Inductor module

Abstract

The inductor module is composed of a body (1) and an insulation assembly (2), and the body is provided with a middle column magnetic core (1.1), a yoke magnetic core (1.2), an annular coil (1.3), a side column (1.4) and a leading-out wire (1.5); the insulation assembly is composed of a binding belt (1.6), a base plate (2.1) and a cover plate (2.2), a yoke iron magnetic core (1.2) is contained in a groove (2.1. 1.1. 1) of the base plate, a center pillar magnetic core is contained in a circular through hole (2.1. 1.2) of the base plate, an annular coil (1.3) is positioned by an annular protrusion (2.1. 1.3), a coil outgoing line welding portion (1.5. 1) is contained in a cuboid-shaped cavity (2.1. 1.7. 1), a perforated chamfer (2.1. 1.7. 2) is used for fixing an outgoing line (1.5) through the binding belt (1.6), and an open groove (2.1. 1.7. 4) plays a guiding role when the cover plate (2.2) is installed. And when the cover plate (2.2) is hooked by the buckle (2.2. 2) to the open hole (2.1. 1.7. 3), the cover plate (2.2) is fixed. According to the invention, the production efficiency is improved, the cost is reduced, and the product reliability is improved. And the assembled body is good in appearance consistency, and automatic production can be achieved easily.

Description

Technical Field

[0001] The present invention relates to an electrical component, in particular to an inductor module. Background Art

[0002] Inductors are crucial passive magnetic components in photovoltaic and energy storage products. As a crucial reliability indicator, their insulation has always been a top priority. Therefore, insulation between the coil and the core or outer metal casing is crucial during the inductor production process. This is particularly true at the lead wire solder joints, where the conductor is exposed and numerous weld burrs and sharp metal protrusions are present. This makes insulation treatment complex, typically requiring three layers of insulation film followed by a casing. This process consumes significant amounts of insulating material and is labor-intensive. The presence of these sharp protrusions and burrs often results in poor insulation at the solder joints even after coating. To prevent contact and compression between the solder joints caused by copper wire deformation and stress release during winding and assembly, cable ties are used to secure the solder joints. Only after these multiple steps can the insulation reliability of the solder joints meet mass production requirements. However, this process inevitably increases labor and material costs. Summary of the Invention

[0003] In order to simplify the application of materials and working hours and improve insulation reliability, the present invention provides an inductor module. The technical solution of the present invention is as follows: it is composed of a body and an insulating component, wherein the body has a center column core, a yoke iron core, a toroidal coil, a side column and a lead wire; the insulating component is composed of a binding belt, a base plate and a cover plate; the base plate has a plate portion, a groove is provided along the normal direction of the plate portion, the groove can accommodate and position the rectangular block yoke iron core, and a circular through hole is provided along the normal direction of the plate portion, the circular through hole can accommodate and position the cylindrical center column core; an annular protrusion is provided on the circumference of the circular through hole, and the outer circumference of the annular protrusion is used to position the toroidal coil; one side of the annular protrusion has another square protrusion in the normal direction of the plate portion. The height of the protrusion is twice the thickness of the wire of the vertically wound annular coil, so that the coil is in an upright state when positioning the annular coil; there are two protrusions at both ends of one side of the plate, and when the inductor is placed horizontally, the protrusion is at the lower part, which serves to limit the height to a certain extent with the shell. There is a concave protrusion on the other side of the plate, and the rectangular cavity of the concave protrusion can accommodate the welding part of the coil output wire; there is a chamfer with a hole on one side of the bottom of the concave protrusion, and the hole with the chamfer with a hole is used to fix the lead-out wire with a binding strap; there is no less than one opening at the bottom of the concave protrusion; there is a slot on the top of the concave protrusion, which serves as a guide when installing the cover plate; the cover plate has at least one protrusion, and there is a buckle on the protrusion, and when the cover plate is installed on the base plate, the buckle can hook the opening on the base plate.

[0004] The beneficial effects of the present invention are as follows: the lead wire welding part is accommodated in the cavity formed by the insulating part and fixed with a cable tie. There is sufficient electrical clearance and creepage distance between the exposed conductor at the welding part and the iron core. The insulating part is strong and does not require additional reinforced insulation treatment in actual production. Even if the lead wire is directly pulled to remove the inductor during installation, the exposed conductor at the welding part will not fall out of the insulating part cavity. Therefore, a large amount of insulating materials such as insulating tape and sleeves and labor hours can be saved in production, which can not only improve production efficiency and reduce costs, but also improve reliability. The components of the present invention use multiple grooves for positioning, and the appearance of the assembly is consistent, which is conducive to the realization of automated production. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 Schematic diagram of the overall structure of the present invention

[0006] Figure 2 、 Figure 3 Schematic diagram of the substrate structure of the present invention

[0007] Figure 4 、 5 Schematic diagram of the cover structure of the present invention

[0008] Figures 6 to 11 Schematic diagram of the assembly steps of the present invention

[0009] Figure 12 Schematic diagram of the glue filling state when the inductor of the present invention is placed horizontally

[0010] In the figure,

[0011] 1: Ontology

[0012] 1.1: Middle column core

[0013] 1.2: Yoke ferromagnetic core

[0014] 1.3: Toroidal Coil

[0015] 1.4: Side Posts

[0016] 1.5: Lead wire

[0017] 1.5.1: Welding parts

[0018] 1.6: Tie-down straps

[0019] 2: Insulation components

[0020] 2.1: Substrate

[0021] 2.2: Cover

[0022] 2.1.1: Plate

[0023] 2.1.1.1: Grooves

[0024] 2.1.1.2: Circular through hole

[0025] 2.1.1.3: Annular protrusion

[0026] 2.1.1.4: Gap

[0027] 2.1.1.5: Square protrusion

[0028] 2.1.1.6: Bump

[0029] 2.1.1.7: Concave convex

[0030] 2.1.1.7.1: Rectangular cavity

[0031] 2.1.1.7.2: Chamfer with hole

[0032] 2.1.1.7.3: Opening

[0033] 2.1.1.7.4: Slotting

[0034] 2.2.1: Protrusion

[0035] 2.2.2: Buckle

[0036] 4: Liquid level DETAILED DESCRIPTION

[0037] like Figure 1 As shown, the present invention consists of a body 1 and an insulating assembly 2, wherein the body comprises a central column core 1.1, a yoke iron core 1.2, a toroidal coil 1.3, a side column 1.4 and a lead wire 1.5; the insulating assembly consists of a binding tape 1.6, a base plate 2.1 and a cover plate 2.2; Figure 2 、 Figure 3 As shown, the substrate has a plate portion 2.1.1, and a groove 2.1.1.1 is provided along the normal positive direction of the plate portion 2.1.1, and the groove can accommodate and position the rectangular block-shaped yoke iron core 1.2. A circular through hole 2.1.1.2 is provided along the normal reverse direction of the plate portion 2.1.1, and the circular through hole can accommodate and position the cylindrical middle column core 1.1; an annular protrusion 2.1.1.3 is provided on the circumference of the circular through hole, and the outer circumference of the annular protrusion can position the annular coil 1.3; on one side of the annular protrusion, there is another square protrusion 2.1.1.5 in the normal reverse direction of the plate portion 2.1.1, and the height of the protrusion is one times the wire thickness of the vertically wound annular coil 1.3, so that the coil can be placed in an upright state when positioning the vertically wound annular coil; there are two protrusions 2.1.1.6 at both ends of one side of the plate portion 2.1.1, as shown Figure 12As shown, when the inductor is placed horizontally, the protrusion 2.1.1.6 is at the bottom, which serves to limit the height of the shell. On the other side of the plate 2.1.1, there is a concave protrusion 2.1.1.7. The rectangular cavity 2.1.1.7.1 of the concave protrusion can accommodate the welding part 1.5.1 of the coil lead. One side of the bottom of the concave protrusion has a chamfered hole 2.1.1.7.2, and the chamfered hole is used for binding tape 1.6 to fix the lead wire 1.5. There is at least one opening 2.1.1.7.3 at the bottom of the concave protrusion. The top of the concave protrusion has a slot 2.1.1.7.4, which serves as a guide when installing the cover plate 2.2. Figure 4 The cover plate 2.2 is provided with at least one protrusion 2.2.1, such as Figure 5 The protrusion shown is provided with a snap 2.2.2, which can hook the opening 2.1.1.7.3 on the base plate when the cover plate 2.2 is mounted on the base plate 2.1.

[0038] The assembly steps of the inductor module of the present invention are as follows:

[0039] Step 1: If Figure 6 As shown, first lay the yoke core 1.2 flat on the platform, then place the insulating substrate 2.1 on the yoke, wherein the yoke core 1.2 should be in the groove 2.1.1.1 of the insulating substrate 2.1, and then place the center column core 1.1 in the through hole 2.1.1.2 of the substrate 2.1.

[0040] Step 2: If Figure 7 As shown, put on the prefabricated vertically wound annular coil 1.3, the start of the annular coil 1.3 should be placed on the other side of the square protrusion 2.1.1.5, and the inner hole of the annular coil 1.3 should be put on the annular protrusion 2.1.1.3.

[0041] Step 3: If Figure 8 As shown, install another insulating substrate 2.1, the welding part of the coil's inlet and outlet wire ends and the electronic wire is in the notch of the concave protrusion 2.1.1.7, and then put the binding tape through the hole with perforated chamfer 2.1.1.7.2 of the insulating substrate 2.1 to fix the outlet wire ends.

[0042] Step 4: If Figure 9 As shown, the yoke iron core 1.2 is placed in the groove 2.1.1.1 of the substrate 2.1.

[0043] Step 5: If Figure 10 As shown, a side column 1.4 is installed at each end of the base plate.

[0044] Step 6: If Figure 11As shown, finally install the insulating cover 2.2, and the buckles 2.2.2 of the cover 2.2 should hook the holes 2.1.1.7.3 on the respective base plates 2.1. The lead wires 1.5 are led out from the notches on both sides of the protruding part 2.2.1 of the cover 2.2.

[0045] like Figure 12 As shown, when in the glue filling state, the main body 1 is placed horizontally in a shell, and the upper edge of the cavity formed by the insulating component 2 is flush with the highest point of the toroidal coil 1.3. The liquid level 4 indicated by the dotted line only needs to be slightly higher than the toroidal coil 1.3 during glue filling, thereby saving glue filling amount; after glue filling, the entire welding position of the present invention is fixed below the glue surface, and only the electronic soft wire is above the glue surface, which not only saves space but also protects the welding part from external bending damage, thereby improving reliability.

[0046] The above-mentioned specific implementation methods are merely exemplary and are intended to better enable those skilled in the art to understand this patent. They should not be understood as limiting the scope of this patent. Any changes or modifications that are essentially the same or equivalent to the technical content of the technical solution disclosed in this patent fall within the scope of this patent.

Claims

1. An inductor module, comprising a body (1) and an insulating assembly (2), wherein the body comprises a center column magnetic core (1.1), a yoke iron core (1.2), a toroidal coil (1.3), side columns (1.4) and lead wires (1.5); characterized in that: The insulating assembly is composed of two parts: a binding belt (1.6), a base plate (2.1) and a cover plate (2.2). The base plate has a plate portion ( 2.1.1), there is a groove along the normal direction of the plate (2.1.1) ( 2.1.1.1), the groove can accommodate and position the rectangular block magnetic core (1.2), along the plate portion (2.1.1) in the reverse direction of the normal direction, there is a circular through hole (2.1.1.2), the circular through hole can accommodate and position the cylindrical middle column magnetic core (1.1); there is an annular protrusion (2.1.1.3) on the circumference of the circular through hole, and the outer circumference of the annular protrusion can position the annular coil (1.3); there is at least one notch (2.1.1.4) on the circumference of the annular protrusion, the notch is used for the glue injection port and exhaust, and one side of the annular protrusion is on the plate portion (2. 1.1) There is another square protrusion (2.1.1.5) in the opposite direction of the normal direction. The height of the protrusion is one times the thickness of the wire of the vertically wound annular coil (1.3). When the annular coil (1.3) is positioned, the coil can be placed in an upright state; there are two protrusions (2.1.1.6) at both ends of one side of the plate (2.1.1). When the inductor is placed horizontally, the protrusion (2.1.1.6) is at the bottom, which plays a role in limiting the height of the shell. There is a concave protrusion (2.1.1.7) on the other side of the plate (2.1.1). The concave protrusion has a rectangular cavity ( 2.1.1.7.1) can accommodate the welding part of the coil wire (1.5.1); the bottom side of the concave convex has a chamfer with a hole ( 2.1.1.7.2), the chamfered hole is used for fixing the lead wire (1.5) with a binding belt (1.6); the bottom of the concave protrusion has at least one opening (2.1.1.7.3); the top of the concave protrusion has a groove (2.1.1.7.4) to serve as a guide when installing the cover plate (2.2); the cover plate (2.2) has at least one protrusion (2.2.1), and the protrusion has a buckle (2.2.2), and when the cover plate (2.2) is installed on the base plate (2.1), the buckle (2.2.2) can hook the opening (2.1.1.7.3) on the base plate.

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