Three-phase four-column magnetic integrated inverter inductor

Abstract

The application discloses a three-phase four-column magnetic integrated inverter inductor, which comprises a bottom plate, a magnetic core structure and a coil group. The magnetic core structure is installed on one side surface of the bottom plate, and the coil group is wound on the magnetic core structure. The magnetic core structure comprises a plurality of magnetic yokes and a plurality of magnetic columns. The magnetic yokes are arranged in parallel with a preset plane respectively, and the magnetic yokes are arranged in a stacked manner along a preset direction. The adjacent magnetic yokes are connected through the magnetic columns. The coil group comprises a plurality of inductor coils, and the inductor coils are wound on the magnetic columns one by one. The three-phase four-column magnetic integrated inverter further comprises a fastening assembly arranged on the bottom plate and connected with the magnetic core structure, so that the magnetic core structure and the bottom plate are stably connected. The magnetic columns of the three-phase four-column magnetic integrated inverter are connected through the corresponding magnetic yokes to realize magnetic integration, and an overall magnetic core structure is obtained, so that the installation space occupied by the inductor in the inverter is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of inductor technology for inverters, and in particular to a three-phase four-column integrated inverter inductor. Background Technology

[0002] An inverter inductor is an inductive element used in inverter circuits (such as solar inverters or electric vehicle inverters). Inverters convert direct current (DC) to alternating current (AC), and inductors play a crucial role in their operation, particularly in filtering and energy storage. Specifically, inductors in inverters store energy and release it when current changes, helping to smooth current fluctuations, reduce high-frequency noise, and improve power quality. They also filter out high-frequency signals, reducing electromagnetic interference (EMI) and ensuring stable operation. Inverter inductors balance output current, reducing waveform fluctuations and improving inverter efficiency. Furthermore, they help maintain voltage stability, preventing voltage surges from affecting the load. In existing technologies, the three-phase four-limb magnetically integrated inverter inductor is a specialized inductor structure for three-phase inverter circuits. Its core design principle combines the magnetic circuitry of the inductor with the characteristics of multi-phase currents, improving inverter efficiency and performance through a rational layout.

[0003] Three-phase four-limb integrated magnetic inverter inductors primarily achieve this by integrating the inductor's magnetic circuit, enabling the three-phase currents to interact within the inductor and optimizing the magnetic field distribution. The inductor's core forms a concentrated magnetic circuit, allowing each phase's current to flow through an independent magnetic flux path, while the magnetic fluxes cancel each other out on the common arm. However, the insufficient integration of the magnetic circuit in existing three-phase four-limb integrated magnetic inverter inductors means there is still room for size reduction, and the insufficient installation stability of the core structure can easily affect the stability of the inductor's installation and application. Summary of the Invention

[0004] Therefore, it is necessary to provide a three-phase four-column magnetic integrated inverter inductor to address the technical problems of insufficient integration and support of existing three-phase four-column magnetic integrated inverter inductors.

[0005] A three-phase four-column magnetically integrated inverter inductor includes a base plate, a magnetic core structure, and a coil assembly. The magnetic core structure is mounted on one side surface of the base plate, and the coil assembly is wound around the magnetic core structure to form a three-phase four-column magnetically integrated inverter inductor.

[0006] The magnetic core structure includes several yokes and several magnetic pillars. The yokes are arranged parallel to a preset plane and are stacked along a preset direction. Adjacent yokes are connected by several magnetic pillars. Correspondingly, the coil group includes several inductor coils, and the inductor coils are wound one-to-one with the magnetic pillars. Thus, the magnetic pillars are magnetically integrated through the corresponding yokes to obtain an integral magnetic core structure.

[0007] The three-phase four-column integrated inverter inductor also includes a fastening assembly, which is set on the base plate and connected to the core structure to achieve a stable connection between the core structure and the base plate.

[0008] The fastening assembly includes several support blocks and several fastening straps. The support blocks are respectively set on the surface of the base plate corresponding to several magnetic yokes. When the magnetic core structure is installed on the base plate, one side surface of each magnetic yoke abuts against the surface of the corresponding support block, so that the magnetic core structure can be stably connected to the base plate. The fastening straps correspond one-to-one with several magnetic yokes. Each fastening strap wraps around the side surface of the corresponding magnetic yoke and connects to the base plate to fasten the corresponding magnetic yoke to the surface of the support block.

[0009] In one embodiment, the aforementioned magnetic core structure is formed by sequentially stacking several magnetic yokes along a straight line direction perpendicular to the preset plane, based on a preset plane with several magnetic yokes that are relatively parallel.

[0010] In one embodiment, the adjacent magnetic yokes are connected by several parallel magnetic pillars to form a closed magnetic circuit structure.

[0011] In one embodiment, the adjacent magnetic yokes are connected by two parallel magnetic pillars, and correspondingly, two inductor coils are wound on the side surfaces of the two magnetic pillars between the adjacent magnetic yokes.

[0012] In one embodiment, each of the above-described magnetic pillars is composed of several independent magnetic blocks stacked along the axial direction.

[0013] In one embodiment, each of the above-described magnetic pillars consists of two independent magnetic blocks stacked axially.

[0014] In one embodiment, the opposing side surfaces of the two magnetic blocks are respectively connected to the corresponding two magnetic yoke surfaces, and the opposing side surfaces of the two magnetic blocks are connected to form a complete magnetic circuit.

[0015] In one embodiment, each of the above-mentioned magnetic blocks is set as a cylindrical block structure of a preset length according to actual application requirements.

[0016] In one embodiment, the cross-section of each of the above-described magnetic blocks can be set to an axisymmetric shape, such as a circle, a square, or a regular polygon.

[0017] In one embodiment, the cross-section of each of the above-mentioned magnetic blocks can be set to a non-axisymmetric shape, such as an ellipse, a parallelogram, or an irregular polygon.

[0018] In one embodiment, the magnetic core structure further includes several partitions, with each pair of partitions respectively disposed on the two end surfaces of a magnetic block. That is, each end surface of a magnetic block is spaced apart from the adjacent magnetic block or yoke by a corresponding partition.

[0019] In one embodiment, the edge of each partition corresponding to the end face of the magnetic block is configured as a plate-like structure with a corresponding shape and a through center.

[0020] In one embodiment, an insulating plate is provided between each of the above-mentioned magnetic yokes and the corresponding inductor coil, and each insulating plate is provided between the end face of the corresponding inductor coil and the surface of the magnetic yoke.

[0021] In one embodiment, the end face of each insulating plate corresponding to the inductor coil is configured as a plate-like structure with a corresponding shape and a through center.

[0022] In one embodiment, the two inductor coils between two adjacent magnetic yokes are electrically connected in parallel.

[0023] In one embodiment, the parallel lead-out ends of the two inductor coils between two adjacent magnetic yokes extend to the other side of the base plate through corresponding connecting portions.

[0024] The aforementioned three-phase four-column magnetically integrated inverter inductor integrates several magnetic columns through corresponding magnetic yokes to form a single magnetic core structure. This significantly reduces the installation space occupied by the inductor in the inverter and effectively optimizes the heat dissipation performance of the inverter inductor. The three-phase four-column structure enables magnetic coupling between the three-phase currents, balancing the three-phase magnetic flux, reducing magnetic saturation, improving magnetic circuit utilization and inductor stability. Furthermore, the magnetic integration of the inverter inductor effectively increases power density to meet the requirements of inverter miniaturization and weight reduction. Based on this, several support blocks are respectively set on the surface of the base plate corresponding to several magnetic yokes. When the magnetic core structure is installed on the base plate, one side surface of each magnetic yoke abuts against the surface of the corresponding support block, so that the magnetic core structure can be stably connected to the base plate. Several fastening straps correspond one-to-one with several magnetic yokes. Each fastening strap wraps around the side surface of the corresponding magnetic yoke and connects to the base plate to fasten the corresponding magnetic yoke to the surface of the support block. This achieves a tight connection between the magnetic core structure and the base plate, ensuring the overall structural stability of the three-phase four-column magnetic integrated inverter inductor, and ensuring the mechanical strength and vibration stability of the overall structure. Attached Figure Description

[0025] Figure 1This is a schematic diagram of the structure of a three-phase four-column magnetic integrated inverter inductor in one embodiment;

[0026] Figure 2 This is a partial structural schematic diagram of a three-phase four-column magnetic integrated inverter inductor in one embodiment;

[0027] Figure 3 This is a partial structural schematic diagram of a three-phase four-column magnetic integrated inverter inductor in one embodiment;

[0028] Figure 4 This is a partial structural schematic diagram of a three-phase four-column magnetic integrated inverter inductor in one embodiment;

[0029] Figure 5 This is a partial structural schematic diagram of a three-phase four-column magnetic integrated inverter inductor in one embodiment. Detailed Implementation

[0030] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0031] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0033] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0035] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0036] Please see Figures 1 to 5The present invention discloses a three-phase four-column magnetic integrated inverter inductor 10, which includes a base plate 100, a magnetic core structure 200 and a coil group 300. The magnetic core structure 200 is mounted on one side surface of the base plate 100, and the coil group 300 is wound on the magnetic core structure 200, thereby forming a three-phase four-column magnetic integrated inverter inductor 10. The magnetic core structure 200 includes several yokes 210 and several magnetic pillars 220. The yokes 210 are arranged parallel to a preset plane and stacked along a preset direction. Adjacent yokes 210 are connected by several magnetic pillars 220. Correspondingly, the coil group 300 includes several inductor coils 310, which are wound one-to-one with several magnetic pillars 220. Thus, the magnetic pillars 220 are magnetically integrated through their corresponding yokes 210 to form an integral magnetic core structure 200. This greatly reduces the installation space occupied by the inductors in the inverter and effectively optimizes the heat dissipation performance of the inverter inductors. The three-phase four-pillar structure enables magnetic coupling between the three-phase currents, which can balance the three-phase magnetic flux, reduce magnetic saturation, improve magnetic circuit utilization and inductor stability. Furthermore, the magnetic integration of the inverter inductors can effectively improve power density to meet the requirements of inverter miniaturization and lightweighting. Based on this, the three-phase four-column magnetic integrated inverter inductor 10 also includes a fastening component 400, which is disposed on the base plate 100 and connected to the magnetic core structure 200 to achieve a stable connection between the magnetic core structure 200 and the base plate 100. Specifically, the fastening assembly 400 includes several support blocks 410 and several fastening straps 420. The support blocks 410 are respectively disposed on the surface of the base plate 100 corresponding to several magnetic yokes 210. When the magnetic core structure 200 is installed on the base plate 100, one side surface of each magnetic yoke 210 abuts against the surface of the corresponding support block 410, so that the magnetic core structure 200 can be stably connected to the base plate. The several fastening straps 420 correspond one-to-one with several magnetic yokes 210. Each fastening strap 420 passes around the side surface of the corresponding magnetic yoke 210 and is connected to the base plate 100 to fasten the corresponding magnetic yoke 210 to the surface of the support block 410. This achieves a fastening connection between the magnetic core structure 200 and the base plate 100, ensuring the overall structural stability of the three-phase four-column integrated inverter inductor 10, and ensuring the mechanical strength and vibration stability of the overall structure.

[0037] Furthermore, based on a preset plane with several yokes 210 relatively parallel, the several yokes 210 are sequentially stacked and arranged along a straight line direction perpendicular to the preset plane, thereby forming a magnetic core structure 200 that extends in a straight line. This ensures the effective magnetic integration of the three-phase four-column magnetic integrated inverter inductor 10, while improving the regularity of the magnetic core structure 200, which is beneficial for practical application installation.

[0038] Furthermore, adjacent magnetic yokes 210 are connected by several parallel magnetic posts 220 to form a closed magnetic circuit structure. In one embodiment, adjacent magnetic yokes 210 are connected by two parallel magnetic posts 220, and correspondingly, between adjacent magnetic yokes 210, two inductor coils 310 are wound on the side surfaces of the two magnetic posts 220 respectively.

[0039] Furthermore, each magnetic column 220 is composed of several independent magnetic blocks 221 stacked axially. Specifically, in one embodiment, each magnetic column 220 is composed of two independent magnetic blocks 221 stacked axially. More specifically, the opposing surfaces of the two magnetic blocks 221 are respectively connected to the surfaces of the corresponding two magnetic yokes 210, and the facing surfaces of the two magnetic blocks 221 are connected to form a complete magnetic circuit. In some embodiments, each magnetic block 221 is set as a cylindrical block structure of a preset length according to actual application requirements. In this embodiment, the cross-sectional shape of each magnetic block 221 is not limited. In some embodiments, the cross-section of each magnetic block 221 can be set as an axisymmetric shape, such as a circle, a square, or a regular polygon. In other embodiments, the cross-section of each magnetic block 221 can be set as a non-axisymmetric shape, such as an ellipse, a parallelogram, or an irregular polygon.

[0040] Furthermore, the magnetic core structure 200 also includes several partitions 230, with each pair of partitions 230 correspondingly disposed on the two end surfaces of a magnetic block 221. That is, each end surface of a magnetic block 221 is spaced apart from adjacent magnetic blocks 221 or yokes 210 by a corresponding partition 230. Specifically, the edge of each partition 230 corresponding to the end surface of the magnetic block 221 is configured as a plate-like structure with a corresponding shape and a through center, thereby creating an air gap between the two ends of the magnetic block 221 and adjacent magnetic blocks 221 or yokes 210.

[0041] Furthermore, an insulating plate 240 is provided between each magnetic yoke 210 and the corresponding inductor coil 310. Each insulating plate 240 is disposed between the end face of the corresponding inductor coil 310 and the surface of the magnetic yoke 210, thereby ensuring the insulation performance of the two ends of each inductor coil 310. Specifically, the end face of each insulating plate 240 corresponding to the inductor coil 310 is set as a plate-like structure with a corresponding shape and a through center.

[0042] In one embodiment, the two inductor coils 310 between two adjacent magnetic yokes 210 are electrically connected in parallel. Specifically, the parallel lead-out ends of the two inductor coils 310 between two adjacent magnetic yokes 210 extend to the other side of the base plate 100 through corresponding connecting portions 320, facilitating actual installation and application.

[0043] In summary, the three-phase four-column magnetically integrated inverter inductor disclosed in this invention achieves magnetic integration of several magnetic columns through corresponding magnetic yokes, resulting in an integral magnetic core structure. This significantly reduces the installation space occupied by the inductor in the inverter, while effectively optimizing the heat dissipation performance of the inverter inductor. The three-phase four-column structure enables magnetic coupling between the three-phase currents, balancing the three-phase magnetic flux, reducing magnetic saturation, improving magnetic circuit utilization and inductor stability. Furthermore, the magnetic integration of the inverter inductor effectively increases power density to meet the requirements of inverter miniaturization and lightweight design. Based on this, several support blocks are respectively set on the surface of the base plate corresponding to several magnetic yokes. When the magnetic core structure is installed on the base plate, one side surface of each magnetic yoke abuts against the surface of the corresponding support block, so that the magnetic core structure can be stably connected to the base plate. Several fastening straps correspond one-to-one with several magnetic yokes. Each fastening strap wraps around the side surface of the corresponding magnetic yoke and connects to the base plate to fasten the corresponding magnetic yoke to the surface of the support block. This achieves a tight connection between the magnetic core structure and the base plate, ensuring the overall structural stability of the three-phase four-column magnetic integrated inverter inductor, and ensuring the mechanical strength and vibration stability of the overall structure.

[0044] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0045] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A three-phase four-pillar magnetic integrated inverter-inductor, characterized in that, The application relates to a three-phase four-column magnetic integrated inverter inductor, which comprises a bottom plate, a magnetic core structure and a coil group. The magnetic core structure is mounted on one side surface of the bottom plate, and the coil group is wound around the magnetic core structure, so that the three-phase four-column magnetic integrated inverter inductor is formed. The magnetic core structure comprises a plurality of magnetic yokes and a plurality of magnetic columns. The magnetic yokes are arranged in parallel with a preset plane, and the magnetic yokes are arranged in a vertical direction of the preset plane. The magnetic columns are connected between adjacent magnetic yokes.

2. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 1, characterized in that, Correspondingly, the coil group comprises a plurality of inductor coils, and the inductor coils are wound around the magnetic columns one by one.

3. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 1, characterized in that, The magnetic columns are magnetically integrated through the magnetic yokes, and an overall magnetic core structure is obtained.

4. The three-phase four-pillar magnetic integrated inverter-inductor of claim 1, wherein, The three-phase four-column magnetic integrated inverter inductor further comprises a fastening assembly arranged on the bottom plate and connected with the magnetic core structure, so that the magnetic core structure and the bottom plate are stably connected.

5. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 3 or 4, characterized in that, The fastening assembly comprises a plurality of supporting blocks and a plurality of fastening belts.

6. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 5, characterized in that, The supporting blocks are arranged on the surface of the bottom plate and correspond to the magnetic yokes.

7. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 6, characterized in that, When the magnetic core structure is mounted on the bottom plate, one side surface of the magnetic yoke abuts against the surface of the corresponding supporting block, so that the magnetic core structure can be stably connected to the bottom plate.

8. The three-phase four-pillar magnetic integrated inverter-inductor of claim 1, wherein, The fastening belts correspond to the magnetic yokes one by one.

9. The three-phase four-pillar magnetic integrated inverter-inductor according to claim 8, characterized in that, Each fastening belt passes through the side surface of the corresponding magnetic yoke and is connected to the bottom plate, so that the corresponding magnetic yoke is fastened to the surface of the supporting block.

10. The three-phase four-pillar magnetic integrated inverter-inductor of claim 4, wherein, Based on the parallel preset planes of the magnetic yokes, the magnetic yokes are arranged in a vertical direction of the preset plane. The magnetic columns are arranged in parallel and form a closed magnetic circuit structure. The magnetic columns are arranged in parallel and correspond to the inductor coils. Each magnetic column is composed of a plurality of independent magnetic blocks arranged in an axial direction. The magnetic core structure further comprises a plurality of partition plates arranged at the end surfaces of the magnetic blocks. The edge of the partition plate corresponds to the end surface of the magnetic block and is provided with a plate-shaped structure with a corresponding shape and a through center. An insulating plate is arranged between the magnetic yoke and the inductor coil. The end surface of the insulating plate corresponds to the inductor coil and is provided with a plate-shaped structure with a corresponding shape and a through center. The two inductor coils between the adjacent magnetic yokes are electrically connected in parallel.

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