A magnetic ring insulation structure and a high-power, high-output multi-winding toroidal inductor

Abstract

This invention discloses a magnetic ring insulation structure and a high-power, high-output multi-winding toroidal inductor, relating to the field of inductor technology. It includes a toroidal shell, an annular mounting groove, an annular cover plate, and at least three mounting seats. Each mounting seat has a mounting portion, and a flexible Nomex paper is connected to the mounting portions of every two adjacent mounting seats. In a plane parallel to the radial direction of the toroidal shell, the paper length L1 of the flexible Nomex paper at two connection points is greater than the straight-line distance L2 between the connection points of the two mounting portions. The flexible Nomex paper has insulating properties. Through the bendability and length setting of the flexible Nomex paper, the winding space formed by the flexible Nomex paper and the corresponding shell winding segment is variable. When dealing with coil windings with a large number of turns, the flexible Nomex paper can be spread out by the coil windings to maximize the use of its length L1, thus utilizing the redundant winding space of the flexible Nomex paper in coil windings with a smaller number of turns.

Description

Technical Field

[0001] This invention relates to the field of inductor technology, and in particular to a magnetic ring insulation structure and a high-power, high-output multi-winding toroidal inductor. Background Technology

[0002] The insulation of the magnetic ring in existing multi-winding toroidal inductors mainly involves painting the surface of the magnetic ring or covering it with insulating tape to achieve a certain level of insulation. However, this insulation strength is far from sufficient for high-power, high-output applications. Furthermore, applying the insulating tape is relatively difficult.

[0003] Therefore, the design of adding an insulating partition to the magnetic ring has been proposed and continuously promoted. Its structure is similar to that of Chinese invention application CN116913646A, "A Ring Inductor with High High Frequency Impedance Characteristics", which includes a ring magnetic core. The outer surface of the ring magnetic core is circumferentially wound with multiple sets of coil windings. The inner wall of the ring magnetic core is circumferentially fixed with multiple slots. The inner side of the slots is provided with slots. An epoxy board is inserted into the slots. The epoxy board is used to separate the multiple coil windings. The top of the ring magnetic core is circumferentially fixed with multiple locking components. The locking components are used to limit the position of the epoxy board.

[0004] However, since the epoxy board is designed as a single unit, when the coil windings are set to 3, 4 or more groups, the single unit epoxy board structure is correspondingly set as triangular, quadrangular (also known as cross-shaped) or other multi-rhomboid shapes. Due to the high strength of the epoxy board, when the single unit multi-rhomboid epoxy board is installed on the magnetic ring, the actual thickness or width of the wire that can be wound in each winding is very limited.

[0005] When multi-winding toroidal inductors are adjusted to have different numbers of turns in each winding, it is easy for a certain winding (such as the winding with fewer turns) to occupy less space in the magnetic ring after winding, while a certain winding (such as the winding with more turns) occupies more space in the magnetic ring after winding. If the aforementioned high-hardness, one-piece multi-diamond epoxy board is still used, it is easy for the space reserved for the winding with fewer turns to be large enough, while the space reserved for the winding with more turns is usually insufficient. In some cases, the wires of the winding with more turns may be squeezed against the epoxy board. When this squeezing is severe, it can, in turn, cause the connection and fixing structure of the epoxy board to be squeezed loose, and the outer insulation layer or outer insulation skin of the winding wires to be damaged and cracked. Summary of the Invention

[0006] To overcome the shortcomings mentioned above, the present invention aims to provide a solution that can solve the aforementioned technical problems.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a magnetic ring insulation structure, comprising an annular outer shell, an annular mounting groove for inserting a magnetic ring is formed on one axial end face of the annular outer shell, an annular cover plate corresponding to the opening of the annular mounting groove is provided on the annular outer shell, at least three mounting seats are spaced apart along the circumferential direction of the annular outer shell, and the adjacent mounting seats in the circumferential direction of the annular outer shell are spaced apart to form a shell winding segment; the mounting seat has a mounting part corresponding to the inner annular channel of the annular outer shell, and a flexible Nomex paper is connected to the mounting part of each two adjacent mounting seats; wherein, in a plane direction parallel to the radial direction of the annular outer shell, the paper length L1 of the flexible Nomex paper from the position where it is connected to the mounting part of the first mounting seat to the position where it is connected to the mounting part of the adjacent mounting seat, satisfies that the paper length L1 is greater than the straight-line distance L2 from the position where the mounting part of the first mounting seat is connected to the position where the mounting part of the adjacent second mounting seat is connected.

[0008] As a further aspect of the present invention: the mounting base has an axial connecting portion close to the outer annular side surface of the annular shell, and a first radial connecting portion and a second radial connecting portion close to two axial end faces of the annular shell respectively; the first radial connecting portion and the second radial connecting portion both extend radially along the annular shell to form a mounting portion, and the mounting portion extends beyond the inner annular side surface of the annular shell and corresponds to the inner annular channel of the annular shell.

[0009] As a further aspect of the present invention: a guide groove is provided on the axial connecting part and / or the second radial connecting part, which is radially arranged along the annular shell; a guide block corresponding to the guide groove is formed on the outer annular side surface and / or the axial end surface of the annular shell.

[0010] As a further aspect of the present invention: a mounting groove is provided through the mounting part along the axial direction of the annular outer shell, and the mounting groove also forms a mounting opening along the radial direction of the annular outer shell away from the axial connecting part; a connecting member that mates with the mounting part is correspondingly provided on the mounting base, the length direction of the connecting member is the same as the axial direction of the annular outer shell, the connecting member is configured to slide along the axial direction of the annular outer shell on the mounting groove, and the length of the connecting member satisfies that the connecting member can be located on the mounting groove of the first radial connecting part and the mounting groove of the second radial connecting part at the same time; the connecting member has a first side plate and a second side plate that mate with the two inner side walls of the mounting groove one by one, and a connecting plate for connecting the first side plate and the second side plate, when the connecting member slides on the mounting groove, the first side plate, the second side plate, the connecting plate and the radial inner bottom wall of the mounting groove together enclose a paper edge receiving space; a through hole corresponding to the connecting plate is provided on the flexible Nomex paper, wherein the through hole satisfies that the first side plate can pass through.

[0011] As a further aspect of the present invention: two inner sidewalls adjacent to the mounting slot opening on the mounting groove are each formed with a slot, and the slot penetrates the mounting part along the axial direction of the annular outer shell; the first side plate and the second side plate are each formed with a locking block that mates with the slot on the corresponding mounting groove.

[0012] As a further aspect of the present invention: a plurality of clearance grooves are formed at intervals on the side of the card block on the first side plate, and the plurality of clearance grooves are arranged at intervals along the axial direction of the annular shell; the clearance grooves extend to the first side plate and the connecting plate in a plane direction parallel to the radial direction of the annular shell; wherein, the clearance grooves completely penetrate the card block, the first side plate and the connecting plate in the plane direction to form a connecting channel from the card block on the first side plate to the connecting plate, and the connecting channel simultaneously forms a connecting paper along the receiving space and the inner ring channel of the annular shell.

[0013] As a further aspect of the present invention: when preparing the insertion hole in the flexible Nomex paper, the connecting edge paper corresponding to the connecting channel is retained.

[0014] As a further aspect of the present invention: after the card block and the card slot slide into place, the connector is fixed to the mounting part by applying glue.

[0015] The present invention also provides the following technical solution: a high-power, high-output multi-winding toroidal inductor, characterized in that it includes the above-mentioned magnetic ring insulation structure, a coil winding is wound on the outer shell winding segment of the magnetic ring insulation structure, and a magnetic ring is installed in the annular mounting groove.

[0016] As a further aspect of the present invention, it also includes a base for fixing the wire ends of the coil winding, the base being connected to the annular outer shell by adhesive dispensing.

[0017] Compared with the prior art, the beneficial effects of this technical solution are as follows: The flexible Nomex paper has insulating properties. By using the flexible Nomex paper for insulation, when multiple sets of coil windings with different numbers of turns are wound in the annular shell, the flexible Nomex paper's bendability and length setting make the winding space formed by the flexible Nomex paper and the corresponding shell winding segment variable. When dealing with coil windings with a large number of turns, the flexible Nomex paper can be spread out by the coil windings to make the most of the paper length L1, so as to utilize the redundant winding space of the flexible Nomex paper for coil windings with a smaller number of turns, allowing the winding space applicable to coil windings with a larger number of turns to be larger.

[0018] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a three-dimensional structural view of the present invention;

[0021] Figure 2 This is the main structural view of the present invention;

[0022] Figure 3 yes Figure 2 Enlarged view of the local structure at point A;

[0023] Figure 4 This is a schematic diagram of the connection structure between the connector and the flexible Nomex paper in this invention;

[0024] Figure 5 This is a schematic diagram of the connector in this invention.

[0025] The corresponding labels in the attached diagram are explained as follows:

[0026] Annular outer shell -1, inner ring side -101, outer ring side -102, first axial end face -103, second axial end face -104, annular mounting groove -105, annular cover plate -106, outer shell winding segment -107.

[0027] Mounting base-2, mounting part-201, axial connecting part-202, first radial connecting part-203, second radial connecting part-204.

[0028] Mounting slot - 2011, Mounting opening - 2012, First inner sidewall - 2013, Second inner sidewall - 2014, Radial inner bottom wall - 2015, Slot - 2016

[0029] Flexible Nomex paper-3, insertion hole-301, connecting paper-302

[0030] Connector-4, First side plate-401, Second side plate-402, Connecting plate-403, Locking block-404, Paper edge receiving space-405, Connecting channel-406. Detailed Implementation

[0031] 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.

[0032] Please see Figure 1-5 In this embodiment, a magnetic ring insulation structure includes an annular shell 1. The annular shell 1 has an inner annular side surface 101, an outer annular side surface 102, and a pair of axial end faces corresponding to the axial direction of the annular shell 1. The pair of axial end faces are a first axial end face 103 and a second axial end face 104, respectively. An annular mounting groove 105 for inserting a magnetic ring is formed on the first axial side surface 103.

[0033] The annular mounting groove 105 is configured such that after the magnetic ring is installed in the annular mounting groove 105, the inner annular channel of the magnetic ring corresponds to the inner annular channel of the annular outer shell 1.

[0034] The annular outer shell 1 is provided with an annular cover plate 106 corresponding to the slot of the annular mounting groove 105.

[0035] At least three mounting seats 2 are provided on the annular shell 1 at intervals along the circumferential direction of the annular shell 1. The mounting seats adjacent to each other in the circumferential direction of the annular shell 1 divide the annular shell 1 into shell winding segments 107. That is, multiple mounting seats divide the annular shell 1 into multiple shell winding segments in the circumferential direction of the annular shell 1.

[0036] Mounting base 2 has a mounting portion 201 corresponding to the inner ring channel of the annular outer shell 1. Flexible Nomex paper 3 is connected to the mounting portions of every two adjacent mounting bases. Flexible Nomex paper, also known as flexible rice paper or flexible Nomex, is a synthetic aromatic amide polymer insulating paper. Calendered Nomex paper has good elasticity, tear resistance, and abrasion resistance; thinner products are flexible. Currently, Nomex paper produced by DuPont is widely used in the market.

[0037] In a plane direction parallel to the radial direction of the annular outer shell 1, the length L1 of the flexible nomex paper 3 from the position where it is connected to the mounting part of the first mounting seat to the position where it is connected to the mounting part of the adjacent mounting seat satisfies the condition that the length L1 is greater than the straight-line distance L2 from the connection position of the mounting part of the first mounting seat to the connection position of the mounting part of the adjacent second mounting seat.

[0038] The flexible Nomex paper 3 has insulating properties. When the annular outer shell 1 is used to wind multiple coil windings with different numbers of turns, the flexible Nomex paper 3's bendability and length allow for a variable winding space formed between it and the corresponding outer shell winding segment 107. For coil windings with a larger number of turns, the flexible Nomex paper 3 can be stretched open by the coil windings to maximize the use of its length L1. This utilizes the redundant winding space of the flexible Nomex paper for coil windings with smaller turns, allowing for a larger winding space for coil windings with larger turns. This reduces the likelihood of the wires of large-turn windings being squeezed against the insulating paper or board, causing loosening of the connecting and fixing structures of the insulating paper or board, or damage and cracking of the outer insulation layer or outer insulating skin of the winding wires.

[0039] In this embodiment, the mounting base 2 is arranged in a U-shape, that is, the mounting base 2 has an axial connecting portion 202 close to the outer annular side surface 102 of the annular shell 1. The length direction of the axial connecting portion 202 is parallel to the axial direction of the annular shell 1. The mounting base 2 has a first radial connecting portion 203 and a second radial connecting portion 204 close to the two axial end faces of the annular shell 1, respectively. The length directions of the first radial connecting portion 203 and the second radial connecting portion 204 are the same as the radial direction of the annular shell 1. The axial connecting portion 202 is used to connect the first radial connecting portion 203 and the second radial connecting portion 204.

[0040] One end of the first radial connecting portion 203 away from the axial connecting portion 202 and one end of the second radial connecting portion 204 away from the axial connecting portion 202 both extend radially along the annular outer shell 1 to form a mounting portion 201, wherein the mounting portion 201 extends beyond the inner annular side surface 101 of the annular outer shell 1 to correspond to the inner annular channel of the annular outer shell 1.

[0041] The mounting part 201 has a mounting groove 2011 extending through the axial direction of the annular outer shell 1. The mounting groove 2011 also has a mounting opening 2012 extending radially away from the axial connecting part 202 along the annular outer shell 1. The two inner sidewalls of the mounting groove 2012 adjacent to the mounting opening 2012 are the first inner sidewall 2013 and the second inner sidewall 2014, respectively. The inner sidewall of the mounting groove 2011 opposite to the mounting opening 2012 is the radial inner bottom wall 2015.

[0042] Both the first inner sidewall 2013 and the second inner sidewall 2014 are formed with slots 2016. The slots 2016 penetrate the mounting part 201 along the axial direction of the annular outer shell 1. The cross-sectional shape of the mounting groove 2011 and the slots 2016 after being combined is convex or T-shaped.

[0043] The mounting base 2 is provided with a connecting member 4 that cooperates with the mounting part 201. The length direction of the connecting member 4 is the same as the axial direction of the annular shell 1. The connecting member 4 can slide on the mounting groove 2011 along the axial direction of the annular shell 1. The length of the connecting member 4 is such that the connecting member 4 can be located on the mounting groove of the first radial connecting part 203 and the mounting groove of the second radial connecting part 204 at the same time.

[0044] The connector 4 has a first side plate 401 that mates with the first inner side wall 2013 of the mounting groove 2011, a second side plate 402 that mates with the second inner side wall 2014 of the mounting groove 2011, and a connecting plate 403 for connecting the first side plate 401 and the second side plate 402. Both the first side plate 401 and the second side plate 402 are formed with a locking block 404 that mates with the locking groove on the corresponding mounting groove.

[0045] When the connector 4 slides on the mounting groove 2011, the first side plate 401, the second side plate 402, the connecting plate 403 and the radial inner bottom wall 2015 of the mounting groove 2011 together enclose and form a paper edge receiving space 405.

[0046] The flexible Nomex paper 3 is provided with an insertion hole 301 corresponding to the connecting plate 403. The insertion hole 301 is configured to allow both the first side plate 401 and the locking block 404 on the first side plate to pass through.

[0047] When installing flexible Nomex paper, the first side plate 404 and the first side plate 401 can be passed through the insertion hole in sequence so that the connecting plate 403 can be inserted into the insertion hole 301. Then, multiple flexible Nomex papers can be connected to the corresponding connectors in sequence. Each flexible Nomex paper can be inserted and mated with two adjacent connectors, and each connector can be inserted and mated with two adjacent flexible Nomex papers.

[0048] After the installation is completed, the connecting plate of the connector is slid into the mounting groove along the axial direction of the annular shell, and the locking blocks on the first side plate and the second side plate are engaged with the corresponding locking grooves, and slid into the mounting parts on the first radial connecting part and the second radial connecting part to engage with the connecting part.

[0049] The paper edge receiving space is used to receive the paper edge of the flexible nomex paper (the part from the insertion hole to the paper edge). The cooperation between the locking block and the locking groove serves two purposes: firstly, to guide the sliding of the connecting plate; secondly, in the absence of other connecting and fastening structures, by combining the connection plate with the insertion hole, the flexible nomex paper can be prevented from falling off when the coil winding with a large number of turns spreads the flexible nomex paper, so as to maintain a relatively stable structure for the next process.

[0050] In some embodiments, a plurality of clearance grooves are formed at intervals on the side of the locking block on the first side plate 401. The plurality of clearance grooves are arranged at intervals along the axial direction of the annular outer shell 1. The clearance grooves extend to the first side plate 401 and the connecting plate 403 in a planar direction parallel to the radial direction of the annular outer shell 1. The clearance grooves completely penetrate the locking block on the first side plate, the first side plate 401, and the connecting plate 403 in the planar direction to form a connecting channel from the locking block on the first side plate to the connecting plate 403. The connecting channel 406 simultaneously forms a connecting paper along the receiving space 405 and the inner ring channel of the annular outer shell 1.

[0051] When preparing the insertion hole 301 in the flexible Nomex paper 3, a connecting edge paper 302 corresponding to the connecting channel 406 is retained. The connection edge paper 302 significantly increases the connection range along the edge of the flexible Nomex paper 3, making it less prone to cracking under stress due to the opening of the insertion hole 301. By dividing the overall connecting plate into multiple connecting plates, allowing for multi-position insertion between the connecting plates and the flexible Nomex paper, the flexible Nomex paper is less likely to detach from the connecting member during pre-installation. In this case, when preparing the connecting member 4, especially when using injection molding, the material usage of the workpiece can be effectively reduced.

[0052] In some embodiments, the diameter of the through hole 301 is larger than the width of the corresponding part of the connecting plate 403, so that the part of the flexible nomex paper 3 with the through hole 301 can be moved and adjusted a distance on the connecting plate 403, especially a distance along the radial direction of the annular shell 1, thereby providing additional space for the flexible nomex paper 3 to open and close, and making it more adaptable.

[0053] In some embodiments, the axial connecting portion 202 and the second radial connecting portion 204 are provided with guide grooves arranged radially along the annular housing 1, and guide blocks corresponding to the guide grooves are formed on the outer annular side surface 102 and the second axial end face 104 of the annular housing 1. By providing guide grooves and guide blocks, on the one hand, the mounting base 2 can be connected to a specified position on the annular housing 1 in a specified form; on the other hand, it can also form a mechanism to limit the circumferential movement of the mounting base 2 on the annular housing 1 to ensure the length of each housing winding segment 107.

[0054] In some embodiments, after the card block 404 and the card slot 2016 slide into place, the connector 4 can be fixed to the mounting part 201 by applying adhesive.

[0055] Please see Figure 1-5In this embodiment, a high-power, high-output multi-winding toroidal inductor includes a magnetic ring insulation structure as described in any of the above embodiments. A coil winding is wound on the outer casing winding segment 107 of the magnetic ring insulation structure, and a magnetic ring is installed in the annular mounting groove 105.

[0056] In some embodiments, the multi-winding toroidal inductor further includes a base for securing the ends of the coil windings, the base being connected to the toroidal housing, for example, by dispensing adhesive.

[0057] 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 invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A magnetic ring insulation structure, comprising an annular outer shell, an annular mounting groove for inserting a magnetic ring formed on one axial end face of the annular outer shell, and an annular cover plate corresponding to the opening of the annular mounting groove, characterized in that, At least three mounting seats are provided at intervals along the circumferential direction of the annular shell, and the mounting seats adjacent to each other in the circumferential direction of the annular shell are spaced to form a shell winding segment. The mounting base has a mounting portion with an inner ring channel corresponding to the annular shell, and a flexible Nomex paper is connected to the mounting portion of each two adjacent mounting bases. In the plane direction parallel to the radial direction of the annular shell, the length L1 of the flexible Nomex paper from the position where it is connected to the mounting part of the first mounting seat to the position where it is connected to the mounting part of the adjacent mounting seat satisfies that the length L1 is greater than the straight-line distance L2 from the position where the mounting part of the first mounting seat is connected to the position where the mounting part of the adjacent second mounting seat is connected.

2. The magnetic ring insulation structure according to claim 1, characterized in that, The mounting base has an axial connecting portion close to the outer annular side of the annular housing, and a first radial connecting portion and a second radial connecting portion respectively close to the two axial end faces of the annular housing; Both the first radial connecting portion and the second radial connecting portion extend radially along the annular outer shell to form a mounting portion, which extends beyond the inner annular side of the annular outer shell and corresponds to the inner annular channel of the annular outer shell.

3. The magnetic ring insulation structure according to claim 2, characterized in that, The axial connecting part and / or the second radial connecting part are provided with guide grooves arranged radially along the annular outer shell; Guide blocks corresponding to the guide grooves are formed on the outer annular side surface and / or the axial end surface of the annular shell.

4. The magnetic ring insulation structure according to claim 2 or 3, characterized in that, The mounting part has a mounting groove that runs through the annular outer shell along the axial direction, and the mounting groove also forms a mounting opening that runs radially away from the axial connection part of the annular outer shell. The mounting base is provided with a connector that mates with the mounting part. The length direction of the connector is the same as the axial direction of the annular shell. The connector is configured to slide along the axial direction of the annular shell on the mounting groove. The length of the connector is such that the connector can be located on the mounting groove of the first radial connecting part and on the mounting groove of the second radial connecting part at the same time. The connector has a first side plate and a second side plate that mate with the two inner side walls of the mounting groove, and a connecting plate for connecting the first side plate and the second side plate. When the connector slides on the mounting groove, the first side plate, the second side plate, the connecting plate and the radial inner bottom wall of the mounting groove together enclose a paper edge receiving space. The flexible Nomex paper has through holes corresponding to the connecting plate, wherein the through holes are also designed so that the first side plate can pass through.

5. The magnetic ring insulation structure according to claim 4, characterized in that, The two inner sidewalls adjacent to the mounting slot opening on the mounting slot are each formed with a slot, which passes through the mounting part along the axial direction of the annular outer shell. Both the first and second side plates have locking blocks formed on them that mate with the corresponding mounting slots.

6. The magnetic ring insulation structure according to claim 5, characterized in that, Multiple clearance grooves are formed at intervals on the side of the card block on the first side plate, and the multiple clearance grooves are arranged at intervals along the axial direction of the annular shell. The clearance groove extends to the first side plate and the connecting plate in a plane direction that is radially parallel to the annular outer shell; The clearance groove completely penetrates the locking block, the first side plate, and the connecting plate in the planar direction to form a connecting channel from the locking block on the first side plate to the connecting plate. The connecting channel also forms an inner ring channel connecting the paper edge receiving space and the annular shell.

7. The magnetic ring insulation structure according to claim 6, characterized in that, When preparing the insertion holes in flexible Nomex paper, the connecting edge paper corresponding to the connecting channel is retained.

8. The magnetic ring insulation structure according to any one of claims 5-7, characterized in that, After the card block and card slot slide into place, the connector is fixed to the mounting part by applying glue.

9. A high-power, high-output multi-winding toroidal inductor, characterized in that, The magnetic ring insulation structure includes the magnetic ring insulation structure according to any one of claims 1-8, wherein a coil winding is wound on the outer shell winding segment of the magnetic ring insulation structure, and a magnetic ring is installed in the annular mounting groove.

10. The multi-winding toroidal inductor according to claim 9, characterized in that, It also includes a base for fixing the ends of the coil windings, which is connected to the annular outer shell by adhesive dispensing.

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