Inductor, power conversion equipment and electric vehicle

Abstract

The invention provides an inductor, power conversion equipment and an electric vehicle, and relates to the field of switching devices. The power conversion equipment comprises a shell, a circuit board arranged on the shell and an inductor accommodated in the shell. The inductor comprises a magnetic core, an insulating plate and a winding, the magnetic core comprises a first magnetic column and a second magnetic column, and the first magnetic column and the second magnetic column are oppositely arranged at an interval in the radial direction of the first magnetic column. The first winding comprises a first coil, a second coil and a third coil, the first coil, the insulating plate and the second coil are sequentially arranged on the first magnetic column in a sleeving mode, the third coil is arranged on the second magnetic column in a sleeving mode, a terminal, back to the insulating plate, of the first coil is connected with one terminal of the third coil, and the other terminal of the third coil is connected with a terminal, back to the insulating plate, of the second coil. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate deviate from the third coil along the first radial direction of the first magnetic column and are arranged on the circuit board. The positions of two terminals of the winding can be flexibly adjusted, and miniaturization is facilitated.

Description

Technical Field

[0001] The present application relates to the field of switching devices, and in particular to an inductor, a power conversion device and an electric vehicle. Background Art

[0002] In the existing power conversion equipment, the inductor is housed in the shell; wherein, the inductor includes a magnetic core and a winding, the magnetic core includes two fixed parts and two magnetic columns arranged between the two fixed parts, the winding is formed by winding a wire on one magnetic column first and then on another magnetic column, and both ends of the winding are mounted on the circuit board. With the miniaturization of power conversion equipment, in order to adapt to the space of the shell, it is necessary to adjust the position of the two terminals of the winding. However, the two terminals of the existing winding are close to one of the fixed parts. Adjusting the position of the two terminals of the winding requires adjusting the position of the entire inductor, resulting in the need to reserve adjustment space in the shell, resulting in space waste, which is not convenient for the miniaturization design of the power conversion equipment. Summary of the invention

[0003] The present application provides an inductor, a power conversion device and an electric vehicle, aiming to solve the problem that the power conversion device is not easy to miniaturize.

[0004] In a first aspect, an embodiment of the present application provides a power conversion device. The power conversion device includes a housing, a circuit board and an inductor, wherein the circuit board is disposed in the housing and the inductor is accommodated in the housing. The inductor includes a magnetic core, an insulating plate and a winding, wherein the magnetic core includes a first magnetic column and a second magnetic column, wherein the first magnetic column and the second magnetic column are opposite and spaced apart in the radial direction of the first magnetic column. The winding includes a first coil, a second coil and a third coil, wherein the third coil is sleeved in the second magnetic column, and along the axial direction of the first magnetic column, the first coil, the insulating plate and the second coil are sleeved in the first magnetic column in sequence. The terminal of the first coil facing away from the insulating plate is connected to one terminal of the third coil, and the other terminal of the third coil is connected to the terminal of the second coil facing away from the insulating plate. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both radially away from the third coil along the first magnetic column and are both mounted on the circuit board.

[0005] In the power conversion device provided in the embodiment of the present application, the winding of the inductor is first wound on the first magnetic column through a wire to form a first coil, then wound on the second magnetic column to form a third coil, and then wound on the first magnetic column to form a second coil. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are the two terminals of the winding. The winding of the inductor receives current through the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate. The design of the insulating plate can avoid electrical accidents such as short circuits caused by contact between the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate, which is beneficial to improving the working safety of the inductor, extending the working life of the inductor, and extending the working life of the power conversion device.

[0006] Compared with the prior art, the embodiment of the present application changes the winding method to make the winding. It only needs to adjust the number of turns of the first coil and the number of turns of the second coil to adjust the position of the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate in the axial direction of the first magnetic column, thereby changing the position of the two ends of the winding, which can avoid adjusting the position of the entire inductor due to the need to adjust the position of the two terminals of the winding. The position requirement of the inductor is low. On the one hand, it can avoid reserving adjustment space in the shell, which is conducive to improving the space utilization rate of the shell, the miniaturization design of the shell, and the miniaturization design of the power conversion device; on the other hand, it can avoid redesigning and processing the shell, which is conducive to reducing the design cost and processing cost of the shell. In addition, this method of adjusting the position of the winding pin can avoid introducing a transition piece (such as a copper bus, an electronic wire or a film-wrapped wire) due to adjusting the position of the two terminals of the winding, which is conducive to improving the reliability of the power conversion device, reducing the processing difficulty of the power conversion device, and reducing the processing cost; and, it avoids increasing the resistance of the winding, thereby avoiding the introduction of additional losses, which is conducive to improving the flow efficiency of the inductor and improving the performance of the power conversion device. In addition, this design is not only easy to adjust and has low processing difficulty, but also the processed inductors have high consistency and high processing efficiency, which is conducive to reducing the processing cost of the inductors.

[0007] In a possible implementation, in the axial direction of the first magnetic column, a terminal of the first coil close to the insulating plate and a terminal of the second coil close to the insulating plate are spaced at least a first distance apart, and the first distance is greater than the thickness of the insulating plate.

[0008] The first spacing is the safety distance. In the axial direction of the first magnetic column, the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate are spaced at least by the first spacing, and the first spacing is designed to be greater than the thickness of the insulating plate. By adjusting the thickness of the insulating plate, it is possible to ensure that the spacing between the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate meets the safety regulations, avoiding the occurrence of sparks due to excessive voltage difference between the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate, which is beneficial to improving the safety of the use of the inductor and the safety of the use of the power conversion equipment.

[0009] In one possible implementation, in the axial direction of the first magnetic column, the terminal of the first coil close to the insulating plate extends radially out of the first coil, and in the axial direction of the first magnetic column, the distance between the terminal of the first coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the first coil.

[0010] In the axial direction of the first magnetic column, the design in which the distance between the terminal of the first coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the first coil is conducive to increasing the distance between the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate, which is conducive to reducing the requirements for the thickness of the insulating plate and reducing the thickness of the insulating plate.

[0011] In a possible implementation, the terminal of the second coil close to the insulating plate extends radially out of the second coil, and in the axial direction of the first magnetic column, the distance between the terminal of the second coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the second coil.

[0012] In the axial direction of the first magnetic column, the design in which the distance between the terminal of the second coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the second coil is beneficial to increasing the distance between the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate, which is beneficial to reducing the requirements for the thickness of the insulating plate and reducing the thickness of the insulating plate.

[0013] In a possible implementation manner, a projection of a terminal of the first coil close to the insulating plate along the axial direction of the first magnetic column overlaps with a projection of a terminal of the second coil close to the insulating plate along the axial direction of the first magnetic column.

[0014] The design in which the projection of the terminal of the first coil close to the insulating plate along the axial direction of the first magnetic column overlaps with the projection of the terminal of the second coil close to the insulating plate along the axial direction of the first magnetic column is beneficial to reducing the size of the inductor in a direction perpendicular to the plane where the axis of the first magnetic column and the axis of the second magnetic column are located, is beneficial to improving the space utilization of the inductor, is beneficial to the miniaturized design of the inductor, and is beneficial to the miniaturized design of the power conversion equipment.

[0015] In a possible implementation, in the direction of the common perpendicular line between the axis of the first magnetic column and the axis of the second magnetic column, the maximum distance between the terminal of the first coil close to the insulating plate and the second magnetic column and the maximum distance between the terminal of the second coil close to the insulating plate and the second magnetic column are equal.

[0016] The design that the maximum distance between the terminal of the first coil close to the insulating plate and the second magnetic column and the maximum distance between the terminal of the second coil close to the insulating plate and the second magnetic column are equal in the direction of the common perpendicular line between the axis of the first magnetic column and the axis of the second magnetic column is beneficial to reducing the size of the inductor in the direction of the common perpendicular line between the axis of the first magnetic column and the axis of the second magnetic column, is beneficial to improving the space utilization of the inductor, is beneficial to the miniaturized design of the inductor, and is beneficial to the miniaturized design of the power conversion equipment.

[0017] In one possible implementation, the number of insulating plates and the number of windings are both multiple, and the multiple windings correspond one-to-one to the multiple insulating plates. In the axial direction of the first magnetic column, two adjacent windings are spaced apart, and in the second coil of one winding and the first coil of another adjacent winding, the spacing between the terminal of the second coil away from the first coil and the terminal of the first coil away from the second coil is greater than the thickness of the insulating plate.

[0018] In the second coil of one winding and the first coil of another winding adjacent thereto, the distance between the terminal of the second coil away from the first coil and the terminal of the first coil away from the second coil is designed to be greater than the thickness of the insulating plate, thereby ensuring that in the second coil of one winding and the first coil of another winding adjacent thereto, the distance between the terminal of the second coil away from the first coil and the terminal of the first coil away from the second coil meets the safety distance, which is beneficial to improving the safety of the use of the inductor and the safety of the use of the power conversion equipment.

[0019] In a possible implementation manner, a winding direction of the third coil is opposite to a winding direction of the first coil and opposite to a winding direction of the second coil.

[0020] The winding direction of the third coil is opposite to that of the first coil and opposite to that of the second coil, which facilitates smooth winding on the first magnetic column and the second magnetic column through a wire, helps to reduce the processing difficulty of the winding and reduces the processing cost of the inductor.

[0021] In a possible implementation, the inductor further includes an inductor shell, which is at least partially housed in the shell, the magnetic core, the insulating plate and the third coil are all housed in the inductor shell, the first coil is partially housed in the inductor shell, and the second coil is partially housed in the inductor shell; wherein the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both located outside the inductor shell.

[0022] Since the magnetic core, the insulating plate and the third coil are all housed in the inductor housing, the first coil is partially housed in the inductor housing and the second coil is partially housed in the inductor housing, the inductor housing can protect the magnetic core, the insulating plate and the winding. Moreover, the design that the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate are both located outside the inductor housing facilitates the connection of the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate with the circuit board, which is conducive to reducing the processing cost of the power conversion equipment.

[0023] In one possible implementation, the circuit board is located on one side of the winding in a direction perpendicular to the plane where the axis of the first magnetic column and the axis of the second magnetic column are located, and the power conversion device also includes a connecting terminal, which is arranged on the side of the first coil facing away from the third coil, and the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both mounted on the circuit board through the connecting terminal.

[0024] The design of the connection terminal ensures that the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate can be mounted on the circuit board, and the circuit board can be arranged on one side of the winding in a direction perpendicular to the plane where the axis of the first magnetic column and the axis of the second magnetic column are located. The circuit board can be arranged in a variety of positions, which is conducive to reducing the difficulty of design and reducing the design cost.

[0025] In one possible embodiment, the connecting terminal includes a plurality of first pins, each of which is provided with a slot, and the slot passes through the first pin along a common perpendicular direction of the axis of the first magnetic column and the axis of the second magnetic column; the plurality of first pins include a first sub-pin and a second sub-pin, and in the axial direction of the first magnetic column, the first sub-pin and the second sub-pin are opposite to and spaced apart from each other, and the terminal of the first coil close to the insulating plate is inserted into the slot of the first sub-pin, and the terminal of the second coil close to the insulating plate is inserted into the slot of the second sub-pin.

[0026] The design in which the terminal of the first coil close to the insulating plate is inserted into the slot of the first sub-pin, and the terminal of the second coil close to the insulating plate is inserted into the slot of the second sub-pin is conducive to improving the space utilization occupied by the inductor and the connecting terminal, and is conducive to reducing the size of the power conversion equipment in the direction of the common perpendicular line of the axis of the first magnetic column and the axis of the second magnetic column, which is conducive to the miniaturization design of the power conversion equipment; moreover, the structure is simple and stable, and the processing difficulty is low, which is conducive to reducing the processing cost of the power conversion equipment.

[0027] In one possible embodiment, the connecting terminal includes a plurality of second pins. In the axial direction of the first magnetic column, the plurality of second pins are located between the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate. The plurality of second pins are spaced apart from each other. The second pins extend in a direction perpendicular to the plane where the axis of the first magnetic column and the axis of the second magnetic column are located and are inserted into the circuit board.

[0028] In the axial direction of the first magnetic column, the design of multiple second pins being located between the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate is beneficial to improving the space utilization occupied by the inductor and the connecting terminals, improving the space utilization of the power conversion equipment, and facilitating the miniaturization design of the power conversion equipment.

[0029] In a possible implementation, the circuit board is located on a side of the first coil facing away from the third coil, and the terminals of the first coil close to the insulating board and the terminals of the second coil close to the insulating board are both inserted into the circuit board.

[0030] The design in which the terminals of the first coil close to the insulating plate and the terminals of the second coil close to the insulating plate are both inserted into the circuit board can avoid the need to set additional connecting terminals between the terminals of the first coil close to the insulating plate and the circuit board and between the terminals of the second coil close to the insulating plate and the circuit board. The structure is simple and stable, which is conducive to reducing the processing cost of the power conversion equipment.

[0031] In the second aspect, the embodiments of the present application also provide an inductor. The inductor includes a magnetic core, an insulating plate and a winding. The magnetic core includes a first magnetic column and a second magnetic column. In the first radial direction of the first magnetic column, the first magnetic column and the second magnetic column are opposite and spaced apart. The winding includes a first coil, a second coil and a third coil. The third coil is sleeved on the second magnetic column. Along the axial direction of the first magnetic column, the first coil, the insulating plate and the second coil are sleeved on the first magnetic column in sequence. The terminal of the first coil facing away from the insulating plate is connected to one terminal of the third coil, and the other terminal of the third coil is connected to the terminal of the second coil facing away from the insulating plate. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both away from the third coil along the radial direction of the first magnetic column.

[0032] In a third aspect, an embodiment of the present application further provides an electric vehicle, wherein the electric vehicle comprises a power battery and the power conversion device described in any one of the first aspects, wherein the power battery is electrically connected to the circuit board. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the background technology, the drawings required for use in the embodiments of the present application or the background technology will be described below.

[0034] Figure 1 It is a structural block diagram of an application scenario of an electric vehicle provided in an embodiment of the present application;

[0035] Figure 2 is a schematic diagram of a three-dimensional structure of a power conversion device provided in an embodiment of the present application;

[0036] Figure 3 yes Figure 2 The three-dimensional structure exploded schematic diagram of the power conversion device shown;

[0037] Figure 4 yes Figure 2 The power conversion device shown is a schematic diagram of a three-dimensional structure in which the second housing, the circuit board, the first power device and the second power device are omitted;

[0038] Figure 5 yes Figure 4The illustrated schematic diagram of the three-dimensional structure of the power conversion device omitting the first housing;

[0039] Figure 6 yes Figure 5 A schematic diagram of a three-dimensional structure decomposition of an inductor (with the inductor housing omitted) of a power conversion device shown;

[0040] Figure 7 yes Figure 6 A schematic diagram of the three-dimensional structure of the insulating plate and the winding shown;

[0041] Figure 8 yes Figure 7 A schematic diagram of the three-dimensional structure of the insulating plate and the winding at another angle is shown;

[0042] Fig. 9 yes Figure 4 The power conversion device shown is a schematic structural diagram at another angle with the first housing omitted;

[0043] Fig.10 yes Fig. 9 An enlarged view of a portion X of the power conversion device shown;

[0044] Fig.11 It is a structural schematic diagram of another power conversion device provided in an embodiment of the present application in which the second shell is omitted. DETAILED DESCRIPTION

[0045] The embodiment of the present application provides an inductor, a power conversion device and an electric vehicle. The inductor is applied to the power conversion device, and the power conversion device is applied to the electric vehicle. The embodiment of the present application aims to solve the problem that the power conversion device is not easy to miniaturize.

[0046] The embodiments of the present application are described below in conjunction with the drawings in the embodiments of the present application.

[0047] See also Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 , Figure 1 It is a structural block diagram of an application scenario of an electric vehicle 1000 provided in an embodiment of the present application. Figure 2 It is a schematic diagram of the three-dimensional structure of a power conversion device 100 provided in an embodiment of the present application. Figure 3 yes Figure 2 The schematic diagram of the three-dimensional structure explosion of the power conversion device 100 is shown. Figure 4 yes Figure 2The power conversion device 100 shown in the figure omits the second housing 12 , the circuit board 20 , the first power device 50 and the second power device 60 .

[0048] like Figure 1 As shown, the electric vehicle 1000 includes a power conversion device 100, a power battery 200 and a motor 300. The power battery 200 is electrically connected to the power conversion device 100 and the motor 300. The power conversion device 100 is used to convert the AC power output by the power grid or the AC power source 2000 into DC power, and store it in the power battery 200. The power battery 200 can output DC power to the motor 300 to drive the motor 300 to work. The motor 300 is used to provide driving force for the electric vehicle 1000. Exemplarily, the power conversion device 100 is an OBC (On-board charger), which can be a 250kw (kilowatt) OBC. In some other embodiments, the power conversion device 100 can also be a rectifier or inverter or other electronic device used for power conversion.

[0049] like Figure 2 , Figure 3 and Figure 4 As shown, the power conversion device 100 includes a housing 10, an inductor 30 and a circuit board 20, and also includes a connecting terminal 40, a first power device 50 and a second power device 60. For the convenience of description, the embodiment of the present application defines any three different directions as a first direction, a second direction and a third direction in sequence, the second direction is perpendicular to the first direction, and the third direction is perpendicular to both the first direction and the second direction. In this embodiment, the length direction of the circuit board 20 is parallel to the first direction (i.e., the X-axis direction shown in the figure), the width direction of the circuit board 20 is parallel to the second direction (i.e., the Y-axis direction shown in the figure), and the thickness direction of the circuit board 20 is parallel to the third direction (i.e., the Z-axis direction shown in the figure). In some other embodiments, the width direction of the circuit board 20 may also be parallel to the X-axis direction or the Z-axis direction, and the length direction of the circuit board 20 may also be parallel to the Y-axis direction or the Z-axis direction. The thickness direction of the circuit board 20 may also be parallel to the Y-axis direction or the X-axis direction.

[0050] The circuit board 20 is disposed in the shell 10. Specifically, the circuit board 20 is disposed on the outside of the shell 10; wherein, in the Z-axis direction (i.e., the third direction), the circuit board 20 is disposed on one side of the shell 10. Specifically, the shell 10 includes a first shell 11 and a second shell 12, and the first shell 11 is provided with a receiving groove 111, and the receiving groove 111 extends along the Z-axis direction. In the Z-axis direction, the second shell 12 is fixedly connected to one side of the first shell 11 and covers the receiving groove 111. The circuit board 20 is fixedly connected to the side of the second shell 12 facing away from the first shell 11 by means including but not limited to welding, threaded connection or adhesive connection. wherein the circuit board 20 is connected to the power battery 200 (such as Figure 1 As shown), the power battery 200 is electrically connected to the circuit board 20.

[0051] The inductor 30 is received in the housing 10. One side of the inductor 30 in the Y-axis direction is exposed to the outside of the housing 10. Specifically, the first housing 11 is further provided with a matching hole 112, which penetrates the first housing 11 along the Y-axis direction and communicates with the receiving groove 111. The inductor 30 is partially received in the receiving groove 111 and partially extends from the matching hole 112. In some other embodiments, the inductor 30 can also be completely received in the receiving groove 111. The inductor 30 is mounted on the circuit board 20 and is electrically connected to the circuit board 20.

[0052] In the Y-axis direction, the connection terminal 40 is disposed on one side of the inductor 30 and is located outside the housing 10. The inductor 30 is mounted on the circuit board 20 through the connection terminal 40. In some other embodiments, the connection terminal 40 may be omitted, the circuit board 20 may be disposed on one side of the housing 10 in the Y-axis direction, and the inductor 30 may be directly mounted on the circuit board 20. In some other embodiments, the circuit board 20 and the connection terminal 40 may also be both accommodated in the housing 10, and the inductor 30 is not exposed outside the housing 10.

[0053] In the Z-axis direction, the first power device 50 is mounted on one side of the circuit board 20 and is electrically connected to the circuit board 20. In the Z-axis direction, the second power device 60 is mounted on one side of the circuit board 20 and is electrically connected to the circuit board 20. In the Z-axis direction, the first power device 50 and the second power device 60 are both mounted on the side of the circuit board 20 facing away from the housing 10. In some other embodiments, the first power device 50 and the second power device 60 may also be mounted on the side of the circuit board 20 facing the housing 10.

[0054] like Figure 1 , Figure 2 and Figure 3 As shown, the AC power output by the power grid or AC power source 2000 is transmitted to the first power device 50 through the circuit board 20 via the inductor 30. The inductor 30 cooperates with the first power device 50 to perform power factor calibration on the AC power and convert the AC power into DC power. The DC power is transmitted to the second power device 60 through the circuit board 20, and the second power device 60 is used to boost the DC power and store the boosted DC power in the power battery 200. In the process of converting AC power into DC power, the power factor calibration process can make the phase of the AC voltage the same as the phase of the current, and the frequency of the AC voltage the same as the frequency of the current. In this way, it is beneficial to reduce the loss of electric energy during the conversion process and to improve the utilization rate of electric energy. It can be understood that the inductor 30 is a power inductor. Specifically, it is a PFC (Power Factor Correction) inductor.

[0055] In some other embodiments, the inductor 30 may also be a filter inductor. Specifically, the first power device 50 may be a DC / AC (Di rect Current / Alternating Current) module. The power conversion device 100 may also include a capacitor. The alternating current output by the power grid or the AC power source 2000 is transmitted to the first power device 50 through the circuit board 20, and the first power device 50 converts the alternating current into direct current. The direct current is transmitted to the second power device 60 through the circuit board 20, and the second power device 60 performs a voltage boost on the direct current. The boosted direct current is transmitted to the inductor 30 and the capacitor through the circuit board 20. The inductor 30 cooperates with the capacitor to filter the direct current. The filtered direct current is stored in the power battery 200. The inductor 30 may be a power inductor or a filter inductor, and the inductor 30 has a wide range of application scenarios.

[0056] See also Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 and Fig.10 , and combined with Figure 1 , Figure 2 and Figure 3 , Figure 5 yes Figure 4 The power conversion device 100 shown is a schematic exploded perspective view of the three-dimensional structure in which the first housing 11 is omitted. Figure 6 yes Figure 5 The schematic diagram of the exploded three-dimensional structure of the inductor 30 (the inductor housing 34 is omitted) of the power conversion device 100 is shown. Figure 7 yes Figure 6 The three-dimensional structural schematic diagram of the insulating plate 32 and the winding 33 is shown. Figure 8 yes Figure 7 The insulating plate 32 and the winding 33 are shown as a three-dimensional structural schematic diagram at another angle. Fig. 9 yes Figure 4 The power conversion device 100 shown is a schematic structural diagram at another angle in which the first housing 11 is omitted. Fig.10 yes Fig. 9 An enlarged view of a portion X of the power conversion device 100 is shown.

[0057] like Figure 3 , Figure 4 and Figure 5As shown, the inductor 30 includes a magnetic core 31, an insulating plate 32 and a winding 33, and also includes an inductor housing 34. The inductor housing 34 is used to accommodate the magnetic core 31, the insulating plate 32 and the winding 33. The inductor housing 34 is at least partially accommodated in the housing 10. In this embodiment, the inductor housing 34 is partially accommodated in the receiving groove 111 of the housing 10, and partially extends from the matching hole 112. Specifically, the inductor housing 34 includes a first matching wall 341, a second matching wall 342, two third matching walls 343 and a fourth matching wall 344. The first matching wall 341, the second matching wall 342, the two third matching walls 343 and the fourth matching wall 344 are surrounded to form a mounting groove 345. The opening 345a of the mounting groove 345 faces the second housing 12. The second housing 12 covers the opening 345a of the mounting groove 345 and closes the mounting groove 345. In the Y-axis direction, the first matching wall 341 and the second matching wall 342 are opposite and spaced apart. In the X-axis direction, the two third matching walls 343 are arranged opposite to each other and spaced apart. In the Z-axis direction, the fourth matching wall 344 is arranged opposite to the opening 345a of the mounting groove 345. The first matching wall 341 partially extends from the matching hole 112. In some other embodiments, the inductor housing 34 can also be completely accommodated in the receiving groove 111 of the housing 10, and the first matching wall 341 partially emerges from the matching hole 112 to the outside of the housing 10. Among them, the shape of the projection of the inductor housing 34 along the Z-axis direction can be rectangular (square or rectangular), circular or other special shapes. The inductor housing 34 can be made of insulating materials such as epoxy resin or rubber.

[0058] like Figure 6 , Figure 7 and Figure 8 As shown, the magnetic core 31 includes a fixing portion 311, a first magnetic column 312 and a second magnetic column 313. The axial direction of the first magnetic column 312 and the axial direction of the second magnetic column 313 are parallel to the X-axis direction, and the radial direction of the first magnetic column 312 and the radial direction of the second magnetic column 313 are perpendicular to the X-axis direction. In the Y-axis direction (i.e., the radial direction of the first magnetic column 312), the first magnetic column 312 and the second magnetic column 313 are opposite and spaced apart. The first magnetic column 312 and the second magnetic column 313 are fixedly connected by the fixing portion 311. Specifically, in the X-axis direction, the fixing portion 311 contacts and is fixedly connected to one side of the first magnetic column 312 and the second magnetic column 313. It can be understood that the direction perpendicular to the plane where the axis of the first magnetic column 312 and the axis of the second magnetic column 313 are located is parallel to the Z-axis direction, and the common perpendicular direction of the axis of the first magnetic column 312 and the second magnetic column 313 is parallel to the Y-axis direction.

[0059] The cross-sectional shape of the first magnetic column 312 and the cross-sectional shape of the second magnetic column 313 may be circular, square or elliptical. The cross-sectional shape of the first magnetic column 312 and the cross-sectional shape of the second magnetic column 313 may also be a runway shape or other special shapes. Specifically, the first magnetic column 312 (the second magnetic column 313) may be provided with a hole that passes through the first magnetic column 312 (the second magnetic column 313) along the X-axis direction, so that the cross-sectional shape of the first magnetic column 312 (the second magnetic column 313) is a runway shape. It should be noted that the cross-sectional shape of the first magnetic column 312 and the cross-sectional shape of the second magnetic column 313 are both perpendicular to the X-axis direction.

[0060] The insulating plate 32 can be made of insulating materials including but not limited to plastic or epoxy resin. The winding 33 includes a first coil 331, a second coil 332 and a third coil 333. The third coil 333 is sleeved on the second magnetic column 313. Along the X-axis direction (i.e., the axial direction of the first magnetic column 312), the first coil 331, the insulating plate 32 and the second coil 332 are sleeved on the first magnetic column 312 in sequence. For the convenience of description, the two terminals of the first coil 331 are defined as the first terminal 331a and the second terminal 331b, respectively. The first terminal 331a is close to the insulating plate 32, and the second terminal 331b is facing away from the insulating plate 32. The two terminals of the second coil 332 are defined as the third terminal 332a and the fourth terminal 332b, respectively. The third terminal 332a is facing away from the insulating plate 32, and the fourth terminal 332b is close to the insulating plate 32.

[0061] The second terminal 331b (i.e., the terminal of the first coil 331 facing away from the insulating plate 32) is connected to one terminal 333a of the third coil 333, and the other terminal 333b of the third coil 333 is connected to the third terminal 332a (i.e., the terminal of the second coil 332 facing away from the insulating plate 32). The first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both away from the third coil 333 along the Y-axis direction (i.e., the radial direction of the first magnetic column 312). It can be understood that the winding 33 is formed by winding a wire. The wire can be a transmission wire such as a round wire, a flat wire or a Litz wire.

[0062] like Figure 3 , Figure 4 and Figure 6As shown, the magnetic core 31, the insulating plate 32 and the third coil 333 are all accommodated in the inductor housing 34, the first coil 331 is partially accommodated in the inductor housing 34, and the second coil 332 is partially accommodated in the inductor housing 34; wherein, the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both located outside the inductor housing 34 and outside the housing 10. Specifically, the magnetic core 31, the insulating plate 32 and the third coil 333 are all accommodated in the mounting groove 345. wherein, the first matching wall 341 is located on the side of the first magnetic column 312 facing away from the second magnetic column 313, and the second matching wall 342 is located on the side of the second magnetic column 313 facing away from the first magnetic column 312. The first coil 331 is partially accommodated in the mounting groove 345, and partially passes through the first matching wall 341 and extends out of the housing 10 from the matching hole 112. The second coil 332 is partially received in the mounting groove 345, and partially passes through the first matching wall 341 and extends out of the housing 10 from the matching hole 112. The first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both located on the side of the first matching wall 341 facing away from the second matching wall 342. It can be understood that in the Z-axis direction (i.e., the direction perpendicular to the plane where the axis of the first magnetic column 312 and the axis of the second magnetic column 313 are located), the circuit board 20 is located on one side of the winding 33.

[0063] The first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both mounted on the circuit board 20. Specifically, in the Y-axis direction, the connecting terminal 40 is arranged on the side of the first coil 331 facing away from the third coil 333, and the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both mounted on the circuit board 20 through the connecting terminal 40. In this embodiment, in the Y-axis direction, the connecting terminal 40 contacts and is fixedly connected to one side of the inductor housing 34 and is located outside the housing 10. Specifically, the connecting terminal 40 contacts and is fixedly connected to the side of the first matching wall 341 facing away from the second matching wall 342. Among them, the connecting terminal 40 and the inductor housing 34 are integrally formed. In this way, it is beneficial to improve the structural stability of the connection between the connecting terminal 40 and the inductor housing 34, and it is beneficial to improve the structural strength of the power conversion device 100. In some other embodiments, the connection terminal 40 and the inductor housing 34 may also be fixedly connected by means including but not limited to welding, adhesive bonding or fasteners. In some other embodiments, the connection terminal 40 may also be fixedly connected to the housing 10 .

[0064] Exemplarily, the number of the fixing parts 311, the number of the first magnetic pillars 312, and the number of the second magnetic pillars 313 can be multiple. In the X-axis direction, the multiple first magnetic pillars 312 are arranged in sequence and spaced apart, and the multiple second magnetic pillars 313 are arranged in sequence and spaced apart. A fixing part 311 is provided between two adjacent first magnetic pillars 312 and between two adjacent second magnetic pillars 313, and the two adjacent first magnetic pillars 312 and the two adjacent second magnetic pillars 313 are fixedly connected by the fixing part 311. Exemplarily, the number of the fixing parts 311 is 3, and the number of the first magnetic pillars 312 and the number of the second magnetic pillars 313 are both 2. In the X-axis direction, the three fixing parts 311 are arranged in sequence and spaced apart, and one first magnetic pillar 312 and one second magnetic pillar 313 are fixedly connected between two adjacent fixing parts 311, and another first magnetic pillar 312 and another second magnetic pillar 313 are fixedly connected between two other adjacent fixing parts 311.

[0065] Exemplarily, the number of insulating plates 32, the number of windings 33 and the number of connecting terminals 40 are all multiple. Specifically, the number of insulating plates 32, the number of windings 33 and the number of connecting terminals 40 are all 2. Each winding 33 corresponds to a first magnetic column 312 and a second magnetic column 313. Multiple windings 33 correspond one-to-one to multiple insulating plates 32 and multiple connecting terminals 40. In the corresponding windings 33 and insulating plates 32, the first terminal 331a is close to the insulating plate 32, the second terminal 331b is back to the insulating plate 32, the third terminal 332a is back to the insulating plate 32, and the fourth terminal 332b is close to the insulating plate 32. In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the multiple windings 33 are arranged in sequence at intervals, and two adjacent windings 33 are arranged at intervals. Multiple connecting terminals 40 are arranged in sequence at intervals. Multiple windings 33 are mounted on the circuit board 20 through corresponding connecting terminals 40. In each winding 33, it can be connected to a power grid or an AC power supply 2000 (such as Figure 1 ) and is electrically connected to the first power device 50. Specifically, the first terminal 331a (or the fourth terminal 332b) of each winding 33 is electrically connected to the single phase of the power grid or the AC power source 2000; the fourth terminal 332b (or the first terminal 331a) is electrically connected to the first power device 50. Among them, multiple windings 33 can be electrically connected to the multi-phase of the power grid or the AC power source 2000 respectively. Specifically, two windings 33 are electrically connected to the two phases of the power grid or the AC power source 2000 respectively. In some other embodiments, multiple windings 33 can also be electrically connected to the single phase of the power grid or the AC power source 2000.

[0066] In the power conversion device 100 provided in the embodiment of the present application, the winding 33 of the inductor 30 is firstly wound on the first magnetic column 312 through a wire to form a first coil 331, then wound on the second magnetic column 313 to form a third coil 333, and then wound on the first magnetic column 312 to form a second coil 332, and the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are two terminals of the winding 33. The winding 33 of the inductor 30 receives current through the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32). The design of the insulating plate 32 can prevent electrical accidents such as short circuits caused by contact between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32), which is beneficial to improving the working safety of the inductor 30, extending the working life of the inductor 30, and extending the working life of the power conversion device 100.

[0067] Compared with the prior art, the embodiment of the present application changes the winding method to form the winding 33. It only needs to adjust the number of turns of the first coil 331 and the number of turns of the second coil 332 to adjust the positions of the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) in the X-axis direction (i.e., the axial direction of the first magnetic column 312), thereby changing the positions of the two terminals of the winding 33. It is possible to avoid adjusting the position of the entire inductor 30 due to the need to adjust the positions of the two terminals of the winding 33. The position requirements for the inductor 30 are low. On the one hand, it is possible to avoid reserving adjustment space in the shell 10, which is beneficial to improving the space utilization rate of the shell 10, facilitating the miniaturized design of the shell 10, and facilitating the miniaturized design of the power conversion device 100. On the other hand, it is possible to avoid redesigning and processing the shell 10, which is beneficial to reducing the design cost and processing cost of the shell 10. In addition, this method of adjusting the position of the winding 33 pins can avoid the introduction of adapters (such as copper bars, electronic wires or film-wrapped wires) due to the adjustment of the positions of the two terminals of the winding 33, which is conducive to improving the reliability of the power conversion device 100, reducing the difficulty of processing the power conversion device 100, and reducing the processing cost; and avoiding increasing the resistance of the winding 33, thereby avoiding the introduction of additional losses, which is conducive to improving the flow efficiency of the inductor 30 and improving the performance of the power conversion device 100. In addition, this design is not only easy to adjust and has low processing difficulty, but also the processed inductor 30 has high consistency and high processing efficiency, which is conducive to reducing the processing cost of the inductor 30.

[0068] Since the magnetic core 31, the insulating plate 32 and the third coil 333 are all accommodated in the inductor housing 34, the first coil 331 is partially accommodated in the inductor housing 34 and the second coil 332 is partially accommodated in the inductor housing 34, the inductor housing 34 can protect the magnetic core 31, the insulating plate 32 and the winding 33. Moreover, the design that the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are both located outside the inductor housing 34 facilitates the connection of the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) with the circuit board 20, which is conducive to reducing the processing cost of the power conversion device 100.

[0069] The design of the connection terminal 40 ensures that the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) can be installed on the circuit board 20. The circuit board 20 can be set on one side of the winding 33 in the Z-axis direction (i.e., the direction perpendicular to the plane where the axis of the first magnetic column 312 and the axis of the second magnetic column 313 are located). The circuit board 20 can be set in a variety of positions, which is conducive to reducing the difficulty of design and reducing the design cost.

[0070] like Figure 3 , Figure 4 and Figure 5 As shown, in some embodiments, the inductor housing 34 is further provided with a through hole 3441, and the through hole 3441 penetrates the fourth matching wall 344 along the Y-axis direction and communicates with the mounting groove 345. The first housing 11 covers the through hole 3441 and closes the mounting groove 345. Exemplarily, the number of through holes 3441 is multiple. In the X-axis direction, multiple through holes 3441 are arranged at intervals. The design of the through hole 3441 is conducive to reducing the weight of the inductor housing 34, and is conducive to the lightweight design of the inductor 30 and the power conversion device 100.

[0071] like Figure 6 , Figure 7 and Figure 8 As shown, in some embodiments, the winding direction W1 of the third coil 333 is opposite to the winding direction W2 of the first coil 331, and opposite to the winding direction W3 of the second coil 332. The design that the winding direction W1 of the third coil 333 is opposite to the winding direction W2 of the first coil 331, and opposite to the winding direction W3 of the second coil 332 facilitates smooth winding on the first magnetic column 312 and the second magnetic column 313 through a single wire, which is conducive to reducing the processing difficulty of the winding 33 and reducing the inductance 30 (such as Figure 4 The processing cost is shown in Figure 2.

[0072] like Figure 4 and Figure 7 As shown, in some embodiments, the projection of the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) along the X-axis direction (i.e., the axial direction of the first magnetic column 312) overlaps with the projection of the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) along the X-axis direction (i.e., the axial direction of the first magnetic column 312). The design of overlapping the projection of the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) along the X-axis direction (i.e., the axial direction of the first magnetic column 312) and the projection of the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) along the X-axis direction (i.e., the axial direction of the first magnetic column 312) is conducive to reducing the size of the inductor 30 in the Z-axis direction (i.e., the direction perpendicular to the plane where the axis of the first magnetic column 312 and the axis of the second magnetic column 313 are located), is conducive to improving the space utilization of the inductor 30, is conducive to the miniaturization design of the inductor 30, and is conducive to the power conversion device 100 (such as Figure 2 The miniaturized design shown in FIG.

[0073] like Figure 4 and Fig. 9 As shown, in some embodiments, in the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the second magnetic column 313), the maximum distance d1 between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the second magnetic column 313, and the maximum distance d2 between the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) and the second magnetic column 313 are equal. In the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the second magnetic column 313), the design that the maximum distance d1 between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the second magnetic column 313, and the maximum distance d2 between the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) and the second magnetic column 313 are equal is conducive to reducing the size of the inductor 30 in the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the axis of the second magnetic column 313), is conducive to improving the space utilization of the inductor 30, is conducive to the miniaturized design of the inductor 30, and is conducive to the power conversion device 100 (such as Figure 2 The miniaturized design shown in FIG.

[0074] like Figure 7 and Fig. 9As shown, in some embodiments, in the X-axis direction (i.e., the axial direction of the first magnetic column 312), the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are spaced at least a first distance, and the first distance is greater than the thickness of the insulating plate 32 (i.e., the size of the insulating plate 32 in the X-axis direction). Specifically, in the X-axis direction (i.e., the first direction), the distance B1 between the first terminal 331a and the fourth terminal 332b is greater than the first distance. In some other embodiments, the distance B1 between the first terminal 331a and the fourth terminal 332b may also be equal to the first distance. The first distance is a safety distance. In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are spaced at least a first distance apart, and the first distance is designed to be greater than the thickness of the insulating plate 32. By adjusting the thickness of the insulating plate 32, it is possible to ensure that the distance B1 between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) meets safety regulations, thereby avoiding the occurrence of sparks due to excessive pressure difference between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32), which is beneficial to improving the use safety of the inductor 30 and the power conversion device 100 (such as Figure 2 safety of use).

[0075] like Figure 6 , Figure 7 and Fig.10As shown, in some embodiments, the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) extends out of the first coil 331 along the Y-axis direction (i.e., the radial direction of the first coil 331), and in the X-axis direction (i.e., the axial direction of the first magnetic column 312), the distance between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the insulating plate 32 is greater than the minimum distance between the insulating plate 32 and the first coil 331. Specifically, the first coil 331 includes a first section 3311, a second section 3312, and a third section 3313, and the first section 3311 is wound around the outside of the first magnetic column 312. The second section 3312 is located on a side of the first section 3311 close to the insulating plate 32 and is connected to the first section 3311 and is away from the third coil 333 along the Y-axis direction. The first terminal 331a is located on a side of the second section 3312 that is away from the insulating plate 32; wherein, the first terminal 331a is located on a side of the first section 3311 that is away from the third coil 333. The third section 3313 is disposed between the first terminal 331a and the second section 3312. The second terminal 331b is located on the side of the first section 3311 facing away from the insulating plate 32 and connected to the first section 3311. The minimum distance between the insulating plate 32 and the first coil 331 is the distance between the second section 3312 and the insulating plate 32 in the X-axis direction.

[0076] The third section 3313 includes a first subsection 3313a, a second subsection 3313b and a third subsection 3313c. In the Y-axis direction, the first subsection 3313a is fixedly connected to the end of the second section 3312 facing away from the third coil 333, and the first subsection 3313a extends along the Y-axis direction. In the X-axis direction, the second subsection 3313b is located on the side of the first subsection 3313a facing away from the insulating plate 32, and in the Y-axis direction, the second subsection 3313b is located on the side of the first subsection 3313a facing away from the second section 3312. The second subsection 3313b is fixedly connected to the first subsection 3313a and has an arc transition. In the X-axis direction, the third subsection 3313c is located on the side of the second subsection 3313b facing away from the first subsection 3313a. And in the Y-axis direction, the third subsection 3313c is located on the side of the second subsection 3313b facing away from the first subsection 3313a. The third sub-segment 3313c is fixedly connected to the second sub-segment 3313b and has an arc transition. In some other embodiments, the third segment 3313 may also be a straight segment, a wavy segment or other special-shaped segments. The structure of the third segment 3313 is diverse, the design difficulty is low, and it is conducive to reducing processing costs.

[0077] In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the design that the distance between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the insulating plate 32 is greater than the minimum distance between the insulating plate 32 and the first coil 331 is conducive to increasing the distance B1 (i.e., the terminal of the first coil 331 close to the insulating plate 32) between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) Fig. 9 As shown), it is beneficial to reduce the requirement on the thickness of the insulating plate 32, and is beneficial to reduce the thickness of the insulating plate 32.

[0078] like Figure 3 , Figure 5 and Fig.10 As shown, the first section 3311, the second section 3312 and the second terminal 331b are all accommodated in the inductor housing 34, and the third section 3313 is embedded in the inductor housing 34. The design of the third section 3313 being embedded in the inductor housing 34 is conducive to reducing the size of the inductor 30 in the Z-axis direction, is conducive to the miniaturized design of the inductor 30, is conducive to the miniaturized design of the power conversion device 100, and is conducive to improving the structural stability and reliability of the inductor 30.

[0079] Specifically, the first section 3311 and the second section 3312 are both received in the mounting groove 345. The inductor housing 34 is further provided with a first groove 346. Specifically, the first groove 346 is provided on the first matching wall 341. The first groove 346 has a first opening 346a, a second opening 346b and a third opening 346c. The first opening 346a is located on the surface of the first matching wall 341 facing the second housing 12. The second opening 346b is located on the surface of the first matching wall 341 facing the mounting groove 345. The third opening 346c is located on the surface of the first matching wall 341 facing away from the mounting groove 345. In the X-axis direction, the third opening 346c is located on the side of the second opening 346b facing away from the insulating plate 32. In the X-axis direction, the third section 3313 is received in the first groove 346. The second housing 12 covers the first opening 346a of the first groove 346 and covers the third section 3313. The first sub-segment 3313a of the third segment 3313 is exposed from the first opening 346a to the outside of the first groove 346 and is fixedly connected to the second segment 3312. The third sub-segment 3313c of the third segment 3313 is exposed from the third opening 346c to the outside of the first groove 346 and is fixedly connected to the first terminal 331a.

[0080] In this embodiment, the first groove 346 includes a first sub-groove 3461, a second sub-groove 3462 and a third sub-groove 3463. The first sub-groove 3461, the second sub-groove 3462 and the third sub-groove 3463 all extend from the first matching wall 341 toward the surface of the second housing 12 along the Z-axis direction. In the X-axis direction, the first sub-groove 3461 and the third sub-groove 3463 are opposite and spaced apart. The first sub-groove 3461 extends along the Y-axis direction to the surface of the first matching wall 341 facing the mounting groove 345 and has a second opening 346b, and the third sub-groove 3463 extends along the Y-axis direction to the surface of the first matching wall 341 facing away from the mounting groove 345 and has a third opening 346c. The second sub-groove 3462 extends along the X-axis direction and is connected to the first sub-groove 3461 and the third sub-groove 3463. The first sub-segment 3313a of the third segment 3313 is received in the first sub-groove 3461, the second sub-segment 3313b is received in the second sub-groove 3462, and the third sub-segment 3313c is received in the third sub-groove 3463. The shape of the first groove 346 matches the shape of the third segment 3313, and the first groove 346 can be adaptively designed according to the third segment 3313. This has a simple structure, is easy to design, and is conducive to reducing processing costs.

[0081] like Figure 6 , Figure 8 and Fig.10 As shown, in some embodiments, the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) extends out of the second coil 332 along the Y-axis direction (i.e., the radial direction of the second coil 332), and in the X-axis direction (i.e., the axial direction of the first magnetic column 312), the distance between the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) and the insulating plate 32 is greater than the minimum distance between the insulating plate 32 and the second coil 332. Specifically, the second coil 332 includes a fourth segment 3321, a fifth segment 3322, and a sixth segment 3323, and the fourth segment 3321 is wound around the outside of the first magnetic column 312. The fifth segment 3322 is located on a side of the fourth segment 3321 close to the insulating plate 32 and is connected to the fourth segment 3321 and is away from the third coil 333 along the Y-axis direction. The fourth terminal 332b is located on the side of the fifth section 3322 facing away from the insulating plate 32; wherein, in the Y-axis direction, the fourth terminal 332b is located on the side of the fourth section 3321 facing away from the third coil 333. The sixth section 3323 is arranged between the fourth terminal 332b and the fifth section 3322. The third terminal 332a is located on the side of the fourth section 3321 facing away from the insulating plate 32 and is connected to the fourth section 3321. The structure of the sixth section 3323 can refer to the specific description of the third section 3313 of the first coil 331, and will not be repeated here. The minimum distance between the insulating plate 32 and the second coil 332 is the distance between the fifth section 3322 and the insulating plate 32.

[0082] In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the design that the distance between the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) and the insulating plate 32 is greater than the minimum distance between the insulating plate 32 and the second coil 332 is conducive to increasing the distance B1 (i.e., the terminal of the first coil 331 close to the insulating plate 32) between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) Fig. 9 As shown), it is beneficial to reduce the requirement on the thickness of the insulating plate 32, and is beneficial to reduce the thickness of the insulating plate 32.

[0083] like Figure 3 , Figure 5 and Fig.10 As shown, the fourth section 3321, the fifth section 3322 and the third terminal 332a are all accommodated in the inductor housing 34, and the sixth section 3323 is embedded in the inductor housing 34. For details, please refer to the relevant description of the first coil 331, which will not be repeated. Among them, in the X-axis direction, the sixth section 3323 is spaced apart from the third section 3313. The design of the sixth section 3323 being embedded in the inductor housing 34 is conducive to reducing the size of the inductor 30 in the Z-axis direction, is conducive to the miniaturized design of the inductor 30, is conducive to the miniaturized design of the power conversion device 100, and is conducive to improving the structural stability and reliability of the inductor 30.

[0084] like Figure 3 and Fig. 9 As shown, in some embodiments, in the second coil 332 of one winding 33 and the first coil 331 of another winding 33 adjacent thereto, the spacing B2 between the fourth terminal 332b (i.e., the terminal of the second coil 332 away from the first coil 331) and the first terminal 331a (i.e., the terminal of the first coil 331 away from the second coil 332) is greater than the thickness of the insulating plate 32. In the second coil 332 of one winding 33 and the first coil 331 of another winding 33 adjacent thereto, the distance B2 between the fourth terminal 332b (i.e., the terminal of the second coil 332 away from the first coil 331) and the first terminal 331a (i.e., the terminal of the first coil 331 away from the second coil 332) is designed to be greater than the thickness of the insulating plate 32, thereby ensuring that in the second coil 332 of one winding 33 and the first coil 331 of another winding 33 adjacent thereto, the distance B2 between the fourth terminal 332b (i.e., the terminal of the second coil 332 away from the first coil 331) and the first terminal 331a (i.e., the terminal of the first coil 331 away from the second coil 332) meets the safety distance, which is beneficial to improving the safety of the inductor 30 and the power conversion device 100.

[0085] Specifically, in the second coil 332 of one winding 33 and the first coil 331 of another winding 33 adjacent thereto, the spacing B2 between the fourth terminal 332b and the first terminal 331a is smaller than the spacing B1 between the first terminal 331a and the fourth terminal 332b in one winding 33. In some other embodiments, in the second coil 332 of one winding 33 and the first coil 331 of another winding 33 adjacent thereto, the spacing B2 between the fourth terminal 332b and the first terminal 331a may also be greater than or equal to the spacing B1 between the first terminal 331a and the fourth terminal 332b in one winding 33.

[0086] like Figure 3 , Figure 4 and Figure 5 As shown, in some embodiments, the connecting terminal 40 includes a plurality of first pins 41, and the first pin 41 is provided with a slot 411, and the slot 411 passes through the first pin 41 along the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the axis of the second magnetic column 313); the plurality of first pins 41 include a first sub-pin 41a and a second sub-pin 41b, and in the X-axis direction (i.e., the axial direction of the first magnetic column 312), the first sub-pin 41a and the second sub-pin 41b are opposite to and spaced apart from each other, the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) is inserted in the slot 411 of the first sub-pin 41a, and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) is inserted in the slot 411 of the second sub-pin 41b. The design that the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) is inserted into the slot 411 of the first sub-pin 41a, and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) is inserted into the slot 411 of the second sub-pin 41b is beneficial to improving the space utilization occupied by the inductor 30 and the connecting terminal 40, and is beneficial to reducing the size of the power conversion device 100 in the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the axis of the second magnetic column 313), and is beneficial to the miniaturization design of the power conversion device 100; moreover, the structure is simple and stable, and the processing difficulty is low, which is beneficial to reducing the processing cost of the power conversion device 100.

[0087] Further, the connection terminal 40 includes a plurality of second pins 42. In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the plurality of second pins 42 are located between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32). The plurality of second pins 42 are arranged at intervals from each other. The second pins 42 extend along the Z-axis direction (i.e., the direction perpendicular to the plane where the axis of the first magnetic column 312 and the axis of the second magnetic column 313 are located) and are inserted into the circuit board 20. Exemplarily, the plurality of second pins 42 include a third sub-pin 42a and a fourth sub-pin 42b. In the X-axis direction, the third sub-pin 42a and the fourth sub-pin 42b are arranged opposite to each other and at intervals. In the X-axis direction (i.e., the axial direction of the first magnetic column 312), the design of multiple second pins 42 being located between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) is beneficial to improving the space utilization occupied by the inductor 30 and the connecting terminal 40, which is beneficial to improving the space utilization of the power conversion device 100 and is beneficial to the miniaturized design of the power conversion device 100.

[0088] In this embodiment, the connecting terminal 40 also includes an insulating body 43. In the Y-axis direction, the insulating body 43 is fixedly connected to the side of the first matching wall 341 facing away from the mounting groove 345, that is, the insulating body 43 is fixedly connected to the side of the first matching wall 341 facing away from the third coil 333. In the X-axis direction, the insulating body 43 is located between the first terminal 331a and the fourth terminal 332b. In the Z-axis direction, the insulating body 43 is located on the side of the first terminal 331a facing away from the second shell 12, and is located on the side of the fourth terminal 332b facing away from the second shell 12. Among them, the insulating body 43 and the inductor shell 34 are integrally formed, which is conducive to improving structural stability and reliability. In some other embodiments, the insulating body 43 can also be fixedly connected to the inductor shell 34 by fasteners, adhesive bonding or welding. The insulating body 43 can be made of insulating materials including but not limited to plastic, rubber or epoxy resin.

[0089] A plurality of first pins 41 correspond to a plurality of second pins 42 one by one, and a through-flow portion 44 is provided between the corresponding first pins 41 and the second pins 42, and the corresponding first pins 41 and the second pins 42 are fixedly connected through the through-flow portion 44. The through-flow portion 44 is at least partially embedded in the insulating body 43. The plurality of first pins 41 and the plurality of second pins 42 are all located outside the insulating body 43. Specifically, in the X-axis direction, the first sub-pin 41a, the third sub-pin 42a, the fourth sub-pin 42b and the second sub-pin 41b are arranged in sequence. The number of the through-flow portions 44 is 2, and the two through-flow portions 44 are respectively the first through-flow portion 44a and the second through-flow portion 44b. Each through-flow portion 44 is roughly L-shaped. The first through-flow portion 44a is fixedly connected between the first sub-pin 41a and the third sub-pin 42a, and the first sub-pin 41a and the third sub-pin 42a are fixedly connected through the first through-flow portion 44a. The first through-flow portion 44a is at least partially embedded in the insulating body 43. In the X-axis direction, the first sub-pin 41a is located on the side of the insulating body 43 facing away from the fourth terminal 332b and extends along the Z-axis direction. In the Z-axis direction, the third sub-pin 42a is located on the side of the insulating body 43 facing the second housing 12 and extends along the Z-axis. Thus, the first terminal 331a can communicate with the circuit board 20 through the first sub-pin 41a, the first flow-through portion 44a and the third sub-pin 42a.

[0090] The second flow-through portion 44b is fixedly connected between the fourth sub-pin 42b and the second sub-pin 41b, and the fourth sub-pin 42b and the second sub-pin 41b are fixedly connected through the second flow-through portion 44b. The second flow-through portion 44b is at least partially embedded in the insulating body 43. In the X-axis direction, the second flow-through portion 44b and the first flow-through portion 44a are arranged at intervals. In the Z-axis direction, the fourth sub-pin 42b is located on the side of the insulating body 43 facing the second housing 12 and extends along the Z-axis. In the X-axis direction, the second sub-pin 41b is located on the side of the insulating body 43 facing away from the first terminal 331a and extends along the Z-axis. Thus, the fourth terminal 332b is connected to the circuit board 20 through the second sub-pin 41b, the second flow-through portion 44b and the fourth sub-pin 42b. The connecting terminal 40 realizes the encapsulation of the first pin 41, the second pin 42 and the flow-through portion 44 through the insulating body 43, which is conducive to improving the structural stability and reliability of the connecting terminal 40.

[0091] See also Fig.11 , and combined with Figure 2 and Fig. 9 , Fig.11 It is a structural schematic diagram of another power conversion device 100 provided in an embodiment of the present application in which the second housing 12 is omitted.

[0092] like Figure 2 , Fig. 9 and Fig.11 As shown, Fig.11 The structure of the embodiment shown is Figure 2 and Fig. 9 The structures of the embodiments shown are similar, and the difference between the two is that the circuit board 20 is arranged differently, and correspondingly, the first power device 50 and the second power device 60 are arranged differently. Fig.11 In the illustrated embodiment, the connection terminal 40 may be omitted. In the Y-axis direction (i.e., the common perpendicular direction of the axis of the first magnetic column 312 and the axis of the second magnetic column 313), the circuit board 20 is located on the side of the first coil 331 facing away from the third coil 333. Specifically, in the Y-axis direction, the circuit board 20 is located outside the housing 10 and fixedly connected to the housing 10, and is fixedly connected to the surface of the first matching wall 341 of the inductor housing 34 facing away from the mounting groove 345. The first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) are inserted into the circuit board 20. In the Y-axis direction, the first power device 50 and the second power device 60 are installed on the side of the circuit board 20 facing away from the inductor 30. Among them, the thickness direction of the circuit board 20 is parallel to the Y-axis direction, the length direction of the circuit board 20 is parallel to the X-axis direction, and the width direction of the circuit board 20 is parallel to the Z-axis direction. In other embodiments, the first terminal 331a and the fourth terminal 332b may be completely accommodated in the housing 10, and the circuit board 20 may also be accommodated in the housing 10. In this way, the first terminal 331a and the fourth terminal 332b may also be inserted into the circuit board 20.

[0093] The design of inserting the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) into the circuit board 20 can avoid setting additional connecting terminals 40 between the first terminal 331a (i.e., the terminal of the first coil 331 close to the insulating plate 32) and the circuit board 20 and between the fourth terminal 332b (i.e., the terminal of the second coil 332 close to the insulating plate 32) and the circuit board 20. The structure is simple and stable, which is conducive to reducing the processing cost of the power conversion device 100.

Claims

1. A power conversion device, characterized in that: The power conversion device comprises a housing, a circuit board and an inductor, wherein the circuit board is arranged in the housing, and the inductor is accommodated in the housing; the inductor comprises a magnetic core, an insulating plate and a winding, and the magnetic core comprises a first magnetic column and a second magnetic column, and in the radial direction of the first magnetic column, the first magnetic column and the second magnetic column are arranged opposite to each other and spaced apart; The winding comprises a first coil, a second coil and a third coil, the third coil is sleeved on the second magnetic column, and along the axial direction of the first magnetic column, the first coil, the insulating plate and the second coil are sequentially sleeved on the first magnetic column; The terminal of the first coil facing away from the insulating plate is connected to one terminal of the third coil, and the other terminal of the third coil is connected to the terminal of the second coil facing away from the insulating plate. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both radially away from the third coil along the first magnetic column and are both mounted on the circuit board.

2. The power conversion device according to claim 1, characterized in that: In the axial direction of the first magnetic column, a terminal of the first coil close to the insulating plate and a terminal of the second coil close to the insulating plate are spaced apart by at least a first distance, and the first distance is greater than a thickness of the insulating plate.

3. The power conversion device according to claim 2, characterized in that: The terminal of the first coil close to the insulating plate extends out of the first coil in the radial direction of the first coil, and in the axial direction of the first magnetic column, the distance between the terminal of the first coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the first coil.

4. The power conversion device according to claim 2, characterized in that: The terminal of the second coil close to the insulating plate extends out of the second coil in the radial direction of the second coil, and in the axial direction of the first magnetic column, the distance between the terminal of the second coil close to the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the second coil.

5. The power conversion device according to claim 1, characterized in that: A projection of a terminal of the first coil close to the insulating plate along the axial direction of the first magnetic column overlaps with a projection of a terminal of the second coil close to the insulating plate along the axial direction of the first magnetic column.

6. The power conversion device according to claim 1, characterized in that: In the direction of the common perpendicular line between the axis of the first magnetic column and the axis of the second magnetic column, the maximum distance between the terminal of the first coil close to the insulating plate and the second magnetic column is equal to the maximum distance between the terminal of the second coil close to the insulating plate and the second magnetic column.

7. The power conversion device according to claim 1, characterized in that: The number of the insulating plates and the number of the windings are both multiple, and the multiple windings correspond to the multiple insulating plates one by one. In the axial direction of the first magnetic column, two adjacent windings are arranged at intervals. In the second coil of one of the windings and the first coil of the other adjacent winding, the distance between the terminal of the second coil away from the first coil and the terminal of the first coil away from the second coil is greater than the thickness of the insulating plate.

8. The power conversion device according to claim 1, characterized in that: The winding direction of the third coil is opposite to that of the first coil and opposite to that of the second coil.

9. The power conversion device according to any one of claims 1 to 8, characterized in that: The inductor also includes an inductor shell, which is at least partially accommodated in the shell. The magnetic core, the insulating plate and the third coil are all accommodated in the inductor shell, and one end of the first coil close to the insulating plate and one end of the second coil close to the insulating plate are both located outside the inductor shell.

10. The power conversion device according to any one of claims 1 to 8, characterized in that: In a direction perpendicular to the plane where the axis of the first magnetic column and the axis of the second magnetic column are located, the circuit board is located on one side of the winding, and the power conversion device also includes a connecting terminal, which is arranged on the side of the first coil facing away from the third coil, and the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate are both mounted on the circuit board through the connecting terminal.

11. The power conversion device according to claim 10, characterized in that: The connecting terminal includes a plurality of first pins, each of which is provided with a slot, and the slot passes through the first pin along the common perpendicular direction of the axis of the first magnetic column and the axis of the second magnetic column; the plurality of first pins include a first sub-pin and a second sub-pin, and in the axial direction of the first magnetic column, the first sub-pin and the second sub-pin are opposite to and spaced apart from each other, and the terminal of the first coil close to the insulating plate is inserted into the slot of the first sub-pin, and the terminal of the second coil close to the insulating plate is inserted into the slot of the second sub-pin.

12. The power conversion device according to claim 10, characterized in that: The connecting terminal includes a plurality of second pins. In the axial direction of the first magnetic column, the plurality of second pins are located between the terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate. The plurality of second pins are spaced apart from each other. The second pins extend in a direction perpendicular to the axis of the first magnetic column and the plane where the axis of the second magnetic column is located and are inserted into the circuit board.

13. The power conversion device according to any one of claims 1 to 8, characterized in that: The circuit board is located on a side of the first coil facing away from the third coil, and the terminals of the first coil close to the insulating board and the terminals of the second coil close to the insulating board are both inserted into the circuit board.

14. An inductor, characterized in that: The inductor comprises a magnetic core, an insulating plate and a winding, wherein the magnetic core comprises a first magnetic column and a second magnetic column, and in a first radial direction of the first magnetic column, the first magnetic column and the second magnetic column are opposite to each other and spaced apart; The winding comprises a first coil, a second coil and a third coil, the third coil is sleeved on the second magnetic column, and along the axial direction of the first magnetic column, the first coil, the insulating plate and the second coil are sequentially sleeved on the first magnetic column; The terminal of the first coil facing away from the insulating plate is connected to one terminal of the third coil, and the other terminal of the third coil is connected to the terminal of the second coil facing away from the insulating plate. The terminal of the first coil close to the insulating plate and the terminal of the second coil close to the insulating plate both face away from the third coil in the radial direction of the first magnetic column.

15. An electric vehicle, characterized in that: The electric vehicle comprises a power battery and the power conversion device according to any one of claims 1 to 13, and the power battery is electrically connected to the circuit board.

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