Magnetic circuit PFC inductor and its magnetic core combination method

Abstract

The present invention discloses a magnetic circuit PFC inductor, comprising: a magnetic core combination structure and a coil assembly, wherein the magnetic core combination structure comprises at least two magnetic parts of different magnetic materials, each magnetic part is combined to form a magnetic core combination structure, and a winding post is arranged on the magnetic core combination structure; the coil assembly is sleeved on the winding post. The magnetic circuit PFC inductor and the magnetic core combination method of the present invention are provided with a magnetic core combination structure and a coil assembly, and the magnetic core combination structure is formed by combining at least two magnetic parts of different magnetic materials, that is, two or more magnetic materials are combined into the same magnetic circuit, so as to improve magneto-electric conversion and make it easier to adjust the electrical performance of the inductor.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic components, and in particular to a magnetic circuit PFC inductor and a magnetic core assembly method thereof. Background Art

[0002] A PFC inductor is an inductor used to form a PFC (Power Factor Correction) circuit. The main function of a PFC inductor is to smooth the current in the circuit, reduce high-order harmonics, reduce ineffective power loss, and improve the power factor of the power supply, thereby improving the stability and efficiency of the circuit.

[0003] However, existing PFC inductors all use a single magnetic material to make the magnetic core, and the magnetic core is an integrated structure. Figure 1 As shown, this structure makes it difficult to adjust the electrical properties of the inductor. Summary of the invention

[0004] The object of the present invention is to overcome the deficiencies in the prior art and provide a PFC inductor with a magnetic collecting circuit, so as to facilitate adjustment of the electrical performance of the inductor.

[0005] The objective of the present invention is achieved through the following technical solutions:

[0006] A magnetic circuit PFC inductor comprises: a magnetic core combination structure and a coil assembly, wherein the magnetic core combination structure comprises at least two magnetic parts made of different magnetic materials, each of the magnetic parts is combined to form the magnetic core combination structure, and a winding post is arranged on the magnetic core combination structure; the coil assembly is sleeved on the winding post.

[0007] In one embodiment, the magnetic core assembly structure includes a first magnetic component and a second magnetic component. The first magnetic component and the second magnetic component are combined to form the magnetic core assembly structure. A winding column is disposed on the magnetic core assembly structure.

[0008] In one embodiment, the first magnetic component includes a first winding post and two core limit blocks, and the second magnetic component includes a second winding post, one end of the first winding post is connected to one of the core limit blocks, one end of the second winding post is connected to the other end of the first winding post, and the other end of the second winding post is connected to another core limit block, and the first winding post and the second winding post are combined to form the winding post.

[0009] In one embodiment, two first winding poles are provided, and two second winding poles are provided, any one of the first winding poles and any one of the second winding poles are combined to form the winding pole, and the winding pole is provided between two of the magnetic core limit blocks.

[0010] In one embodiment, the first magnetic component is a metal powder core, and the second magnetic component is a ferrite column.

[0011] In one embodiment, the coil assembly includes a first coil and a second coil, and the first coil and the second coil are respectively mounted on the two winding poles.

[0012] In one embodiment, the first magnetic member and the second magnetic member are detachably connected in combination.

[0013] In one of the embodiments, a base is further included, and the magnetic core assembly structure and the coil assembly are respectively arranged on the base.

[0014] In one embodiment, the base is a heat dissipation base.

[0015] A magnetic core assembly method, applied to the above-mentioned magnetic circuit PFC inductor, comprising:

[0016] Select a variety of magnetic materials with different Ui values;

[0017] Testing the inductance values ​​of the magnetic materials with different Ui values ​​without applying bias current;

[0018] According to the required inductance specification of the inductor, magnetic materials with matching inductance values ​​under the condition of no bias current are combined to obtain the magnetic core combination structure;

[0019] Testing the inductance value of the magnetic core combination structure under the condition of applying a bias current;

[0020] According to the required inductance specification of the inductor, the size and air gap of the magnetic core assembly structure are adjusted so that the magnetic core assembly structure can achieve the required inductance value of the inductor under the condition of applying bias current.

[0021] Compared with the prior art, the present invention has at least the following advantages:

[0022] The magnetic circuit PFC inductor and the magnetic core assembly method thereof of the present invention are provided by setting a magnetic core assembly structure and a coil assembly, and the magnetic core assembly structure is composed of magnetic parts of at least two different magnetic materials, that is, two or more magnetic materials are integrated into the same magnetic circuit, so as to improve magneto-electric conversion. At the same time, compared with the existing integrated magnetic core structure of a single magnetic material, it is easier to adjust the electrical performance of the inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below.

[0024] Figure 1It is a structural schematic diagram of an existing magnetic core structure;

[0025] Figure 2 Schematic diagram of the structure of a magnetic collecting circuit PFC inductor in one embodiment of the present invention;

[0026] Figure 3 for Figure 2 A schematic diagram of the structure of the magnetic core combination structure of the magnetic collecting circuit PFC inductor;

[0027] Figure 4 for Figure 3 Schematic diagram of the exploded structure of the magnetic core combination structure;

[0028] Figure 5 for Figure 2 A schematic diagram of the structure of the base of the magnetic collecting circuit PFC inductor;

[0029] Figure 6 for Figure 2 A schematic structural diagram of another embodiment of a base of a magnetic collecting circuit PFC inductor; DETAILED DESCRIPTION

[0030] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings.

[0031] See also Figure 2 , Figure 3 and Figure 4 As shown, a magnetic circuit PFC inductor includes: a magnetic core assembly structure 100 and a coil assembly 200, the magnetic core assembly structure 100 includes at least two magnetic parts of different magnetic materials, each magnetic part is combined to form the magnetic core assembly structure 100, and a winding post is arranged on the magnetic core assembly structure 100; the coil assembly 200 is sleeved on the winding post.

[0032] It should be noted that the magnetic core combination structure 100 is composed of at least two magnetic parts of different magnetic materials, that is, two or more magnetic materials are integrated into the same magnetic circuit, which improves magneto-electric conversion and makes it easier to adjust the electrical properties of the inductor. In addition, compared with the same size of traditional single material magnetic cores, under the condition of ensuring the same electrical properties, the magnetic circuit PFC inductor of the present invention can reduce the number of windings of the coil assembly 200 by adjusting the electrical properties of the magnetic core combination structure 100, thereby reducing the volume of the coil, realizing a miniaturized design, reducing costs to a certain extent, and further reducing the DC resistance.

[0033] In one embodiment, the magnetic core assembly structure 100 includes a first magnetic member 110 and a second magnetic member 120. The first magnetic member 110 and the second magnetic member 120 are combined to form a magnetic core assembly structure, and a winding post is provided on the magnetic core assembly structure 100. In this way, by combining two magnetic materials in the same magnetic circuit, the magnetoelectric conversion can be improved, and then the number of windings of the coil assembly 200 can be changed to reduce the coil volume while ensuring the electrical performance, thereby realizing the miniaturization design of the inductor.

[0034] Specifically, the first magnetic component 110 includes a first winding pole 111 and two core limit blocks 112, and the second magnetic component 120 includes a second winding pole 121, one end of the first winding pole 111 is connected to one of the core limit blocks 112, one end of the second winding pole 121 is connected to the other end of the first winding pole 111, and the other end of the second winding pole 121 is connected to another core limit block 112, and the first winding pole 111 and the second winding pole 121 are combined to form a winding pole.

[0035] It should be noted that by splitting the winding post into the first winding post 111 and the second winding post 121 of different magnetic materials, the two magnetic materials can be integrated into the same magnetic circuit to improve the magneto-electric conversion, thereby facilitating the adjustment of the electrical performance. In this embodiment, the first magnetic component 110 and the second magnetic component 120 can be split and combined for connection. For example, the connection can be formed by relying on the magnetism of the magnetic component itself. In this way, it is not only convenient to adjust the electrical performance of the inductor, but also convenient for the winding assembly of the coil. Figure 1 The above is an existing magnetic core structure. The magnetic core of a conventional inductor is made of a single material and is an integrated structure. For example Figure 1 The magnetic core of the invention is in a U-shaped structure. Since the magnetic core is a whole, this structure is not conducive to the winding operation of the coil, which makes the winding of the coil more difficult. At the same time, the magnetic core is a whole, which is not convenient for adjusting the electrical performance. Compared with the traditional U-shaped magnetic core, the magnetic core of the PFC inductor of the present invention is divided into a plurality of block-shaped magnetic core combination structures 100. It is only necessary to put the coil assembly 200 into the winding column on the magnetic core combination structure 100, so that the winding is more convenient and the production efficiency can be improved. At the same time, compared with the magnetic core structure of a single magnetic material, the magnetic core combination structure 100 of the present invention can be used in combination with several materials, so that the electrical performance can be adjusted conveniently.

[0036] Furthermore, two first winding posts 111 are provided, and two second winding posts 121 are provided. Any one of the first winding posts 111 and any one of the second winding posts 121 are combined to form a winding post, and the winding post is provided between two magnetic core limit blocks 112. That is, two winding posts are provided on the magnetic core combination structure 100. Correspondingly, in this embodiment, the coil assembly 200 includes a first coil 210 and a second coil 220. The first coil 210 and the second coil 220 are respectively sleeved on two winding posts. Since the magnetic core combination structure 100 is detachable, it is easier to assemble the first coil 210 and the second coil 220, reduce the difficulty of winding the coil, and improve production efficiency.

[0037] It should also be noted that, since the two first winding posts 111, the two second winding posts 121 and the two magnetic core limit blocks 112 are block structures that can be detached and connected, they have the following three outstanding advantages over the traditional one-piece magnetic core structure of a single material:

[0038] 1. The magnetic core assembly structure 100 composed of block magnetic materials is more convenient for coil winding, reduces winding difficulty and improves efficiency.

[0039] 2. The magnetic core assembly structure 100 composed of a plurality of different block magnetic materials is more convenient to adjust the electrical performance. For example, it is more convenient to adjust the air gap of the magnetic core assembly structure. By adjusting the air gap, the inductance value can be effectively controlled, and the linearity and temperature stability of the magnetic circuit PFC inductance can be improved. The flexibility of the magnetic core assembly structure 100 is improved. For another example, the electrical performance may also be adjusted by changing the selection of magnetic materials, such as changing the second winding column 121.

[0040] 3. Compared with the traditional magnetic core structure of the same size, the number of windings can be reduced by adjusting the magnetic core combination structure 100. Under the same electrical performance, the number of coils can be reduced to reduce the volume of the coil, achieve miniaturized design, reduce costs, and further reduce DC resistance.

[0041] Preferably, the first magnetic component 110 is a metal powder core, and the second magnetic component 120 is a ferrite column. The metal powder core has a high magnetic permeability, and the ferrite column also has good magnetic conductivity. The magnetic core combination structure 100 formed by the combination of the metal powder core and the ferrite column can further improve the magnetic permeability of the magnetic circuit PFC inductor, thereby enhancing the inductance and efficiency of the magnetic circuit PFC inductor. At the same time, the first magnetic component 110 and the second magnetic component 120 are designed into a plurality of block structures, and combined to form the magnetic core combination structure 100, so that the electrical performance of the magnetic circuit PFC inductor can be adjusted by changing and adjusting the first magnetic core component and the second magnetic component 120, and the assembly of the magnetic core combination structure 100 can be facilitated, thereby reducing the requirements of the magnetic core on the coil winding and improving the winding efficiency;

[0042] See also Figure 5 As shown, in one embodiment, the magnetic circuit PFC inductor further includes a base 300, and the magnetic core assembly structure 100 and the coil assembly 200 are respectively arranged on the base 300. Among them, the connection end on the coil assembly 200 passes through the base 300 to facilitate connection with other components.

[0043] In this embodiment, the base 300 is a heat dissipation base 300, so as to improve the heat dissipation effect of the magnetic collecting circuit PFC inductor. For example, the heat dissipation base 300 can be made of a metal material, such as copper metal, to ensure the heat dissipation effect. For applications with high insulation requirements, the metal heat dissipation base 300 can be wrapped with a layer of insulating heat dissipation glue, such as thermal conductive silicone and thermal conductive potting glue.

[0044] In order to improve the position limitation of the coil assembly 200, reduce the risk of displacement between the magnetic core assembly structure 100 and the coil assembly 200, and increase the contact between the coil assembly 200 and the base 300, thereby improving the heat dissipation effect, in this embodiment, the base 300 is provided with a heat dissipation limit groove 310 and a limit boss 320, the limit boss 320 is arranged on one side of the heat dissipation limit groove 310, the bottom of the coil assembly 200 is located in the heat dissipation limit groove 310, and the limit boss 320 is located on the side of the coil assembly 200. The heat dissipation limit groove 310 cooperates with the limit boss 320 to limit the coil assembly 200. At the same time, the heat dissipation limit groove 310 can increase the contact area between the coil assembly 200 and the base 300, thereby improving the heat dissipation efficiency. In this embodiment, in order to match two coils, two heat dissipation limit grooves 310 are provided, and two limit bosses 320 are also provided, and the two limit bosses 320 are located on both sides of the two heat dissipation limit grooves 310.

[0045] Since the base 300 is a flat plate structure, when the magnetic collecting circuit PFC inductor is installed on the corresponding electronic module, the gap between the bottom surface of the base 300 and the electronic module is small, and the ventilation effect is poor, resulting in poor heat dissipation of the base 300, and furthermore, most of the heat is transferred to the corresponding electronic module, reducing the performance of the electronic module. Therefore, in this embodiment, a heat insulation layer is provided on one side of the base 300 away from the coil assembly 200 and the magnetic core combination structure 100. The heat insulation layer may be made of heat insulation materials such as epoxy resin, polyurethane foam and aerogel felt, thereby preventing heat from continuing to be transferred from the base 300 to the corresponding electronic module. At the same time, in this embodiment, in order to further improve the heat dissipation effect, please refer to Figure 6 As shown, the base 300 is provided with a heat dissipation reinforcement structure 310, the heat dissipation reinforcement structure 310 includes a heat dissipation extension part 311 and a heat dissipation reinforcement part 312, one end of the heat dissipation extension part 311 is connected to the base 300, the other end of the heat dissipation extension part 311 extends in a direction away from the base 300, and the heat dissipation reinforcement part 312 is arranged on the heat dissipation extension part 311. In this way, the heat dissipation reinforcement structure 310 cooperates with the heat insulation layer to greatly increase the heat dissipation area and improve the heat dissipation effect. For example, the heat dissipation reinforcement part 312 is a copper heat sink.

[0046] A magnetic core assembly method, applied to the above-mentioned magnetic circuit PFC inductor, comprises:

[0047] Step S01: Select a plurality of magnetic materials with different Ui (initial magnetic permeability) values; for example, materials such as FeSi-26, FeSi-40, FeSi-60, and FeSi-75; materials such as ferrite 95, ferrite 96, ferrite 91, and ferrite 28.

[0048] Step S02: testing the inductance values ​​of magnetic materials with different Ui values ​​without bias current;

[0049] Step S03: according to the required inductance specification of the inductor, a magnetic material having an inductance value matching without bias current is combined to obtain a magnetic core combination structure 100;

[0050] Step S04: testing the inductance value of the magnetic core assembly structure 100 under the condition of applying a bias current;

[0051] Step S05: According to the required inductance specification of the inductor, adjust the size and air gap of the magnetic core combination structure so that the magnetic core combination structure can reach the required inductance value of the inductor under the condition of bias current. In this way, the required magnetic circuit PFC inductor can be combined and matched. Since the inductance reduction of different magnetic materials after the bias current is added is different, the magnetic core combination structure needs to be adjusted to achieve the required inductance specification; the traditional single-material integrated magnetic core can no longer adjust its electrical performance.

[0052] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be based on the attached claims.

Claims

1. A magnetic circuit PFC inductor, characterized in that: include: A magnetic core assembly structure, the magnetic core assembly structure comprising at least two magnetic parts made of different magnetic materials, each of the magnetic parts being assembled to form the magnetic core assembly structure, and a winding post being arranged on the magnetic core assembly structure; and A coil assembly is sleeved on the winding post.

2. The magnetic collecting circuit PFC inductor according to claim 1, characterized in that: The magnetic core assembly structure includes a first magnetic component and a second magnetic component. The first magnetic component and the second magnetic component are combined to form the magnetic core assembly structure. A winding column is arranged on the magnetic core assembly structure.

3. The magnetic collecting circuit PFC inductor according to claim 2, characterized in that: The first magnetic component includes a first winding post and two core limit blocks, and the second magnetic component includes a second winding post, one end of the first winding post is connected to one of the core limit blocks, one end of the second winding post is connected to the other end of the first winding post, and the other end of the second winding post is connected to another core limit block, and the first winding post and the second winding post are combined to form the winding post.

4. The magnetic collecting circuit PFC inductor according to claim 3, characterized in that: Two first winding poles are provided, and two second winding poles are provided. Any one of the first winding poles and any one of the second winding poles are combined to form the winding pole, and the winding pole is provided between the two magnetic core limit blocks.

5. The magnetic collecting circuit PFC inductor according to any one of claims 2 to 4, characterized in that: The first magnetic component is a metal powder core, and the second magnetic component is a ferrite column.

6. The magnetic collecting circuit PFC inductor according to claim 4, characterized in that: The coil assembly includes a first coil and a second coil, and the first coil and the second coil are respectively sleeved on the two winding posts.

7. The magnetic collecting circuit PFC inductor according to any one of claims 2 to 4, characterized in that: The first magnetic component and the second magnetic component are detachably connected in combination.

8. The magnetic collecting circuit PFC inductor according to any one of claims 2 to 4, characterized in that: It also includes a base, and the magnetic core combination structure and the coil component are respectively arranged on the base.

9. The magnetic collecting circuit PFC inductor according to claim 8, characterized in that: The base is a heat dissipation base.

10. A magnetic core assembly method, applied to the magnetic field collector PFC inductor according to any one of claims 1 to 9, characterized in that: include: Select a variety of magnetic materials with different Ui values; Testing the inductance values ​​of the magnetic materials with different Ui values ​​without applying bias current; According to the required inductance specification of the inductor, magnetic materials with matching inductance values ​​under the condition of no bias current are combined to obtain the magnetic core combination structure; Testing the inductance value of the magnetic core combination structure under the condition of applying a bias current; According to the required inductance specification of the inductor, the size and air gap of the magnetic core assembly structure are adjusted so that the magnetic core assembly structure can achieve the required inductance value of the inductor under the condition of applying bias current.

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