Inductance, power conversion device and electric vehicle

Abstract

The application provides an inductor, a power conversion device and an electric vehicle, and relates to the field of switching devices. The power conversion device comprises a shell, a circuit board arranged in 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. In the radial direction of the first magnetic column, the first magnetic column and the second magnetic column are oppositely and spacedly arranged. 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 sleeved on the first magnetic column. The third coil is sleeved on the second magnetic column. The terminal of the first coil away from the insulating plate is connected with one terminal of the third coil. The other terminal of the third coil is connected with the terminal of the second coil 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 depart from the third coil along the first radial direction of the first magnetic column and are both arranged on the circuit board. The position of the terminals of the winding can be flexibly adjusted, and the miniaturization is facilitated.

Description

Technical Field

[0001] This application relates to the field of switching devices, and more particularly to an inductor, power conversion device and electric vehicle. Background Technology

[0002] In existing power conversion devices, inductors are housed within a casing. The inductor includes a magnetic core and windings. The magnetic core comprises two fixed portions and two magnetic posts positioned between the fixed portions. The windings are formed by first winding wire onto one magnetic post and then onto the other magnetic post. Both ends of the windings are mounted on a circuit board. With the miniaturization of power conversion devices, the positions of the two terminals of the windings need to be adjusted to fit within the casing space. However, in existing devices, both terminals of the windings are close to one of the fixed portions. Adjusting the positions of the winding terminals requires adjusting the entire inductor, resulting in wasted space within the casing and hindering the miniaturization design of power conversion devices. Summary of the Invention

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

[0004] In a first aspect, embodiments of this application provide a power conversion device. The power conversion device includes a housing, a circuit board, and an inductor. The circuit board is disposed within the housing, and the inductor is housed within the housing. The inductor includes a magnetic core, an insulating plate, and a winding. The magnetic core includes a first magnetic post and a second magnetic post, which are positioned radially opposite to and spaced apart from each other. The winding includes a first coil, a second coil, and a third coil. The third coil is sleeved on the second magnetic post. Along the axial direction of the first magnetic post, the first coil, the insulating plate, and the second coil are sequentially sleeved on the first magnetic post. A terminal of the first coil facing away from the insulating plate is connected to a terminal of the third coil, and the other terminal of the third coil is connected to a terminal of the second coil facing away from the insulating plate. The terminals of the first coil and the second coil near the insulating plate are both radially away from the third coil and mounted on the circuit board.

[0005] In the power conversion device provided in this application embodiment, the inductor winding is first wound on a first magnetic post to form a first coil, then wound on a second magnetic post to form a third coil, and finally wound on the first magnetic post to form a second coil. The terminals of the first coil and the second coil near the insulating plate are the two terminals of the winding. The inductor winding receives current through the terminals of the first coil and the second coil near the insulating plate. The design of the insulating plate can prevent electrical accidents such as short circuits caused by contact between the terminals of the first coil and the second coil near 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 to existing technologies, the embodiments of this application, by changing the winding method, only require adjusting the number of turns of the first coil and the second coil to adjust the axial position of the terminals of the first coil and the second coil near the insulating plate on the first magnetic post. This changes the position of both ends of the winding, avoiding the need to adjust the entire inductor position due to the need to adjust the position of the two terminals of the winding. This reduces the positional requirements of the inductor, eliminating the need for adjustment space in the housing, improving the space utilization of the housing, and facilitating miniaturization of the housing and power conversion equipment. Furthermore, it avoids redesigning and processing the housing, reducing design and processing costs. In addition, this method of adjusting the winding lead position avoids the introduction of adapters (such as copper busbars, electronic wires, or film-coated wires) due to adjusting the position of the two terminals, improving the reliability of the power conversion equipment, reducing processing difficulty, and lowering processing costs. Moreover, it avoids increasing the winding resistance, thus avoiding additional losses, improving the current-carrying efficiency of the inductor, and ultimately enhancing the performance of the power conversion equipment. In addition, this design is not only easy to adjust and easy to process, but also produces inductors with high consistency and high processing efficiency, which helps to reduce the processing cost of inductors.

[0007] In one possible implementation, along the axial direction of the first magnetic post, there is a first gap between the terminal of the first coil near the insulating plate and the terminal of the second coil near the insulating plate, the first gap being greater than the thickness of the insulating plate.

[0008] The first spacing is the safety standard distance. Along the axial direction of the first magnetic post, the terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate are spaced at least this first spacing. This first spacing is greater than the thickness of the insulating plate. By adjusting the thickness of the insulating plate, the spacing between the terminals of the first coil and the second coil near the insulating plate can be ensured to meet safety standards. This prevents excessive voltage difference between the terminals of the first and second coils near the insulating plate, which could lead to arcing. This improves the safety of inductor use and the overall safety of power conversion equipment.

[0009] In one possible implementation, in the axial direction of the first magnetic post, the terminal of the first coil near the insulating plate extends radially out of the first coil, and in the axial direction of the first magnetic post, the distance between the terminal of the first coil near 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 post, the distance between the terminal of the first coil near the insulating plate and the insulating plate is greater than the minimum distance between the insulating plate and the first coil. This design is beneficial to increasing the distance between the terminal of the first coil near the insulating plate and the terminal of the second coil near the insulating plate, which is beneficial to reducing the thickness requirement of the insulating plate and reducing the thickness of the insulating plate.

[0011] In one possible implementation, the terminal of the second coil near the insulating plate extends radially from the second coil, and the distance between the terminal of the second coil near the insulating plate and the insulating plate in the axial direction of the first magnetic post is greater than the minimum distance between the insulating plate and the second coil.

[0012] In the axial direction of the first magnetic post, the design that the distance between the terminal of the second coil near 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 near the insulating plate and the terminal of the second coil near the insulating plate, which is beneficial to reducing the thickness requirement of the insulating plate and reducing the thickness of the insulating plate.

[0013] In one possible implementation, the projection of the terminal of the first coil near the insulating plate along the axial direction of the first magnetic post overlaps with the projection of the terminal of the second coil near the insulating plate along the axial direction of the first magnetic post.

[0014] The design that the projection of the terminal of the first coil near the insulating plate along the axial direction of the first magnetic post overlaps with the projection of the terminal of the second coil near the insulating plate along the axial direction of the first magnetic post is beneficial to reducing the size of the inductor in the direction perpendicular to the plane containing the axes of the first and second magnetic posts. This is beneficial to improving the space utilization of the inductor, miniaturizing the inductor, and miniaturizing the power conversion equipment.

[0015] In one possible implementation, in the direction of the common perpendicular of the axis of the first magnetic post and the axis of the second magnetic post, the maximum distance between the terminal of the first coil near the insulating plate and the second magnetic post is equal to the maximum distance between the terminal of the second coil near the insulating plate and the second magnetic post.

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

[0017] In one possible implementation, there are multiple insulating plates and multiple windings, with each winding corresponding to a different insulating plate. In the axial direction of the first magnetic post, two adjacent windings are spaced apart. In the second coil of one winding 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.

[0018] In the design of the second coil of one winding 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. This design ensures that 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 in one winding and the first coil of the other adjacent winding meets the safety regulations. This is beneficial to improving the safety of inductor use and the safety of power conversion equipment.

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

[0020] The design of the third coil having a winding direction opposite to that of the first coil and the second coil facilitates smooth winding on the first and second magnetic posts using a single wire, which helps reduce the processing difficulty of the winding and the processing cost of the inductor.

[0021] In one possible implementation, the inductor further includes an inductor housing, which is at least partially housed within the housing. The magnetic core, the insulating plate, and the third coil are all housed within the inductor housing. The first coil is partially housed within the inductor housing, and the second coil is partially housed within the inductor housing. The terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate are located outside the inductor housing.

[0022] Since the magnetic core, insulating plate, and third coil are all housed within the inductor housing, as are portions of the first and second coils, the inductor housing provides protection for the magnetic core, insulating plate, and windings. Furthermore, the design that the terminals of the first and second coils near the insulating plate are located outside the inductor housing facilitates connection between these terminals and the circuit board, reducing the manufacturing 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 containing the axes of the first and second magnetic pillars. The power conversion device also includes a connection terminal, which is disposed on the side of the first coil facing away from the third coil. The terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate are both mounted on the circuit board via the connection terminal.

[0024] The design of the connection terminals ensures that the terminals of the first coil and the second coil near the insulating plate can be mounted on the circuit board. The circuit board can be positioned on one side of the plane perpendicular to the axes of the first and second magnetic pillars. This allows for various possible placement of the circuit board, reducing design complexity and costs.

[0025] In one possible implementation, the connection terminal includes a plurality of first pins, each first pin having a slot that extends through the first pin along the common perpendicular direction of the axis of the first magnetic post and the axis of the second magnetic post; the plurality of first pins include first sub-pins and second sub-pins, the first sub-pins and the second sub-pins being opposite to and spaced apart along the axial direction of the first magnetic post, the terminal of the first coil near the insulating plate being inserted into the slot of the first sub-pin, and the terminal of the second coil near the insulating plate being inserted into the slot of the second sub-pin.

[0026] The design of inserting the terminal of the first coil near the insulating plate into the slot of the first sub-pin and inserting the terminal of the second coil near the insulating plate into the slot of the second sub-pin is beneficial to improving the space utilization of the inductor and the connection terminal, reducing the size of the power conversion device in the direction of the common perpendicular of the axis of the first magnetic column and the axis of the second magnetic column, and facilitating the miniaturization design of the power conversion device; moreover, the structure is simple and stable, and the processing difficulty is low, which helps to reduce the processing cost of the power conversion device.

[0027] In one possible implementation, the connection terminal includes a plurality of second pins. Along the axial direction of the first magnetic post, the plurality of second pins are located between the terminal of the first coil near the insulating plate and the terminal of the second coil near 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 containing the axis of the first magnetic post and the axis of the second magnetic post and are inserted into the circuit board.

[0028] The design of multiple second pins located on the axial direction of the first magnetic post between the terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate is beneficial to improving the space utilization of the inductor and connection terminals, improving the space utilization of the power conversion equipment, and facilitating the miniaturization design of the power conversion equipment.

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

[0030] The design, in which the terminals of the first coil and the second coil near the insulation plate are both inserted into the circuit board, avoids the need for additional connection terminals between the terminals of the first coil and the insulation plate and the circuit board, and between the terminals of the second coil and the insulation plate. This design results in a simple and stable structure, which helps reduce the processing cost of power conversion equipment.

[0031] Secondly, embodiments of this application also provide an inductor. The inductor includes a magnetic core, an insulating plate, and a winding. The magnetic core includes a first magnetic post and a second magnetic post, which are positioned opposite each other and spaced apart along a first radial direction. The winding includes a first coil, a second coil, and a third coil. The third coil is sleeved on the second magnetic post. Along the axial direction of the first magnetic post, the first coil, the insulating plate, and the second coil are sequentially sleeved on the first magnetic post. A terminal of the first coil facing away from the insulating plate is connected to a terminal of the third coil, and the other terminal of the third coil is connected to a terminal of the second coil facing away from the insulating plate. The terminals of the first coil and the second coil near the insulating plate are both radially away from the third coil along the first magnetic post.

[0032] Thirdly, embodiments of this application also provide an electric vehicle. The electric vehicle includes a power battery and the power conversion device described in any of the first aspects, wherein the power battery is electrically connected to a circuit board. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of this application or the background art, the accompanying drawings used in the embodiments of this application or the background art will be described below.

[0034] Figure 1 This is a structural block diagram of an application scenario for an electric vehicle provided in an embodiment of this application;

[0035] Figure 2 This is a three-dimensional structural schematic diagram of a power conversion device provided in an embodiment of this application;

[0036] Figure 3 yes Figure 2 The diagram shows an exploded three-dimensional structure of the power conversion device.

[0037] Figure 4 yes Figure 2 The power conversion device shown is a three-dimensional structural diagram omitting the second housing, circuit board, first power device, and second power device.

[0038] Figure 5 yes Figure 4The power conversion device shown is an exploded three-dimensional structural diagram omitting the first housing.

[0039] Figure 6 yes Figure 5 An exploded three-dimensional structural diagram of the inductor (inductor housing omitted) of the power conversion device shown.

[0040] Figure 7 yes Figure 6 A three-dimensional structural diagram of the insulating plate and windings shown;

[0041] Figure 8 yes Figure 7 A three-dimensional structural diagram of the insulating plate and windings shown from another angle;

[0042] Figure 9 yes Figure 4 The power conversion device shown omits a schematic diagram of the first housing from another angle;

[0043] Figure 10 yes Figure 9 An enlarged view of the X section of the power conversion device shown;

[0044] Figure 11 This is a schematic diagram of another power conversion device provided in this application, omitting the second housing. Detailed Implementation

[0045] This application provides an inductor, a power conversion device, and an electric vehicle. The inductor is used in the power conversion device, and the power conversion device is used in the electric vehicle. This application aims to solve the problem that power conversion devices are not easy to miniaturize.

[0046] The embodiments of this application are described below with reference to the accompanying drawings.

[0047] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 , Figure 1 This is a structural block diagram of an application scenario of an electric vehicle 1000 provided in an embodiment of this application. Figure 2 This is a three-dimensional structural diagram of a power conversion device 100 provided in an embodiment of this application. Figure 3 yes Figure 2 The diagram shows an exploded three-dimensional structure of the power conversion device 100. Figure 4 yes Figure 2The power conversion device 100 shown is a three-dimensional structural schematic diagram omitting the second housing 12, circuit board 20, first power device 50, and 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 converts the alternating current (AC) output from the power grid or AC power source 2000 into direct current (DC) and stores it in the power battery 200. The power battery 200 can output DC power to the motor 300 to drive the motor 300. The motor 300 provides driving force to the electric vehicle 1000. For example, the power conversion device 100 is an OBC (On-board charger), specifically a 250 kW (kilowatt) OBC. In other embodiments, the power conversion device 100 may also be a rectifier or inverter, or other electronic devices 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, as well as a connection terminal 40, a first power device 50, and a second power device 60. For ease of description, in this embodiment, any three different directions are sequentially defined as a first direction, a second direction, and a third direction, where the second direction is perpendicular to the first direction, and the third direction is perpendicular to both the first and second directions. 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 or Z-axis, and the length direction of the circuit board 20 may also be parallel to the Y-axis or Z-axis. The thickness direction of the circuit board 20 may also be parallel to the Y-axis or X-axis.

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

[0051] The inductor 30 is housed within the housing 10. One side of the inductor 30 in the Y-axis direction protrudes from the exterior of the housing 10. Specifically, the first housing 11 also provides a mating hole 112, which penetrates the first housing 11 along the Y-axis and communicates with a receiving groove 111. The inductor 30 is partially housed in the receiving groove 111 and partially extends from the mating hole 112. In some other embodiments, the inductor 30 may be entirely housed in the receiving groove 111. The inductor 30 is mounted on and 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 located outside the housing 10. The inductor 30 is mounted to the circuit board 20 via the connection terminal 40. In some other embodiments, the connection terminal 40 may be omitted, and the circuit board 20 may be disposed on one side of the housing 10 in the Y-axis direction, with the inductor 30 directly mounted on the circuit board 20. In other embodiments, both the circuit board 20 and the connection terminal 40 may be housed within the housing 10, and the inductor 30 may not be exposed outside the housing 10.

[0053] In the Z-axis direction, a first power device 50 is mounted on one side of the circuit board 20 and electrically connected to the circuit board 20. In the Z-axis direction, a second power device 60 is mounted on one side of the circuit board 20 and electrically connected to the circuit board 20. Specifically, in the Z-axis direction, both the first power device 50 and the second power device 60 are 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, AC power output from the grid or AC power source 2000 is transmitted to the first power device 50 via circuit board 20 and inductor 30. Inductor 30 and the first power device 50 work together to perform power factor correction processing on the AC power and convert it to DC power. The DC power is then transmitted to the second power device 60 via circuit board 20. The second power device 60 boosts the DC power and stores the boosted DC power in the power battery 200. During the AC-to-DC conversion process, the power factor correction process ensures that the phase of the AC voltage is the same as the phase of the current, and the frequency of the AC voltage is the same as the frequency of the current. This helps reduce energy loss during the conversion process and improves energy utilization. Inductor 30 can be understood as a power inductor, specifically a PFC (Power Factor Correction) inductor.

[0055] In some other embodiments, inductor 30 may also be a filter inductor. Specifically, the first power device 50 may be a DC / AC (Digital Current / Alternating Current) module. The power conversion device 100 may also include a capacitor. The AC power output from the grid or AC power supply 2000 is supplied to the first power device 50 through circuit board 20, and the first power device 50 converts the AC power into DC power. The DC power is supplied to the second power device 60 through circuit board 20, and the second power device 60 boosts the DC power. The boosted DC power is supplied to inductor 30 and capacitor through circuit board 20. Inductor 30 and capacitor work together to filter the DC power. The filtered DC power is stored in the power battery 200. Inductor 30 may be a power inductor or a filter inductor, and inductor 30 has a wide range of applications.

[0056] Please see Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 and Figure 10 and combined Figure 1 , Figure 2 and Figure 3 , Figure 5 yes Figure 4 The power conversion device 100 shown is an exploded three-dimensional structural diagram omitting the first housing 11. Figure 6 yes Figure 5 An exploded three-dimensional structural diagram of the inductor 30 (inductor housing 34 omitted) of the power conversion device 100 shown. Figure 7 yes Figure 6 The diagram shows a three-dimensional structure of the insulating plate 32 and the winding 33. Figure 8 yes Figure 7 The schematic diagram of the insulating plate 32 and winding 33 from another angle. Figure 9 yes Figure 4 The power conversion device 100 shown is a schematic diagram of the first housing 11 from another angle, omitting the first housing 11. Figure 10 yes Figure 9 An enlarged view of the X portion of the power conversion device 100 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 house the magnetic core 31, the insulating plate 32, and the winding 33. The inductor housing 34 is at least partially housed in the housing 10. In this embodiment, the inductor housing 34 is partially housed in the receiving groove 111 of the housing 10, and partially extends out from the mating hole 112. Specifically, the inductor housing 34 includes a first mating wall 341, a second mating wall 342, two third mating walls 343, and a fourth mating wall 344. The first mating wall 341, the second mating wall 342, the two third mating walls 343, and the fourth mating wall 344 together 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 mating wall 341 and the second mating wall 342 are opposite to each other and spaced apart. In the X-axis direction, two third mating walls 343 are positioned opposite each other and spaced apart. In the Z-axis direction, a fourth mating wall 344 is positioned opposite the opening 345a of the mounting groove 345. A portion of the first mating wall 341 extends out of the mating hole 112. In some other embodiments, the inductor housing 34 may also be entirely housed in the receiving groove 111 of the housing 10, with a portion of the first mating wall 341 exposed outside the housing 10 through the mating hole 112. The shape of the projection of the inductor housing 34 along the Z-axis direction can be rectangular (square or rectangular), circular, or other irregular 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 part 311, a first magnetic post 312, and a second magnetic post 313. The axial directions of both the first magnetic post 312 and the second magnetic post 313 are parallel to the X-axis direction, and the radial directions of both are perpendicular to the X-axis direction. In the Y-axis direction (i.e., the radial direction of the first magnetic post 312), the first magnetic post 312 and the second magnetic post 313 are positioned opposite each other and spaced apart. The first magnetic post 312 and the second magnetic post 313 are fixedly connected by the fixing part 311. Specifically, in the X-axis direction, the fixing part 311 contacts and is fixedly connected to one side of the first magnetic post 312 and the second magnetic post 313. It can be understood that the direction perpendicular to the plane containing the axes of the first magnetic post 312 and the second magnetic post 313 is parallel to the Z-axis direction, and the direction of the common perpendicular of the axes of the first magnetic post 312 and the second magnetic post 313 is parallel to the Y-axis direction.

[0059] The cross-sectional shapes of the first magnetic post 312 and the second magnetic post 313 can be circular, square, or elliptical. They can also be racetrack-shaped or other irregular shapes. Specifically, the first magnetic post 312 (and the second magnetic post 313) can have a hole penetrating through it along the X-axis, thus making the cross-sectional shape of the first magnetic post 312 (and the second magnetic post 313) racetrack-shaped. It should be noted that the cross-sections of both the first magnetic post 312 and the second magnetic post 313 are perpendicular to the X-axis.

[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 post 313. Along the X-axis (i.e., the axial direction of the first magnetic post 312), the first coil 331, the insulating plate 32, and the second coil 332 are sequentially sleeved on the first magnetic post 312. For ease of description, the two terminals of the first coil 331 are defined as first terminal 331a and second terminal 331b, respectively. First terminal 331a is close to the insulating plate 32, and second terminal 331b faces away from the insulating plate 32. The two terminals of the second coil 332 are defined as third terminal 332a and fourth terminal 332b, respectively. Third terminal 332a faces away from the insulating plate 32, and 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. 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are both located away from the third coil 333 along the Y-axis direction (i.e., the radial direction of the first magnetic post 312). It can be understood that the winding 33 is formed by winding a single wire. The wire can be a round wire, a flat wire, or a Litz wire, etc., transmission line.

[0062] like Figure 3 , Figure 4 and Figure 6As shown, the magnetic core 31, insulating plate 32, and third coil 333 are all housed in the inductor housing 34. The first coil 331 is partially housed in the inductor housing 34, and the second coil 332 is partially housed in the inductor housing 34. The first terminal 331a (the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (the terminal of the second coil 332 near the insulating plate 32) are both located outside the inductor housing 34 and outside the housing 10. Specifically, the magnetic core 31, insulating plate 32, and third coil 333 are all housed in the mounting groove 345. The first mating wall 341 is located on the side of the first magnetic post 312 facing away from the second magnetic post 313, and the second mating wall 342 is located on the side of the second magnetic post 313 facing away from the first magnetic post 312. The first coil 331 is partially housed in the mounting groove 345, and partially passes through the first mating wall 341 and extends out of the housing 10 from the mating hole 112. The second coil 332 is partially housed in the mounting groove 345, partially passes through the first mating wall 341, and extends out of the housing 10 from the mating hole 112. The first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are both located on the side of the first mating wall 341 facing away from the second mating wall 342. It can be understood that in the Z-axis direction (i.e., the direction perpendicular to the plane containing the axis of the first magnetic post 312 and the axis of the second magnetic post 313), 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are both mounted on the circuit board 20. Specifically, in the Y-axis direction, the connecting terminal 40 is located on the side of the first coil 331 facing away from the third coil 333, and both the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are 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 mating wall 341 facing away from the second mating wall 342. The connecting terminal 40 and the inductor housing 34 are integrally formed. This improves the structural stability of the connection between the connecting terminal 40 and the inductor housing 34 and enhances 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, gluing, or fasteners. In other embodiments, the connection terminal 40 may also be fixedly connected to the housing 10.

[0064] For example, the number of fixing parts 311, the number of first magnetic pillars 312, and the number of second magnetic pillars 313 can be multiple. In the X-axis direction, multiple first magnetic pillars 312 are arranged at intervals, and multiple second magnetic pillars 313 are arranged at intervals. A fixing part 311 is provided between two adjacent first magnetic pillars 312 and between two adjacent second magnetic pillars 313. Two adjacent first magnetic pillars 312 and two adjacent second magnetic pillars 313 are fixedly connected by the fixing part 311. For example, the number of fixing parts 311 is 3, and the number of first magnetic pillars 312 and second magnetic pillars 313 is 2 each. In the X-axis direction, the 3 fixing parts 311 are arranged at intervals. 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] For example, there are multiple insulating plates 32, multiple windings 33, and multiple connecting terminals 40. Specifically, there are two insulating plates 32, two windings 33, and two connecting terminals 40. Each winding 33 corresponds to a first magnetic post 312 and a second magnetic post 313. Multiple windings 33 correspond one-to-one with 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 faces away from the insulating plate 32, the third terminal 332a faces away from 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 post 312), multiple windings 33 are arranged sequentially at intervals, with adjacent two windings 33 spaced apart. Multiple connecting terminals 40 are arranged sequentially at intervals. Multiple windings 33 are mounted on the circuit board 20 through corresponding connecting terminals 40. Each winding 33 can be connected to the power grid or AC power supply 2000 (e.g., Figure 1 The winding 33 is electrically connected to a single phase of the power grid or AC power supply 2000 (as shown), and 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 a single phase of the power grid or AC power supply 2000; the fourth terminal 332b (or the first terminal 331a) is electrically connected to the first power device 50. Multiple windings 33 can be electrically connected to multiple phases of the power grid or AC power supply 2000. Specifically, two windings 33 are electrically connected to two phases of the power grid or AC power supply 2000, respectively. In some other embodiments, multiple windings 33 can also be electrically connected to a single phase of the power grid or AC power supply 2000.

[0066] In the power conversion device 100 provided in this application embodiment, the winding 33 of the inductor 30 is first wound on a first magnetic post 312 to form a first coil 331, then wound on a second magnetic post 313 to form a third coil 333, and finally wound on the first magnetic post 312 to form a second coil 332. A first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and a fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are the 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 equipment 100.

[0067] Compared to existing technologies, the embodiments of this application, by changing the winding method of the winding 33, only need to adjust the number of turns of the first coil 331 and the second coil 332 to adjust the position of the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) in the X-axis direction (i.e., the axial direction of the first magnetic column 312), thereby changing the position of the two terminals of the winding 33. This avoids the need to adjust the position of the entire inductor 30 due to the need to adjust the position of the two terminals of the winding 33, and the position requirements of the inductor 30 are low. On the one hand, it avoids reserving adjustment space in the housing 10, which is conducive to improving the space utilization of the housing 10, and is conducive to the miniaturization design of the housing 10 and the miniaturization design of the power conversion device 100. On the other hand, it avoids redesigning and processing the housing 10, which is conducive to reducing the design cost and processing cost of the housing 10. Furthermore, this method of adjusting the position of the leads of winding 33 avoids the introduction of adapters (such as copper busbars, electronic wires, or film-coated wires) due to adjusting the position of the two terminals of winding 33. This improves the reliability of the power conversion device 100, reduces the processing difficulty of the power conversion device 100, and reduces processing costs. Moreover, it avoids increasing the resistance of winding 33, thereby avoiding the introduction of additional losses, which improves the current-carrying efficiency of inductor 30 and enhances 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 produces inductors 30 with high consistency and high processing efficiency, which helps reduce the processing cost of inductors 30.

[0068] Since the magnetic core 31, the insulating plate 32, and the third coil 333 are all housed in the inductor housing 34, and the first coil 331 and the second coil 332 are partially housed in the inductor housing 34, the inductor housing 34 can protect the magnetic core 31, the insulating plate 32, and the winding 33. Furthermore, the design that the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) to the circuit board 20, helps reduce the processing cost of the power conversion device 100.

[0069] The design of the connecting terminal 40 ensures that the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) can be mounted on the circuit board 20. The circuit board 20 can be positioned on one side of the winding 33 in the Z-axis direction (i.e., the direction perpendicular to the plane containing the axes of the first magnetic post 312 and the second magnetic post 313). The circuit board 20 can be positioned in various ways, which helps reduce design difficulty and 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, which penetrates the fourth mating wall 344 along the Y-axis and communicates with the mounting groove 345. The first housing 11 covers the through hole 3441 and closes the mounting groove 345. Exemplarily, there are multiple through holes 3441. In the X-axis direction, the multiple through holes 3441 are spaced apart. The design of the through holes 3441 helps to reduce the weight of the inductor housing 34 and facilitates 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. This design, where 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 post 312 and the second magnetic post 313 using a single wire. This helps reduce the processing difficulty of the winding 33 and reduces the inductance 30 (e.g., ...). Figure 4 The processing cost is shown in the figure.

[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 near the insulating plate 32) along the X-axis (i.e., the axial direction of the first magnetic post 312) overlaps with the projection of the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) along the X-axis (i.e., the axial direction of the first magnetic post 312). This design, where the projection of the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) along the X-axis (i.e., the axial direction of the first magnetic post 312) overlaps with the projection of the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) along the X-axis (i.e., the axial direction of the first magnetic post 312), is beneficial for reducing the size of the inductor 30 in the Z-axis direction (i.e., the direction perpendicular to the plane containing the axis of the first magnetic post 312 and the axis of the second magnetic post 313), improving the space utilization of the inductor 30, facilitating the miniaturization of the inductor 30, and benefiting the power conversion device 100 (such as...). Figure 2 The miniaturized design is shown in the figure.

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

[0074] like Figure 7 and Figure 9As shown, in some embodiments, in the X-axis direction (i.e., the axial direction of the first magnetic post 312), the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are spaced at least a first gap, which is greater than the thickness of the insulating plate 32 (i.e., the dimension of the insulating plate 32 in the X-axis direction). Specifically, in the X-axis direction (i.e., the first direction), the gap B1 between the first terminal 331a and the fourth terminal 332b is greater than the first gap. In other embodiments, the gap B1 between the first terminal 331a and the fourth terminal 332b may also be equal to the first gap. The first gap is a safety distance. In the X-axis direction (i.e., the axial direction of the first magnetic post 312), the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) are spaced at least by a first gap, which is greater than the thickness of the insulating plate 32. By adjusting the thickness of the insulating plate 32, it is ensured that the gap B1 between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) complies with safety regulations. This avoids excessive voltage difference between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32), which could lead to arcing. This improves the safety of the inductor 30 and enhances the power conversion equipment 100 (e.g., ...). Figure 2 (As shown) Safety of use.

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

[0076] The third segment 3313 includes a first sub-segment 3313a, a second sub-segment 3313b, and a third sub-segment 3313c. In the Y-axis direction, the first sub-segment 3313a is fixedly connected to the end of the second segment 3312 facing away from the third coil 333, and extends along the Y-axis direction. In the X-axis direction, the second sub-segment 3313b is located on the side of the first sub-segment 3313a facing away from the insulating plate 32, and in the Y-axis direction, the second sub-segment 3313b is located on the side of the first sub-segment 3313a facing away from the second segment 3312. The second sub-segment 3313b is fixedly connected to the first sub-segment 3313a and has a rounded transition. In the X-axis direction, the third sub-segment 3313c is located on the side of the second sub-segment 3313b facing away from the first sub-segment 3313a. And in the Y-axis direction, the third sub-segment 3313c is located on the side of the second sub-segment 3313b facing away from the first sub-segment 3313a. The third segment 3313c is fixedly connected to the second segment 3313b and transitions with an arc. In some other embodiments, the third segment 3313 can also be a straight line segment, a wavy line segment, or other irregularly shaped segment. The structure of the third segment 3313 is diverse, the design is simple, and it helps to reduce processing costs.

[0077] In the X-axis direction (i.e., the axial direction of the first magnetic post 312), the design that the distance between the first terminal 331a (i.e., the terminal of the first coil 331 near 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 beneficial to increasing the distance B1 between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32). Figure 9 As shown, this is beneficial to reducing the thickness requirement of the insulation board 32 and thus reducing the thickness of the insulation board 32.

[0078] like Figure 3 , Figure 5 and Figure 10 As shown, the first segment 3311, the second segment 3312, and the second terminal 331b are all housed in the inductor housing 34, and the third segment 3313 is embedded in the inductor housing 34. The design of embedding the third segment 3313 in the inductor housing 34 is beneficial to reducing the size of the inductor 30 in the Z-axis direction, which is beneficial to the miniaturization design of the inductor 30, the miniaturization design of the power conversion device 100, and also to improving the structural stability and reliability of the inductor 30.

[0079] Specifically, both the first segment 3311 and the second segment 3312 are received in the mounting groove 345. The inductor housing 34 also has a first recess 346. Specifically, the first recess 346 is disposed in the first mating wall 341. The first recess 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 mating wall 341 facing the second housing 12. The second opening 346b is located on the surface of the first mating wall 341 facing the mounting groove 345. The third opening 346c is located on the surface of the first mating 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 segment 3313 is received in the first recess 346. The second housing 12 covers the first opening 346a of the first recess 346 and covers the third segment 3313. In this section, the first sub-segment 3313a of the third segment 3313 protrudes from the first opening 346a outside the first groove 346 and is fixedly connected to the second segment 3312; the third sub-segment 3313c of the third segment 3313 protrudes from the third opening 346c outside 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 along the Z-axis from the surface of the first mating wall 341 toward the second housing 12. In the X-axis direction, the first sub-groove 3461 and the third sub-groove 3463 are opposite to each other and spaced apart. The first sub-groove 3461 extends along the Y-axis to the surface of the first mating wall 341 facing the mounting groove 345 and has a second opening 346b. The third sub-groove 3463 extends along the Y-axis to the surface of the first mating 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 and communicates with the first sub-groove 3461 and the third sub-groove 3463. The first sub-segment 3313a of the third segment 3313 is housed in the first sub-groove 3461, the second sub-segment 3313b is housed in the second sub-groove 3462, and the third sub-segment 3313c is housed in the third sub-groove 3463. The shape of the first groove 346 is adapted to the shape of the third segment 3313, and the first groove 346 can be adaptively designed according to the third segment 3313. This structure is simple, easy to design, and helps to reduce processing costs.

[0081] like Figure 6 , Figure 8 and Figure 10 As shown, in some embodiments, the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 post 312), the distance between the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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. The fourth segment 3321 is wound around the outside of the first magnetic post 312. The fifth segment 3322 is located on the side of the fourth segment 3321 near 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 segment 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 segment 3321 facing away from the third coil 333. The sixth segment 3323 is disposed between the fourth terminal 332b and the fifth segment 3322. The third terminal 332a is located on the side of the fourth segment 3321 facing away from the insulating plate 32 and is connected to the fourth segment 3321. The structure of the sixth segment 3323 can be referred to the specific description of the third segment 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 segment 3322 and the insulating plate 32.

[0082] In the X-axis direction (i.e., the axial direction of the first magnetic post 312), the design that the distance between the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 beneficial to increasing the distance B1 between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32). Figure 9 As shown, this is beneficial to reducing the thickness requirement of the insulation board 32 and thus reducing the thickness of the insulation board 32.

[0083] like Figure 3 , Figure 5 and Figure 10 As shown, the fourth segment 3321, the fifth segment 3322, and the third terminal 332a are all housed in the inductor housing 34, and the sixth segment 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 here. In the X-axis direction, the sixth segment 3323 is spaced apart from the third segment 3313. The design of embedding the sixth segment 3323 in the inductor housing 34 helps to reduce the size of the inductor 30 in the Z-axis direction, facilitates the miniaturization design of the inductor 30, benefits the miniaturization design of the power conversion device 100, and also improves the structural stability and reliability of the inductor 30.

[0084] like Figure 3 and Figure 9 As shown, in some embodiments, in the second coil 332 of one winding 33 and the first coil 331 of the other adjacent winding 33, 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 greater than the thickness of the insulating plate 32. In the design of the second coil 332 of one winding 33 and the first coil 331 of the other adjacent winding 33, 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. This design ensures that 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) in the second coil 332 of one winding 33 and the first coil 331 of the other adjacent winding 33 can meet the safety distance requirements. This is beneficial to improving the safety of the inductor 30 and the safety of the power conversion device 100.

[0085] Specifically, in the second coil 332 of one winding 33 and the first coil 331 of the adjacent winding 33, the distance B2 between the fourth terminal 332b and the first terminal 331a is less than the distance B1 between the first terminal 331a and the fourth terminal 332b in one winding 33. In some other embodiments, the distance B2 between the fourth terminal 332b and the first terminal 331a in the second coil 332 of one winding 33 and the first coil 331 of the adjacent winding 33 may also be greater than or equal to the distance 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 connection terminal 40 includes a plurality of first pins 41, each first pin 41 having a slot 411 extending through the first pin 41 along the Y-axis direction (i.e., the direction of the common perpendicular of the axis of the first magnetic post 312 and the axis of the second magnetic post 313); the plurality of first pins 41 include a first sub-pin 41a and a second sub-pin 41b, which are positioned opposite to and spaced apart in the X-axis direction (i.e., the axial direction of the first magnetic post 312), and a first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) is inserted into the slot 411 of the first sub-pin 41a, and a fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) is inserted into the slot 411 of the second sub-pin 41b. The design of inserting the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) into the slot 411 of the first sub-pin 41a and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) into the slot 411 of the second sub-pin 41b is beneficial to improving the space utilization of the inductor 30 and the connection terminal 40, and to reducing the size of the power conversion device 100 in the Y-axis direction (i.e., the direction of the common perpendicular of the axis of the first magnetic column 312 and the axis of the second magnetic column 313), which 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 helps to reduce the processing cost of the power conversion device 100.

[0087] Furthermore, 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 post 312), the plurality of second pins 42 are located between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32). The plurality of second pins 42 are spaced apart from each other. The second pins 42 extend along the Z-axis direction (i.e., the direction perpendicular to the plane containing the axes of the first magnetic post 312 and the second magnetic post 313) 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 opposite to and spaced apart. The design of multiple second pins 42 located between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) in the X-axis direction (i.e., the axial direction of the first magnetic post 312) is beneficial to improving the space utilization of the inductor 30 and the connection terminal 40, improving the space utilization of the power conversion device 100, and facilitating the miniaturization design of the power conversion device 100.

[0088] In this embodiment, the connecting terminal 40 further includes an insulating body 43. In the Y-axis direction, the insulating body 43 is fixedly connected to the side of the first mating wall 341 facing away from the mounting groove 345, that is, the insulating body 43 is fixedly connected to the side of the first mating 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 housing 12, and on the side of the fourth terminal 332b facing away from the second housing 12. The insulating body 43 is integrally formed with the inductor housing 34, which is beneficial for improving structural stability and reliability. In other embodiments, the insulating body 43 can also be fixedly connected to the inductor housing 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] Multiple first pins 41 correspond one-to-one with multiple second pins 42. A current-passing portion 44 is provided between the corresponding first pin 41 and second pin 42, and the corresponding first pin 41 and second pin 42 are fixedly connected through the current-passing portion 44. The current-passing portion 44 is at least partially embedded in the insulating body 43. The multiple first pins 41 and multiple 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 alternately in sequence. There are two current-passing portions 44, namely the first current-passing portion 44a and the second current-passing portion 44b. Each current-passing portion 44 is approximately L-shaped. The first current-passing 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 current-passing portion 44a. The first current-passing 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 pass through the first sub-pin 41a, the first current-passing portion 44a, and the third sub-pin 42a to the circuit board 20.

[0090] The second current-passing 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 current-passing portion 44b. The second current-passing portion 44b is at least partially embedded in the insulating body 43. In the X-axis direction, the second current-passing portion 44b is spaced apart from the first current-passing portion 44a. 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 passes through the second sub-pin 41b, the second current-passing portion 44b, and the fourth sub-pin 42b to the circuit board 20. The connection terminal 40 encapsulates the first pin 41, the second pin 42, and the current-passing portion 44 through the insulating body 43, which helps to improve the structural stability and reliability of the connection terminal 40.

[0091] Please see Figure 11 and combined Figure 2 and Figure 9 , Figure 11 This is a schematic diagram of another power conversion device 100 provided in this application embodiment, omitting the second housing 12.

[0092] like Figure 2 , Figure 9 and Figure 11 As shown, Figure 11 The structure of the embodiment shown is similar to Figure 2 and Figure 9 The structures of the illustrated embodiments are similar, the difference being that the arrangement of the circuit board 20 is different, and correspondingly, the arrangements of the first power device 50 and the second power device 60 are different. Figure 11 In the illustrated embodiment, the connection terminal 40 can be omitted. In the Y-axis direction (i.e., the direction perpendicular to the common perpendicular of the axes of the first magnetic post 312 and the second magnetic post 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 fixedly connected to the surface of the first mating 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near 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 mounted on the side of the circuit board 20 facing away from the inductor 30. 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 both be housed entirely within the housing 10, and the circuit board 20 may also be housed within the housing 10. In this way, the first terminal 331a and the fourth terminal 332b can 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 near the insulating plate 32) and the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) into the circuit board 20 avoids the need to set additional connection terminals 40 between the first terminal 331a (i.e., the terminal of the first coil 331 near the insulating plate 32) and the circuit board 20, and between the fourth terminal 332b (i.e., the terminal of the second coil 332 near the insulating plate 32) and the circuit board 20. The structure is simple and stable, which helps to reduce the processing cost of the power conversion device 100.

Claims

1. A power conversion device, characterized in that, The power conversion device includes a housing, a circuit board, and an inductor. The circuit board is disposed in the housing, and the inductor is housed in the housing. The inductor includes a magnetic core, an insulating plate, and a winding. The magnetic core includes a first magnetic post and a second magnetic post. In the radial direction of the first magnetic post, the first magnetic post and the second magnetic post are opposite to each other 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 post. Along the axial direction of the first magnetic post, the first coil, the insulating plate, and the second coil are sequentially sleeved on the first magnetic post. 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 terminals of the first coil and the second coil near the insulating plate are both radially away from the third coil along the first magnetic post and are both mounted on the circuit board.

2. The power conversion device according to claim 1, characterized in that, Along the axial direction of the first magnetic post, there is a first gap between the terminal of the first coil near the insulating plate and the terminal of the second coil near the insulating plate, the first gap being greater than the thickness of the insulating plate.

3. The power conversion device according to claim 2, characterized in that, The terminal of the first coil near the insulating plate extends radially from the first coil, and the distance between the terminal of the first coil near the insulating plate and the insulating plate in the axial direction of the first magnetic post 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 near the insulating plate extends radially from the second coil, and the distance between the terminal of the second coil near the insulating plate and the insulating plate in the axial direction of the first magnetic post 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, The projection of the terminal of the first coil near the insulating plate along the axial direction of the first magnetic post overlaps with the projection of the terminal of the second coil near the insulating plate along the axial direction of the first magnetic post.

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 post and the axis of the second magnetic post, the maximum distance between the terminal of the first coil near the insulating plate and the second magnetic post is equal to the maximum distance between the terminal of the second coil near the insulating plate and the second magnetic post.

7. The power conversion device according to claim 1, characterized in that, The number of insulating plates and the number of windings are both multiple, and the multiple windings correspond one-to-one with the multiple insulating plates. On the axial direction of the first magnetic post, two adjacent windings are spaced apart. In the second coil of one winding 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 also 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 housing, which is at least partially housed within the housing. The magnetic core, the insulating plate, and the third coil are all housed within the inductor housing. The ends of the first coil near the insulating plate and the ends of the second coil near the insulating plate are both located outside the inductor housing.

10. The power conversion device according to any one of claims 1 to 8, characterized in that, In a direction perpendicular to the plane containing the axes of the first and second magnetic pillars, the circuit board is located on one side of the winding. The power conversion device further includes a connection terminal, which is disposed on the side of the first coil facing away from the third coil. The terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate are both mounted on the circuit board through the connection terminal.

11. The power conversion device according to claim 10, characterized in that, The connection terminal includes a plurality of first pins, each first pin having a slot that extends through the first pin along the common perpendicular direction of the axis of the first magnetic post and the axis of the second magnetic post. The plurality of first pins include first sub-pins and second sub-pins. On the axial direction of the first magnetic post, the first sub-pins and the second sub-pins are opposite to and spaced apart. The terminal of the first coil near the insulating plate is inserted into the slot of the first sub-pin, and the terminal of the second coil near 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 connection terminal includes a plurality of second pins. On the axial direction of the first magnetic post, the plurality of second pins are located between the terminal of the first coil near the insulating plate and the terminal of the second coil near 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 containing the axis of the first magnetic post and the axis of the second magnetic post 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 the side of the first coil facing away from the third coil, and the terminals of the first coil near the insulating plate and the terminals of the second coil near the insulating plate are both inserted into the circuit board.

14. An inductor, characterized in that, The inductor includes a magnetic core, an insulating plate, and a winding. The magnetic core includes a first magnetic post and a second magnetic post. The first magnetic post and the second magnetic post are opposite to each other and spaced apart in a first radial direction of the first magnetic post. The winding includes a first coil, a second coil, and a third coil. The third coil is sleeved on the second magnetic post. Along the axial direction of the first magnetic post, the first coil, the insulating plate, and the second coil are sequentially sleeved on the first magnetic post. 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 terminals of the first coil and the second coil near the insulating plate are both radially away from the third coil along the first magnetic post.

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

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