Vehicle-mounted high-frequency boost inductor with copper sheet for auxiliary heat dissipation

Abstract

A vehicle-mounted high-frequency boost inductor with a copper sheet for auxiliary heat dissipation comprises a shell, and a framework assembly, a magnetic core assembly, a winding assembly and a heat conduction assembly are arranged in the shell. The framework assembly comprises three stand column frameworks and two end frameworks, and the three stand column frameworks and the two end frameworks are each of a thin shell structure. The three stand column frameworks are arranged in parallel in a pairwise spaced mode in the transverse direction of the shell. The two end frameworks are symmetrically arranged at the two ends of the three stand column frameworks. Accommodating cavities are formed in the three stand column frameworks; the winding assembly is wound on the framework assembly; the magnetic core assembly is arranged on the containing cavities in a sleeving mode and comprises three stand column magnetic cores arranged in the three containing cavities respectively. The upper yoke magnetic core and the lower yoke magnetic core are connected with the two ends of the stand column magnetic core respectively; the heat conduction assembly comprises a plurality of heat conduction copper sheets, the thickness of each heat conduction copper sheet is smaller than 1 mm, and the heat conduction copper sheets wrap the upper end face, the front end face and the rear end face of the upper yoke magnetic core, the lower end face, the front end face and the rear end face of the lower yoke magnetic core and the rear side face of the stand column magnetic core; and a plurality of mutually independent strip-shaped holes are formed in the heat-conducting copper sheet.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle-mounted boost inductors, and in particular to a vehicle-mounted high-frequency boost inductor with a copper sheet for auxiliary heat dissipation. Background Art

[0002] As a transition from gasoline-powered vehicles to electric vehicles, hybrid vehicles (HEVs) have become a key development direction in the current automotive industry. Because the batteries in hybrid vehicles are smaller than those in pure electric vehicles and cannot directly achieve high voltage output, a boost circuit is required to achieve this. To meet this requirement, a key component, the boost inductor, is required in the boost circuit. However, during operation, the boost inductor generates losses and heat due to the current passing through it. If the heat dissipation is poor, it can lead to reduced efficiency, excessive temperature rise, and even device damage. To address this problem, the existing technology attempts to increase the cross-sectional area of the boost inductor's winding coil. Although the heat loss of the boost inductor decreases with the increase in the winding's cross-sectional area, the increase in the winding's cross-sectional area also increases the boost inductor's volume. Due to practical space limitations, the volume of the boost inductor cannot be increased indefinitely. Therefore, how to improve the heat dissipation performance of high-frequency boost inductors in vehicles within the limited space has become a pressing issue. Summary of the Invention

[0003] In view of this, it is necessary to provide a vehicle-mounted high-frequency boost inductor with excellent heat dissipation performance and a copper sheet for auxiliary heat dissipation.

[0004] A vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation includes: a shell, a skeleton component, a magnetic core component, a winding component and a heat-conducting component are arranged in the shell; the magnetic core component and the winding component are fixedly connected to the shell through the skeleton component; wherein the skeleton component includes: three column skeletons and two end skeletons, each of which is a thin shell structure; the three column skeletons are arranged in parallel with each other in pairs along the horizontal direction of the shell, and the top and bottom edges of the three column skeletons are connected to each other; the two end skeletons are symmetrically arranged at both ends of the three column skeletons and connected to the upper half side edges of the two ends of the three column skeletons; each of the three column skeletons has an accommodating cavity; the winding component is wound on the skeleton component; the magnetic core component is sleeved in the accommodating cavity The upper part includes: three column magnetic cores, an upper yoke magnetic core and a lower yoke magnetic core; the three column magnetic cores are respectively arranged in three accommodating cavities; the upper yoke magnetic core is in a step-like shape, the lower end face of the upper yoke magnetic core is fixedly connected to the top of the three column magnetic cores, and the upper yoke magnetic core is half-wrapped in the corresponding end frame; the lower yoke magnetic core is in an inverted step-like shape, the upper end face of the lower yoke magnetic core is fixedly connected to the bottom of the three column magnetic cores, and the lower yoke magnetic core is half-wrapped in the corresponding end frame; the heat-conducting component includes: a plurality of heat-conducting copper sheets, each with a thickness of less than 1 mm, which are respectively coated on the upper end face and front and rear end faces of the upper yoke magnetic core, the lower end face and front and rear end faces of the lower yoke magnetic core, and the rear side face of the column magnetic core; a plurality of independent long strip holes are opened on the heat-conducting copper sheets.

[0005] Preferably, the column cores are evenly divided into two core blocks, and an air gap is set between the core blocks; the heat-conducting component also includes: a ceramic sheet, which is set in the air gap; a plurality of heat-conducting copper sheets, including: two first heat-conducting copper sheets, both of which are trapezoidal and completely cover the front end faces of the upper yoke core and the lower yoke core respectively; six second heat-conducting copper sheets, all of which are rectangular, three of which are completely covered on the upper end face of the upper yoke core in pairs along the horizontal direction, and the other three are completely covered on the lower end face of the lower yoke core in pairs along the horizontal direction; four third heat-conducting copper sheets, two of which are respectively covered on both sides of the rear end face of the upper yoke core and half of the core block surface of the column core on both sides connected to it, and the other two They are respectively covered on both sides of the rear end face of the lower yoke magnetic core and half of the core block surface of the column magnetic core on both sides connected to it; two fourth thermally conductive copper sheets are both rectangular, one of which is covered on the middle part of the rear end face of the upper yoke magnetic core and half of the core block surface of the middle column magnetic core connected to it, and the other is covered on the middle part of the rear end face of the lower yoke magnetic core and half of the core block surface of the middle column magnetic core connected to it; the end of the second thermally conductive copper sheet close to the first thermally conductive copper sheet is connected to the first thermally conductive copper sheet; the end of the second thermally conductive copper sheet close to the third thermally conductive copper sheet is connected to the third thermally conductive copper sheet; the end of the second thermally conductive copper sheet close to the fourth thermally conductive copper sheet is connected to the fourth thermally conductive copper sheet.

[0006] Preferably, three long strip holes are provided on the first thermally conductive copper sheet, and the three long strip holes are parallel to the bottom edges of the front end surfaces of the upper yoke magnetic core and the lower yoke magnetic core; one of the long strip holes is close to the shorter bottom edges of the front end surfaces of the upper yoke magnetic core and the lower yoke magnetic core; the other two are close to the longer bottom edges of the front end surfaces of the upper yoke magnetic core and the lower yoke magnetic core, and are located on the same straight line.

[0007] Preferably, a long strip hole is opened on the half of the second thermally conductive copper sheet close to the third thermally conductive copper sheet or the fourth thermally conductive copper sheet, and the above-mentioned long strip hole is perpendicular to the intersection of the second thermally conductive copper sheet and the third thermally conductive copper sheet or the fourth thermally conductive copper sheet, and the foot of the vertical hole is located at the midpoint of the intersection of the second thermally conductive copper sheet and the third thermally conductive copper sheet or the fourth thermally conductive copper sheet.

[0008] Preferably, the third thermally conductive copper sheet has a diamond-shaped portion covering the rear end surface of the upper yoke magnetic core or the lower yoke magnetic core, and a rectangular portion covering the surface of the column magnetic core; a long strip hole in the shape of a broken line is provided on the third thermally conductive copper sheet along the transverse center line; the long strip hole on the third thermally conductive copper sheet is connected to the long strip hole on the second thermally conductive copper sheet.

[0009] Preferably, a straight long hole is provided on the fourth heat-conducting copper sheet along the transverse center line; the long hole on the fourth heat-conducting copper sheet is connected to the long hole on the second heat-conducting copper sheet.

[0010] Preferably, the winding assembly includes: a conductive bar bracket, a first winding coil, a second winding coil, a first connecting copper bar, a second connecting copper bar and a first conductive bar, a second conductive bar and a third conductive bar; wherein the conductive bar bracket is mounted above the skeleton assembly; the first winding coil and the second winding coil are respectively wound on the column skeletons on both sides; the conductive bar bracket includes: a bracket body, which is I-shaped; a first connecting copper bar and a second connecting copper bar, which are respectively and parallelly wrapped around the front and rear ends of the bracket body; both ends of the first connecting copper bar and the second connecting copper bar are exposed from the bracket body, and the two ends of the first connecting copper bar and the second connecting copper bar are respectively connected to the two ends of the first winding coil and the second winding coil; the first conductive bar, the second conductive bar and the third conductive bar are parallel to each other, and one end is wrapped and arranged in the rear end of the bracket body; one end of the first conductive bar, the second conductive bar and the third conductive bar arranged in the rear end of the bracket body is vertically contacted and connected with the second connecting copper bar.

[0011] Preferably, the first winding coil and the second winding coil are both wound in a single-layer rectangular wire vertical winding manner; the first winding coil and the second winding coil have the same winding direction.

[0012] Preferably, the heat-conducting assembly further includes: two heat-conducting silicone gaskets, which are arranged at the bottom of the shell and correspond to the positions of the first winding coil and the second winding coil respectively.

[0013] Preferably, the heat-conducting component also includes: a heat-conducting hole, which is rectangular and opened at the front end of the middle column frame; a heat-conducting flow channel, which is arranged in the interlayer at the bottom of the shell; a flow channel inlet, which is arranged at the front end of the outer surface of the shell; a flow channel outlet, which is arranged on the outside of the bottom of the shell; and a plurality of heat-dissipating columns, which are arranged at positions in the heat-conducting flow channel corresponding to the first winding coil and the second winding coil.

[0014] The above-mentioned on-board high-frequency boost inductor with copper sheet auxiliary heat dissipation dissipates heat for the on-board high-frequency boost inductor through the following six aspects: First, by arranging thermal conductive copper sheets with a thickness of less than 1mm on the upper end face and front and rear end faces of the upper yoke magnetic core, the lower end face and front and rear end faces of the lower yoke magnetic core, and the rear side face of the column magnetic core, the heat generated by the magnetic core during operation is dissipated; Second, by arranging long strip holes on the thermal conductive copper sheet, the eddy current loss of the copper sheet itself is reduced, and the heat dissipation effect of the copper sheet is improved; Third, by evenly dividing the column magnetic core into two magnetic core blocks, an air gap is arranged between the magnetic core blocks, and a ceramic sheet is arranged in the air gap. Since the ceramic sheet has a good thermal conductivity, it is beneficial to the heat dissipation and cooling of the air gap part of the column magnetic core; Fourth, by arranging two thermal conductive silicone gaskets at the bottom of the shell, respectively connected to the first winding coil and the second The positions of the winding coils correspond to each other, which improves the heat dissipation capacity of the first winding coil and the second winding coil; fifth, by opening a heat conduction hole on the middle column frame, the heat dissipation capacity of the middle column magnetic core is improved; sixth, by arranging a heat conduction channel at the bottom of the shell, the coolant flows through the heat conduction channel to cool the device; therefore, compared with the technology in the prior art that reduces heat loss by increasing the cross-sectional area of the winding coil in the boost inductor, the present invention adopts a multi-faceted technology to cool the boost inductor under limited vehicle space. On the one hand, it can greatly reduce the temperature of the magnetic core. On the other hand, under the same load conditions, there is no need to increase the cross-sectional area of the winding coil, which can make the spatial layout of the boost inductor more optimized. Under the same temperature rise requirements, the volume of the vehicle-mounted boost inductor provided by the present invention can be smaller. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic three-dimensional diagram of the first overall structure of the present invention.

[0016] Figure 2 It is a schematic three-dimensional diagram of the second overall structure of the present invention.

[0017] Figure 3 It is a schematic diagram of the three-dimensional structure of the present invention which only includes the skeleton component, the magnetic core component and the winding component.

[0018] Figure 4 This is a schematic diagram of the three-dimensional structure of the present invention without including the skeleton component, magnetic core component and winding component.

[0019] Figure 5 It is a schematic diagram of the vertical structure of the skeleton assembly in the present invention.

[0020] Figure 6 It is a schematic diagram of the horizontal structure of the skeleton assembly in the present invention.

[0021] Figure 7 It is a schematic diagram of the vertical structure of the magnetic core assembly in the present invention.

[0022] Figure 8 For and from Figure 5 Schematic diagram of the vertical structure of the magnetic core component viewed from the back.

[0023] Figure 9 It is a schematic diagram of the three-dimensional structure of the winding assembly in the present invention.

[0024] Figure 10 It is a schematic diagram of the three-dimensional structure of the conductive bar bracket in the present invention.

[0025] Figure 11 It is a schematic diagram of the cross-sectional structure of the bottom of the shell in the present invention.

[0026] In the figure: shell 1; skeleton assembly 2; column skeleton 20; end skeleton 21; accommodating cavity 22; bushing 23; first fixing plate 24; core assembly 3; column core 30; core block 300; air gap portion 301; upper yoke core 31; lower yoke core 32; winding assembly 4; conductive bar bracket 40; bracket body 400; leg 401; second fixing plate 402; first winding coil 41; second winding coil 42; first connecting copper bar 43; second connecting copper bar 44; first conductive bar 45; second conductive bar 46; third conductive bar 47; ceramic sheet 50; first thermal conductive copper sheet 51; second thermal conductive copper sheet 52; third thermal conductive copper sheet 53; fourth thermal conductive copper sheet 54; long hole 55; thermal conductive silicone gasket 56; thermal hole 57; thermal channel 58; heat dissipation column 59; channel inlet 580; channel outlet 581; threaded hole 6; potting compound 7. DETAILED DESCRIPTION

[0027] The technical solutions and technical effects of the embodiments of the present invention are further elaborated below in conjunction with the accompanying drawings of the present invention.

[0028] In the accompanying drawings of the present invention, Figure 1 In the first overall three-dimensional structural diagram, Figure 2 In the second overall three-dimensional structural diagram, and Figure 3 In the three-dimensional structural diagram, the skeleton component 2 and the magnetic core component 3 are both presented in a horizontal perspective. Figure 5 In the figure, skeleton component 2 is presented in a vertical perspective. Figure 7 and Figure 8 In the figure, the magnetic core assembly 3 is presented in a vertical perspective; Figure 7 The column core 30 in the Figure 1 In the embodiment of the present invention, the description of the skeleton component 2 and the core component 3 are described in terms of the orientation when viewed from a vertical perspective.

[0029] Please see Figure 1 、 3, 5 and 7, a vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation, comprising: a shell 1, in which a skeleton component 2, a magnetic core component 3, a winding component 4 and a heat-conducting component are arranged; the magnetic core component 3 and the winding component 4 are fixedly connected to the shell 1 through the skeleton component 2; wherein, the skeleton component 2 comprises: three column skeletons 20 and two end skeletons 21, all of which are thin-shell structures; the three column skeletons 20 are arranged in parallel with each other in pairs along the transverse direction of the shell 1, and the top and bottom edges of the three column skeletons 20 are connected to each other; the two end skeletons 21 are symmetrically arranged at both ends of the three column skeletons 20, and are connected to the upper half side edges of the two ends of the three column skeletons 20; the three column skeletons 20 have an accommodating cavity 22; the winding component 4 is wound on the skeleton component 2; the magnetic core component 3 is sleeved in the accommodating cavity 22 The upper portion includes: three column cores 30, an upper yoke core 31 and a lower yoke core 32; the three column cores 30 are respectively arranged in three accommodating cavities 22; the upper yoke core 31 is in a step-like shape, and the lower end surface of the upper yoke core 31 is fixedly connected to the top of the three column cores 30, and the upper yoke core 31 is half-wrapped in the corresponding end frame 21; the lower yoke core 32 is in an inverted step-like shape, and the upper end surface of the lower yoke core 32 is fixedly connected to the bottom of the three column cores 30, and the lower yoke core 32 is half-wrapped in the corresponding end frame 21; the heat-conducting component includes: a plurality of heat-conducting copper sheets, each with a thickness of less than 1 mm, which are respectively coated on the upper end surface and front and rear end surfaces of the upper yoke core 31, the lower end surface and front and rear end surfaces of the lower yoke core 32, and the rear side surface of the column core 30; a plurality of independent long strip holes 55 are opened on the heat-conducting copper sheets.

[0030] In this embodiment, the end frame 21 is terraced, with bushings 23 provided at the four corners of the end frame 21, and threaded holes 6 provided on the bushings. Threaded holes 6 are provided at the four corners of the bottom of the shell 1, which are opposite to the threaded holes 6 on the bushings 23, so that the frame assembly 2 can be fixed to the shell 1; the frame assembly 2 is made of reinforced glass fiber material FR530, which has good insulation performance, strong heat resistance, good corrosion resistance, and high mechanical strength, and can well support the magnetic core assembly 3 and the winding assembly 4; the magnetic core material of the magnetic core assembly 3 is iron silicon bar; In this embodiment, heat generated by the magnetic core during operation is dissipated by arranging thermally conductive copper sheets with a thickness of less than 1 mm on the upper end face and front and rear end faces of the upper yoke magnetic core 31, the lower end face and front and rear end faces of the lower yoke magnetic core 32, and the rear side face of the column magnetic core 30; and by arranging long strip holes 55 on the thermally conductive copper sheets, the eddy current loss of the copper sheets themselves is reduced, thereby improving the heat dissipation effect of the copper sheets.

[0031] In this embodiment, the heat-conducting copper sheet is arranged on the rear side of the column magnetic core 30, corresponding to the column magnetic core 30 at Figure 1 and Figure 2The upper side surface in the overall structural diagram is because the rear side surface of the column core 30 is the side away from the bottom of the shell 1, and the bottom of the shell 1 is the heat outlet. Because it is far away from the bottom of the shell 1, the heat generated on this side is not easy to be discharged, and the heat dissipation conditions are poor. Therefore, a thermal conductive copper sheet is provided to guide the heat to the side close to the bottom of the shell 1 to accelerate the heat dissipation.

[0032] Further, see Figure 7 and 8 In order to better improve the heat dissipation effect, the column core 30 is evenly divided into two core blocks 300, and an air gap portion 301 is set between the core blocks 300; the heat conduction component also includes: a ceramic sheet 50, which is arranged in the air gap portion 301; a plurality of heat-conducting copper sheets, including: two first heat-conducting copper sheets 51, both of which are trapezoidal and completely cover the front end surfaces of the upper yoke core 31 and the lower yoke core 32 respectively; six second heat-conducting copper sheets 52, all of which are rectangular, three of which are completely covered on the upper end surface of the upper yoke core 31 in pairs along the horizontal direction, and the other three are completely covered on the lower end surface of the lower yoke core 32 in pairs along the horizontal direction; four third heat-conducting copper sheets 53, two of which are respectively covered on both sides of the rear end surface of the upper yoke core 31 and the surface of half of the core blocks 300 of the column core 30 on both sides connected to it, and The two pieces are respectively covered on both sides of the rear end surface of the lower yoke magnetic core 32, and the surfaces of half of the core blocks 300 of the column cores 30 on both sides connected to it; the two fourth thermally conductive copper sheets 54 are both rectangular, one of which is covered on the middle part of the rear end surface of the upper yoke magnetic core 31, and the surface of half of the core block 300 of the middle column magnetic core 30 connected to it, and the other is covered on the middle part of the rear end surface of the lower yoke magnetic core 32, and the surface of half of the core block 300 of the middle column magnetic core 30 connected to it; the end of the second thermally conductive copper sheet 52 close to the first thermally conductive copper sheet 51 is connected to the first thermally conductive copper sheet 51 as a whole; the end of the second thermally conductive copper sheet 52 close to the third thermally conductive copper sheet 53 is connected to the third thermally conductive copper sheet 53 as a whole; the end of the second thermally conductive copper sheet 52 close to the fourth thermally conductive copper sheet 54 is connected to the fourth thermally conductive copper sheet 54 as a whole.

[0033] In this embodiment, the column core 30 is evenly divided into two core blocks 300, an air gap portion 301 is set between the core blocks 300, and a ceramic sheet 50 is set in the air gap portion 301. Since the ceramic sheet 50 has a good thermal conductivity coefficient, on the one hand, the ceramic sheet 50 supports the column core 30, and on the other hand, it is beneficial to the heat dissipation and cooling of the air gap portion 301 of the column core 30.

[0034] Further, see Figure 7In order to reduce the eddy current loss of the copper sheet itself and further improve the heat dissipation effect of the copper sheet, three long strip holes 55 are opened on the first heat-conducting copper sheet. The three long strip holes 55 are all parallel to the bottom edges of the front end surfaces of the upper yoke magnetic core 31 and the lower yoke magnetic core 32; one of them is close to the shorter bottom edge of the front end surface of the upper yoke magnetic core 31 or the lower yoke magnetic core 32; the other two are close to the longer bottom edges of the front end surfaces of the upper yoke magnetic core 31 and the lower yoke magnetic core 32, and are located on the same straight line.

[0035] In this embodiment, the above arrangement takes into account the trapezoidal front end surfaces of the upper yoke core 31 and the lower yoke core 32. Two unconnected elongated holes 55 located on the same straight line are provided near the longer bottom edges of the front end surfaces of the upper yoke core 31 and the lower yoke core 32. This arrangement significantly reduces eddy current losses generated by the first thermally conductive copper sheet 51 covering the front end surfaces of the upper yoke core 31 and the lower yoke core 32 near the shorter bottom edges of the front end surfaces of the upper yoke core 31 or the lower yoke core 32. At the same time, the copper sheet's attachment area to the front end surfaces of the upper yoke core 31 and the lower yoke core 32 is maximized, thereby ensuring effective heat dissipation. In this embodiment, the long strip hole close to the shorter bottom edge of the front end surface of the upper yoke core 31 and the lower yoke core 32 and the other two long strip holes 55 located on the same straight line are evenly distributed longitudinally along the front end surface of the upper yoke core 31 or the lower yoke core 32.

[0036] Further, see Figure 7 In order to reduce the eddy current loss of the copper sheet itself and further improve the heat dissipation effect of the copper sheet, a long hole 55 is opened on the half of the second thermally conductive copper sheet 52 close to the third thermally conductive copper sheet 53 or the fourth thermally conductive copper sheet 54. The above-mentioned long hole 55 is perpendicular to the intersection of the second thermally conductive copper sheet 52 and the third thermally conductive copper sheet 53 or the fourth thermally conductive copper sheet 54, and the foot of the vertical hole is located at the midpoint of the intersection of the second thermally conductive copper sheet 52 and the third thermally conductive copper sheet 53 or the fourth thermally conductive copper sheet 54.

[0037] Further, see Figure 8 In order to reduce the eddy current loss of the copper sheet itself and further improve the heat dissipation effect of the copper sheet, the third thermally conductive copper sheet 53 has a diamond-shaped portion covering the rear end surface of the upper yoke magnetic core 31 or the lower yoke magnetic core 32, and a rectangular portion covering the surface of the column magnetic core 30; a zigzag elongated hole 55 is provided on the third thermally conductive copper sheet 53 along the horizontal center line; the elongated hole on the third thermally conductive copper sheet 53 is connected to the elongated hole 55 on the second thermally conductive copper sheet 52.

[0038] Further, see Figure 8 A straight strip hole 55 is formed on the fourth heat-conducting copper sheet 54 along the horizontal center line; the strip hole on the fourth heat-conducting copper sheet 54 is connected to the strip hole 55 on the second heat-conducting copper sheet 52 .

[0039] Further, see Figure 3、 6 , 9 and 10, the winding assembly 4, including: a conductive bar bracket 40, a first winding coil 41, a second winding coil 42, a first connecting copper bar 43, a second connecting copper bar 44 and a first conductive bar 45, a second conductive bar 46, and a third conductive bar 47; wherein the conductive bar bracket 40 is mounted above the skeleton assembly 2; the first winding coil 41 and the second winding coil 42 are respectively wound on the column skeleton 20 on both sides; the conductive bar bracket 40 includes: a bracket body 400, which is in an I-shape; the first connecting copper bar 43 and the second connecting copper bar 44 are respectively and parallelly wrapped around the bracket. The front and rear ends of the main body 400; both ends of the first connecting copper bar 43 and the second connecting copper bar 44 are exposed from the bracket main body 400, and the two ends of the first connecting copper bar 43 and the second connecting copper bar 44 are respectively connected to the two ends of the first winding coil 41 and the second winding coil 42; the first conductive bar 45, the second conductive bar 46 and the third conductive bar 47 are parallel to each other, and one end is wrapped and arranged in the rear end of the bracket main body 400; one end of the first conductive bar 45, the second conductive bar 46 and the third conductive bar 47 arranged in the rear end of the bracket main body 400 is vertically contacted with the second connecting copper bar 44.

[0040] In this embodiment, the first winding coil 41 and the second winding coil 42 are connected together by the first connecting copper bar 43 and the second connecting copper bar 44. The first conductive bar 45, the second conductive bar 46, and the third conductive bar 47 are connected to the first winding coil 41 and the second winding coil 42 by connecting the second connecting copper bar 44 to the first conductive bar 45, the second conductive bar 46, and the third conductive bar 47. The first conductive bar 45, the second conductive bar 46, and the third conductive bar 47 serve as the input end, the common end, and the output end of the winding assembly 4, respectively. In this embodiment, four first fixing plates 24 are respectively provided on the inner side of the connection part of two adjacent column skeletons 20, and threaded holes 6 are provided on the first fixing plates 24; the conductive row bracket 40 also includes: two supporting legs 401, which are parallel to each other and vertically arranged at the left and right ends of the waist of the bracket body 400; four second fixing plates 402, which are respectively arranged at the four inner corners of the I-shaped ends of the bracket body 400, and threaded holes 6 are provided on the second fixing plates 402; when the conductive row bracket 40 is placed above the skeleton assembly 2, the two supporting legs 401 are clamped into the two sides of the column skeleton 20 located in the middle, and the threaded holes 6 on the first fixing plates 24 and the second fixing plates 402 are opposite, and nuts are used to fix the conductive row bracket 40 and the skeleton assembly 2 together.

[0041] Further, see Figure 9 The first winding coil 41 and the second winding coil 42 are both wound by vertically winding a single-layer rectangular wire; the first winding coil 41 and the second winding coil 42 have the same winding direction.

[0042] In this embodiment, a single layer of rectangular wire is wound vertically around the first and second coils 41, 42. This improves the heat dissipation of the magnetic core and increases space utilization. By aligning the winding directions of the first and second coils 41, 42, the magnetic flux lines generated within the first and second coils 41, 42 are aligned, resulting in oppositely coupled magnetic paths.

[0043] Further, see Figure 4 The heat-conducting component also includes: two heat-conducting silicone gaskets 56, which are arranged at the bottom of the shell 1 and correspond to the positions of the first winding coil 41 and the second winding coil 42 respectively.

[0044] In this embodiment, two thermally conductive silicone gaskets 56 are provided at the bottom of the housing 1 , corresponding to the positions of the first winding coil 41 and the second winding coil 42 , respectively, thereby improving the heat dissipation capacity of the first winding coil 41 and the second winding coil 42 .

[0045] Further, see Figure 2 、 5 As shown in Figure 11, the heat-conducting component also includes: a heat-conducting hole 57, which is rectangular and opened at the front end of the middle column frame 20; a heat-conducting channel 58, which is arranged in the bottom interlayer of the shell 1; a channel inlet 580, which is arranged at the front end of the outer surface of the shell 1; a channel outlet 581, which is arranged on the outside of the bottom of the shell 1, and a plurality of heat dissipation columns 59, which are arranged in the heat-conducting channel 58 at positions corresponding to the first winding coil 41 and the second winding coil 42.

[0046] In this embodiment, by opening a heat conduction hole 57 on the middle column frame 20, the heat dissipation capacity of the middle column core 30 is improved; by setting a heat conduction channel 58 in the bottom interlayer of the shell 1, the coolant flows through the heat conduction channel 58 to cool the core assembly 3 and the winding assembly 4 in the shell 1; in this embodiment, the heat dissipation column 59 is in the shape of a water droplet, and the heat dissipation column 59 is fixedly connected to the upper and lower surfaces of the interlayer of the shell 1. By setting the heat dissipation column 59, the cooling area of the coolant is increased and the heat dissipation effect is improved; in this embodiment, the shell 1 is filled with potting glue 7 as a whole.

[0047] The above-mentioned vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation dissipates heat for the vehicle-mounted high-frequency boost inductor through the following six aspects: First, by arranging thermally conductive copper sheets with a thickness of less than 1 mm on the upper end face and front and rear end faces of the upper yoke core 31, the lower end face and front and rear end faces of the lower yoke core 32, and the rear side face of the column core 30, the heat generated by the core during operation is dissipated; Second, by arranging long strip holes 55 on the thermally conductive copper sheets, the eddy current loss of the copper sheets themselves is reduced, and the heat dissipation effect of the copper sheets is improved; Third, by evenly dividing the column core 30 into two core blocks, an air gap portion 301 is arranged between the core blocks 300, and a ceramic sheet 50 is arranged in the air gap portion 301. Since the ceramic sheet 50 has a good thermal conductivity coefficient, it is beneficial to the heat dissipation and cooling of the air gap portion 301 of the column core 30; Fourth, by arranging two thermally conductive silicone gaskets 56 at the bottom of the shell 1, respectively with the first winding The positions of the first winding coil 41 and the second winding coil 42 correspond to each other, which improves the heat dissipation capacity of the first winding coil 41 and the second winding coil 42; fifth, by opening a heat conduction hole 57 on the middle column frame 20, the heat dissipation capacity of the middle column magnetic core 30 is improved; sixth, by arranging a heat conduction channel 58 at the bottom of the shell 1, the coolant flows through the heat conduction channel 58 to cool the device; therefore, compared with the technology in the prior art that reduces heat loss by increasing the cross-sectional area of the winding coil in the boost inductor to reduce heat loss, the present invention adopts a multi-faceted technology to cool the boost inductor under limited vehicle space. On the one hand, it can greatly reduce the temperature of the magnetic core. On the other hand, under the same load conditions, there is no need to increase the cross-sectional area of the winding coil, which can make the spatial layout of the boost inductor more optimized. Under the same temperature rise requirements, the volume of the vehicle-mounted boost inductor provided by the present invention can be smaller.

[0048] The above disclosure is only a preferred embodiment of the present invention, and it is certainly not intended to limit the scope of the present invention. A person skilled in the art can understand that all or part of the processes of the above embodiment and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A high-frequency boost inductor for vehicles with copper sheet for auxiliary heat dissipation, characterized in that: It includes: a shell, in which a skeleton component, a magnetic core component, a winding component and a heat conduction component are arranged; The core assembly and the winding assembly are fixedly connected to the shell through the skeleton assembly; wherein the skeleton assembly includes: three column skeletons and two end skeletons, all of which are thin shell structures; the three column skeletons are arranged in parallel with each other in pairs along the transverse direction of the shell, and the top and bottom edges of the three column skeletons are connected to each other; the two end skeletons are symmetrically arranged at both ends of the three column skeletons, and are connected to the upper half side edges of the two ends of the three column skeletons; the three column skeletons are provided with a receiving cavity; the winding assembly is wound on the skeleton assembly; the core assembly is sleeved on the receiving cavity, and includes: three column cores, an upper yoke core, and a lower yoke core ... sleeved on the The column magnetic cores are respectively arranged in the three accommodating cavities; the upper yoke magnetic core is in a step-like shape, the lower end surface of the upper yoke magnetic core is fixedly connected to the tops of the three column magnetic cores, and the upper yoke magnetic core is half-enclosed in the corresponding end frame; the lower yoke magnetic core is in an inverted step-like shape, the upper end surface of the lower yoke magnetic core is fixedly connected to the bottoms of the three column magnetic cores, and the lower yoke magnetic core is half-enclosed in the corresponding end frame; the heat-conducting component includes: a plurality of heat-conducting copper sheets, each with a thickness of less than 1 mm, which are respectively covered on the upper end surface and front and rear end surfaces of the upper yoke magnetic core, the lower end surface and front and rear end surfaces of the lower yoke magnetic core, and the rear side surface of the column magnetic core; a plurality of independent long strip holes are opened on the heat-conducting copper sheets.

2. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation according to claim 1, characterized in that: The column core is evenly divided into two core blocks, and an air gap is set between the core blocks; The heat-conducting component also includes: a ceramic sheet, which is arranged in the air gap; a plurality of heat-conducting copper sheets, including: two first heat-conducting copper sheets, both of which are trapezoidal and completely cover the front end surfaces of the upper yoke magnetic core and the lower yoke magnetic core respectively; six second heat-conducting copper sheets, all of which are rectangular, three of which are spaced two by two in the horizontal direction and completely cover the upper end surface of the upper yoke magnetic core, and the other three are spaced two by two in the horizontal direction and completely cover the lower end surface of the lower yoke magnetic core; four third heat-conducting copper sheets, two of which are respectively covered on both sides of the rear end surface of the upper yoke magnetic core and half of the core block surface of the column magnetic core on both sides connected to it, and the other two are respectively covered on both sides of the rear end surface of the lower yoke magnetic core. and half the surface of the core blocks of the column magnetic cores on both sides connected to it; two fourth thermally conductive copper sheets, both of which are rectangular, one of which is covered on the middle part of the rear end surface of the upper yoke magnetic core and half the surface of the core block of the middle column magnetic core connected to it, and the other is covered on the middle part of the rear end surface of the lower yoke magnetic core and half the surface of the core block of the middle column magnetic core connected to it; one end of the second thermally conductive copper sheet close to the first thermally conductive copper sheet is connected to the first thermally conductive copper sheet as a whole; one end of the second thermally conductive copper sheet close to the third thermally conductive copper sheet is connected to the third thermally conductive copper sheet as a whole; one end of the second thermally conductive copper sheet close to the fourth thermally conductive copper sheet is connected to the fourth thermally conductive copper sheet as a whole.

3. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 2, characterized in that: Three long holes are opened on the first heat-conducting copper sheet, and all three long holes are parallel to the bottom edges of the front end surfaces of the upper yoke magnetic core and the lower yoke magnetic core; one of the long holes is close to the shorter bottom edge of the front end surface of the upper yoke magnetic core or the lower yoke magnetic core; the other two are close to the longer bottom edge of the front end surface of the upper yoke magnetic core or the lower yoke magnetic core, and are located on the same straight line.

4. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 2, characterized in that: A long strip hole is opened on the half of the second thermally conductive copper sheet close to the third thermally conductive copper sheet or the fourth thermally conductive copper sheet. The long strip hole is perpendicular to the intersection of the second thermally conductive copper sheet and the third thermally conductive copper sheet or the fourth thermally conductive copper sheet, and the foot of the vertical hole is located at the midpoint of the intersection of the second thermally conductive copper sheet and the third thermally conductive copper sheet or the fourth thermally conductive copper sheet.

5. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 2, characterized in that: The third thermally conductive copper sheet has a diamond-shaped portion covering the rear end surface of the upper yoke magnetic core or the lower yoke magnetic core, and a rectangular portion covering the surface of the column magnetic core; a zigzag-shaped elongated hole is provided on the third thermally conductive copper sheet along the transverse center line; the elongated hole on the third thermally conductive copper sheet is connected to the elongated hole on the second thermally conductive copper sheet.

6. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 2, characterized in that: A straight long hole is provided on the fourth heat-conducting copper sheet along the transverse center line; the long hole on the fourth heat-conducting copper sheet is connected to the long hole on the second heat-conducting copper sheet.

7. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 1, characterized in that: The winding assembly includes: a conductive bar bracket, a first winding coil, a second winding coil, a first connecting copper bar, a second connecting copper bar and a first conductive bar, a second conductive bar and a third conductive bar; wherein the conductive bar bracket is mounted above the skeleton assembly; the first winding coil and the second winding coil are respectively wound on the column skeletons on both sides; the conductive bar bracket includes: a bracket body, which is I-shaped; a first connecting copper bar and a second connecting copper bar, which are respectively and parallelly wrapped around the front and rear ends of the body; both ends of the first connecting copper bar and the second connecting copper bar are exposed from the bracket body, and the two ends of the first connecting copper bar and the second connecting copper bar are respectively connected to the two ends of the first winding coil and the second winding coil; the first conductive bar, the second conductive bar and the third conductive bar are parallel to each other, and one end is all wrapped and arranged in the rear end of the body; one end of the first conductive bar, the second conductive bar and the third conductive bar arranged in the rear end of the body is vertically contacted and connected with the second connecting copper bar.

8. The vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation as claimed in claim 7, characterized in that: The first winding coil and the second winding coil are both wound in a single-layer rectangular wire vertical winding manner; the first winding coil and the second winding coil have the same winding direction.

9. The vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation according to claim 7, comprising: The heat-conducting component also includes: two heat-conducting silicone gaskets, which are arranged at the bottom of the shell and correspond to the positions of the first winding coil and the second winding coil.

10. The vehicle-mounted high-frequency boost inductor with copper sheet auxiliary heat dissipation according to claim 7, characterized in that: The heat conduction component also includes: a heat conduction hole, which is rectangular and opened at the front end of the middle column frame; a heat conduction channel, which is arranged in the interlayer at the bottom of the shell; a channel inlet, which is arranged at the front end of the outer surface of the shell; a channel outlet, which is arranged on the outside of the bottom of the shell; and a plurality of heat dissipation columns, which are arranged in the heat conduction channel at positions corresponding to the first winding coil and the second winding coil.

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