurately docked with the first core, thereby ensuring that the magnetic circuit between the two is unobstructed.

[0018] Preferably, the two coil windings are wound alternately on the outer surface of the second core.

[0019] By adopting the above technical solution and using the staggered winding coil method, a more uniform magnetic field distribution can be achieved, thereby effectively reducing the occurrence of local hot spots and magnetic saturation phenomena.

[0020] Preferably, the two sub-windings are respectively located at two relative positions of the second core, and the coils in the two sub-windings are wound in opposite directions.

[0021] By adopting the above technical solution, since the winding directions of the two sub-windings are opposite, the generated magnetic fields have opposite polarities; when current passes through the two sub-windings, their magnetic fields will cancel each other out to a certain extent, thereby achieving precise control of the electromagnetic characteristics.

[0022] Preferably, the winding method of the integrated magnetic component winding structure comprises the following steps: S1: Core preparation: First, prepare an iron core with the required shape and size and good magnetic conductivity; S2: Coil winding design: According to application requirements, design at least two coil windings, each coil winding including at least two sub-windings; and determine the number of turns, wire diameter and winding direction of each sub-winding; S3: Staggered winding: Wind the first sub-winding of the first coil winding on the iron core, and pay attention to maintaining the uniformity and tightness of the winding; Next, wind the first sub-winding of the second coil winding between or outside the first sub-windings, making sure there is enough interleaving between the two; Repeat the above steps to wind the second sub-winding of the first coil winding and the second sub-winding of the second coil winding in sequence, until all sub-windings are wound in an interlaced manner according to the design requirements; during the winding process, ensure the insulation performance between the sub-windings and between different coil windings to prevent short circuit or leakage; S4: Terminal connection: Lead out the wiring terminals for each sub-winding and connect them to the external circuit; the wiring terminals should be firm and reliable and have good conductivity.

[0023] By adopting the above technical solution, the winding structure of the integrated magnetic component adopts a simple winding method, and the coupling degree between the two windings is significantly improved, thereby effectively reducing the leakage inductance problem of the transformer; in addition, this design also simplifies the process flow and reduces manufacturing costs.

[0024] Preferably, in S1, the iron core is assembled by butting a first core body and a second core body.

[0025] By adopting the above technical solution, the iron core adopts a method of butt-jointing and assembling the first core body and the second core body, so that the first core body and the second core body are combined with each other to form a continuous magnetic circuit; this design effectively reduces magnetic flux leakage, thereby improving the use efficiency of the magnetic core.

[0026] In summary, this application has the following beneficial effects: 1. The winding structure of the integrated magnetic component can make each sub-winding have more opportunities to share magnetic flux with other sub-windings by staggered winding of sub-windings, thereby effectively reducing leakage inductance; on the iron core, different sub-windings of the coil are staggered, that is, when the sub-winding of a coil is inlaid, the laying position of the subsequent sub-windings must be considered, so that the relative position between each sub-winding can maximize the overlap, thereby improving the coupling degree.

[0027] 2. The winding structure of the integrated magnetic component adopts a simple winding method, and the coupling between the two windings is significantly improved, thereby effectively reducing the leakage inductance problem of the transformer; in addition, this design also simplifies the process flow and reduces manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a schematic diagram of the overall structure of the winding structure of the integrated magnetic component in this embodiment; Figure 2 is an exploded view between the iron core and the coil winding in this embodiment; Figure 3 is a flow chart of a winding method of an integrated magnetic component winding structure in this embodiment; Explanation of the accompanying drawings: 1. Iron core; 11. Base; 12. First core body; 13. Second core body; 2. Coil winding; 21. Sub-winding. DETAILED DESCRIPTION

[0029] The present application is further described in detail below in conjunction with the accompanying drawings. It is necessary to point out here that the following specific implementation methods are only used to further illustrate the present application and cannot be understood as limiting the scope of protection of the present application. Technical personnel in this field can make some non-essential improvements and adjustments to the present application based on the above application content. Example

[0030] The present invention discloses an integrated magnetic component winding structure and a winding method thereof. Figure 1 and Figure 2As shown, the integrated magnetic component winding structure includes an iron core 1 and two coil windings 2, each coil winding 2 includes at least two sub-windings 21, which are used to generate magnetic flux in the iron core 1 when an electrical signal is passed, or to induce an electrical signal according to the magnetic flux in the iron core 1. The sub-windings 21 in each coil winding 2 are interlaced with each other on the iron core 1. By interlacing the sub-windings 21, each sub-winding 21 can have more opportunities to share magnetic flux with other sub-windings 21, thereby effectively reducing leakage inductance; interlaced winding means that after each coil winding 2 is nested on the iron core 1, there are sub-windings 21 in other coil windings 2 between the sub-windings 21 in each coil winding 2; on the iron core 1, different sub-windings 21 of the coil are interlaced, that is, when the sub-winding 21 of a coil is embedded, the laying position of the subsequent sub-winding 21 should be considered, so that the relative position between each sub-winding 21 can maximize the overlap, thereby improving the coupling degree.

[0031] like Figure 1 and Figure 2 As shown, by staggeredly winding sub-windings 21 on a plurality of coil windings 2 on the same core 1, the magnetic flux coupling between different coil windings 2 can be increased; thus, the current in a certain coil winding 2 can more effectively induce a voltage in the coils near it, thereby improving the energy transmission efficiency of the transformer.

[0032] like Figure 1 and Figure 2 As shown, specifically, when current passes through a wire, a magnetic field, namely magnetic flux, is generated around it; conversely, when the magnetic field (magnetic flux) changes, an electromotive force is induced in the wire, which may in turn generate current; this is the basis of Faraday's law of electromagnetic induction.

[0033] like Figure 2 As shown, by staggered winding of different coil windings 2 and their sub-windings 21, the space of the core 1 can be more effectively utilized, and the complexity and intersection of the magnetic flux path can be increased; this design helps to enhance the electromagnetic coupling between coils, improve energy conversion efficiency, and reduce leakage flux and energy loss.

[0034] like Figure 2 As shown, each coil winding 2 includes multiple sub-windings 21, which can flexibly control the direction and magnitude of the current in different sub-windings 21, thereby more accurately controlling the distribution and change of the magnetic field; this is particularly important for applications that require precise control of the magnetic field direction (such as motors).

[0035] like Figure 2As shown, the core 1 includes a base 11, on which a first core body 12 is arranged. The existence of the base 11 can effectively isolate the first core body 12 from the external environment, thereby increasing electrical insulation and safety during operation. The design with the base 11 provides a stable role support, which makes it easier to assemble and install, and is also convenient for integration with other electronic components.

[0036] like Figure 2 As shown, the first core 12 is one of a U-shape, E-shape, U-shape, and C-shape, and the base 11 is fixedly connected to the first core 12; the design of specific shapes such as a U-shape, E-shape, U-shape, and C-shape can minimize the leakage of magnetic flux and ensure that more magnetic flux is concentrated in the iron core 1, thereby improving the coil surge capacity and the efficiency of the transformer; the design of the first core 12 of different shapes can effectively construct a closed magnetic circuit, thereby optimizing the flow of magnetic flux in the first core 12; the magnetic material can effectively guide the magnetic field within a certain range and increase the overall strength of the magnetic flux.

[0037] like Figure 2 As shown, a second core 13 is provided on the first core 12, and the second core 13 is one of an inverted U-shape, an inverted E-shape, an inverted U-shape, and an inverted C-shape. The shape of the second core 13 can effectively supplement the magnetic circuit of the first core 12 to form a more complete magnetic flux path. By combining the upper and lower parts, the overall magnetic permeability can be improved, and the concentration and stability of the magnetic field can be enhanced. The second core 13 can usually generate additional magnetic field effects during operation to improve energy storage capacity. The two-layer core design can achieve stronger electromagnetic coupling efficiency, thereby effectively improving performance in transformers and inductors. The second core 13 is disassembled and arranged between the first core 12. It is easy to maintain and replace, and provides flexibility to adapt to different working conditions or applications requiring different magnetic properties. The second core 13 can be adjusted or replaced according to actual needs to adapt to different working conditions and performance requirements, thereby reducing maintenance costs.

[0038] like Figure 2 As shown, specifically, a slot matching the first core 12 is provided at the bottom of the second core 13, and the slot is designed to enable the second core 13 to be accurately docked with the first core 12, thereby ensuring a good magnetic circuit between the two; the shape and position of the slot are precisely designed to adapt to the structural characteristics of the first core 12 to form a stable mechanical and magnetic contact; through the close docking of the slot, the magnetic gap between the second core 13 and the first core 12 can be effectively reduced; it helps to achieve a uniform magnetic field, improve the flow efficiency of the magnetic flux, and enhance the performance of the entire system.

[0039] like Figure 2As shown, the two coil windings 2 are wound alternately on the outer surface of the second core 13. By winding the coils in an alternate manner, a more uniform magnetic field distribution can be achieved, reducing the occurrence of local hot spots and magnetic saturation. This uniformity is particularly important in transformers and inductors. Due to the good magnetic coupling between the two, the interlaced winding can significantly improve the conversion efficiency of electrical energy, especially in applications such as transformers, induction heating and power transmission.

[0040] like Figure 2 As shown, the two sub-windings 21 are respectively located at two relative positions of the second core 13, and the coils in the two sub-windings 21 are wound in opposite directions; since the two sub-windings 21 are wound in opposite directions, the generated magnetic fields have opposite polarities; when current flows through the two sub-windings 21, the magnetic fields of each other will cancel each other out to a certain extent, so that precise control of the electromagnetic characteristics can be achieved; this arrangement ensures the symmetry of the magnetic field, helps to balance the electromagnetic environment of the equipment during operation, and improves the stability of the overall system.

[0041] like Figure 2 As shown, the opposite winding directions can reduce electromagnetic interference from the power supply or other devices, which helps to improve the system's anti-interference ability; due to the uniformity and stability of the magnetic field, this design helps to improve the energy conversion efficiency of the transformer or inductive equipment and reduce energy loss.

[0042] like Figure 2 and Figure 3 As shown, the winding method of the above integrated magnetic component winding structure comprises the following steps: S1: Core 1 preparation: First, a core 1 with excellent magnetic conductivity, shape and size that meet the design requirements is selected; the core 1 should have a suitable geometric shape to optimize the magnetic flux distribution and reduce energy loss; the material of the core 1 should be selected to ensure that its magnetic permeability meets the expected design index; S2: Coil Winding 2 Design: According to the specific application requirements, the coil winding 2 is designed in detail; the design process should include the following: first, the layout of at least two coil windings 2; second, each coil winding 2 contains at least two sub-windings 21; third, the number of turns, wire diameter and winding direction of each sub-winding 21 are determined to ensure matching with the overall electrical performance and mechanical structure; during the design process, the coupling effect and staggered arrangement between coils should be considered to improve the overall performance of components; S3: Staggered winding: Winding the first sub-winding 21 of the first coil winding 2 evenly and tightly on the iron core 1, ensuring the consistency and neatness of the turns during the winding process; Next, the first sub-winding 21 of the second coil winding 2 is wound in the gap or around the first sub-winding 21 to ensure effective interleaving between the two, thereby optimizing the electromagnetic characteristics; According to the above method, the winding of the second sub-winding 21 of the first coil winding 2 and each sub-winding 21 of the second coil winding 2 is completed in sequence until all sub-windings 21 are interlaced and wound according to the design requirements; this process ensures that there is proper insulation and mechanical support between each layer of windings to improve the reliability and safety of the product; S4: Terminal connection: After winding is completed, a lead terminal is set for each sub-winding 21 to facilitate connection with the external circuit; the design of the terminal should meet the following requirements: first, the terminal connection should be firm and reliable to ensure good contact under operation and environmental changes; second, the terminal should have excellent conductive properties to reduce contact resistance and ensure the stability of current transmission; third, in the management of the terminal, appropriate identification and protection measures should be taken to facilitate subsequent maintenance and debugging.

[0043] like Figure 2 and Figure 3 As shown, in S1, the iron core 1 is assembled by butting the first core body 12 and the second core body 13. The iron core 1 is assembled by butting so that the two core bodies are combined with each other to form a continuous magnetic circuit. This design can effectively reduce magnetic flux leakage, thereby improving the utilization efficiency of the magnetic core. The material of the iron core 1 is silicon steel sheet. The silicon steel sheet has high magnetic permeability and can significantly reduce iron loss after siliconization treatment. This means that when operating in an alternating magnetic field, the loss of electrical energy converted into heat energy is small, thereby improving the efficiency and performance of magnetic components.

[0044] Specifically, the high magnetic permeability of silicon steel sheets enables the core 1 to carry more magnetic flux in a relatively small volume, thereby improving the inductance and effective energy storage capacity of the winding; and the use of silicon steel sheets can significantly reduce the iron loss caused by eddy current effects, thereby improving overall energy efficiency; in high-frequency applications, the core 1 using this material can effectively reduce heat generation and improve the energy conversion efficiency of the system.

[0045] Working principle: When current passes through a coil winding 2, a magnetic field is generated around it and a magnetic flux is formed in the iron core 1; according to Faraday's law of electromagnetic induction, the change in magnetic flux will induce an electromotive force in the adjacent coil winding 2, which may then generate current; wherein, the staggered design between the sub-windings 21 enables each sub-winding 21 to have more opportunities to share magnetic flux with other sub-windings 21, thereby effectively reducing leakage inductance; the staggered placement increases the magnetic flux coupling between different coil windings 2, thereby improving energy transfer efficiency.

[0046] In general, through the interlaced coils and sub-windings 21, the integrated magnetic component can efficiently generate and sense magnetic flux, achieve superior magnetic field control and energy transmission, and thus perform well in a variety of electromagnetic applications.

[0047] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. An integrated magnetic component winding structure, comprising an iron core (1) and two coil windings (2), characterized in that: Each of the coil windings (2) comprises at least two sub-windings (21) for generating magnetic flux in the iron core (1) when an electrical signal is passed through, and the sub-windings (21) in each of the coil windings (2) are wound on the iron core (1) in an interlaced manner. Interlaced winding means that after each coil winding (2) is nested on the iron core (1), there are sub-windings (21) in other coil windings (2) between the sub-windings (21) in each coil winding (2).

2. The integrated magnetic component winding structure according to claim 1, characterized in that: The iron core (1) comprises a base (11), and a first core body (12) is arranged on the base (11).

3. The integrated magnetic component winding structure according to claim 2, characterized in that: The first core (12) is one of a U-shape, an E-shape, a U-shape, and a C-shape.

4. The integrated magnetic component winding structure according to claim 3, characterized in that: A second core (13) matching the first core (12) is provided on the first core (12), and the second core (13) is detachably arranged from the first core (12).

5. The integrated magnetic component winding structure according to claim 4, characterized in that: The second core (13) is one of an inverted U-shape, an inverted E-shape, an inverted U-shape, and an inverted C-shape.

6. The integrated magnetic component winding structure according to claim 5, characterized in that: The bottom of the second core (13) is provided with a slot matching the first core (12).

7. The integrated magnetic component winding structure according to claim 5, characterized in that: The two coil windings (2) are both wound alternately on the outer surface of the second core (13).

8. The integrated magnetic component winding structure according to claim 7, characterized in that: The two sub-windings (21) are respectively located at two relative positions of the second core (13), and the coils in the two sub-windings (21) are wound in opposite directions.

9. A method for winding an integrated magnetic component winding structure according to any one of claims 1 to 8, characterized in that: The winding steps include: S1: Iron core (1) Preparation: First, prepare an iron core (1) with a shape and size that meets the requirements and has good magnetic conductivity; S2: Coil winding (2) design: According to application requirements, at least two coil windings (2) are designed, each coil winding (2) comprising at least two sub-windings (21); and the number of turns, wire diameter and winding direction of each sub-winding (21) are determined; S3: Staggered winding: Winding the first sub-winding (21) of the first coil winding (2) on the iron core (1), and paying attention to maintaining the uniformity and tightness of the winding; Next, the first sub-winding (21) of the second coil winding (2) is wound between or outside the first sub-winding (21), ensuring sufficient interleaving between the two; Repeat the above steps to sequentially wind the second sub-winding (21) of the first coil winding (2) and the second sub-winding (21) of the second coil winding (2) until all sub-windings (21) are wound in an interlaced manner according to design requirements; S4: Terminal connection: A wiring terminal is provided for each sub-winding (21) and connected to an external circuit; the wiring terminal should be firm and reliable and have good electrical conductivity.

10. The method for winding an integrated magnetic component winding structure according to claim 9, characterized in that: In S1, the iron core (1) is assembled by butting a first core body (12) and a second core body (13).

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