Vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation
By introducing various heat dissipation methods such as thermally conductive copper sheets, ceramic sheets, and cooling channels into the high-frequency boost inductor in automotive applications, the heat dissipation problem of boost inductors in limited space has been solved, achieving more efficient heat dissipation and a smaller inductor size, thus avoiding efficiency degradation and device damage caused by poor heat dissipation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- NINGXIA YINLI ELECTRICAL CO LTD
- Filing Date
- 2025-05-23
- Publication Date
- 2026-07-03
AI Technical Summary
In the existing technology, the heat dissipation performance of automotive high-frequency boost inductors is insufficient in limited space, which leads to the risk of reduced efficiency and device damage. Although the existing methods reduce heat loss by increasing the cross-sectional area of the winding coil, they also increase the size of the inductor, which cannot be effectively solved in practical space.
The design employs copper sheet-assisted heat dissipation, which improves heat dissipation efficiency in a limited space by setting thermally conductive copper sheets, ceramic sheets and thermal channels on the magnetic core and winding assembly, combined with multiple heat dissipation methods, including setting air gaps and thermal holes on the magnetic core, using thermally conductive silicone pads and coolant channels, and optimizing space layout.
Without increasing the cross-sectional area of the winding coil, the core temperature is significantly reduced, the space arrangement of the boost inductor is optimized, and a smaller inductor volume and higher heat dissipation performance are achieved, thus avoiding device damage.
Smart Images
Figure CN120452998B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of automotive boost inductor technology, and in particular to an automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation. Background Technology
[0002] As a transition from gasoline-powered vehicles to electric vehicles, hybrid electric vehicles (HEVs) have become an important development direction in the current automotive industry. Because the batteries in HEVs are smaller than those in pure electric vehicles, they cannot directly achieve high-voltage output. Therefore, a boost circuit is needed to achieve high-voltage output. To meet this requirement, a key component, the boost inductor, is required in the boost circuit. However, the boost inductor generates losses and heat during operation due to current flow. Poor heat dissipation can lead to decreased efficiency, excessive temperature rise, and even component damage. Current technologies attempt to address this issue by maximizing the cross-sectional area of the winding coil in the boost inductor. While the heat loss of the boost inductor decreases with increasing the cross-sectional area of the winding coil, this also increases the size of the boost inductor. Due to space limitations, the size of the boost inductor cannot be increased indefinitely. Therefore, improving the heat dissipation performance of onboard high-frequency boost inductors within limited space is a pressing problem to be solved. Summary of the Invention
[0003] In view of this, it is necessary to provide an automotive high-frequency boost inductor with excellent heat dissipation performance and copper sheet-assisted heat dissipation.
[0004] A vehicle-mounted high-frequency boost inductor with copper sheet-assisted heat dissipation includes: a housing, within which a frame assembly, a magnetic core assembly, a winding assembly, and a heat-conducting assembly are disposed; the magnetic core assembly and the winding assembly are both fixedly connected to the housing via the frame assembly; wherein, the frame assembly includes: three column frames, each with a thin-shell structure, and two end frames; the three column frames are arranged parallel to each other in pairs along the transverse direction of the housing, and the top and bottom edges of the three column frames are connected to each other; the two end frames are symmetrically arranged at both ends of the three column frames and are connected to the upper half side edges of both ends of the three column frames; each of the three column frames has a receiving cavity; the winding assembly is wound on the frame assembly; and the magnetic core assembly is sleeved in the receiving 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 set in three receiving cavities; the upper yoke magnetic core is truncated trapezoidal, and its lower end face is fixedly connected to the top of the three column magnetic cores, and the upper yoke magnetic core is partially enclosed in the corresponding end frame; the lower yoke magnetic core is truncated trapezoidal, and its upper end face is fixedly connected to the bottom of the three column magnetic cores, and the lower yoke magnetic core is partially enclosed in the corresponding end frame; the heat-conducting component includes: several heat-conducting copper sheets, each with a thickness of less than 1 mm, which respectively cover 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 of the column magnetic core; several independent elongated holes are opened on the heat-conducting copper sheets.
[0005] Preferably, each column magnetic core is evenly divided into two core blocks, with an air gap between the core blocks; the heat-conducting component further includes: a ceramic sheet disposed in the air gap; and several heat-conducting copper sheets, including: two first heat-conducting copper sheets, both trapezoidal, completely covering the front end faces of the upper and lower yoke magnetic cores respectively; six second heat-conducting copper sheets, all rectangular, of which three are spaced apart laterally and completely cover the upper end face of the upper yoke magnetic core, and the other three are spaced apart laterally and completely cover the lower end face of the lower yoke magnetic core; and four third heat-conducting copper sheets, of which two are respectively covering both sides of the rear end face of the upper yoke magnetic core and half of the core block surface of the column magnetic core connected thereto, and the other two... Two rectangular fourth thermally conductive copper sheets are respectively wrapped around the rear end face of the lower yoke magnetic core and the surface of half of the column magnetic core connected to it; one of them is wrapped around the middle of the rear end face of the upper yoke magnetic core and the surface of half of the column magnetic core connected to it, and the other is wrapped around the middle of the rear end face of the lower yoke magnetic core and the surface of half of the column magnetic core connected to it; the end of the second thermally conductive copper sheet near the first thermally conductive copper sheet is integrated with the first thermally conductive copper sheet; the end of the second thermally conductive copper sheet near the third thermally conductive copper sheet is integrated with the third thermally conductive copper sheet; the end of the second thermally conductive copper sheet near the fourth thermally conductive copper sheet is integrated with the fourth thermally conductive copper sheet.
[0006] Preferably, the first heat-conducting copper sheet has three elongated holes, all of which are parallel to the bottom edge of the front end face of the upper and lower yoke magnetic cores; one of them is close to the shorter bottom edge of the front end face of the upper and lower yoke magnetic cores; the other two are close to the longer bottom edge of the front end face of the upper and lower yoke magnetic cores and are located on the same straight line.
[0007] Preferably, an elongated hole is formed on the second thermally conductive copper sheet near the half of the third or fourth thermally conductive copper sheet. The elongated hole is perpendicular to the intersection of the second and third or fourth thermally conductive copper sheets, and the foot of the perpendicular is located at the midpoint of the intersection of the second and third or fourth thermally conductive copper sheets.
[0008] Preferably, the third heat-conducting copper sheet has a rhomboid shape for the portion covering the rear end face of the upper or lower yoke magnetic core and a rectangular shape for the portion covering the surface of the column magnetic core; a long, zigzag-shaped hole is formed on the third heat-conducting copper sheet along the transverse center line; the long, zigzag hole on the third heat-conducting copper sheet is connected to the long, zigzag hole on the second heat-conducting copper sheet.
[0009] Preferably, a straight elongated hole is formed on the fourth heat-conducting copper sheet along the transverse center line; the elongated hole on the fourth heat-conducting copper sheet is connected to the elongated hole on the second heat-conducting copper sheet.
[0010] Preferably, the winding assembly includes: a conductor busbar support, a first winding coil, a second winding coil, a first connecting copper busbar, a second connecting copper busbar, and a first conductive busbar, a second conductive busbar, and a third conductive busbar; wherein, the conductor busbar support is mounted above the frame assembly; the first winding coil and the second winding coil are respectively wound on the two side column frames; the conductor busbar support includes: a support body, which is I-shaped; a first connecting copper busbar and a second connecting copper busbar, which are respectively parallel to each other and wrapped around the front and rear ends of the support body; both ends of the first connecting copper busbar and the second connecting copper busbar are exposed from the support body, and both ends of the first connecting copper busbar and the second connecting copper busbar are connected to the two ends of the first winding coil and the second winding coil, respectively; the first conductive busbar, the second conductive busbar, and the third conductive busbar are parallel to each other, and one end of each is wrapped around the rear end of the support body; the ends of the first conductive busbar, the second conductive busbar, and the third conductive busbar disposed in the rear end of the support body are perpendicularly contacted and connected to the second connecting copper busbar.
[0011] Preferably, both the first winding coil and the second winding coil are wound using a single-layer flat wire vertical winding method; the first winding coil and the second winding coil have the same winding direction.
[0012] Preferably, the heat-conducting component further includes: two thermally conductive silicone pads, which are placed on the bottom of the housing and correspond to the positions of the first winding coil and the second winding coil, respectively.
[0013] Preferably, the heat-conducting component further includes: a rectangular heat-conducting hole located at the front end of the central column frame; a heat-conducting channel located in the bottom interlayer of the housing; a channel inlet located at the front end of the outer surface of the housing; a channel outlet located on the outer side of the bottom of the housing; and several heat dissipation columns located in the heat-conducting channel at positions corresponding to the first winding coil and the second winding coil.
[0014] The aforementioned automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation achieves heat dissipation through the following six aspects: First, heat-conducting copper sheets with a thickness of less than 1mm are installed on the upper end face and front and rear end faces of the upper yoke core, the lower end face and front and rear end faces of the lower yoke core, and the rear side of the column core to dissipate the heat generated by the core during operation; Second, elongated holes are provided on the heat-conducting copper sheets to reduce the eddy current loss of the copper sheets themselves and improve the heat dissipation effect of the copper sheets; Third, the column core is evenly divided into two core blocks, with an air gap between the core blocks, and a ceramic sheet is placed in the air gap. Since the ceramic sheet has a good thermal conductivity, it is beneficial to heat dissipation and cooling of the air gap of the column core; Fourth, two thermally conductive silicone pads are placed at the bottom of the housing, respectively connected to the first winding coil and the second winding coil. The corresponding positions of the winding coils improve the heat dissipation capacity of the first and second winding coils; fifth, by opening heat-conducting holes on the middle column frame, the heat dissipation capacity of the middle column core is improved; sixth, by setting a heat-conducting channel at the bottom of the housing, the coolant flows through the heat-conducting channel to cool the device; therefore, compared with the existing technology of reducing heat loss by increasing the cross-sectional area of the winding coils in the boost inductor, the present invention uses multi-directional technology to cool the boost inductor in a limited vehicle space. On the one hand, it can greatly reduce the temperature of the core; on the other hand, under the same load conditions, there is no need to increase the cross-sectional area of the winding coils, which can optimize the space arrangement in the boost inductor. Under the same temperature rise requirements, the vehicle boost inductor provided by the present invention can be smaller in size. Attached Figure Description
[0015] Figure 1 This is a three-dimensional schematic diagram of the first overall structure of the present invention.
[0016] Figure 2 This is a three-dimensional schematic diagram of the second overall structure of the present invention.
[0017] Figure 3 This is a three-dimensional structural diagram of the present invention, which includes only the skeleton assembly, the magnetic core assembly, and the winding assembly.
[0018] Figure 4 This is a three-dimensional structural diagram of the present invention, excluding the skeleton assembly, magnetic core assembly, and winding assembly.
[0019] Figure 5 This is a schematic diagram of the vertical structure of the skeleton component in this invention.
[0020] Figure 6 This is a schematic diagram of the horizontal structure of the skeleton component in this invention.
[0021] Figure 7 This is a schematic diagram of the vertical structure of the magnetic core assembly in this invention.
[0022] Figure 8 In order to be with from Figure 5 A schematic diagram of the vertical structure of the magnetic core assembly viewed from the rear.
[0023] Figure 9 This is a three-dimensional structural diagram of the winding assembly in this invention.
[0024] Figure 10 This is a three-dimensional structural diagram of the conductive busbar support in this invention.
[0025] Figure 11 This is a schematic diagram of the cross-sectional structure of the bottom of the shell in this invention.
[0026] In the diagram: 1. Shell; 2. Skeleton assembly; 20. Column skeleton; 21. End skeleton; 22. Receiving cavity; 23. Bushing; 24. First fixing plate; 3. Magnetic core assembly; 30. Column magnetic core; 300. Magnetic core block; 301. Air gap portion; 31. Upper yoke magnetic core; 32. Lower yoke magnetic core; 4. Winding assembly; 40. Conductor busbar bracket; 400. Bracket body; 401. Second fixing plate; 402. First winding coil; 41. Second winding coil; 42. First connecting copper busbar; 43. Second connecting copper busbar; 44. First conductive busbar; 45. Second conductive busbar; 46. Third conductive busbar; 47. Ceramic sheet; 50. First thermally conductive copper sheet; 51. Second thermally conductive copper sheet; 52. Third thermally conductive copper sheet; 53. Fourth thermally conductive copper sheet; 54. Elongated hole; 55. Thermally conductive silicone pad; 56. Thermal hole; 57. Thermal flow channel; 58. Heat dissipation column; 59. Flow channel inlet; 580. Flow channel outlet; 581. Threaded hole; 7. Encapsulating glue. Detailed Implementation
[0027] The technical solutions and effects of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.
[0028] In the accompanying drawings of this 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, both the skeleton assembly 2 and the magnetic core assembly 3 are presented from a horizontal perspective, while Figure 5 In the middle, skeletal component 2 is presented from a vertical perspective. Figure 7 and Figure 8 In the middle, the magnetic core assembly 3 is presented from a vertical perspective; Figure 7 The column core 30 in the middle, its rear side is in Figure 1 Presented from the upper side; in embodiments of the present invention, the skeleton assembly 2 and the magnetic core assembly 3 are described from the orientation of a vertical view.
[0029] Please refer to Figure 1 , 35 and 7, an automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation, comprising: a housing 1, wherein a frame assembly 2, a magnetic core assembly 3, a winding assembly 4, and a heat-conducting assembly are disposed within the housing 1; the magnetic core assembly 3 and the winding assembly 4 are both fixedly connected to the housing 1 via the frame assembly 2; wherein, the frame assembly 2 comprises: three column frames 20, each with a thin shell structure, and two end frames 21; the three column frames 20 are arranged parallel to each other in pairs along the transverse direction of the housing 1, and the top and bottom edges of the three column frames 20 are connected to each other; the two end frames 21 are symmetrically arranged at both ends of the three column frames 20 and are connected to the upper half side edges of both ends of the three column frames 20; each of the three column frames 20 has a receiving cavity 22; the winding assembly 4 is wound on the frame assembly 2; the magnetic core assembly 3 is sleeved in the receiving cavity 22. The upper part includes: three column magnetic cores 30, an upper yoke magnetic core 31, and a lower yoke magnetic core 32; the three column magnetic cores 30 are respectively disposed in three receiving cavities 22; the upper yoke magnetic core 31 is truncated trapezoidal, and the lower end face of the upper yoke magnetic core 31 is fixedly connected to the top of the three column magnetic cores 30, and the upper yoke magnetic core 31 is partially enclosed in the corresponding end frame 21; the lower yoke magnetic core 32 is truncated trapezoidal, and the upper end face of the lower yoke magnetic core 32 is fixedly connected to the bottom of the three column magnetic cores 30, and the lower yoke magnetic core 32 is partially enclosed in the corresponding end frame 21; the heat-conducting component includes: several heat-conducting copper sheets, each with a thickness of less than 1 mm, which respectively cover 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 of the column magnetic core 30; several independent elongated holes 55 are opened on the heat-conducting copper sheets.
[0030] In this embodiment, the end frame 21 is trapezoidal, and bushings 23 are provided at the four corners of the end frame 21. Threaded holes 6 are provided on the bushings. Threaded holes 6 are provided at the four corners of the bottom of the housing 1, corresponding to the positions of the threaded holes 6 on the bushings 23, so that the frame assembly 2 can be fixed to the housing 1. The frame assembly 2 is made of reinforced glass fiber material FR530, which has the characteristics of 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 in the magnetic core assembly 3 is iron-silicon strip.
[0031] In this embodiment, heat-conducting copper sheets with a thickness of less than 1 mm are provided 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 of the column core 30 to dissipate the heat generated by the core during operation; and by providing elongated holes 55 on the heat-conducting copper sheets, the eddy current loss of the copper sheets themselves is reduced, thereby improving the heat dissipation effect of the copper sheets.
[0032] In this embodiment, the heat-conducting copper sheet is disposed 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 in the overall structural diagram is because the rear side of the column magnetic core 30 is away from the bottom of the housing 1. The bottom of the housing 1 is the heat outlet. Because it is far from the bottom of the housing 1, the heat on this side is not easy to be dissipated, and the heat dissipation conditions are poor. Therefore, by setting a heat-conducting copper sheet, the heat is directed to the side near the bottom of the housing 1 to accelerate heat dissipation.
[0033] Further, please see Figure 7 and 8 To improve heat dissipation, each column magnetic core 30 is evenly divided into two core blocks 300, with an air gap 301 between the core blocks 300. The heat-conducting component also includes: a ceramic plate 50 disposed in the air gap 301; and several heat-conducting copper plates, including: two first heat-conducting copper plates 51, both trapezoidal, completely covering the front end faces of the upper yoke magnetic core 31 and the lower yoke magnetic core 32 respectively; six second heat-conducting copper plates 52, all rectangular, with three of them completely covering the upper end face of the upper yoke magnetic core 31 along the lateral direction and the other three completely covering the lower end face of the lower yoke magnetic core 32 along the lateral direction; and four third heat-conducting copper plates 53, with two of them covering the rear end face of the upper yoke magnetic core 31 on both sides and the surface of half of the core block 300 of the column magnetic core 30 connected thereto, and the remaining... Two pieces of thermally conductive copper sheet 54 are respectively wrapped around the rear end face of the lower yoke core 32 and the surface of half core block 300 of the column core 30 connected thereto. Two fourth thermally conductive copper sheets 54 are rectangular. One of them is wrapped around the middle of the rear end face of the upper yoke core 31 and the surface of half core block 300 of the middle column core 30 connected thereto. The other is wrapped around the middle of the rear end face of the lower yoke core 32 and the surface of half core block 300 of the middle column core 30 connected thereto. The end of the second thermally conductive copper sheet 52 near the first thermally conductive copper sheet 51 is integrated with the first thermally conductive copper sheet 51. The end of the second thermally conductive copper sheet 52 near the third thermally conductive copper sheet 53 is integrated with the third thermally conductive copper sheet 53. The end of the second thermally conductive copper sheet 52 near the fourth thermally conductive copper sheet 54 is integrated with the fourth thermally conductive copper sheet 54.
[0034] In this embodiment, the column magnetic core 30 is evenly divided into two magnetic core blocks 300, and an air gap 301 is provided between the magnetic core blocks 300. A ceramic sheet 50 is provided in the air gap 301. Since the ceramic sheet 50 has a good thermal conductivity, on the one hand, the ceramic sheet 50 supports the column magnetic core 30, and on the other hand, it is conducive to heat dissipation and cooling of the air gap 301 of the column magnetic core 30.
[0035] Further, please 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 elongated holes 55 are opened on the first heat-conducting copper sheet. All three elongated holes 55 are parallel to the bottom edge of the front end face of the upper yoke core 31 and the lower yoke core 32. One of them is close to the shorter bottom edge of the front end face of the upper yoke core 31 or the lower yoke core 32. The other two are close to the longer bottom edge of the front end face of the upper yoke core 31 and the lower yoke core 32 and are located on the same straight line.
[0036] In this embodiment, with the above-mentioned arrangement, considering that the front end faces of the upper yoke core 31 and the lower yoke core 32 are trapezoidal, two non-connected elongated holes 55 located on the same straight line are provided near the longer bottom edge of the front end face of the upper yoke core 31 and the lower yoke core 32. Near the shorter bottom edge of the front end face of the upper yoke core 31 or the lower yoke core 32, the eddy current loss generated on the first heat-conducting copper sheet 51 covering the front end face of the upper yoke core 31 and the lower yoke core 32 can be greatly reduced, while at the same time, the adhesion area of the copper sheet on the front end face of the upper yoke core 31 and the lower yoke core 32 is maximized, thus ensuring the heat dissipation effect.
[0037] In this embodiment, the elongated holes near the shorter bottom edge of the front end face of the upper yoke core 31 and the lower yoke core 32, along with two other elongated holes 55 located on the same straight line, are evenly distributed longitudinally along the front end face of the upper yoke core 31 or the lower yoke core 32.
[0038] Further, please 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, an elongated hole 55 is provided on the second heat-conducting copper sheet 52 near the half of the third heat-conducting copper sheet 53 or the fourth heat-conducting copper sheet 54. The elongated hole 55 is perpendicular to the intersection of the second heat-conducting copper sheet 52 and the third heat-conducting copper sheet 53 or the fourth heat-conducting copper sheet 54, and the foot of the perpendicular is located at the midpoint of the intersection of the second heat-conducting copper sheet 52 and the third heat-conducting copper sheet 53 or the fourth heat-conducting copper sheet 54.
[0039] Further, please 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 heat-conducting copper sheet 53 has a rhomboid shape on the rear end face of the upper yoke core 31 or the lower yoke core 32, and a rectangular shape on the surface of the column core 30. A long strip hole 55 in the shape of a broken line is opened on the third heat-conducting copper sheet 53 along the transverse center line. The long strip hole on the third heat-conducting copper sheet 53 is connected to the long strip hole 55 on the second heat-conducting copper sheet 52.
[0040] Further, please see Figure 8 A straight elongated hole 55 is formed on the fourth heat-conducting copper sheet 54 along the transverse center line; the elongated hole on the fourth heat-conducting copper sheet 54 is connected to the elongated hole 55 on the second heat-conducting copper sheet 52.
[0041] Further, please see Figure 3 , 6 9 and 10, winding assembly 4, including: a conductor busbar support 40, a first winding coil 41, a second winding coil 42, a first connecting copper busbar 43, a second connecting copper busbar 44, and a first conductive busbar 45, a second conductive busbar 46, and a third conductive busbar 47; wherein, the conductor busbar support 40 is mounted above the frame assembly 2; the first winding coil 41 and the second winding coil 42 are respectively wound on the two side column frames 20; the conductor busbar support 40 includes: a support body 400, which is I-shaped; the first connecting copper busbar 43 and the second connecting copper busbar 44 are respectively parallel to each other and wrapped around the support. Both ends of the main body 400; the first connecting copper busbar 43 and the second connecting copper busbar 44 are exposed from the main body 400. The two ends of the first connecting copper busbar 43 and the second connecting copper busbar 44 are respectively connected to the two ends of the first winding coil 41 and the second winding coil 42; the first conductive busbar 45, the second conductive busbar 46 and the third conductive busbar 47 are parallel to each other, and one end of each is covered and disposed inside the rear end of the main body 400; the one end of the first conductive busbar 45, the second conductive busbar 46 and the third conductive busbar 47 disposed inside the rear end of the main body 400 is perpendicularly contacted and connected to the second connecting copper busbar 44.
[0042] In this embodiment, the first winding coil 41 and the second winding coil 42 are connected by the first connecting copper busbar 43 and the second connecting copper busbar 44. Furthermore, the first conductive busbar 45, the second conductive busbar 46, and the third conductive busbar 47 are connected to the first winding coil 41 and the second winding coil 42 through the connection of the second connecting copper busbar 44 with the first conductive busbar 45, the second conductive busbar 46, and the third conductive busbar 47. The first conductive busbar 45, the second conductive busbar 46, and the third conductive busbar 47 serve as the input terminal, the common terminal, and the output terminal of the winding assembly 4, respectively.
[0043] In this embodiment, four first fixing plates 24 are respectively provided on the inner side of the connecting part of two adjacent column frames 20, and threaded holes 6 are provided on the first fixing plates 24; the conductive busbar bracket 40 also includes: two 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 are respectively arranged at the four corners of the inner side 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 busbar bracket 40 is placed on the frame assembly 2, the two legs 401 are inserted into the two sides of the column frame 20 located in the middle, the threaded holes 6 on the first fixing plates 24 and the second fixing plates 402 are opposite to each other, and nuts are used to fix the conductive busbar bracket 40 and the frame assembly 2 together.
[0044] Further, please see Figure 9 Both the first winding coil 41 and the second winding coil 42 are wound using a single-layer flat wire vertical winding method; the first winding coil 41 and the second winding coil 42 are wound in the same direction.
[0045] In this embodiment, by employing a single-layer flat wire vertical winding method, the first winding coil 41 and the second winding coil 42 are wound with only a single layer of flat wire in a vertical winding manner, thereby improving the heat dissipation performance of the magnetic core and increasing space utilization. By setting the winding direction of the first winding coil 41 and the second winding coil 42 to be the same, the magnetic lines of force generated inside the first winding coil 41 and the second winding coil 42 are in the same direction, and the magnetic circuits of the first winding coil 41 and the second winding coil 42 are coupled in opposite directions.
[0046] Further, please see Figure 4 The heat-conducting component also includes two thermally conductive silicone pads 56, which are placed at the bottom of the housing 1 and correspond to the positions of the first winding coil 41 and the second winding coil 42, respectively.
[0047] In this embodiment, by providing two thermally conductive silicone pads 56 at the bottom of the housing 1, corresponding to the positions of the first winding coil 41 and the second winding coil 42 respectively, the heat dissipation capacity of the first winding coil 41 and the second winding coil 42 is improved.
[0048] Further, please see Figure 2 , 5 As shown in Figure 11, the heat-conducting assembly further includes: a rectangular heat-conducting hole 57, which is opened at the front end of the central column frame 20; a heat-conducting channel 58, which is disposed in the bottom interlayer of the housing 1; a channel inlet 580, which is disposed at the front end of the outer surface of the housing 1; a channel outlet 581, which is disposed on the outer side of the bottom of the housing 1; and several heat dissipation columns 59, which are disposed in the heat-conducting channel 58 at positions corresponding to the first winding coil 41 and the second winding coil 42.
[0049] In this embodiment, by opening heat-conducting holes 57 on the middle column frame 20, the heat dissipation capacity of the middle column magnetic core 30 is improved; by setting heat-conducting channels 58 in the bottom interlayer of the housing 1, the coolant flows through the heat-conducting channels 58 to cool down the magnetic core assembly 3 and winding assembly 4 inside the housing 1; in this embodiment, the heat dissipation column 59 is teardrop-shaped and is fixedly connected to the upper and lower surfaces of the interlayer of the housing 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 entire housing 1 is filled with potting compound 7.
[0050] The aforementioned automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation achieves heat dissipation through the following six aspects: First, by setting thermally 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 core 31, the lower end face and front and rear end faces of the lower yoke core 32, and the rear side of the column core 30, the heat generated by the core during operation is dissipated; Second, by setting elongated holes 55 on the thermally conductive copper sheets, the eddy current loss of the copper sheets themselves is reduced, improving the heat dissipation effect of the copper sheets; Third, by evenly dividing the column core 30 into two core blocks, an air gap 301 is set between the core blocks 300, and a ceramic sheet 50 is set in the air gap 301. Since the ceramic sheet 50 has a good thermal conductivity, it is beneficial to the heat dissipation and cooling of the air gap 301 of the column core 30; Fourth, by setting two thermally conductive silicone pads 56 at the bottom of the housing 1, respectively connected to 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 heat conduction holes 57 on the middle column frame 20, the heat dissipation capacity of the middle column magnetic core 30 is improved; sixth, by setting a heat conduction channel 58 at the bottom of the housing 1, the coolant flows through the heat conduction channel 58 to cool down the device; therefore, compared with the prior art technology of reducing heat loss by increasing the cross-sectional area of the winding coil in the boost inductor, the present invention uses multi-directional technology to cool down the boost inductor in a 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 optimize the space arrangement in the boost inductor. Under the same temperature rise requirements, the vehicle boost inductor provided by the present invention can be smaller in size.
[0051] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.
Claims
1. A vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation, characterized in that, Includes: a housing, within which a frame assembly, a magnetic core assembly, a winding assembly, and a heat-conducting assembly are housed; The magnetic core assembly and winding assembly are both fixedly connected to the housing via a frame assembly. The frame assembly includes three column frames (all thin-shell structures) and two end frames. The three column frames are arranged parallel to each other in pairs along the transverse direction of the housing, with their top and bottom edges connected to each other. The two end frames are symmetrically arranged at both ends of the three column frames and connected to the upper half of the ends of the three column frames. Each of the three column frames has a receiving cavity. The winding assembly is wound on the frame assembly. The magnetic core assembly, fitted onto the receiving cavity, includes three column magnetic cores, an upper yoke core, and a lower yoke core. The columnar magnetic cores are respectively housed in three receiving cavities; the upper yoke core is shaped like a trapezoid, and its lower end face is fixedly connected to the top of the three columnar magnetic cores, with the upper yoke core partially enclosed within the corresponding end frame; the lower yoke core is shaped like an inverted trapezoid, and its upper end face is fixedly connected to the bottom of the three columnar magnetic cores, with the lower yoke core partially enclosed within the corresponding end frame; the heat-conducting assembly includes: several heat-conducting copper sheets, each less than 1 mm thick, which respectively cover the upper end face and front and rear end faces of the upper yoke core, the lower end face and front and rear end faces of the lower yoke core, and the rear side of the columnar magnetic cores; several independent elongated holes are formed on the heat-conducting copper sheets; Each column magnetic core is evenly divided into two core blocks, with an air gap between them. The heat-conducting assembly also includes: a ceramic plate disposed in the air gap; and several heat-conducting copper sheets, including: two first heat-conducting copper sheets, both trapezoidal, completely covering the front ends of the upper and lower yoke magnetic cores respectively; six second heat-conducting copper sheets, all rectangular, with three of them completely covering the upper end face of the upper yoke magnetic core along the horizontal direction, and the other three completely covering the lower end face of the lower yoke magnetic core along the horizontal direction; and four third heat-conducting copper sheets, with two of them covering both sides of the rear end face of the upper yoke magnetic core and half of the core block surface of the column magnetic core connected to it, and the other two covering half of the core block surface of the upper yoke magnetic core and half of the core block surface of the column magnetic core respectively. The lower yoke core is covered on both sides of its rear end face and on the surface of half of the column core connected to it; two fourth thermally conductive copper sheets, both rectangular, one of which covers the middle of the rear end face of the upper yoke core and on the surface of half of the column core connected to it, and the other covers the middle of the rear end face of the lower yoke core and on the surface of half of the column core connected to it; the second thermally conductive copper sheet is integrated with the first thermally conductive copper sheet at the end closest to the first thermally conductive copper sheet; the second thermally conductive copper sheet is integrated with the third thermally conductive copper sheet at the end closest to the third thermally conductive copper sheet; the second thermally conductive copper sheet is integrated with the fourth thermally conductive copper sheet at the end closest to the fourth thermally conductive copper sheet.
2. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 1, characterized in that: The first heat-conducting copper sheet has three elongated holes, all of which are parallel to the bottom edge of the front face of the upper and lower yoke magnetic cores. One of the holes is close to the shorter bottom edge of the front face of the upper or lower yoke magnetic core, while the other two are close to the longer bottom edge of the front face of the upper or lower yoke magnetic core and are located on the same straight line.
3. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 1, characterized in that: A long hole is provided on the second heat-conducting copper sheet near the half of the third or fourth heat-conducting copper sheet. The long hole is perpendicular to the intersection of the second and third or fourth heat-conducting copper sheets, and the foot of the perpendicular is located at the midpoint of the intersection of the second and third or fourth heat-conducting copper sheets.
4. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 1, characterized in that: The third heat-conducting copper sheet has a rhomboid shape covering the rear end face of the upper or lower yoke core, and a rectangular shape covering the surface of the column core. A long, zigzag-shaped hole is formed along the transverse center line on the third heat-conducting copper sheet. The long hole on the third heat-conducting copper sheet is connected to the long hole on the second heat-conducting copper sheet.
5. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 1, characterized in that: A straight, elongated hole is made on the fourth heat-conducting copper sheet along the transverse center line; the elongated hole on the fourth heat-conducting copper sheet is connected to the elongated hole on the second heat-conducting copper sheet.
6. The automotive high-frequency boost inductor with copper sheet auxiliary heat dissipation as described in claim 1, characterized in that: The winding assembly includes: a conductor busbar support, a first winding coil, a second winding coil, a first connecting copper busbar, a second connecting copper busbar, and a first conductive busbar, a second conductive busbar, and a third conductive busbar; wherein, the conductor busbar support is mounted above the frame assembly; the first winding coil and the second winding coil are respectively wound on the two side column frames; the conductor busbar support includes: a support body, which is I-shaped; a first connecting copper busbar and a second connecting copper busbar, which are respectively parallel to each other and wrapped around the front and rear ends of the body; both ends of the first connecting copper busbar and the second connecting copper busbar are exposed from the support body, and both ends of the first connecting copper busbar and the second connecting copper busbar are connected to the two ends of the first winding coil and the second winding coil, respectively; the first conductive busbar, the second conductive busbar, and the third conductive busbar are parallel to each other, and one end of each is wrapped around the rear end of the body; the ends of the first conductive busbar, the second conductive busbar, and the third conductive busbar disposed in the rear end of the body are perpendicularly contacted and connected to the second connecting copper busbar.
7. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 6, characterized in that: Both the first winding coil and the second winding coil are wound using a single-layer flat wire vertical winding method; the first winding coil and the second winding coil are wound in the same direction.
8. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 6, comprising: The heat-conducting component also includes two thermally conductive silicone pads, which are placed on the bottom of the housing and correspond to the positions of the first winding coil and the second winding coil.
9. The vehicle-mounted high-frequency boost inductor with copper sheet assisted heat dissipation according to claim 6, characterized in that: The heat-conducting component further includes: a rectangular heat-conducting hole located at the front end of the central column frame; a heat-conducting channel located in the bottom interlayer of the housing; a channel inlet located at the front end of the outer surface of the housing; a channel outlet located on the outer side of the bottom of the housing; and several heat dissipation columns located in the heat-conducting channel at positions corresponding to the first winding coil and the second winding coil.