Frameless high-power common-mode inductor

Abstract

The invention relates to the technical field of inductors, in particular to a frameless high-power common-mode inductor which comprises a substrate, a supporting isolation plate, a magnetic core, a first winding coil, a second winding coil and an iron core, a clamping part is arranged at the lower end of the supporting isolation plate, and a clamping groove in butt joint with the clamping part is formed in the substrate. The supporting isolation plate is vertically installed on the base plate through clamping matching of the clamping parts and the clamping grooves, the magnetic core penetrates through and is fixedly installed on the supporting isolation plate, the first winding coil and the second winding coil are wound on the magnetic core in an insulated mode, and the first winding coil and the second winding coil are isolated through the supporting isolation plate. The assembly process is simple and convenient to operate, when rework or maintenance occurs in the later period, other parts of the inductor can be disassembled only by removing the sizing material for bonding the iron core and disconnecting the welding position of the first winding coil and the second winding coil, and the interior of the inductor cannot be damaged in the whole disassembly process.

Description

Technical Field

[0001] The invention relates to the technical field of inductors, and in particular to a frameless high-power common-mode inductor. Background Art

[0002] Common-mode inductors are often used to suppress common-mode interference signals in circuits. There are various noises and interferences in the circuits. Common-mode interference refers to interference signals that appear in the same direction and amplitude in two or more wires.

[0003] The two coils of the common-mode inductor are wound on the same high-permeability magnetic core with the same number of turns and phase, but opposite winding directions. When a normal differential-mode signal passes through, that is, when two signals of equal magnitude and opposite directions pass through the circuit, the magnetic fields generated by the two coils cancel each other out, and the differential-mode signal can pass through without attenuation. When a common-mode current flows through the coil, that is, when currents of the same direction and amplitude in two or more wires flow through the coil, the magnetic fluxes in the magnetic rings are superimposed on each other, which will produce a considerable inductance, making the coil present a high impedance, thereby producing a strong damping effect on the common-mode current, achieving the purpose of attenuating common-mode interference signals. Therefore, the common-mode inductor can not only filter out the common-mode interference signals entering the circuit from the outside and protect the electronic components in the circuit from interference; it can also suppress the influence of the common-mode interference signals generated by the circuit itself when it is working on the outside.

[0004] However, existing circuit components similar to common-mode inductor structures basically adopt a wire package method, that is, a skeleton plus multiple twisted wires. Due to the skeleton, this structure occupies a large space and consumes a lot of man-hours, and the rework cost and subsequent maintenance cost are high, which leads to inconvenience in operation. Summary of the invention

[0005] In order to overcome the above-mentioned shortcomings, the present invention aims to provide a technical solution that can solve the above-mentioned problems.

[0006] A skeleton-free high-power common-mode inductor comprises a substrate, a support isolation plate, a magnetic core, a first winding coil, a second winding coil and an iron core. A clamping portion is provided at the lower end of the support isolation plate, a clamping groove connected to the clamping portion is provided on the substrate, the support isolation plate is vertically mounted on the substrate by clamping cooperation between the clamping portion and the clamping groove, the magnetic core penetrates and is fixedly mounted on the support isolation plate, the first winding coil and the second winding coil are respectively insulated and wound on the magnetic core, and the first winding coil and the second winding coil are separated by the support isolation plate, connecting pins connecting the two ends of the first winding coil and the second winding coil are provided on the substrate, and the connecting pins extend to the lower end of the substrate; the iron core is bonded and fixed on the substrate, the iron core is a frame-like structure surrounding the support isolation plate, the magnetic core, the first winding coil and the second winding coil, and the iron core is arranged to restrict the disassembly of the support isolation plate.

[0007] Preferably, the cross section of the clamping groove has an expansion portion at the bottom and a connection portion at the top that matches the thickness of the supporting isolation plate, and the clamping portion matches the expansion portion.

[0008] Preferably, the snap-in groove extends through both sides of the substrate, so that the snap-in portion slides into the snap-in groove along one side of the substrate to restrict the longitudinal direction of the support isolation plate, and the inner side of the iron core abuts against the support isolation plate to restrict the lateral direction of the support isolation plate.

[0009] Preferably, three support isolation plates are provided, and three corresponding snap-in grooves are provided. The three support isolation plates are respectively connected to the front, middle and rear positions of the magnetic core, and the first winding coil and the second winding coil are provided between two adjacent support isolation plates.

[0010] Preferably, the outer surfaces of the first winding coil and the second winding coil are wrapped with an insulating layer, the insulating layer is made of poly(m-phenylene isophthalamide), and the magnetic core is arranged without an air gap.

[0011] Preferably, the support isolation plate is made of high temperature resistant material, and a mounting hole connected to the magnetic core is opened on the support isolation plate. A high temperature resistant rubber ring is arranged around the inner side of the mounting hole. The magnetic attraction and the support isolation plate are damped and fixed by the high temperature resistant rubber ring, and both ends of the magnetic core are abutted against the inner side of the iron core.

[0012] Preferably, support blocks are provided at the corners of the substrate, and the iron core is supported on the support blocks, so that a gap is formed between the iron core and the substrate, and the gap between the iron core and the substrate is filled with adhesive.

[0013] Preferably, tin-through plates are provided on both sides of the bottom of the substrate.

[0014] Compared with the prior art, the present invention has the following beneficial effects: By setting the inductor to have a structural design of first assembling and then bonding and fixing the substrate, the supporting isolation plate, the magnetic core, the first winding coil, the second winding coil and the iron core, it is not necessary to add other connecting parts such as screws, bolts, excessive adhesive, etc. during the assembly process. The assembly process is simple and easy to operate. When rework or maintenance occurs in the later stage, the other parts of the inductor can be disassembled by removing the adhesive bonding the iron core and disconnecting the first winding coil and the second winding coil at the welding position. The whole disassembly process will not cause damage to the inside of the inductor, and the disassembly is convenient. There is no skeleton structure, and the winding wire and the magnetic core ring are easy to take out and recycled, thereby ensuring that the magnetic core and the winding coil can maintain their original form for repeated use; in addition, the structural design also removes the skeleton mechanism, which can make the matching between the winding coil and the magnetic core tighter, thereby improving the compactness of the inductor and enabling the inductor to be set to a smaller size.

[0015] By setting a snap-in groove extending through both sides of the substrate, the snap-in portion slides into the snap-in groove along one side of the substrate to restrict the longitudinal direction of the support isolation plate, and the inner side of the iron core abuts against the support isolation plate to restrict the lateral direction of the support isolation plate. Through this restriction method, which is similar to the mortise and tenon connection method, the magnetic core, the winding coil and the support isolation plate can be firmly fixed in the substrate and the iron core, and the fixation can be completed only by gluing in sequence. The operation is simple, and the snap-in groove and the snap-in portion are set to a sliding connection method, which will ensure that it can be connected multiple times without causing wear and tear, and can also improve the smoothness of the connection.

[0016] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0018] Figure 1 It is a structural schematic diagram of a viewing angle of the present invention; Figure 2 It is a structural schematic diagram of another perspective of the present invention; Figure 3 It is a schematic diagram of the cross-sectional structure of the present invention taken along the axis direction of the magnetic core; Figure 4 The present invention Figure 3 The structural diagram at A in the middle; Figure 5 It is a schematic diagram of the cross-sectional structure of the present invention taken along a direction perpendicular to the axis of the magnetic core; Figure 6 It is a schematic diagram of the explosion structure of the present invention.

[0019] The reference numerals and names in the figures are as follows: Base plate 10, snap-fit ​​groove 11, expansion portion 111, connection portion 112, connection pin 12, support block 13, tin-through plate 14, support isolation plate 20, snap-fit ​​portion 21, mounting hole 22, high temperature resistant rubber ring 23, magnetic core 30, first winding coil 40, second winding coil 50, iron core 60. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] See also Figure 1-6 In an embodiment of the present invention, a skeleton-free high-power common-mode inductor is provided, including a substrate 10, a support isolation plate 20, a magnetic core 30, a first winding coil 40, a second winding coil 50 and an iron core 60. A clamping portion 21 is provided at the lower end of the support isolation plate 20. A clamping groove 11 connected to the clamping portion 21 is provided on the substrate 10. The support isolation plate 20 is vertically mounted on the substrate 10 by clamping the clamping portion 21 and the clamping groove 11. The clamping portion 21 and the clamping groove 11 cooperate to constrain the support isolation plate 20 in the vertical direction by the substrate 10 so that it cannot be taken out, thereby achieving the purpose of fixing the support isolation plate 20 and the clamping portion 21; the magnetic core 30 penetrates and is fixedly mounted on the support isolation plate 20 The first winding coil 40 and the second winding coil 50 are respectively insulated and wound on the magnetic core 30, and the first winding coil 40 and the second winding coil 50 are separated by the supporting isolation plate 20, that is, the supporting isolation plate 20 not only realizes the isolation effect, but also fixes the magnetic core 30, and a connecting pin 12 connecting the first winding coil 40 and the second winding coil 50 is provided on the substrate 10, and the connecting pin 12 extends to the lower end of the substrate 10; the iron core 60 is bonded and fixed on the substrate 10, and the iron core 60 is a frame-like structure surrounding the supporting isolation plate 20, the magnetic core 30, the first winding coil 40 and the second winding coil 50, and the iron core 60 is configured to restrict the disassembly of the supporting isolation plate 20.

[0022] During the production and assembly process, first, the support isolation plate 20 and the magnetic core 30 are fixedly installed. In this process, the stability of the installation must be ensured. At the same time, the first winding coil 40 and the second winding coil 50 are insulated and wound on the magnetic core 30 respectively. When winding, attention should be paid to the number of turns, flatness and insulation treatment of the coils to ensure good insulation performance between the coils and between the coils and the iron core 60 to prevent short circuits and other problems during later use. Next, the magnetic core 30, the support isolation plate 20, the first winding coil 40 and the second winding coil 50 are installed on the substrate 10. During installation, the clamping portion 21 at the lower end of the support isolation plate 20 is used to clamp with the clamping groove 11 on the substrate 10. When clamping, it is necessary to ensure that the clamping is firm so that the support isolation plate 20 is stably restrained by the substrate 10 in the vertical direction to achieve preliminary fixation. This step requires precise operation to ensure the accurate position of subsequent components. Next, the two ends of the first winding coil 40 and the second winding coil 50 are respectively welded to the corresponding connection pins 12 on the substrate 10. During the welding process, appropriate welding tools and materials should be used to ensure that the welding points are firm and have good conductivity. At the same time, attention should be paid to controlling the welding temperature and time to avoid damage to the coils, magnetic core 30, substrate 10 and other components. Finally, the iron core 60 is sleeved on the outer periphery of the magnetic core 30, the supporting isolation plate 20, the first winding coil 40 and the second winding coil 50, and then the iron core 60 is bonded to the substrate 10 by gluing. Choose appropriate glue to ensure that the bonding strength is sufficient to fix the iron core 60 and provide a certain protection for the internal components. The glue should be applied evenly to avoid the situation where too much or too little glue affects the bonding effect.

[0023] In the later rework or maintenance operation, when rework or maintenance is needed later, first remove the glue bonding the iron core 60, and use appropriate solvents or tools to clean it, but be careful not to damage other parts, then disconnect the first winding coil 40 and the second winding coil 50 at the welding position, and then the other parts of the inductor can be disassembled. Be careful during the disassembly process to avoid damage to the magnetic core 30 and the winding coil, and ensure that they can maintain their original form for reuse. Since there is no skeleton structure, the winding coil and the magnetic core 30 are easier to take out and recycle after disassembly. This structural design not only improves the convenience of maintenance, but also reduces costs. At the same time, since the skeleton structure is removed, the winding coil and the magnetic core 30 fit more closely, which improves the compactness of the inductor and is conducive to the realization of a smaller size inductor design.

[0024] Please refer to Figure 3-6On the basis of the above technical solution, it is further proposed that the cross section of the clamping groove 11 has an expansion portion 111 at the bottom and a connection portion 112 at the top that matches the thickness of the support isolation plate 20, and the clamping portion 21 matches the expansion portion 111; this structural design enables the clamping portion 21 to be tightly clamped with the clamping groove 11, and after the clamping, it can ensure that the support isolation plate 20 is vertically fixed on the base plate 10; in addition, in order to facilitate the clamping without causing damage, the clamping groove 11 extends through both sides of the base plate 10, so that the clamping portion 21 slides into the clamping groove 11 along one side of the base plate 10. The longitudinal direction of the support isolation plate 20 is restricted, and the inner side of the iron core 60 is in contact with the support isolation plate 20 to restrict the lateral direction of the support isolation plate 20. Through this restriction method, which is similar to the mortise and tenon connection method, the magnetic core 30, the wound coil and the support isolation plate 20 can be firmly fixed in the substrate 10 and the iron core 60. The fixation can be completed only by gluing in sequence. The operation is simple, and the snap-in groove 11 and the snap-in portion 21 are set to a sliding connection method, which will ensure that it can be connected multiple times without causing wear and tear, and can also improve the smoothness of the connection.

[0025] Please refer to Figure 1 , Figure 3 and Figure 6 On the basis of the above technical solution, it is further proposed that three support isolation plates 20 are provided, and three corresponding clamping grooves 11 are provided. The three support isolation plates 20 are respectively connected to the front, middle and rear positions of the magnetic core 30, and the first winding coil 40 and the second winding coil 50 are provided between two adjacent support isolation plates 20; through this arrangement, during the assembly process, the middle support isolation plate 20 is first fixedly installed with the magnetic core 30, and then the first winding coil 40 and the second winding coil 50 are wound, and then the middle support isolation plate 2 0 is fixed to the substrate 10, the first winding coil 40 and the second winding coil 50 are welded to the substrate 10, and finally the front and rear supporting isolation plates 20 are fixed to the substrate 10 and then fixedly connected to the magnetic core 30. Through this installation sequence, the whole can be assembled from the inside to the outside in sequence, and there will not be too much shielding and interference during the assembly process, ensuring the simplicity and speed of the assembly process. The supporting isolation plates 20 are set to three pieces, which can fully support and fix the magnetic core 30, ensuring that the magnetic core 30 is firmly and stably installed inside the iron core 60.

[0026] On the basis of the above technical solution, it is further proposed that the outer surface of the first winding coil 40 and the second winding coil 50 is wrapped with an insulating layer, the insulating layer is made of polyisophthalamide, and the magnetic core 30 is set without an air gap. Among them, the insulating layer made of polyisophthalamide has excellent insulation performance, which can effectively prevent the short circuit between the first winding coil 40 and the second winding coil 50 and the coil and other components, ensure the safety and stability of the inductor during use, reduce the risk of equipment failure caused by short circuit, improve the reliability of equipment operation, and reliably isolate the circuit under conditions such as high voltage and complex electromagnetic environment to ensure the normal function of each component; the magnetic core 30 is set without an air gap to improve the magnetic permeability, so that the inductor can store and transfer energy more effectively. Compared with the magnetic core 30 with an air gap, the magnetic core 30 without an air gap has better magnetic circuit continuity and is easier to pass through, thereby reducing magnetic loss and improving the efficiency of the inductor, which helps to improve the performance of the entire circuit system. For example, in a power conversion circuit, it can improve the power factor and reduce energy loss.

[0027] Please refer to Figure 5-6 On the basis of the above technical scheme, it is further proposed that the support isolation plate 20 is made of high temperature resistant material, and a mounting hole 22 connected to the magnetic core 30 is opened on the support isolation plate 20, and a high temperature resistant rubber ring 23 is arranged around the inner side of the mounting hole 22. The magnetic attraction and the support isolation plate 20 are damped and fixed by the high temperature resistant rubber ring 23, and both ends of the magnetic core 30 are in contact with the inner side of the iron core 60; the high temperature resistant rubber ring 23 has the same heat insulation effect as the support isolation plate 20, and at the same time has a certain damping effect, so that the magnetic core 30 can be initially fixed by the high temperature resistant rubber ring 23 after passing through the support isolation plate 20 along the high temperature resistant rubber ring 23, and then the two ends of the magnetic core 30 are in contact with the inner side of the iron core 60, so that the magnetic core 30 can be firmly fixed between the iron core 60 and the support isolation plate 20.

[0028] Please refer to Figure 1 and Figure 6 On the basis of the above technical solution, for the structural features of the substrate 10, it is further proposed that support blocks 13 are provided at the corners of the substrate 10, and the iron core 60 is carried on the support blocks 13, so that a gap is formed between the iron core 60 and the substrate 10, and the gap between the iron core 60 and the substrate 10 is filled with adhesive. Through this setting, the adhesive can be fully bonded and the adhesive can be easily removed during the later disassembly process. Tin-through plates 14 are provided on both sides of the bottom of the substrate 10. The tin-through plates 14 are mainly used to assist the wave soldering or manual soldering process to ensure the soldering connection between the circuit board and the substrate 10.

[0029] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive in all respects, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention.

Claims

1. A frameless high-power common-mode inductor, characterized in that: The invention comprises a base plate (10), a support isolation plate (20), a magnetic core (30), a first winding coil (40), a second winding coil (50) and an iron core (60); a clamping portion (21) is provided at the lower end of the support isolation plate (20); a clamping groove (11) is provided on the base plate (10) and is connected to the clamping portion (21); the support isolation plate (20) is vertically mounted on the base plate (10) by clamping the clamping portion (21) and the clamping groove (11); the magnetic core (30) penetrates and is fixedly mounted on the support isolation plate (20); the first winding coil (40) and the second winding coil (50) are respectively insulated and wound on the magnetic core (30) ), and the first winding coil (40) and the second winding coil (50) are separated by a supporting isolation plate (20); a connecting pin (12) is provided on the substrate (10) for connecting the two ends of the first winding coil (40) and the second winding coil (50), and the connecting pin (12) extends to the lower end of the substrate (10); the iron core (60) is bonded and fixed on the substrate (10); the iron core (60) is a frame-like structure surrounding the supporting isolation plate (20), the magnetic core (30), the first winding coil (40) and the second winding coil (50), and the iron core (60) is arranged to restrict the disassembly of the supporting isolation plate (20).

2. A frameless high-power common-mode inductor according to claim 1, characterized in that: The cross section of the clamping groove (11) comprises a lower expansion portion (111) and an upper connection portion (112) matching the thickness of the supporting isolation plate (20), and the clamping portion (21) matches the expansion portion (111).

3. A frameless high-power common-mode inductor according to claim 2, characterized in that: The clamping groove (11) extends through both sides of the base plate (10), so that the clamping portion (21) slides into the clamping groove (11) along one side of the base plate (10) to restrict the longitudinal direction of the support isolation plate (20), and the inner side of the iron core (60) abuts against the support isolation plate (20) to restrict the lateral direction of the support isolation plate (20).

4. A frameless high-power common-mode inductor according to any one of claims 1-3, characterized in that: Three supporting isolation plates (20) are provided, and three corresponding clamping grooves (11) are provided. The three supporting isolation plates (20) are respectively connected to the front, middle and rear positions of the magnetic core (30), and the first winding coil (40) and the second winding coil (50) are provided between two adjacent supporting isolation plates (20).

5. The frameless high-power common-mode inductor according to claim 1, characterized in that: The outer surfaces of the first winding coil (40) and the second winding coil (50) are wrapped with an insulating layer, the insulating layer is made of polyisophthalamide (m-phenylene isophthalamide), and the magnetic core (30) is arranged without an air gap.

6. The frameless high-power common-mode inductor according to claim 1, characterized in that: The support isolation plate (20) is made of a high temperature resistant material, and a mounting hole (22) is provided on the support isolation plate (20) to be connected to the magnetic core (30). A high temperature resistant rubber ring (23) is arranged around the inner side of the mounting hole (22). The magnetic attraction and the support isolation plate (20) are fixed by damping through the high temperature resistant rubber ring (23), and both ends of the magnetic core (30) are in contact with the inner side of the iron core (60).

7. The frameless high-power common-mode inductor according to claim 1, characterized in that: Support blocks (13) are provided at corners of the substrate (10), and the iron core (60) is supported on the support blocks (13) so that a gap is formed between the iron core (60) and the substrate (10), and the gap between the iron core (60) and the substrate (10) is filled with adhesive.

8. The frameless high-power common-mode inductor according to claim 1, characterized in that: Tin-penetrating plates (14) are provided on both sides of the bottom of the base plate (10).

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